Chapter 1 – Robot Safety

It is difficult to summarize robotics safety because industrial safety varies depending on the specific
company, application and jurisdiction. Many of the robot safety guidelines that are implemented to
safeguard a company, facility or machine are found in the ANSI/RIA R15.06 safety standards. This
document is updated yearly, but a review of the Chapter 3 Definitions indicates the scope of the
standard, and provides talking points for a general review to students and operators.

1
2
3
The article on the next page was written in preparation for implementation of ANSI/RIA R15.06,
and provides a good summary of some of the safety methods that may easily be implemented in a
high school or college robot training course.

A fun safety video to watch that is related in industrial robots is on the Willow PR2 located at:
https://www.youtube.com/watch?v=9OQK_h6ZB6Q

The following Practical Robot Safety assignment can be given at the start of each year.

Practical Robot Safety

Intro to Robot & Robot 1

Read “Practical Robot Safety” and use complete sentences to list 15 safety methods
designed to protect the people who may come into contact with the Robot. I.e. Do
not let unauthorized people within the work envelope of the robot.

Robot 2 & 3

Read “Practical Robot Safety” and give specific examples of the 15 safety methods
that relate to last years lab activities. I.e. The operating limits of the robot should be
known. Example: The skate wheels cell had a gripper that weighed too much and
was beyond the operating limits of the robot. The robot didn’t work correctly.

4
5
6
7
Practical Robot Safety Answers
8
Intro to Robot & Robot 1
Read “Practical Robot Safety” and list 15 safety methods designed to protect the people who may
come into contact with the Robot. Ie. Do not let unauthorized people within the work envelope of
the robot.

Robot 2 & 3
Read “Practical Robot Safety” and give specific examples of the 15 safety methods that relate to
last years lab activities. Ie. The operating limits of the robot should be known. Example: The
skate wheels cell had a gripper that weighed too much and was beyond the operating limits of the
robot. The robot didn’t work correctly.

1. Guarding, usually some type of six foot fence goes around every robot.
2. Access gates are interlocked so motion is stopped immediately when an employee opens a gate
during the run cycle.
3. An amber light on every robot is lighted whenever drive power to the robot in on. A red strobe
light is on when the robot is in the teach mode and interlocks are disconnected.
4. Two disconnects are provided so the encoder can remain energized and only the connection to
the drive power is locked out.
5. The master control panel is mounted outside the working envelope, and outside the guards.
6. The robot should be in sight of the control panel.
7. Robot movement is restricted only to the amount of space that is needed to do a particular job.
8. Dimensions of the robot work envelope are painted on the floor, where possible.
9. An emergency stop is installed on the teach pendant.
10. Install emergency stops outside the workcell.
11. Operate the robot at slow speeds in the manual teach mode and restrict speed of the robot to 15-
20 inches per second.
12. Axes are marked on the teach pendant to correspond to the direction buttons.
13. Signs warn of special hazards, such as when the worker may be in the working envelope of two
robots.
14. Electrical interlocks prevent two neighboring robots from being in the teach mode at the same
time.
15. Install pressure sensitive mats in the work cell to shut down the robot arm when a danger zone is
about to be entered.
16. Magnetic field detectors – a robot with this device has antennas that put out a magnetic field to
sense if the robot arm is approaching danger.
17. Light curtains may be used to stop the robot arm if someone intrudes into the work area, or if
the robot arm breaches the work area.
18. Lock front and back control doors.
19. Lock power switches to control panel and welding power supplies.
20. Use explosive proof switches when appropriate.
21. Equip the operator with protective clothing and equipment.
22. Use monitors to scan for harmful atmospheric gases.
23. Program a safe point for reentry into the workcell.
24. Simulate welding torch movement before striking the arc.
25. Install interlocking switches to welding jigs and fixtures to indicate safe clamping and removal.
26. Zone 1 is the robot’s work envelope. Zone 2 is the operator’s work area. Zone 3 is the space
outside the workcell.

