HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY

GRADUATION THESIS

APPLICATION OF COLLABORATIVE ROBOT IN

ASSEMBLING CAR’S COMPONENTS
PHAM NGOC SON
son.pn163564@sis.hust.edu.vn

NGUYEN QUANG VINH

vinh.nq164689@sis.hust.edu.vn

Instructor: PhD. Nguyen Thu Ha

Signature
Department: Automatic Control
School: Electrical Engineering

HANOI, 07/2021
MINISTRY OF TRAINING AND EDUCATION SOCIALIST REPUBLIC OF VIETNAM
HANOI UNIVERSITY OF SCIENCE AND Independence – Freedom – Happiness
TECHNOLOGY –––––––––––––––––
––***––

GRADUATION THESIS ASSIGNMENT

Student Name: PHAM NGOC SON 20163564

Course: 61
School/Department: School of Electrical Engineering
Major: Automatic Control
1. Topic:
Application of collaborative robot in assembling car’s components.
2. Design content:
• Make a study of Industrial Robot
• Research about structure, principle of operation of collaborative robot
Omron
• Pick and place application: Assembling relays in car’s fuse box
3. Instructor: Ph.D Nguyen Thu Ha
4. Assign date:
5. Finishing date:

......./......../2021
HEAD OF DEPARTMENT INSTRUCTOR
(Signature and full name) (Signature and full name)

STUDENT
(Signature and full name)
 Acknowledgement

This graduation project has been completed in 5 months, from February 22, 2021
to June 28, 2021. With the thoughtful instruction from teachers, we have been
able to complete this project:
“Application of collaborative robot in assembling car’s components”
First of all, we would like to express our most sincere thanks to our instructor –
Mrs. Nguyen Thu Ha - who gave us various of useful guides and enthusiastic
supports during the implementation of this graduation project.
Secondly, we would like to thank to the director and colleagues of Cuong Linh
Trading and Technical Service Co., Ltd, where we were assigned a professional
apprenticeship. Especially, Mr. Nguyen Xuan Son who directly lead us to
participate, study the practical equipment and work tasks at company.
Last but not least, we would like to thank the Department of Automatic Control
for enabling us to have this important and rewarding graduation project. Finally,
we are grateful that our families and friends provide us supports and help to
complete our project. Thank you all for everything!
Due to the limited time and practical knowledge of a student, this thesis can not
avoid shortcomings. We look forward to receiving the advices and suggestions
from the teachers so that we have the opportunity to supplement our knowledge,
better at practical work in the future.
Our Sincerely.
Hanoi, July, 2020
 Abstract

The project target is to make a study of collaborative robot and apply to assembly
car components. In order to achieve this purpose, the implementation to the
problem is organized as follow:
1. Research the brief history, structure and some applications of
industrial robot.
• Industrial robots play an important role in today's industrial
production lines. Understanding the structure and operating
principle will help a lot in the process of designing and using
robots.
2. Introducing and programming the TM14 OMRON collaborative
robot.
• Hardware: Structure and specifications of TM14 Cobot.
• Software: TMflow-Specialized software to program the Cobot
OMRON.
3. Applying to the problem of assembling relays in car fuse boxes.
• Study structure and how the car fuse box works.
• Program the robot arm to perform the process of fitting the relay to
the fuse on TM flow software.
4. Practical results
• Scientific significance: Theoretical research on structure,
operational process of an industrial robot as well as collaborative
robot.
• Practical significance: The thesis contributes to factual application
for assembling relays in the fuse box.
 TABLE OF CONTENT

Introduction to Industrial Robot ............................................... 1

1.1 Development history .................................................................................. 1
1.2 Robot Classification ................................................................................... 1
Classification of robots by the geometry of the active space ..... 1
Classification of robots by generation ........................................ 3
1.3 General structure of industrial robot .......................................................... 4
Basic components ....................................................................... 4
Manipulator ................................................................................. 5
Drive system ............................................................................... 7
Controller .................................................................................... 9
1.4 Controlling AC Servo Motor ................................................................... 10
Control Servo Motor Configuration.......................................... 10
Function of Servo Motor Drive ................................................. 10
Servo Motor Control Signal ...................................................... 11
Feedback in Servo Motor System ............................................. 11
Control Loop of Servo Motor ................................................... 12
Encoder ..................................................................................... 13
1.5 Applications of industrial robots .............................................................. 13
Robot application in material transportation and handling ....... 13
Applications in the field of material processing ....................... 14
Robot application in product assembly and inspection ............ 15
Overview of Collaborative Robot Omron ............................... 17
2.1 System Hardware ..................................................................................... 17
Robot arm .................................................................................. 17
Control box ............................................................................... 20
2.2 Software ................................................................................................... 22
Overview ................................................................................... 22
Connection ................................................................................ 22
Operation Interface ................................................................... 23
Point and Base ........................................................................... 23
Assembling relays in car’s fuse box ......................................... 27
3.1 What is a Fuse Box? ................................................................................. 27
3.2 How automotive relays and fuses work? ................................................. 27
Relays ........................................................................................ 27
Fuses.......................................................................................... 28
3.3 Programming with TM14 Collaborative Robot ....................................... 29
Problem Proposal ...................................................................... 29
Object ........................................................................................ 29
Programming ............................................................................. 30
CONCLUSION .......................................................................... 38
4.1 Thesis summary ....................................................................................... 38
4.2 Direction of the project development....................................................... 38
REFERENCES ................................................................................................... 39
APPENDIX ......................................................................................................... 40
 LIST OF FIGURES
Figure 1.1 Rectilinear Robot .................................................................................. 2
Figure 1.2 Cylindrical Robot.................................................................................. 2
Figure 1.3 Spherical robot ...................................................................................... 3
Figure 1.4 Articulated Robot.................................................................................. 3
Figure 1.5 Structure of Industrial Robot ................................................................ 5
Figure 1.6 Manipulator structure............................................................................ 5
Figure 1.7 Robot arm [1] ........................................................................................ 5
Figure 1.8 Robot’s wrist [1] ................................................................................... 6
Figure 1.9 Robot using Hydraulic drive system .................................................... 8
Figure 1.10 Robot using Pneumatic drive system.................................................. 9
Figure 1.11 Servo motor control signal [2] .......................................................... 11
Figure 1.12 Control loop [2] ................................................................................ 12
Figure 1.13 Closed-loop system [2] ..................................................................... 12
Figure 1.14 Stacking box on a pallet .................................................................... 14
Figure 1.15 Arc welding system [1] ..................................................................... 15
Figure 1.16 Robot in installing multi-pin semiconductor elements ..................... 16
Figure 2.1 Robot assembly diagram [3] ............................................................... 17
Figure 2.2 TM14 payload diagram [3] ................................................................. 18
Figure 2.3 Robot End Effector [3] ....................................................................... 19
Figure 2.4 EIH camera [3] ................................................................................... 20
Figure 2.5 Robot stick [3] .................................................................................... 20
Figure 2.6 Electrical Interface [3] ........................................................................ 21
Figure 2.7 Wired network connection method [3] ............................................... 22
Figure 2.8 TM flow interface [4] ......................................................................... 23
Figure 2.9 Base value of the point [4] .................................................................. 23
Figure 2.10 Right-hand Base [4] .......................................................................... 24
Figure 2.11 Robot base [4] ................................................................................... 25
Figure 2.12 Servoing vision base is on the Camera [4] ....................................... 25
Figure 2.13 Fix-point vision base is on the object [4] ......................................... 25
Figure 2.14 Tool coordinate [4] ........................................................................... 26
Figure 3.1 Fuse box .............................................................................................. 27
Figure 3.2 Relays ................................................................................................. 28
Figure 3.3 Type of fuses....................................................................................... 28
Figure 3.4 The difference between good and blown fuse .................................... 29
Figure 3.5 Algorithm diagram.............................................................................. 30
Figure 3.6 Vision node [5] ................................................................................... 31
Figure 3.7 TM landmark ...................................................................................... 32
Figure 3.8 Calibration plate [5] ............................................................................ 32
Figure 3.9 Relay pattern ....................................................................................... 33
Figure 3.10 Classification result .......................................................................... 34
Figure 3.11 Point to point example [4] ................................................................ 34
Figure 3.12 Line example [4] ............................................................................... 35
Figure 3.13 Variables list ..................................................................................... 35
Figure 3.14 Main function on TMflow ................................................................ 37

