BFP A3735d
BFP A3735d
RV-5AS-D
SAFETY PRECAUTIONS
Read the separate "Collaborative Robot Safety Manual" thoroughly before using this product. Take precautions as necessary.
1
CONTENTS
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BASIC PRECAUTIONS AND IMPORTANT POINTS WHEN USING COLLABORATIVE ROBOTS. . . . . . . . . . . .1
2
Acquiring/relinquishing operation rights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2 Direct teaching modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 How to use direct teaching with operation buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 How to use direct teaching in RT VisualBox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5 Direct teaching parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.6 Dedicated I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CONTENTS
5.2 How to check values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Status variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Status variable list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Status variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
APPENDIX 45
Appendix 1 Safe stopping distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REVISIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
TRADEMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
3
1 BEFORE USE
*1 Instances where the CR800-D controller is mentioned also refer to the CR800-05VD.
1 BEFORE USE
4 1.1 Instruction manuals
1.3 System configuration
1
8) Emergency stop switch
9) Emergency stop switch
1) Robot: RV-5AS-D connection cable
6) Mode selector switch 10) Earth leakage breaker
7) Mode selector switch 11) Primary power supply
connection cable connection cable
2) Machine cable
4) Safety
extension unit *2
1 BEFORE USE
1.3 System configuration 5
No. Item Specifications/Recommended products Remarks
14) 24 V power cable Recommended cable specifications Supplied by customer
Conductor size: 0.5 to 1.42 mm2, (20 to 16 AWG)
Outer sheath diameter: 1.8 to 2.8 mm
Shielded
15) Robot arm grounding cable AWG11 (4.2 mm2) or above Supplied by customer
16) Electric hand Use a hand that satisfies the needs of the customer. For recommended Supplied by customer
hands, refer to the following manual:
RV-5AS-D Standard Specifications (BFP-A3727)
17) Electric hand manipulators Use manipulators that satisfy the needs of the customer. Supplied by customer
18) Tablet/Computer Refer to the following manual: Supplied by customer
RV-5AS-D Standard Specifications (BFP-A3727)
19) LAN/USB cable LAN: 10BASE-T / 100BASE-TX Supplied by customer
USB: USB Type-A to Mini USB Type-B
1 BEFORE USE
6 1.3 System configuration
2 SAFETY MONITORING FUNCTION
2.1 Terms
Term Description
2
Power and force limiting Power and force limiting is one method of collaborative operation mentioned in ISO/TS 15066.
A method of ensuring that the force and pressure generated in a collision between a human and a robot does not exceed a
predetermined value by limiting both power and force. This robot uses the SLS and STR functions to achieve power and force
limiting.
The system builder must do the following before considering functional safety.
• Clarify what a collision is (e.g. how and where a collision occurs).
• Reduce inherent collision risks (use a collision-free system layout).
Maximum space All the space that the robot (including its end effector and workpiece) is capable of entering.
Monitored space The space monitored by devices such as area sensors and light curtains that detect the presence of humans.
Restricted space The area within the maximum space in which the robot's movement is restricted by limiting devices.
Operating space The area within the restricted space which the robot uses to execute all of its program-specified operations.
High-speed operation The robot operation mode when people are not in the monitored space (i.e. when people are not near the robot). The
maximum operation speed is 1000 [mm/s].
Collaborative space A space within the robot system (including workpieces) where the robot and humans can work together.
Collaborative operation The robot operation mode when people are in the monitored space (i.e. when people are near the robot).
An operation mode that collectively refers to standard operation mode and low-speed operation mode.
Standard Operation The robot operation mode when people are in the monitored space (people are beside the robot) and robot monitor models are
not in the low-speed space.
The maximum operation speed is 250 [mm/s]. Use this operation mode only in situations where there is no risk of body parts,
such as hands and fingers, becoming trapped. Use devices, such as area sensors, to monitor spaces when switching from
High-speed operation mode to Standard operation mode.
Low-speed space The space in the collaboration area where it is necessary to reduce the possibility of harm to people.
Low-speed operation The robot operation mode when people are in the monitored space (people are beside the robot) and robot monitor models are
in the low-speed space.
The maximum operation speed is 50 [mm/s]. Use this operation mode only in situations where there is a risk of body parts,
such as hands and fingers, becoming trapped or where collision points cannot be limited.
Monitored space
Collaborative
Low speed space
workspace (Low speed
Space where the operation)
robot does not operate
at low speed.
(Standard operation)
Operating
space Robot
Maximum space
Definition of space
For terms other than the above, refer to the following.
Robot Safety Option Instruction Manual (BFP-A3531)
The following table shows additional functions associated with the above safety monitoring functions.
Additional functions
No. Item Description Reference
1 Automatic speed Automatically adjusts the operation speed of the robot to the speed specified in the SLS
adjusting function monitoring speed or less.