Name _____________

9
 Robotics Safety Test
1. T or F The two most important safety practices in the shop are the wearing of safety
glasses and attitude.
2. T or F The robot does not need to be in sight of the control panel.
3. T or F You don’t need the safety signs in the area of two robots when the
disconnects are engaged.
4. T or F All front and back door control panels need to be locked.
5. T or F An amber light on every robot is on when the main drive power is on.
6. T or F You need to have emergency switches outside the work cell.
7. T or F Entrance gates do not need to have interlock switches.
8. T or F An emergency stop is installed on the teach pendant.
9. T or F The robot movement should be restricted to the movement of the particular job.
10. T or F Mechanical stops may be used when the robot exceeds a danger zone.
11. T or F You should use explosive proof switches in volatile areas.
12. T or F You do not need protective clothing because the robot will be doing the work.
13. T or F Dimensions of the robot work envelope are painted on the floor.
14. T or F In guarding, usually a six foot fence goes around the robot.
15. T or F Signs are only for the visitors and are not needed for the regular personnel.
16. T or F You can always trust a good technician when it comes to safety because
he/she has a lot of experience.
17. T or F Limit switches may be used to stop a system before a danger zone is reached.
18. T or F The amber light is not needed when in the teach mode and the disconnects are
all disabled.
19. T or F The first time and in the teach mode the speed is limited to a slower rate.
20. T or F Axis are marked on the teach pendant to correspond to the direction buttons.
21. T or F A safe point for reentry to the program should always be in the cycle.
22. T or F You are ultimately responsible for the safety of yourself, others and the robot.
23. T or F Single point control is not needed when teaching.
24. T or F The restricted space is the portion of the maximum space to which a robot is
restricted by limiting devices.
25. T or F An interlock is an arrangement where the operation of one control allows or
prevents the operation of another.

Project Start-Up – Robot Homing

Industrial robots have three main parts. Perhaps the most recognizable component is the
mechanical arm to which the end of arm tooling (gripper, welder, paint sprayer, etc.) is attached to.
10
The robot controller is the part of the system that coordinates the output movement of the
mechanical arm and field devices and also processes inputs from the sensors. The power supply
provides electricity for the controller and the power needed to drive the motion of the mechanical
arm. The Scorbot arm utilizes electric motors coupled to gears and belts to move the arm through a
programmed trajectory.

The analogy of a robot to a human is that the mechanical arm is your body. Your body converts the
food you eat into energy, which allows your muscles and ligaments to move the different parts of
your body in motion to complete the task you are working on. The robot controller is the brain and
utilizes input sensors such as your eyes, ears and touch to make decisions in order to perform
outputs such as talking and walking.

A major component of the robot controller is

the means of programming. The robot is
usually programmed using a teach pendant
(pictured to the right) and / or a computer.
The following Scorbot Startup activity will
allow you to become familiar with the
Scorbot robot system.

Robot - Scorbot Start-Up

Purpose: To home the robot, teach positions and write a small program.

Before beginning, find and identify the following equipment.

11
Mechanical Arm – The Scorbot robot arm will most likely be blue (ER4u) or green
(ER4pc), although orange (ER3), red (ER2u) and gray (ER5+) arms also exist.
Find the model of your Scorbot printed on the robot and circle the type of arm that
you are using from the list below. Note the ER5 model designation is a Roman
Numeral V or V+. Circle the robot arm you are using:

ER 4u Upgraded to ER4u ER 4pc ER5+ ER 2u ER 3 ER5

If you have an ER3 or ER5, this procedure will not work for homing.
Controller – Trace the cable coming from the robot into the controller. Be sure the
robot connection to the controller is tight. NEVER CONNECT OR
DISCONNECT THE ROBOT CABLE WHEN THE CONTROLLER IS ON.
Your controller may be a metal enclosure approximately 1 foot square by 6 inches
high or it may be a larger metal enclosure approximately 2 foot square by 6 inches
high. The type of controller is indicated on the back where the cable connects.
Circle the type of controller you have:

ER 4u ER 4pc ER5+ ER3 ER5

If you have an ER3 or ER5 controller, this procedure will not work for homing.
Computer – This may be a laptop or desktop depending on the model and will be
used to startup, program and run the robot.

Computer Controller Cable – Trace the cable coming from the computer to the
robot controller. Some computers utilize a USB computer cable that connects to a
USB port on the robot controller (ER4u). Some computers will utilize a USB
computer cable that connects to the 25 pin robot controller port (ER5+). Some
computers utilize a 9 pin computer port that connects to the 25 pin robot controller
port. Some computers utilize a large 50 pin cable that connects to a 50 pin robot
controller port (ER 4pc). Be sure these cables are tight and circle your
connection:

USB to USB USB to 25 pin 9 pin to 25 pin 50 pin to 50 pin

Power Supply – Be sure the power cables for the computer, monitors and controller
are plugged in.