LIST OF TABLE
Table 1-1 Basic types of joints ............................................................................... 1
Table 2-1 Specifications of TM Robot arm [3].................................................... 18
Table 2-2 Function of Robot stick [3] .................................................................. 20
Table 2-3 Specification of control box [3] ........................................................... 22
 Introduction to Industrial Robot

Nowadays, the need to improve productivity and product quality is increasingly

demanding the wide application of production automation means. The trend of
creating highly flexible automatic equipment lines is growing. Therefore, this
first chapter covers the brief history, structure and some applications of industrial
robot.
1.1 Development history
The term "Robot" appeared in 1920 in a literary work of Czechoslovakian writer
Karel Capek. The term Industrial Robot(IR) first appeared in the US by the AMF
(American Machine and Foundry) company advertising to simulate a device that
looks and has some functions like a human hand; which is automatically
controlled to perform a certain task called Vesatran.
The development process of IR is summarized as follows:
• From the 1950s in the US appeared the first research institute.
• In the UK, people started researching and manufacturing IR under US
copyright since 1967.
• In other western European countries such as Germany, Italy, France,
Sweden, they started to produce IR since the 1970s.
• Asia has Japan, which started researching IR applications in 1968.
• Up to now, there are over 200 IR manufacturing companies in the world,
among which there are 80 Japanese companies, 90 Western European
companies, 30 US companies and some Russian and Czech companies...
1.2 Robot Classification
Classification of robots by the geometry of the active space
The joint is the link between two connecting rods with the function of
transmitting motion to perform the robot's movement. Some basic types of joints
used in robots show in the table below:
Table 1-1 Basic types of joints

Number Name Symbol Diagram Relative

DOF
1 Ball joint S 3

2 Slip joint T 1

3 Rotary joint R 1

4 Cylindrical C 2
joint
5 Threaded H 2
joint

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• Rectilinear Robot has 3 orders of translational motion along 3
perpendicular axes.

Figure 1.1 Rectilinear Robot

X- horizontal, left and right motions

Y- Vertical, up and down motions
Z- horizontal, forward and backward motions
• Cylindrical Robot has 3 basic motions including 2 translational motions
and 1 rotational motion.

Figure 1.2 Cylindrical Robot

X- Horizontal rotation of 360°, left and right motions

Y- Vertical, up and down motions
Z- Horizontal, forward and backward motions

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• Spherical robot includes 1 translational motion and 2 rotational motions

Figure 1.3 Spherical robot

X- Horizontal rotation of 360°, left and right motions

Y- Vertical rotation of 270°, up and down motions
Z- Horizontal, forward and backward motions
• Articulated robot has 3 rotational motions

Figure 1.4 Articulated Robot

X- Horizontal rotation of 360°, left and right motions

Y- Vertical rotation of 270°, up and down motions
Z – Horizontal & vertical rotation of 90° to 180°, forward and backward
motions
Classification of robots by generation
• First-generation robots: include types of robots that operate repeatedly in a
constant cycle, according to a predetermined program

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 Characteristic:
- Using switches and pistons
- Opened-loop control
- Commonly used in pick-place applications
• Second-generation robots: robot with programmed control but can self-
adjust to adapt to changes in the operating environment (equipped with
sensors that allow feedback to the control system)
Characteristic:
- Closed-loop control of manipulator movements
- Program can be selected based on sensor feedback
- The robot's operation is programmable
• Third-generation robots: The robots are equipped with algorithms that
handle adaptive logical reflexes according to information and the impact
of the environment on them; so the robot knows what to do to complete
the job that has been set for them; equipped with an image acquisition
system in the control (vision systems- camera).
Characteristic:
- Has low-level recognition capabilities such as distinguishing
objects of quite different shapes and sizes.
- Control base on processing information that received from vision
system.
• Fourth-generation robots: Includes robots using adaptively controlled
robots and algorithms that are initially equipped with the ability to select
responses according to a defined computational model in order to generate
behaviors which are suitable for the conditions of the operating
environment.
Characteristic:
• Capable of reprogramming operations based on the signals received
from the sensor.
• Has relatively large memory to solve optimization problems with
undefined boundary conditions.
1.3 General structure of industrial robot
Basic components
Some basic components of robot arm include:
• Manipulator: are the mechanical structures that include the skeleton of the
entire robot arm and the engines that perform the task. This component is
main responsible for the work.
• Drive System: it can be electric, hydraulic, pneumatic supplying the
working mechanism.
• Controller: The controller is responsible for controlling all the arm's
operations.

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 Figure 1.5 Structure of Industrial Robot

Manipulator
Is a mechanical structure consisting of stitches and joints. They form arms to
create the basic movements, the wrist for dexterity and flexibility, and the hand
(End Effector) to directly complete operations on the object.

Figure 1.6 Manipulator structure

a) Degrees of freedom (DOF) of the robot arm

The degree of freedom of a manipulator is number of independent motions in the
active space.
To improve flexibility, manipulators must have a high number of DOFs, but it
should not exceed 6. Six DOFs usually include 3 basic movements (positioning
motion) and 3 additional movements (directional movement).