2 Operation status output Outputs the collaborative operation status with the dedicated output signal "SFMODE" to Page 30 Dedicated Output
signal external devices.
*1 To use this product at a performance level of SIL 3, Category 4, PL e, set the relevant parameters. For details, refer to "Safety diagnosis
function (test pulse diagnosis)" in the following manual.
RV-5AS-D Standard Specifications (BFP-A3727)
*2 The robot controller PFH or PFHd (Probability of Dangerous Failure per Hour). The PFH of the emergency stop switch and enable
switch on the teaching pendant is shown in the table below.
B10d Nop MTTFd DC PFH
Teaching pendant Switch [cycle] [cycle/year] [year] [%] [1/hour]
R32TB Emergency stop 1×106 6000 1667 ≥ 99 2.47×10-8
switch
Enable switch 6000 ≥ 99 2.47×10-8
1×106 1667
R56TB Emergency stop 1×106 6000 1667 ≥ 99 2.47×10-8
switch
Enable switch 6000 60 ≤ DC < 90 1.57×10-7
7×106 11667
*3 For systems using the I/O signals of the safety extension unit, add the PFH value in the table below. Safety performance of the safety
extension unit complies with PL d/Category 3.
MTTFd DC PFH
[[year] [%] [1/hour]
318 90 2.41×10-8
Recovery-Mode
When this robot is in recovery mode, SLP and STR stop states can be temporarily released. The default value of dedicated
output signal number for the recovery-mode is "5".
For the operation procedure of the recovery-mode, refer to the following.
Robot Safety Option Instruction Manual (BFP-A3531)
Precautions
When using recovery mode, check that the R32TB software version is 1.9.5 or later.
Operation Status
The robot's operation status will change under the following conditions:
Operation mode Conditions
High speed operation No presence of anyone in the monitored space that is monitored by area sensors, etc. (No one is approaching the robot.)
(1000 mm/s) The robot can be set to operate at low speed in low-speed spaces. Do not use this setting for collaborative operation with
humans.
Collaborati Standard • A person is in the monitored space. (Someone is approaching the robot.)
ve operation*1 Use devices, such as area sensors, to monitor spaces when switching from High-speed operation mode to Standard operation
operation (250 mm/s) mode.
• The robot is not in the low-speed space*3. (The robot is operating outside the low-speed space*3.)
Low-speed • A person is in the monitored space. (Someone is approaching the robot.)
operation*2 • The robot is in the low-speed space*3. (The robot is operating inside the low-speed space*3.)
(50 mm/s)
*1 Use this operation mode only in situations where there is no risk of body parts, such as hands and fingers, becoming trapped.
*2 Use this operation mode only in situations where there is a risk of body parts, such as hands and fingers, becoming trapped or where
collision points cannot be limited.
*3 The low-speed space*2 is specified by a cuboid.
DANGER
Design the robot system so that people are prevented from approaching the robot during High-speed operation. The robot will not be able to stop safely if a
collision occurs while it is operating at high speed.
CAUTION
When using High-speed operation, always connect the safety sensors (such as area sensors and light curtains) or interlock to DSI1 according to the result of
the risk assessment.
[Standard operation]
Decelerating
Monitored space movement
(monitored by area sensor and light curtain) 250mm/s
* Make sure to install an area sensor or light
curtain when using a system where the robot
switches from high speed mode to standard
operation mode.
High speed
movement
1000mm/s
Low speed
movement
50mm/s
Low High
Operation status High speed Standard speed speed
Robot position The robot is outside the low speed space. The robot is inside the low speed space.
70
410
Monitored area A2
664
Robot origin
254
164.4
For further information on monitored areas, refer to the following manual:
Robot Safety Option Instruction Manual (BFP-A3531)
• The monitored speed cannot be set to a higher speed than the initial one.
• Do not use compliance control, force sense control, real-time external control, Ex-T control interpolation,
spline interpolation, the tracking function, or the direct teaching function outside the monitored speed limit.
Ex.
When axes J1 or J2 rotate while the arm is folded at the elbow, the end of the elbow will be the furthest point from the 2
monitored positions.
To limit the speed of the surface of the robot, reduce the speed limit.
The SLS function monitors the speed of tool monitor models T1 to T4 even if the radius is set to 0. If X, Y, Z, and the radius are
all set to 0 (no settings), the center of the mechanical interface is monitored.
Overview
Based almost entirely on the movements of the robot, a permissible torque range is established from the estimated torque of
each motor. This function checks whether the actual torque (feedback torque) is within the torque range. When the torque
feedback exceeds the permissible limit, error H221n ("n" is the joint axis number) occurs, and the robot is stopped by the SS1
function.
The torque limit values cannot be modified.
CAUTION
• Pre-use inspection
Before using the robot, check that the STR function is operating properly.