1. Turn on the computer. The stations have a laptop or desktop

computer depending on the model. If the computer is already on,
restart for best results.
2. Turn on the controller. The switch is located on the right side or
back of the controller depending which type you have.
12
 3. Select the correct Scorbase Icon from the desktop.

4. Once Scorbase loads, select FILE….New Project

5. Once the “combo” screen is loaded, select OPTIONS and then ON-Line
to initialize the controller.

6. Select the “House” icon to Home the robot. This will take a few
minutes as the cams on the robot arms / axis find the limit switch.

13
7. Move the robot around by clicking and holding down the axis controls.
Example: clicking and holding 1 will cause the robot to rotate the
base. Clicking and holding Q will cause the robot to rotate the base
the other direction. You may also use the computer keyboard or
teach pendant to move the individual axis.

8. Record 3 different positions by entering the position number and

clicking RECORD. Practice moving the different axis 1-5 before
you click RECORD. The axis corresponds to the following:

1 – Base
2 – Shoulder
3 – Elbow
4 – Wrist Pitch
5 – Wrist Roll
6 – Gripper Open and Close

9. Use the GP command to write a program to go to the 3 positions.

10. Run the program single step, then single cycle then continuous
14
Upon Completion of the activity you should be able to:

• Power up the computer and controller

• Home the robot
• Teach robot positions
• Write a program
• Execute a program

It is important to understand the difference between teaching positions and

programming. You teach positions by moving the individual axis until the end
effecter is located where it needs to be. When you execute the program, the arm will
only go to the points where the positions were taught in the order that the program
specifies. The robot will NOT follow the path you drove the arm through when you
taught the position; it will just go to the final point that you taught.

In summary, recording position 1, 2, 3, etc. is NOT programming. Once you have

recorded these positions you can program them in any order or program a position
multiple times.

1 GP 1 s5
2 GP 3 s5
3 GP 2 s5
4 GP 1 s5
5 GP 2 s5 or whatever order you need to call the positions.
Project 1 – Robot Positioning
Industrial robots utilize closed loop, feedback control to operate at a specific speed and trajectory.
As the Scorbot controller executes the program to move through the positions you have taught,
optical encoders monitor the progress of the robot arm and send signals back to controller.

15
The robot controller counts the number and frequency of signal pulses in order to adjust the robot
velocity and stop the arm at specific locations. For example, the command GP1 (Goto Position)
might required motor 1 to turn through 2718 signal pulses in 6.7 seconds, motor 2 to turn through
1819 signal pulses in 6.7 seconds and motor 3 to turn through 2111 signal pulses in 6.7 seconds.
The signal pulses could be recorded from the HOME position.

The homing of the robot is important because this moves the robot to a set location and zeros the
signal pulse counts.

You can check the encoder counts as you move the robot arm to witness the counting of the signal
pulses. Select View then Dialog Bars then Encoder Counts. The values appear at the bottom of the
screen.

Each Scorbot axis has a limit switch that is activated by a rotary cam. When homing, the Scorbot
finds each of the limit switches to return to the same homing position each time.

16
Many industrial robots have absolute encoders that retain their value because they connected to a
batter backup. In the event of a battery backup failure, these robots also must be “homed” or
“calibrated” to a set reference position similar to the way Scorbot is prior to each use.

There are two other ways that industrial robots store the locations of the positions that are taught.
One such way is joint angles. For example the Scorbot base could be rotated through an angle of 91
degrees, the shoulder could be rotated through an angle of 42 degrees and the elbow could be
rotated through an angle of 21 degrees. This would locate the end of arm at a specific location
relative to the mounting of the base. You can see the joint angles by selecting View then Dialog
Bars then Joints. The values will appear at the bottom of the screen.

A final way positions are recorded are Cartesian coordinates of the tool center point. The end of the
gripper could be located at 18.1” in the x direction, 9.7” in the y direction and 6.3” in the z
direction. The pitch could be 45 degrees and the roll 21 degrees. This description provides a single
point where the gripper would be located relative to a specific origin. The origin and Cartesian
system are often located from the base of the robot. You can see the Cartesian coordinates by
selecting View then Dialog Bars then XYZ. The values will appear at the bottom of the screen.

Robot - Scorbot Project 1

Purpose To use the computer to teach/edit and save a robot program.

17
Instructions:
1. Complete the lab using the following grading criteria.
C = correctly running program with: hand written program + printed program
with diagram of positions and program remarks
B = Include Flow Chart using Inspiration or have cycle time under 20
seconds
A = Include Flow Chart using Inspiration and have cycle time under 20
seconds
2. Save your flow chart and program to your flash drive.