Figure 1.7 Robot arm [1]

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The positioning motions are usually reciprocating or rotating, each step of the
movement has its own source of drive.
Additional movements are usually rotations to increase flexibility.
b) Robot’s wrist rotation (or additional movements)
In addition to the three basic movements to perform positioning movement, the
manipulator will be supplemented with a maximum of three additional
movements in the form of three motions about three perpendicular axes,
including:
- Wrist Roll
- Wrist Yaw
- Wrist pitch

Figure 1.8 Robot’s wrist [1]

c) Robotic Hand (End effector)

The robotic hand attached to the robot's wrist ensures that the robot performs
various tasks in the workspace. The hand mechanism has two different forms
according to the function of the robot in the production line: the gripper
mechanism and the tool mechanism.
• Gripper: used to hold an object or part in robots in assembly lines,
packaging combined with conveyors.
o Objects also come in different types and shapes: bottles, boxes of
raw materials...
o Gripper normally consists of two or more fingers. Fingers function
is to convert some form of energy (electrical, mechanical,
pneumatic or hydraulic) by means of an actuator into force to hold
an object. It is capable of opening, closing fingers and producing
enough force to hold an object in the hand.
• Tools: In many production lines, robots perform tasks like a tool for
metalworking or a special technology such as painting, welding… To

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 implement these technologies, the tool can be clamped on the robot hand
or a tool is fixed to the robot's wrist. Some types of tools are: drill bit,
cutting tool, grinding wheel, spot welding mechanism, arc welding…
Coupling between robot and hand: Normally, the robotic hand is mechanically
coupled to the wrist by means of a flange. That coupling structure must satisfy
three requirements: rigidity, flexibility and overload protection. The robotic hand
needs energy to perform the tasks of the technological chain and control signals
to modify the operation of the hand mechanism. The main methods of
transmitting energy and signals to the hand are: pneumatic, electrical, hydraulic
and mechanical; in which the pneumatic transmission method is the most widely
used.
Drive system
Drive system used to create motion for the steps of the manipulator. The driving
source of the actuators is the motor of all kinds: electric, hydraulic, pneumatic or
combined. Movement of the joints in the manipulator is performed by the drive
system, it has the following parts: power supply, amplifier power, engine, engine
transmission.
Electric drive system
The electric drive system in a robot is a set of devices including electrical,
electro-magnetic and electronic equipment for converting electrical energy into
mechanical energy.
In robotics, many different electric motors can be used, but in fact, there are two
most common types: DC motor and AC motor
a. DC motor
DC motor has 2 main parts: Stator and rotor
There are 4 commonly used DC motor:
- Separately excited dc motor
- Shunt wound DC motor
- Series wound DC motor
- Compound wound DC motor
b. AC motor
Produced in many different models and capacities which can be divided into two
types: 3-phase and 1-phase motors.
- 3- phase AC motor: The rotating magnetic field is created by passing a
three-phase current into three electromagnets that are placed apart on a
circle. When the motor is connected to a three-phase network, the rotating
magnetic field caused by the stator causes the rotor to rotate on the axis.
The rotation of the rotor is transmitted out by the machine and used to
operate the machine tools or other moving devices.
- 1-phase AC motor: The stator of this type of motor consists of two
windings set apart at an angle, one wire is connected directly to the
electrical network, the other wire is connected to the electrical network

7
 through a capacitor. This connection causes the two currents in two coils
are out of phase and create a rotating magnetic field. Single-phase motors
only achieve small, medium power.
• Advantages:
o Fast and precise action
o Apply complex control techniques
o High torque, reduced weight and fast response
• Disadvantages:
o Quite high speed
o Cause overheating when overloaded
o Need to use brake to pin position and joint
Hydraulic drive system

Figure 1.9 Robot using Hydraulic drive system

Hydraulic system transmits motion by means of pressure or kinetic energy

of the liquid stream. It is divided into two types:
- Dynamic hydraulic transmission system: Working based on controlling
the kinetic energy of the fluid flow.
- Volumetric hydraulic transmission system: Working based on controlling
potential energy of the fluid (the flow of the fluid).
• Advantages:
o High load
o Small inertia, easy to change motion
o Easy to control automatically
• Disadvantages:
o Quite big compare to pneumatic and electric drives
o Large investment cost
o Not suitable for fast rotating mechanism

8
 Pneumatic drive system

Figure 1.10 Robot using Pneumatic drive system

Pneumatic drive system: widely used in the mounting industry assembly and
processing, especially in areas where hygiene, explosion-proof or toxic
environments are required. For example, the field of electronic assembly; food
processing; the stages of product classification and packaging belong to
automatic production lines. There are 2 types of drives using pneumatic: straight
drive and rotary drive.
• Advantages:
o Compact
o Easy to use and turn around
• Disadvantages:
o The movement is often accompanied by oscillation, requiring
additional lubricating equipment.
o Difficult to control speed, inaccurate stopping.
Controller
The robot controller consists of a central processing unit, memory and
input/output unit combined with a display screen divided into modules.
a) Central processing unit (CPU)
The center of the controller is a CPU which is responsible for managing
information about memory, managing input and output, processing information
and controlling each axis of the robot; then implement control algorithms and
output control signals to the signal converter.
It can be:
• Using a whole small computer
• Using existing computer circuit modules
• Using an 8 or 16-bit processor
• Using a separate computer to communicate with the robot controller

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 b) Memory
Memory used to store programs and feedback from the operating environment
c) Input/output unit
• I/O is used to put the program into the processor, check and monitor the
operation during manipulation.
• I/O usually includes a monitor, keyboard, and communication ports
d) Types of controller
• Robot controller in open system
Open-loop system is also known as non-servo system. Open control uses
step motion where the distance or angle of displacement is proportional to
the number of control pulses. This type is simple, but low accuracy.
• Robot controller in close system
Closed-loop system is also known as servo system. Closed control uses
position feedback to increase control accuracy. There are two types of
servo control: point-to-point control and line control (contour)
- Point-to-point control: robot moves from one point to another in a
straight line at a low speed. It only works at breakpoints. This type
of control is used on spot welding, transport, riveting, nail shooting
robots…
- Line control (contour) ensures that the robot moves in any
trajectory, at a controllable speed. This type of control can be
encountered on arc welding and paint spraying robots.
1.4 Controlling AC Servo Motor
The difference of AC Servo Motor from conventional motors is that it is
integrated with many electronic tools and sensors to transmit information and
control such as amplifiers, controllers, encoders and monitors. This increases
accuracy as well as ease of control, which is one of the requirements for
industrial production in the current era of industrial revolution 4.0.
Control Servo Motor Configuration
A servomotor is a linear actuator or rotary actuator that allows for precise control
of linear or angular position, acceleration, and velocity.
For correct operation, the servo motor must be combined with:
➢ Controller: is used to run the specific program to satisfy system
requirements.
➢ Motor drive: Electronic device sufficiently supply energy to motor.
➢ Encoder: generates feedback for motor operation.
Function of Servo Motor Drive
The main task of servo motor is to supply energy sufficiently at the right time
with the right amount to control position, speed and torque correspond to input
from controller and the feedback from encoder.