With the robot stopped and the servos in the ON state, check that the STO function turns the servos off when force is applied to the robot arm.
• Set the hand and workpiece conditions correctly. The force cannot be detected correctly when incorrect values are set. The force generated upon an impact
may also be larger than if the correct values were set, and errors may occur during operation.
• Torque feedback is calculated based on information acquired from sensors. These sensors have a function that detects faults. However, the STR function will
not detect a fault in the following cases: There is a low level fault with the sensor or the joint has stopped. If there is a fault with a sensor but the fault has not
been detected, there is the risk that the force generated during a collision will not be reduced. Run the axes using an override speed of 10% or more for
about 10 seconds before using the robot to check if any of the sensors are faulty. For further information, refer to "RESIDUAL RISK (SPECIFIC TO EACH
FUNCTION)" in the following manual:
Collaborative Robot Safety Manual (BFP-A3733)
• The STR function is activated even when the direct teaching function is used. Moving the robot arm abruptly
may trigger error H221n.
• The STR function may not detect changes in torque accurately at low temperatures, causing the error
"H221n" to occur. To clear this error, warm up the robot using the warm-up operation while the robot is in
High-speed operation mode. Warming up an affected joint by releasing its brake and moving it around will
also clear this error.
• If torque is limited with the Torq command, the STR function may not detect changes in torque accurately.
Servo ON/OFF ON
OFF
ON(Inactive)
STR command
OFF(Active)
ON(Inactive)
STR monitoring OFF(Active)
2
Collision detection function
If the collision detection function detects a collision, this robot will stop in a different manner from what the FR series does. FR
series robots come to a complete stop after servo OFF. However, the RV-5AS-D comes to a complete stop after the arm has
decelerated to a stop and the servos have turned off.
LoadSet command
For FR series robots, the LoadSet command affects the settings of hands and workpieces when a program is reset and when
the END line is executed. The LoadSet command does not affect the settings of the RV-5AS-D. In the aforementioned
situations, the hand and workpiece settings of FR series robots will be reset to default values, but the RV-5AS-D will retain its
current settings.
Parameter settings
The following parameters are related to safety monitoring, and they can only be written using RT ToolBox3 (Ver. 1.70Y or
later), RT VisualBox, or the R56TB (Ver. 4.2 or later).
• Hand and workpiece conditions: HNDDAT0 to HNDDAT8, WRKDAT0 to WRKDAT8, HNDHOLD1 to HNDHOLD8
• Gravity direction: MEGDIR
• Tool data: MEXTL, MEXTLNO, MEXTL1 to MEXTL16
Attempting to write these parameters using devices not mentioned above (such as the R32TB) will trigger the error C7081
(The parameter CRC value is illegal).
Connecting RT VisualBox
To configure the safety monitoring function settings, connect RT VisualBox to the controller and configure them while the robot
is online.
For information on online operation, refer to the following manual:
RT VisualBox Instruction Manual (BFP-A3696)
CAUTION
These settings greatly affect the safety of the robot. Before configuring these settings, read "Basic Precautions and Important Points when Using Collaborative
Robots" in this document and the separate "Collaborative Robot Safety Manual" thoroughly, and take appropriate measures accordingly.
If the robot is connected to this software, a password must be entered to change these settings.
Precautions
The settings of some windows/screens cannot be configured using RT VisualBox if safety parameters have been set with RT
ToolBox3. If the error message below appears, configure the settings in RT ToolBox3.
The safety settings cannot be changed without changing the default password. When the default password is entered, the
Change Password screen will appear. Change the password.
Precautions
Even if a password has not been entered, it is still possible to view the Safety Settings screen. However, the setting values
cannot be changed.
The password must be 8 to 32 characters long. Passwords are case-sensitive and only single-byte alphanumeric characters
(0 to 9 and A to Z) can be used.
Safety settings cannot be set without entering the correct password so ensure the password is something that is not easily
forgotten. To reset the password, the robot controller must be returned to factory settings. Resetting the robot type will clear
the controller memory and return it to factory settings. For further information on resetting the robot type, refer to the following
manual:
Detailed explanations of functions and operations (BFP-A3478)
To prevent inadvertent changes to the safety settings, keep your password secret and do not share it with third parties.
Tool Model
Define the shape of the tool (hand, vision sensor, etc.) with up to four spheres. Create a shape that is roughly the size of the
tool that is attached to the robot. If the radius is greater than 0, the tool model will be subject to position monitoring.
The center of the tool model sphere will also be subject to speed monitoring. All tool models are subject to speed monitoring
by default. Use RT ToolBox3 to disable the speed monitoring of specific tool models.