1. Program cycle the robot to a safe location.

2. Robot to pick up Part #1 from the stack.
3. Robot to put down Part #1 at pallet.
4. Robot to pick up Part #2 from the stack.
5. Robot to put down Part #2 at the pallet.
6. Robot will return to HOME.
7. Approach and Depart: use only 7 locations.

APPROACH #2 APPROACH #4
SAFE #1

BLK1 LOC #3 LOC #5 BLK2

BLK2 LOC #6 LOC #7 BLK1

STACK PALLET

ORDER OF POSITIONS: 1 2 3 2 4 7 4 2 6 2 4 5 4 1

*** Gripper OPEN or CLOSE gripper are independent of position ***

Scorbot Project 1 Instructor Notes

W Wait _____ (In tenths of a second)

GP Go to Position #_____
GL Go linear to Position #_____ (Use when picking up and setting down blocks)
OG Open Grip
18
CG Close Grip

Safe Position – A location free of hazards where the robot idles while awaiting
movement commands. (Use GP fast commands)

Pallet – A location that contains parts that need to be moved.

Stack – A location that will receive moved parts from the pallet.

Approach – Slow, linear movement from a “safe” location close to a stack or pallet.
(Use GP, Speed 3)

Depart – Slow linear movement away from a stack or pallet to a “safe” location. (Use
GP, Speed 3)

Wait (1/10 second) after commands at Approach and Depart locations.

Remark (RE:) – Describe major processes of robot operation.

⇒ Teach positions first (There are 7 positions)

⇒ Write Program
⇒ Run Program – Step Through, Single Cycle, Continuous

Student Procedure:
Create Diagram of 7 positions. (provided on the lab cover sheet)
Write out program. (should be 19 lines without remarks)
1. GP 1, fast Safe location
2. GP 2, fast Pick approach above blocks
3. OG Open Gripper
4. GP 3, s 3 First block pick location
5. CG Close Gripper
6. GP 2, s 3 Pick depart above blocks
7. Etc, etc, etc.

Once program is approved, teach positions and program robot.

Instructor Rubric - Scorbot Project 1 Documented
1. GP1, s7
2. RE: Pick Block 1
3. GP 2, s7
4. OG
5. GP 3, s3 PICK 1
6. CG
19
 7. GP 2, s3
8. RE: Drop Block 1
9. GP 4, s7
10. GP 5, s3 DROP 1
11. OG
12. GP 4, s3
13. RE: Pick Block 2
14. GP 2, s7
15. GP 6, s3 PICK 2
16. CG
17. GP 2, s3
18. RE: Drop Block 2
19. GP 4, s7
20. GP 7, s3 DROP 2
21. OG
22. GP 4, s3
23. GP 1, s7

Pos Describe
1 Safe
2 Pick Approach
3 Pick Block 1
4 Drop Approach
5 Drop Block 1
6 Pick Block 2
7 Drop Block 2

Robot - Scorbot Project 1A

Purpose: To document robot positioning.

Instructions:
1. Move the robot to each of the 7 positions from project 1 and have your partner
help record the positional data.
20
Position 1:
Joint: Base ____ Shoulder ____ Elbow ____ Pitch ____ Roll ______
XYZ: X ____ Y ____ Z ____ Pitch ____ Roll ______
Encoder: 1 ____ 2 ____ 3 ____ 4 ____ 5 ______

Position 2:
Joint: Base ____ Shoulder ____ Elbow ____ Pitch ____ Roll ______
XYZ: X ____ Y ____ Z ____ Pitch ____ Roll ______
Encoder: 1 ____ 2 ____ 3 ____ 4 ____ 5 ______

Position 3:
Joint: Base ____ Shoulder ____ Elbow ____ Pitch ____ Roll ______
XYZ: X ____ Y ____ Z ____ Pitch ____ Roll ______
Encoder: 1 ____ 2 ____ 3 ____ 4 ____ 5 ______

Position 4:
Joint: Base ____ Shoulder ____ Elbow ____ Pitch ____ Roll ______
XYZ: X ____ Y ____ Z ____ Pitch ____ Roll ______
Encoder: 1 ____ 2 ____ 3 ____ 4 ____ 5 ______

Position 5:
Joint: Base ____ Shoulder ____ Elbow ____ Pitch ____ Roll ______
XYZ: X ____ Y ____ Z ____ Pitch ____ Roll ______
Encoder: 1 ____ 2 ____ 3 ____ 4 ____ 5 ______

Position 6:
Joint: Base ____ Shoulder ____ Elbow ____ Pitch ____ Roll ______
XYZ: X ____ Y ____ Z ____ Pitch ____ Roll ______
Encoder: 1 ____ 2 ____ 3 ____ 4 ____ 5 ______

Position 7:
Joint: Base ____ Shoulder ____ Elbow ____ Pitch ____ Roll ______
XYZ: X ____ Y ____ Z ____ Pitch ____ Roll ______
Encoder: 1 ____ 2 ____ 3 ____ 4 ____ 5 ______

Essay: Which positioning method appears to produce the most dramatic change in values from
position to position? Why do you think this is?