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Also, the servo drive is responsible for receiving command signal (pulse) from
controller and transmitting the command to the servo motor to control the servo
motor to operate according to the command. At the same time, it continuously
receives the current position and speed of servo motor from encoder. From the
feedback signal, the servo drive will compare with the command signal and make
appropriate adjustments, ensuring the servo motor works properly as required.
The sub-task of servo drive is processing I/O signal from safety devices or output
signal of operational status.
Servo Motor Control Signal
Depend on requirement for controlling servo motor, the controller receive signals
to perform a specific motion.
Signal from use to control servo has the following types:
• Analog signal.
• Pulse signal.
• Serial packet signal.

Figure 1.11 Servo motor control signal [2]

Feedback in Servo Motor System

The Servo motor system use a close loop feedback system to perform the
operation.
Reference input/command receives input or task from the user. After that, the
programmable position controller interprets this data and turns it into discrete
electric signals to send to the motor to perform the task. The amplifier increases
this signal so that is powerful enough to drive the motor.
The feedback encoder compares practical position, velocity, torque to the input
data to determine errors. The programmable controller uses this error to modify
the operation of the system to make the system operate accurately as required.

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 Figure 1.12 Control loop [2]

Control Loop of Servo Motor

Servo motors operate in a closed-loop system, which includes a feedback device,
an amplifier, and a controller.
The controller uses output from the feedback device to compare the commanded
value (position, velocity, or torque) to the achieved value and issues commands
to the drive to correct any errors. This process of monitoring feedback and
making corrections is referred to as a control loop.
Depending on the application and performance requirements, a servo system can
include any combination of three types of control loops: a position loop, a
velocity loop, and/or a current loop.

Figure 1.13 Closed-loop system [2]

a. Current loop:
Current control is needed when the system requires time response. The primary
goal of the current loop is to control torque, which influences speed, and
therefore, position.
The current loop takes a current command (usually just the output of the velocity
loop) and compares it to a current feedback signal and generates an output that is
essentially a voltage command. If the system needs more torque, the current loop
responds by increasing the voltage applied to the motor until the right amount of
current is produced.

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 b. Velocity loop:
The velocity loop is the most common servo control loop. It compares the
commanded velocity to the actual velocity via an encoder and issues commands
to increase or decrease the motor’s speed accordingly. The velocity loop
produces a torque command to minimize the error between velocity command
and velocity feedback.
c. Position loop:
The position of servo motor can be described as the absolute angular position of
the servo motor shaft, or in some cases, is the position of the device driven by the
servo motor.
The position loop determines the following error, which is the deviation between
the actual and commanded positions, and issues velocity commands to reduce or
eliminate the following error. For applications that require control of position, a
position loop can be added in cascade or series with the velocity loop. In a
cascaded system, the position loop typically uses only a proportional gain.
Encoder
Encoder is a sensing device that provides feedback about rotation angle and
linear displacement. It converts motion to an electrical signal that can be read by
controller. That signal can be called as feedback signal that can be used to
determine position, count, speed, or direction.
There are 2 types of encoders:
• Incremental encoder.
• Absolute encoder.
1.5 Applications of industrial robots
Robots are widely used in many different industries. Industrial applications of
robots can be classified into the following main areas: transportation, material
handling, machining, exploration assembly and etc…
Robot application in material transportation and handling
In the transport application, the robot is responsible for moving the object from
one location to another. This task of the robot is performed by picking and
placing objects. The robot picks up the part from one location and transfers it to
another. The robot can pick up a part in a fixed position or on a moving conveyor
and place it in another fixed position or place it on another moving conveyor
with part orientation. The robot is capable of loading and unloading and
transporting parts of different shapes and sizes thanks to standard part
information stored in memory, and the robot uses sensors to recognize the real
part. In the production line, robots are used to take the part in and take the part
out of a metalworking machine, CNC machine, plastic injection machine or
casting line. In the packaging stage, the robot is responsible for stacking
materials (rectangular blocks) on a shelf (pallet) and packing; unloading
materials from pallets; put products in a carton or pick up parts out of the box.

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 Figure 1.14 Stacking box on a pallet

Applications in the field of material processing

In the material processing industry, robots perform tasks like a machining
machine. The robot arm therefore attaches a tool instead of a clamping
mechanism (gripper). Applications of robots in the material processing industry
include the following technologies: spot welding, continuous arc welding,
coating, metalworking technology.
Spot welding is a common application of robots in the automotive
assembly industry. The robot hand will attach a spot welding gun and the robot
will be programmed to perform the welding sequence on the product. At the car
assembly line, dozens of spot welding robots will work together according to a
preset program. The spot welding robot must be large in size and capable of
carrying loads to control the high-volume welding gun accurately. The benefits
of automating spot welding technology using robots are improved product
quality, safer operation and better control of the welding process.
Arc welding used in line welding technology: joining two parts of metal
or welding pipes, welding wheel rims... The working environment for arc
welding worker is very dangerous and toxic: high temperature, ultraviolet rays
generated during welding will cause danger to human’s eyes. The use of robots
in the arc welding industry will greatly improve human working conditions,
while improving productivity and product quality. Due to some technical
problems such as improving welding quality when there is a change in the
composition of the welding consumables and economic problems, robots are only
used in arc welding technology in production lines which have medium and large
output.
Surface coatings using robots are popular in industry to replace humans to
improve working conditions. A paint spray gun is mounted on the robot arm. The
controlled parameters are spray paint flow and pressure. In the industrial robot is

14
used to paint the surface of automobiles, machine equipment surfaces, household
appliances, etc. In the production line, the painting robot is a part of the system,
working with conveyor systems carrying parts to be painted. Therefore, the
synchronous work between the painting robot and other stages in the line is also
set out in the design of automation of the paint line.
In addition to the above basic applications, robots are also used in metal
processing lines such as drilling, grinding, polishing, in electric spark cutting
machines, laser cutting.

Figure 1.15 Arc welding system [1]

Robot application in product assembly and inspection

Assembly technology is the fitting of a part into another part. Robots are used in
conventional assembly lines in the following four forms: hole-in-hole, hole-in-
piece, multi-pin-hole assembly, and stack mounting.
• At the stage of inserting the part into the hole, the robot picks up a part to
fit into another machine part. The part can be round cylinder or
rectangular box. Robots used in general assembly have 5-6 degrees of
freedom to be able to precisely fit the right angle of the hole into the
corner of the hole.
• In the semiconductor production line, robots are used to install multi-pin
semiconductor elements into positions on electronic circuit boards. In this
application, the robot requires a high number of degrees of freedom to be
able to position and orient any part on the circuit board.
• The final form is stack mounting, which the robot will install the part on
top of the part in a stack or a slot. For example, mounting thin steel plates
of DC motor hardware.
In the assembly industry, robots can work alone to complete a piece of
equipment or work in a line, in which each robot will be responsible for
assembling a part in a machine device.