The coordinates are set in the mechanical interface coordinate system. By default (all coordinates set to "0"), the center of the
mechanical interface is subject to speed monitoring. For information on the mechanical interface coordinate system, refer to
the following manual:
Detailed explanations of functions and operations (BFP-A3478)
Speed Limiting
The maximum speed and low-speed area can be set for each operation mode.
This setting is used for the speed-limiting safety function (SLS). This function monitors the speed of the robot arm and tools so
that the speed does not exceed the specified value. For further information on this function, refer to the following manual:
Robot Safety Option Instruction Manual (BFP-A3531)
The maximum speed for each operation mode can be set.
Operating procedure
2.
1.
3.
4.
2. Enter two diagonal points. An area will appear on-screen once valid values have been set.
Diagonal points can also be set while moving the robot. To set points while moving the robot, tap/click the [Operate Robot]
button, and move the robot to the desired destination. Then, tap/click the [Teach] button. The current position is stored in the
X, Y, and Z coordinates of the currently selected diagonal point.
3. Set which side of the created area is to be set as the low-speed area with the [Activate low-speed outside of area] check
box.
CAUTION
If [Enable even during high speed operation (non collaborative)] indicated by "a" and the area switch of a low-speed area are set to On, the robot operating at
high speed will slow down upon entry into the low-speed area. In this situation, the robot is not in Collaborative operation mode. To work with the robot in the
same space, follow risk assessments, use Safety input 1 and operate the robot in Collaborative operation mode.
Assign the inputs show in the table below. Safety input 1 cannot be changed from "Collaborative operation". "Collaborative
operation" can only be assigned to Safety input 1.
Input Description
Collaborative operation When the input is enabled (Open), the robot is set to Collaborative operation mode*1. When the input is disabled (Closed), the
robot is set to High-speed operation mode.
Safe stop (servo OFF) When the input is enabled (Open), Safe stop 1 (SS1)*2 is activated.
Safe stop (servo ON) When the input is enabled (Open), Safe stop 2 (SS2)*3 is activated.
Safety areas 1 and 2 When input is enabled (Open), the area which the robot is not permitted to enter is enabled. Safety areas are set in "Position
Limiting".
*1 Collaborative operation mode switches depending on whether the monitored area of the robot is in the low-speed area.
*2 Safe stop 1: stops the robot safely and shuts off power to the motors after the robot has stopped.
*3 Safe stop 2: stops the robot safely, maintains control over the motors even after they have stopped, and ensures that the robot does not
move.
For further information, refer to the following manual:
Robot Safety Option Instruction Manual (BFP-A3531)
㾎 㾎
DSI
㾎 㾎
㾎 㾎 㾎
• Do not change the safety input settings multiple times during the SLS deceleration monitoring time (about
1.5 s). Doing so may cause error H242 "Fault in safety data (S_STS)".
*1 Safe Torque Off: shuts off power to the motors in the robot.
*2 Safe Operating Stop: checks that the robot has stopped without shutting off power to the motors in the robot. For further information,
refer to the following manual:
Robot Safety Option Instruction Manual (BFP-A3531)
• Advanced settings can be configured with RT ToolBox3. For further information, refer to the following
manual:
RT ToolBox3 / RT ToolBox3 mini User's Manual (BFP-A3495)
• Servo OFF:
When the robot servos are off, the safety outputs that set the robot’s operation mode turn off.
CAUTION
There is a delay of up to 21.3 ms from when the duplicated output signals turn off until the safety outputs turn off. This may temporarily cause multiple operation
mode commands to be output at the same time (e.g. High speed and Standard operation mode commands output at the same time). Conduct a risk
assessment to ensure safety.
Operating procedure
1.
3. 2.
4.
5.
1. Select the plane or area to set by selecting the [Plane] or [Area] tab.
2. Tap/click the [Set] button, and set a plane or area in the Plane settings or Area settings screen.
3. Use the ON/OFF buttons to enable/disable the conditions for each plane or area. ON/OFF buttons are only available if a
plane or area has been created. Create a plane or area first.
4. Configure the settings then check them. Using the [Show/Hide] check boxes, show or hide a plane or area and check
whether the conditions for enabling the plane or area are correct.
Operating procedure
2
1.
2.
3.
4.
1. Enter points A to C. After the three points have been entered, a plane passing through the points will appear on the
screen.
The points can also be set while moving the robot. To set points while moving the robot, tap/click the [Operate Robot] button,
and move the robot to the desired destination. Then, tap/click the [Teach] button. The current position is stored in X, Y, and Z
of the currently selected point.
2. The robot cannot access the area on the pink side of the plane. By default, the area on the outside of the plane is
inaccessible. To change the setting, select the [Deny access to area on opposite side] check box.
3. To keep previously set planes and areas visible while creating a new plane, select the [Show other planes and areas]
check box.
4. After setting the plane, tap/click the [< Back] button to return to the Position Limiting screen.
[Deny access to area on opposite side]: OFF [Deny access to area on opposite side]: ON
Operating procedure
1.