15
Robots are also used in testing and inspection. One of the applications is
coordinate measurement machine (CMM). CMM machines are widely used to
check the size, position and shape of machine parts or mechanical parts. In the
automotive manufacturing industry, CMMs are used to measure and inspect
automotive components. In the steel smelting industry, CMMs equipped with 3D
sensors to determine dimensions will be used for accurate measurement in high
temperature environments. Thereby reducing production costs by saving
redundant materials.

Figure 1.16 Robot in installing multi-pin semiconductor elements

16
 Overview of Collaborative Robot Omron

In industry, many production lines require us to identify, sort and select product
to package. Using human resource do not guarantee having high productivity and
accurate yet, in addition consume much money on salary. Therefore, the Omron
Tm collaborative robot is designed to work with both humans and machines, this
robot is the latest in a long line of innovations in automation technology for
industrial applications. Safe and transportable, with built-in vision, this robot
allows for quick start-ups and rapid changeovers. Its intuitive software enables
the robot to be easily trained to perform almost any task wherever you may need
it. In this chapter, structure and operation of collaborative robot Omron are
presented.
2.1 System Hardware
This chapter introduces the mechanical interface of the TM Robot System. TM
robot is made up of the robot arm and control box (including a robot stick).
Robot arm
As introduced in the previous chapter, the robotic arm plays an important role in
the collaborative robot system.

Figure 2.1 Robot assembly diagram [3]

TM14 series are the robots which have 6 degree of freedom to improve dexterity
and flexibility. Six DOFs usually include 3 positioning movements and 3
directional movements. The figure above shows us 6 joints and each joint has its
own source of drive. At the end of robot arm, a camera is attached that makes the
robot work more informative as images are transmitted directly through the
camera to the controller without using external vision.

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To operate the robot safely and efficiently, we need to take care of the robot's
specifications. The table below will indicate some parameters:
Table 2-1 Specifications of TM Robot arm [3]

Name TM14 TM14M TM14M SEMI

Weight (Kg) 32.6
Max payload (kg) 14
Reach (mm) 1100
Joint Joint 1 ±270°
Range Joint 2, 4, 5 ±180°

Joint 3 ±163°
Joint 6 ±270°
Joint Joint 1,2 120°/s
Speeds Joint 3 180°/s
Joint 4,5 150°/s
Joint 6 180°/s
Integrated Camera 5M pixels, 5M pixels, 5M pixels,
color color color
Power supply 100-240 22-60VDC 22-60VDC
VAC, 50-
60Hz
Payload
The maximum allowed payload of the robot arm is related to its center of gravity
offset, which is defined as the distance from the center point of tool flange to the
payload’s center of gravity.
The following figure shows the relationship between payload and the center of
gravity offset:

Figure 2.2 TM14 payload diagram [3]

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 Robot end module components
On the robot end module is equipped with push buttons which provides the
convenience to move the robot as well as shortens the robot movement time
while programming:
+ Hold the FREE Button on the End Module to release the brakes and manually
move the robot to a relatively safe position by hand guiding.
+ Press the POINT Button to let the project flow generate the point.
+ Press the VISION or GRIPPER button to use vision and gripper node in TM
flow.
Whenever you hold or press any button above, these nodes will appear
respectively with the name of the button in TM flow.

Figure 2.3 Robot End Effector [3]

TM Robot’s EIH camera

The TM Robot's built-in Vision Designer system integrates hands, eyes and
brains of conventional robots into one. This not only enables users to execute
high precision jobs but also provides flexibility for fast line changes. We can
move the robot to right above the object and press the Vision button on the
camera to generate a Vision node in TM flow for subsequent visual job
programming.
The field of view of TM Robot’s EIH camera varies linearly in accordance with
the working distance. The minimum working distance is about 100 mm and the
maximum working distance is about 300 mm. The zero working distance point is
approximately 49 mm in front of the flange surface and right behind the center of
the protection lens.

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 Figure 2.4 EIH camera [3]

Control box
Robot stick

Figure 2.5 Robot stick [3]

The Robot Stick has 6 function buttons, 3 indicator lights, 1 Emergency Switch,
and 1 QR-code. Their functions are as follow:
Table 2-2 Function of Robot stick [3]

Items Basic function

Emergency Default emergency button for the robot
Switch
Power button Power initiation (single press)/ Shutdown (long
press)
M/A Mode Toggle Manual/Auto Mode (single press)
Switch Button
Play/Pause Play/Pause Project
Button
Stop Button Press this button to stop any project.
+- Button Adjust project speed (single press) under Manual
Trial Run Mode.
Power Indicator This indicator shows the robot's power status.
Not on: Switched off
Flashing: Booting
Constant: Startup completed

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 Mode Indicator One is Manual Mode, the other one is Auto Mode.
Lights They show the robot's current operating mode. Once
boot up is complete only one will always be on
QR Code Label The content of the SSID is also the robot's name in
TCP/IP network.
• Emergency switch: If any accidents occur during the operation of the
robot, the user can stop all movement by pressing the Emergency Switch.
When the robot stops, the user must ensure that all fault conditions are
eliminated before manually restarting the robot. The Emergency Switch is
only used in critical conditions. When the user presses the emergency
switch, the TM Robot product will disconnect the power of robot and
activate the brake after the robot motion is stopped. The indication light
ring of the robot will not display light, and the three lights from the robot
stick will be constantly blinking.
• To stop the robot during normal operations use the Stop Button on the
system controller.
• When the robot performs trial run in Manual Mode, the project speed will
start with the initial speed at 5%. Therefore, in the process of teaching
robot, we have to choose manual mode.
Electrical Interface

Figure 2.6 Electrical Interface [3]

The control box is designed with I/O for connecting to peripheral devices.
• Digital I/O: Inputs and outputs can be set to either sink or source by
selection.
• The USB port of the control box is used for connecting the keyboard,
mouse and external storage devices.