2.
3.
4.
1. Enter two diagonal points. An area will appear on-screen once valid values have been set.
Diagonal points can also be set while moving the robot. To set points while moving the robot, tap/click the [Operate Robot]
button, and move the robot to the desired destination. Then, tap/click the [Teach] button. The current position is stored in the
X, Y, and Z coordinates of the currently selected diagonal point.
2. By default, the area on the outside of a defined area is inaccessible. To change the settings, select the [Deny access to
inside of area] check box.
3. To keep previously set planes and areas visible while creating a new plane, select the [Show other planes and areas]
check box.
4. After setting the area, tap/click the [< Back] button to return to the Position Limiting screen.
[Deny access to inside of area]: OFF [Deny access to inside of area]: ON
The robot will stop moving before it leaves the defined area. The robot will stop moving before it enters the blue area.
Status variable
M_CollaboSts
■Function
This function acquires which operation mode the robot is in (High-speed operation mode or Collaborative operation mode
[standard/low-speed operation]).
-1: Disabled
0: High-speed operation
1: Standard operation
2: Low-speed operation
■Syntax
Ex.
<Numerical variable> = M_CollaboSts
■Term
<Numerical variable>: Specify a numerical variable to which a value is to be assigned.
■Reference program
1 Select M_CollaboSts 'Judgment by the operation status
2 Case 1 'For standard operation
3 M_Out(65) = 1 'The signal number 65 is turned on
4 Break
5 Case 2 'For low-speed operation
6 M_Out(66) = 1 'The signal number 66 is turned on
7 Break
8 Default 'When operation is not the collaborative operation
9 Break
10 End Select
■Explanation
1. Returns the robot's current operation mode (High-speed operation mode or Collaborative operation mode [standard/low-
speed operation]).
2. According to the enabled SLS speed-limiting and STR torque restriction state, this status variable is as follows.
SLS1 monitoring and SLS2 monitoring and SLS3 monitoring and M_CollaboSts Operation status
STR1 monitoring STR2 monitoring STR2 monitoring
*1
Disabled Disabled Disabled -1 (Disabled)
Enabled Disabled Disabled 0 (High-speed operation) High-speed operation
Enabled Disabled Enabled -1 (Disabled)
Enabled Enabled Disabled 1 (Standard operation) Standard operation
Enabled Enabled Enabled 2 (Low-speed operation) Low-speed operation
*1 When functional safety is disabled (the Safety extension unit is not connected or the origin has been lost) or the robot is in the servo-off
state.
4. Always returns "-1" as the SLS and STR monitoring functions are disabled at servo-OFF.
5. Always returns "-1" for robots that are not collaborative robots.
6. Read-only.
■Supplement
Variables that can be described in <Numerical variable>
Item Numeric value type Position type Joint type Character
Integer Long- Real number Double- string type
Example) precision Position precision
M1% integer component real number
Example) Joint
M1& component
Constant
Variable
Logical/arithmetic
expression
Function
2.7 Parameter
The specifications of this robot's "SFMODE" have been changed so that the operation status (high-speed operation/standard
operation/low-speed operation) can be output to external devices.
Parameter Parameter name No. of Description Factory setting
arrays
Operation status output SFMODE Integer 2 Set the start number and end number of the signal that outputs -1, 6
signal the operation status.
First element: System reservation
Second element: Start number of operation status output signal
Setting range: -1 to 19999
When the output signal area for 3 bits from the signal start
number does not exist, an error occurs.
*1 When functional safety is disabled (the Safety extension unit is not connected or the origin has been lost) or the robot is in the servo-off
state.
LED
3
3 OPERATION BUTTONS
3.1 Operation buttons 31
CAUTION
Before opening/closing the hand, ensure that doing so will not cause workpieces to fall or fingers to become trapped.
Pressing or holding any button during program execution will stop the robot and suspend the program.
3 OPERATION BUTTONS
32 3.1 Operation buttons
4 DIRECT TEACHING
Direct teaching is the operation performed by holding and moving the robot by hand.
CAUTION
• If the settings for the hand are not configured correctly, the arm may rise or fall when direct teaching is turned on. Furthermore, the safety functions may not
work properly. Ensure the settings are correct.
• Workpiece settings are not enabled during direct teaching. The robot arm may fall depending on the weight of the workpiece. Do not release your hands from
the robot arm until it stops completely.
• If using one of the hand settings from HADDAT1 to HADDAT8 set in RT ToolBox3, be aware that the hand setting in the controller will be reset to HNDDAT0
if the controller's power is cycled. In this case, the arm may rise or fall as the correct hand settings will no longer be set.
4
4.1 Operation rights
Multiple devices, such as the operation buttons on the robot arm, RT VisualBox, or external signals, can be used to operate
the robot controller. However, only one of these devices can operate the controller at the same time as another device
(commands for operation, servo ON, etc.). This single device has "operation rights".
Operations that involve risk require operation rights. It is essential that other workers are not able to obtain operation rights
when you are near the robot while it is operating.
Operations that start the robot, such as starting a program or servo ON, require operation rights. For safety reasons,
operations that stop the robot, such as stopping a program or servo OFF, do not require operation rights.
Operation buttons on
the arm *2
High
T/B operation
RT VisualBox *2 panel
Low
*1 RT ToolBox3 does not have a function to take control of operation rights. When an operation that requires operation rights is performed,
they will be acquired or released automatically.
*2 Priority when operation rights have been secured. If operation rights have not been secured, the priority is the same as RT ToolBox3.
When an operation that requires operation rights is performed, they will be acquired or released automatically.
4 DIRECT TEACHING
4.1 Operation rights 33
Conditions required to acquire operation rights from other devices
Operation rights can only be acquired from devices of lower priority.
They cannot be acquired from devices with the same or lower level of priority.
For example, if RT VisualBox has operation rights, the operation buttons on the robot arm are capable of acquiring operation
rights (operation rights are transferred from RT VisualBox to the operation buttons). However, operation rights are not given to
external signals (RT VisualBox has operation rights at all times).
Precautions
Operation rights are not required to change the settings such as the installation type, hand settings, workpiece settings, and
workpiece grasp position. Ensure it is safe to do so before changing these settings.
The settings cannot be changed during direct teaching or automatic operation.
LED status
On: operation rights acquired
Off: operation rights relinquished
■Location
■Status
This icon indicates that operation rights have not been requested.
Tap/click the icon to request operation rights.
This icon indicates that operation rights have been requested but have not yet
been secured. Other devices, such as the operation buttons or teaching pendant,
may have already taken operation rights. Tap/click this icon to cancel the request
for operation rights.
This icon indicates that operation rights have been secured. Tap/click the icon to
release operation rights.
4 DIRECT TEACHING
34 4.1 Operation rights
4.2 Direct teaching modes
There are three direct teaching modes.
Direct teaching modes
Mode Description Operation image
Joint free Axes can be moved individually or collectively to the desired position.
With the J4 axis and J6 axis aligned (singular posture), the J4 axis may
rotate when the J6 axis is operated.
4
Translational The robot arm can be moved relative to the tool center point in the tool
motion coordinate system. Refer to the following figure for information on the tool
coordinate system.
Tool length
-X
-Z
-Y
+Y
+Z
+X
Tool center point
Rotational The robot arm can be rotated about the tool center point in the tool
(Supported coordinate system. Refer to the following figure for information on the tool
with controller coordinate system.
software
version B1c or
later.)
Tool length
-X Hold the end effector
so that the tool center point
-Z (red dot) does not move.
-
-Y
+ + +Y If the tool center point itself moves (red dot), the STR robot
- -
+Z torque error (H221n) will occur.
+X
+
Tool center point
Change the tool center point according to the hand being used.
• When teaching positions directly in Translational mode, hold an area of the robot which is close to the tool
center point, such as the hand.
• When teaching positions directly in Rotational mode, use the tool center point as the fulcrum.
• When teaching positions in Translational or Rotational mode, more force will be required to move the robot
arm near the singularities stated below due to vibration and coasting control.
Translational
J3 axis: -30° to +30°
Rotational
J3 axis: -25° to +25°
• The SLS function is enabled even during direct teaching. Moving the robot arm at a speed exceeding the
speed limit will trigger an error. Move the robot arm at a speed below the speed limit. Be aware that is it
easy to exceed the monitored speed in Low-speed operation mode.
• Switching to Translational or Rotational mode near singularities will cause an error and direct teaching will
turn off. If an error occurs in this situation, switch to Joint free mode and retry direct teaching.
• The STR function is activated even when the direct teaching function is used. Moving the robot arm abruptly
will trigger the STR robot torque error (H221n).
4 DIRECT TEACHING
4.2 Direct teaching modes 35
4.3 How to use direct teaching with operation buttons
This section explains how to use direct teaching with operation buttons.
• Direct teaching can only be turned on when the robot is in AUTOMATIC mode or Collaborative operation
mode (standard operation or low-speed operation).
• Direct teaching cannot be turned on with the teaching pendant.
CAUTION
• Place an emergency stop switch in an easily accessible place near the robot. Connect the emergency stop switch to the external emergency stop terminals
of the robot controller.
• If the settings for the hand are not configured correctly, the arm may rise or fall when direct teaching is turned on. Furthermore, the safety functions may not
work properly. Ensure the settings are correct.
• Inertia may cause the robot arm to move. Do not release your hands from the robot arm until it stops completely.