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 Table 2-3 Specification of control box [3]

Power supply 100-240 VAC, 50-60Hz

I/O ports Control box Digital In: 16
Digital Out: 16
Analog In: 2
Analog Out: 1
I/O Interface 3xCOM, 1xHDMI, 3xLAN,
4xUSB 2.0, 2xUSB 3.0
Communication RS232, Ethernet(master),
Modbus TCP/RTU (master
& slave)
I/O power supply 24V 1.5A (control box,
tool)
2.2 Software
Overview
TM flow is a graphical HMI. Its purpose is to provide users with a complete,
convenient and simple interface for robot motion and logic programming
environments. Through the graphical HMI, users can simply manage and set the
parameters of the robot, and use the graphical flow chart to plan the robot
movement and process logic.
Connection
To program robot, we have to connect TM flow and the TM robot in ways as
below:
➢ Connect with the monitor, keyboard and mouse to the Control Box. This
enables to start TM flow.
➢ Download the TM flow Client from customer area of the official website,
and then install it on a Windows-based computer (e.g. Windows Laptop/
Windows Tablet). Connect to the robot in a wired or a wireless network.
In our project, we connect laptop with the TM robot using wired network
connection method.

Figure 2.7 Wired network connection method [3]

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 Operation Interface
This part will introduce the operation interface of TM flow, including the icons
in the function menu: Login/Logout, Connect, View, Run Setting, Project,
Setting, and System.

Figure 2.8 TM flow interface [4]

Point and Base

Overview
In the project of any point in three-dimensional space is the position of the point
on the Base.

Figure 2.9 Base value of the point [4]

To describe a point, in addition to X, Y, Z coordinate positions, it is also

necessary to define its direction in the space Rx, Ry, Rz to describe the posture of
the point in the space. The Base is a system that defines the corresponding
position and posture of the robot in three-dimensional space. In the TM Robot,
Base is divided into four categories: Robot Base, Custom Base, Tool Coordinate,
and Vision Base.

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This part will define the physical meaning of the Robot Base, so that users can
understand the Base of robot, and use the controller system to move the robot in
the specified Base.
Base and Right-hand Rule
a) Right-hand Rule
The Right-hand Rule is a method of determining the direction of the three-
dimensional Base. In the system of Base of robot, the right-hand coordinate
system can be used to determine the positive direction of the Z-axis, as shown in
the illustration, the thumb, index finger, and middle finger represent the right
hand coordinate X-axis, Y-axis, and Z-axis respectively, and three fingers are
perpendicular to each other. In addition, the Right-hand Rule also determines the
positive rotation direction of the coordinate axis in the three-dimensional space,
bending finger. The direction pointed by the finger is the positive rotation
direction of the coordinate axis.

Figure 2.10 Right-hand Base [4]

b) Types of Base
The Bases defined in the robot are Robot Base, Custom Base, Vision Base and
Tool Coordinate according to the purpose. Users can complete the point planning
and application in the space using intuitive methods, according to these different
base applications.
• Robot base: is also called the world coordinate system. It is defined as the
Base of the robot. When the robot is running, no matter how the position
or posture is changed, it will not affect the direction and position of the
initial point of the coordinates.

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 Figure 2.11 Robot base [4]

• Vision base: can be further divided into visual servoing positioning and
fixed-point positioning. The concept of visual servoing positioning is to
approach the object with camera, so the Base is created on the camera. In
fixed-point positioning, the relationship between the image coordinate and
the robot is known to calculate the positioning object with absolute
coordinates and its Base is created on the object.

Figure 2.12 Servoing vision base is on the Camera [4]

Figure 2.13 Fix-point vision base is on the object [4]

The robot's vision can be simply built with the Base in parallel to the operation
plane, allowing users to complete assembly, processing, and other related
applications on an inclined plane, and can also use the Vision Base to position
the robot in the space.

25
• Tool coordinate: is used to define the position and orientation of the robot
TCP (Tool Centre Point). Normally, the flange center point will be used as
the origin of the Base.

Figure 2.14 Tool coordinate [4]

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 Assembling relays in car’s fuse box

Before applying a collaborative robot, the important task is to study what the fuse
box in detail. In this chapter, we will give a general opening about a typical car’s
fuse box by showing the structure and working principle of a Fuse Box.
3.1 What is a Fuse Box?
Most vehicles are equipped with two fuse boxes. One is located in the engine
compartment and is used to protect engine components such as the cooling
system, anti-lock brake pump, and the engine control unit. The other is often
found in the cabin area in or under the dashboard, on the driver’s side to protect
interior electrical items. The fuse box houses a variety of fuses and relays in one
convenient place, protected from outside elements. Car fuse box replacement
isn’t often necessary unless the vehicle has experienced severe physical damage
or electrical problems.

Figure 3.1 Fuse box

3.2 How automotive relays and fuses work?

Relays
Remember that certain devices require considerable current (amps) and that, in
turn, require thicker wire. High current devices require big, heavy switches to
handle the current. Unfortunately, these would be ugly and expensive, so
engineers use relays.
A relay consists of a small coil of wire around a central iron core. When the
actuating switch energizes the coil this core moves heavy-duty contacts together,
thus allowing high current to be passed to the device. That's how a small switch
can control a high-current device.
You already know the starter solenoid is a high-current relay. Other devices that
typically utilize relays are the horns, power antenna, air conditioning compressor,
power seats, power windows, engine cooling fans, and power tops. Sometimes,

27
headlights and accessory driving lights use them too. It's important to know this
because many electrical failures occur in the relays themselves.

Figure 3.2 Relays

Fuses
Almost everything in a car is wired through a fuse. Fuses come in all shapes,
sizes, and colors and are used to even out and reduce the electrical current that
flows through wires to prevent damaging electronics from too much electricity.
Often, fuses come in a rectangular or tube-like shape. A rectangular fuse is
composed of two push in-connectors linked by a fuse wire in a protective
covering, typically made of plastic, which will burn through or blow, as it is
often referred to, when overloaded. Tube fuses have a similar likeness to a
fluorescent light bulb, on a much smaller scale, where the tube portion is long
and at either end is a protective housing made of glass between them. Running
between the metal ends and protected by the glass, is a thin fuse wire which
burns through and will blow when overloaded.

Figure 3.3 Type of fuses

Without fuses, a large, overloaded electrical current could cause the wires to
overheat, melt the insulation, and could result in fire. A high current to any

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component equals instant failure, therefore, the fuse ensures that current stays at
a reasonable level for the component to continue to function. Still, if the current
is too high, the fuse will blow. Drivers will notice trouble with fuses when the
vehicle’s windshield wipers, headlights, interior lights, seat warmers, or radio do
not function. In some cases, the vehicle may also have difficulty starting.
If there is overcurrent in the circuit, a fuse blows, disconnecting an appliance
from the power supply. Thus, it protects the appliance from failure. If one of your
car’s electrical devices got out of order, the blown fuse may be the issue. In this
case, you need simply to replace it to solve the problem.