• Workpiece settings are not enabled during direct teaching. The robot arm may fall depending on the weight of the workpiece. Do not release your hands from
the robot arm until it stops completely.
• If using one of the hand settings from HADDAT1 to HADDAT8 set in RT ToolBox3, be aware that the hand setting in the controller will be reset to HNDDAT0
if the controller's power is cycled. In this case, the arm may rise or fall as the correct hand settings will no longer be set.
2. Hold the [DIRECT TEACHING] button (for 2+ seconds) to turn on direct teaching. Check that the LED of the [DIRECT
TEACHING] button is on or the status indicator LED is on or flashing green.
3. Hold the robot arm directly with your hands, and move it to the desired position/posture.
4. Press the [DIRECT TEACHING] button once to change mode. The mode switches in the following order:
Joint free → Translational → Rotational → Joint free
5. Press the [TEACH] button once to teach the current position. Then, the current position is applied to RT VisualBox.
6. Hold the [DIRECT TEACHING] button again (for 2+ seconds) to turn off direct teaching. Check that the LED of the
[DIRECT TEACHING] button turns off or the status indicator LED changes from green to blue.
4 DIRECT TEACHING
36 4.3 How to use direct teaching with operation buttons
The LED behavior of the [DIRECT TEACHING] button is as follows.
• Off: Direct teaching is off
• On: Direct teaching is on (Joint free mode)
• Quick flashing: Direct teaching is on (Translational mode)
• Slow flashing: Direct teaching is on (Rotational mode)
(Rotational mode is supported with controller software version B1c or later.)
RT VisualBox is required in order to teach positions.
Direct teaching is turned off under the following conditions:
• If the robot arm is not moved for a certain period of time (the initial value is 60 seconds) after direct teaching
is turned on.
To change the time until direct teaching automatically turns off, change parameter DTTMR. 4
• When stop signals are input
• When a high or low level error occurs. For further information on errors, refer to the following manual:
Troubleshooting (BFP-A3480)
• If communication with RT VisualBox is lost for 30 seconds.
4 DIRECT TEACHING
4.3 How to use direct teaching with operation buttons 37
4.4 How to use direct teaching in RT VisualBox
This section explains how to use direct teaching in RT VisualBox.
• Direct teaching can only be turned on when the robot is in AUTOMATIC mode or Collaborative operation
mode (standard operation or low-speed operation).
• Direct teaching cannot be turned on with the teaching pendant.
CAUTION
• Place an emergency stop switch in an easily accessible place near the robot. Connect the emergency stop switch to the external emergency stop terminals
of the robot controller.
• If the settings for the hand are not configured correctly, the arm may rise or fall when direct teaching is turned on. Furthermore, the safety functions may not
work properly. Ensure the settings are correct.
• Inertia may cause the robot arm to move. Do not release your hands from the robot arm until it stops completely.
• Workpiece settings are not enabled during direct teaching. The robot arm may fall depending on the weight of the workpiece. Do not release your hands from
the robot arm until it stops completely.
• If using one of the hand settings from HADDAT1 to HADDAT8 set in RT ToolBox3, be aware that the hand setting in the controller will be reset to HNDDAT0
if the controller's power is cycled. In this case, the arm may rise or fall as the correct hand settings will no longer be set.
3. Tap/click the [Operate Robot] button to display the Robot Operation panel.
4 DIRECT TEACHING
38 4.4 How to use direct teaching in RT VisualBox
5. Tap/click the [Direct Teaching] switch in the Robot Operation panel to turn on direct teaching. Direct teaching will remain
enabled until the [Direct Teaching] switch is turned off.
Direct teaching is automatically turned off when switching to the Jog, Inching, or Joint windows, or when an
error occurs.
6. Hold the robot arm directly with your hands, and move it to the desired position/posture.
7. Tap/click the [Teach] button in the Robot Operation panel to teach the current position. RT VisualBox is required for it to
be possible to teach positions using this button.
4 DIRECT TEACHING
4.4 How to use direct teaching in RT VisualBox 39
8. Tap/click the [Direct Teaching] switch again in the Robot Operation panel to turn off direct teaching.
4 DIRECT TEACHING
40 4.5 Direct teaching parameters
5 PREVENTIVE MAINTENANCE FUNCTION
As a guide, it is recommended that the robot is overhauled before the servo ON time reaches the specified hours (robot arm:
36,000 hours, robot controller: 36,000 hours). Note that the degree of part wear and degradation may differ depending on the
environment. Use the following formulas to gauge how fast the robot operation will wear out the robot's parts. If the results
from the formulas indicate that the robot's parts will wear out quickly, address the issue by reducing the speed or using
another method. Otherwise, the robot arm may need to be overhauled before 36000 hours have passed.
5.1 Formulas
If a value larger than 1.0 is obtained by the following formulas, it indicates that the robot operation will wear the parts in a
shorter period of time than the number of hours specified.