Figure 3.4 The difference between good and blown fuse

We discuss the control of robots when their dynamical model is uncertain. This
may arise because of the robot is carrying an unknown load or because the exact
evaluation of the robot’s dynamics is too costly. The robust controllers in this
chapter are obtain from modifications to the controllers.
3.3 Programming with TM14 Collaborative Robot
Problem Proposal
Our task is to use the robot's camera to determine the coordinates of the relays,
then pick up the relay and place it in the corresponding positions on the fuse box.
Object
In this project, we use relays with 3 different colors: 6 black relays, 1 blue relay
and 1 brown relay with size 20mm*30mm. These objects are selected because:
➢ Size is fitted to the gripper which is available on the collaborative robot
(cobot) to facilitate for pick&place.
➢ Relay with three striking colors on the white background of robot desk.
Vision will check the shape and color of the product, is a rectangular product
with black, blue and brown; so other objects will not be picked up.

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 Programming
Algorithm diagram

Figure 3.5 Algorithm diagram

Explain:
- Counter variables are created at the beginning to keep track of the
number of relays which was successfully placed:
o Black_Relays_Counter = 0
o Brown_Relays_Counter = 0
o Blue_Relays_Counter = 0
- By pressing the power button on the robot stick, robot will go to the
location where the TM landmark has been set up before.
o If it couldn’t detect the TM landmark in search range, robot
will warn user and stop right away.
o If the TM landmark was detected, its coordinate will be
recorded and become a vision base system for fuse box.
- Robot then move onto workplace where camera can capture object.

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 o If robot couldn’t detect object, it will remind users to put
object in workspace before standing idle for 5 seconds. Then
robot will capture workspace again.
o If relay is detected, the robot will classify color of the
object.
- Before picking up the object, we need to compare the
corresponding counter value of each color with the max value
where is the maximum number of relay positions on the fuse box.
- Robot arm will pick up object.
- After picking up object: [corresponding color]_Relays_Counter =
[corresponding color]_Relays_Counter + 1.
- Place object in the corresponding position on the fuse box. In the
following step, robot will to check quality of object.
o If the relays are successfully placed in the right position, the
robot will continue to pick and place until the job is
completed.
o If not, robot will stop immediately.
Vision node
The Vision node is the most important part of this project. It provides the
creation of plane with fixed-point type, object type as well as a variety of AOI
identification functions. The display of a Vision node in flow is shown in the
figure below:

Figure 3.6 Vision node [5]

The Base icon on the right side is for which Base is to record the Vision node of
this Vision Job, and the Base icon on the left side is for which Base is to be
generated by this Vision Job.
a) Landmark
Landmark provides a fast, simple and flexible base system positioning method as
a reference to the environment. Capturing Landmark with TM Robot will
generate the position information of six degrees of freedom (including X, Y, Z,
RX, RY, RZ) once to build a base system accordingly for users to record
following points and motions. When the robot is repurposed or relocated, when
the relative position of the robot and landmark changed, it's simple - use the robot
to take a photo of Landmark again, to regain 6 DOF of the new location and
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renew the landmark base system. The recorded points and motions on the
Landmark base system will be converted to the base system automatically to
make the robot move to the same positions as before.

Figure 3.7 TM landmark

In this node, vision will take pictures to determine the direction and location of
the landmark. Therefore, a vision base will be created. In the next step, when we
want to place relays into corresponding position, we will set up node base on this
vision base. These positions are defined based on its relative position to TM
landmark.
b) Calibration function

Figure 3.8 Calibration plate [5]

The fixed positioning function is designed with a pre-set object placement area
and pre-set height for vision jobs. We can create a workspace with the TM
calibration plate. When using the TM calibration plate for fixed-point alignment,
the relative height of the camera and the work plane is also defined. When using
fixed-point alignment to establish a workspace, we have to ensure that the
absolute height of camera and object is equal to the workspace created by the TM

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calibration plate. Workspace calibration includes automatic and manual
calibration to help users create workspaces for fixed-point vision jobs.

In our project, we use Automatic Calibration.

c) Find Shape pattern

Figure 3.9 Relay pattern

➢ This function uses the geometrical shape of the object as its pattern model
and matches it to the input image to find the object in the image.
➢ Because relays are symmetrical object, so we have to set rotation angle
smaller: rectangles (-90~90), squares (-45~45), and circles (0~1)
➢ Minimum score: Smaller minimum scores reduces omissions from
judgments at the cost of more misjudgments. So we used value fall
between 0.75 and 0.85 to get better results.
d) Color classifier

After finding pattern from image, we used “color classifier” function to assist
users in dealing with a color identification.
Users are required to set up color classification area and select the color feature
area for identification before starting the training process. In addition, we are
required to place patterns of different colors as prompted and name each color
during the training process: Black, blue and brown

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 Figure 3.10 Classification result

Once trained successfully, the TM vision can classify color of the object to its
most suitable category. This works by matching the list of color with color
classification area to get a matching score.

Motion programming
We chose to use point node, which the robot will use to determine the mode of
moving to the point according to setting.
a) Point to point
- The point to point (PTP) mode determines the robot’s motion by
calculating the angular variation of each axis, and is not limited by
the singularity point. The robot’s motion in this project is not
limited, so we chose to use PTP movement.
- The PTP speed is based on the motion joint that takes the longest
time. Speed percentage and time to top speed can be set in PTP
speed setting.

Figure 3.11 Point to point example [4]

b) Line
- A straight line is the shortest distance between two points. The Line
mode specifies that the path between two points is planned as a
straight line.
- Line mode may cause joint speeding, so we chose to use it only on
approaching – departing object’s situation to avoid speeding close
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 to a singularity point or make a posture large-angle movements
over a short distance.

Figure 3.12 Line example [4]

Logic programming
We will introduce the logic nodes which we chose to use in the project, in order
to explain its basic features and use methods.
a) Local variables
- We used local variables which can only call in a single project, and
effect only on the project where they were created.
- Six types: int, float, string, double, bool, byte
- Two categories: single, array

Figure 3.13 Variables list

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b) SET node
- Set the state of IO
- Change type and value of variables (add or subtract)
- All parameters go through this node will be changed to the set
result. For example, the variable Black_Fuses_Counter was
initially set as 0 – each time it passes through the SET Node
Increase_, the count value is increased by 1. The number of times
the project has been run can be show on Display mode.
c) IF node
- Judge or compare the state of IO, variables.
- Separate to YES and NO path. In this project, we mostly use IF
node to judge or compare the state of a Variable as well as take the
YES or NO path according to whether the condition of judgement
is reached.
- For example,
d) Gateway node
- Similar to IF note, but has multiple output called CASE.
- Will be judge from left to right on the project. If any condition is
met, the project flow would continue from that CASE, and other
CASEs would be ignored.
e) WaitFor node
- The main function of WaitFor node is to hold the project, and
continue to run after the set conditions are met.
- In this project, we set the condition according to Time (ms) so that
the delay time when using SET node will not affect next
movement.
f) Subflow node
- When the number of Nodes in the flow becomes large, certain
blocks of the project may be used repeatedly. If the Nodes in these
repeated blocks need to be modified, it may cause inconsistencies
in the parameters; therefore, the Subflow Node of TMflow can be
used.
- This Node will create a new page, and share the Variables, Tool
parameters, Bases with the original page. The concept of
modularization created with this method allows users to simplify
the project editing flow, and improves the readability of the flow.
- In this project, we used 2 subflow node: Place_Blackrelays and
Pick_Relays