Formula 1: Wear ratio of overhaulable parts [%] / (cumulative servo ON time [hours] / 36,000 [hours] 100)
Formula 2: Wear ratio of consumable parts [%] / (cumulative servo ON time [hours] / 36,000 [hours] 100) 5
5.2 How to check values
In the Variable Monitor window of RT VisualBox, you can check the wear ratio of overhaulable parts, cumulative servo ON
time, and wear ratio of consumable parts. Refer to the table below for formulas and their respective variables.
Formula Variable
Wear ratio of overhaulable parts [%] M_PMCsmOH
Cumulative servo ON time [hours] M_SrvOnTime
Wear ratio of consumable parts [%] M_PMCsmMnt
Operating procedure
1. In RT VisualBox, tap/click [Monitor] → [Variable Monitor] from the menu. The Variable Monitor window will appear.
2. Tap/click the [Add] button and enter "M_PMCsmOH" in the variable name input window. Then, tap/click the [Add] button.
3. Check that the variable has been added and its value appears in the window.
M_PMCsmOH
■Function
Returns the overall wear ratio of overhaulable parts (reduction gears, bearings, ball screws, and ball splines). (Unit: %)
■Syntax
Ex.
<Numerical variable> = M_PMCsmOH
■Term
<Numerical variable>: Specify a numerical variable to which a value is to be assigned.
■Reference program
1 M1 = M_PMCsmOH 'M1 indicates the overall wear ratio of overhaulable parts.
■Explanation
1. Returns the overall wear ratio of overhaulable parts (reduction gears, bearings, ball screws, and ball splines) used in the
robot (mechanism 1).
2. Read-only.
M_SrvOnTime
■Function
Returns the robot's cumulative servo ON time since the last overhaul. (Unit: hours)
■Syntax
Ex.
<Numerical variable> = M_SrvOnTime
■Term
<Numerical variable>: Specify a numerical variable to which a value is to be assigned.
■Reference program
1 M1 = M_SrvOnTime 'M1 indicates the cumulative servo ON time of the robot (mechanism 1).
■Explanation
1. Returns the cumulative servo ON time of the robot (mechanism 1). "Cumulative time" indicates the time since the last
overhaul.
2. Read-only.
■Syntax
Ex.
<Numerical variable> = M_PMCsmMnt
■Term
<Numerical variable>: Specify a numerical variable to which a value is to be assigned.
■Reference program
1 M1 = M_PMCsmMnt 'M1 indicates the overall wear ratio of consumable parts.
■Explanation
1. Returns the overall wear ratio of consumable parts (grease and timing belts) of the robot (mechanism 1) . 5
2. Read-only.
Low speed
space 1
(AREA1 input)
Stand
Operating
space A
Low speed
space 2
(AREA2 input)
Machine guard
(Area where entry of
Area sensor 1 human is prohibited)
(DSI1)
The safe stopping distance (ddec) can be calculated using the following variables: human speed (Vh), time from detection of
human in monitored area until deceleration initiation (Tres), Max. time from deceleration initiation until deceleration stops
(Tmax), and a safety factor of 1 or more (). The formula used to calculate the safe stopping distance is as follows:
ddec = Vh (Tres + Tmax)
In the following conditions, the safe stopping distance is 2259.68 [mm]. This is the distance required between the operating
space border and monitored space border.
• Movement speed of humans Vh: 1600 [mm/s]
• Deceleration start time Tres: 132.3 [ms] + 10 [ms]*1
• Maximum deceleration time Tmax: 1.27 [sec]
• Safety factor : 1.0
*1 Reaction time of the area sensor (example). Check the specifications of the area sensor used.
APPX
Appendix 1 Safe stopping distance 45
MEMO
APPX
46 Appendix 1 Safe stopping distance
REVISIONS
*The manual number is on the bottom left of the back cover.
Revision date *Manual No. Description
April 2020 BFP-A3735 First edition
October 2020 BFP-A3735-A Added Rotational mode to direct teaching.
July 2021 BFP-A3735-B Revised "4.1 Operation rights".
April 2023 BFP-A3735-C • Corrected "2.3 Specifications".
• Corrected "2.4 Differences from FR Series".
June 2023 BFP-A3735-D • Corrected "2.3 Specifications".
This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot
be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual.
This document was created by Mitsubishi Electric.
This is the original document.
47
TRADEMARKS
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The company names, system names, and product names mentioned in this manual are either registered trademarks or
trademarks of their respective companies.
In some cases, trademark symbols such as '' or '' are not specified in this manual.
48
BFP-A3735-D(2306)MEE
HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
NAGOYA WORKS: 1-14, YADA-MINAMI 5-CHOME, HIGASHI-KU, NAGOYA 461-8670, JAPAN