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After applying these nodes, we have got the whole project which shows in the
figure below:

Figure 3.14 Main function on TMflow

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 CONCLUSION

4.1 Thesis summary

In general, in this project, we deeply learn about the structure and operating
principle of industrial robots. Industrial robots are pre-programmed in a certain
sequence and used for the purpose of assembling, manufacturing or processing
products. Robots greatly assist humans. Especially in harsh, toxic and dangerous
environments. Industrial robots have high precision and efficiency that is
superior to manual production.
With the requirement to identify and pick relays then place them in the fuse box,
the Cobot TM14 OMRON work precisely as we demand. This cobot successfully
identifies relays, classifies color and also does the pick-up and placing operation
correctly. However, the project also has many limitations that the cobot
sometimes works inaccurately because there are some objective reasons that
affect the result of robot operation such as: the light of the room cause shadow on
objects or technical error of the robot.
In the working process of doing the project, we have learned knowledge and
useful skills that help us improve ourselves for researching and working in the
future. We have learned to take the information from the documents and how to
apply it to configure the robot in practical. In addition, by fixing and debugging
the fault that happens during setting up the robot, we have improved our
problem-solving skill so that we have many experiences to deal with trouble in
the future. Moreover, doing the project at the professional working environment
helps us improve teamwork skill: how to communicate with teammates and also
arrange workload and time.
4.2 Direction of the project development
Due to the high applicability of Cobot TM14 Omron, this cobot can be
suitable for different problems depending on each production line. Although, due
to insufficient equipment conditions, as well as knowledge and knowledge, we
realize that robots can develop in the following directions:
• Improved object recognition: Enables object recognition of different sizes
and colors.
• Combine with conveyor tracking; safety light curtain to protect personnel
from injury and also safeguard machines from damage

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 REFERENCES

[1] Ph.D Nguyen Manh Tien, "Dieu khien Robot cong nghiep", Hanoi University
of science and technology.
[2] OMRON, TM12/TM14 Series Manual, 02/2020.
[3] OMRON, TMflow software Manual, 04/2021.
[4] OMRON, TMvision software Manual, 04/2021.
[5] OMRON, "Elearning," OMRON, [Online]. Available:
https://omronlearning.com/.

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 APPENDIX

Display of Indication Light Ring

Users can recognize the operation mode and status of TM Robot from the
Indication Light Ring. Each light indication is the combination of a maximum 2
different colors. The colors are additionally combined with different ratios of
blinking time period to provide additional status information of the robot. There
are 2 main categories of light indication: Special Light Indication and Regular
Light Indication.
➢ Special Light Indication
Initializing: Alternating between Red and Light Off equally
Updating: Alternating between Red and Light Off equally (doubled speed)
Safe Start Up Mode: Alternating between Light Blue and Light Off equally
Fatal Error (Need to re-boot): Solid Red Light (Buzzer emits a long beep)
➢ Regular Light Indication
The regular Light Indication is alternating between 2 categories of light
indication: Operation Mode Light Indication and Auxiliary Light Indication. The
ratio of blinking time period of these 2 light indications indicates different status
of the robot. In addition, the display color of Auxiliary Light Indication is
prioritized according to the status.
➢ Operation Mode Light Indication
Auto Mode: Blue
Manual Mode: Green
Not in Operation: Light Off
➢ Auxiliary Light Indication (Sort by display priority)
Error: Red
Trip User Connected External Safeguard Input Port for Human - Machine Safety
Settings: Purple
Entering Reduced Space: White
Normal: Light Off

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 ❖ Ratio of blinking time period
The table below shows the rule of ratio of blinking time period between
Operation Mode Light Color and Auxiliary Light Color.
Blinking Ratio
Status Operation Mode Auxiliary Light
Light Indication Indication
Error 50% 50%

Paused 10% 90%

(Trip User Connected External Safeguard
Input Port or paused in project)
Normal 100% -
Trip User Connected 90% 10%
External Safeguard
Input Port for
Project is Human - Machine
not running Safety Settings or
Not (Incl. Step entering Reduced
Paused Run) Space

Project is running (Incl. Trial Run) 50% 50%

The table below show shows all combination of Regular Light Indication.
Operation Running status Space/Status of Operation Auxiliary Light
mode Safety Trigger Mode Light Indication
Indication
Full Speed Space Green (10%) Light Off (90%)
/Normal
Paused
Reduced Space Green (10%) White (90%)
(Trip User
Trip User Green (10%) Purple (90%)
Connected
Connected
External
External
Safeguard
Safeguard Input
Input Port Port
Port for Human -
or paused in
Machine Safety
Trial Run)
Settings
Error Green (50%) Red (50%)
Project is not Full Speed Space Blue (100%) -
running /Normal

41
 Reduced Space Blue (90%) White (10%)
Trip User Blue (90%) Purple (10%)
Connected
External
Safeguard Input
Port for Human -
Machine Safety
Settings
Error Blue (50%) Red (50%)
Full Speed Space Blue (50%) Light Off (50%)
/Normal
Reduced Space Blue (50%) White (50%)
Trip User Blue (50%) Purple (50%)
Project is Connected
running External
Safeguard Input
Port for Human -
Machine Safety
Settings
Error Blue (50%) Red (50%)
Full Speed Space Blue (10%) Light Off (90%)
/Normal
Paused
Reduced Space Blue (10%) White (90%)
(Trip User
Trip User Blue (10%) Purple (90%)
Connected
Connected
External
External
Safeguard
Safeguard Input
Input Port or
Port for Human -
paused in
Machine Safety
project)
Settings
Error Blue (50%) Red (50%)

The table below is a quick reference of how to recover from different kinds of
error/ status.

Color/Blinking Description Troubleshooting

Alternating Manual Mode Error Press the FREE Button in
between the End Module or the
Green/Red light Stop Button on Robot
(with 2 beeps Stick to troubleshoot the
from buzzer) error.
Alternating Auto Mode Error After switching to
between Manual Mode, press the
Blue/Red light FREE Button in the End
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(with 2 beeps Module or the Stop
from buzzer) Button on Robot Stick to
troubleshoot
Light blue light Safe Start up Mode Press Stop Button for 3
seconds to return to
original Mode
Flashing red Robot is initializing Not Applicable
light
Light off Emergency stop pressed Release the Emergency
Switch to turn to Safe
Start up Mode
Light off Category 0 stop Shutdown and Restart
Buzzer emits a required
long beep
Solid red light Fatal error Shutdown and Restart
Buzzer emits a required
long beep

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1