Project 2 – Accuracy and Repeatability

Industrial robots are utilized in a variety of different application due to their ability to be accurate
and repeatable. The definitions are different.

Accuracy – The ability of a robot to move to a specific point. The Scorbot is accurate to .02”
depending on the payload that the gripper is carrying. The Scorbot has a maximum payload of 2.2
lbs. Attempting to move objects greater than 2.2. lbs will reduce the robots accuracy. Increasing
the speed will also reduce the accuracy of the robot.

21
Repeatability - The ability of the robot to return to the specific point on each cycle of the program.
This definition is similar to Accuracy, but is different because it defines accuracy over a repeated
number of cycles. If is better to be more repeatable than more accurate. For example, if a robot
“misses” the taught position by .02” in the x-direction every time, then the programmer can adjust
for this anticipated error.

If you are attempting to position small parts that require accuracy that is greater than .02”, other
techniques such as passive compliance will need to be incorporated. Some industrial robots are
much more accurate than the .02” of the Scorbot.

An understanding of the Degrees of Freedom and the axis is important to understanding robot
positioning. Each joint or movable axis on the robot arm represents a Degree of Freedom (DOF).
Thus the Scorobt has 5 degrees of freedom (base, shoulder, elbow, pitch, roll) plus gripper control.
A robot with 6 degrees of freedom adds yaw, in addition to pitch and roll, to the wrist providing
movement similar to the human wrist.

The axis are categorized into two groups, the position axes which are base, shoulder and elbow and
the orientation axes which are pitch, roll, yaw. The position axes are usually much more sturdy
than the orientation axes and can move larger payloads through a trajectory with higher accuracy
and repeatability. The robots accuracy is usually limited by the ability of the orientation axes as
these are used to finely define a programmable point and are affected by greater payloads.

When teaching, the orientation axes (axis 1, 2, 3) are driven in joint mode to move the robot arm
very quickly to approximate locations. The approximate location of the orientation axes (4,5) are
also set using joint mode.

Once the robot position has been approximated, it helpful to switch to World (XYZ) mode or Tool
(XYZ) mode to move the robot in the Cartesian plane to determine exact robot positions.

22
Referencing the above pictorial, World (XYZ) mode is determined by the Cartesian coordinate
system located as the base. The Cartesian Scorbot robot movement is accomplished by selecting
XYZ instead of JOINT.

It is useful to move the robot in the XYZ mode but change back to JOINT prior to teaching the
position as this results in less math for the robot controller resulting in faster robot movement.

Referencing the above pictorial, TOOL mode aligns the Cartesian coordinate system such that it
moves in the direction of the gripper or tool center point. This is particularly useful because the
robot will move linearly in the direction of the tool which makes teaching part insertion easier. The
Scorbot is not capable of operating in TOOL mode but industrial robots typically are.

Robot - Scorbot Project 2

23
Purpose To see the accuracy of your robot positions using repeatability.

Instructions:
1. Complete the lab using the following grading criteria.
C = correctly running program with: hand written program + printed program
with diagram of positions and program remarks
B = Include Flow Chart using Inspiration or have cycle time under 100
seconds with accurate block placement.
A = Include Flow Chart using Inspiration and have cycle time under 100
seconds with accurate block placement.
2. Save your flow chart and program to your flash drive.

Process:

1. Repeat the steps 1-9 from Project 1.

2. Continue your program and have the robot go to the safe location after moving
the blocks to a “pallet.”
3. The robot should wait 2 seconds, then move from SAFE, repeat the process and
move the blocks back to the original “Stack.”
4. Repeat step 3 - three times by using a variable counter.
5. The blocks should not move or shift as the robot performs this task.

Procedure:

Create a diagram of positions (Hint: It’s the same as project 1)

Write the program out on a piece of paper (Hint: It’s between 35-40 lines not
counting remarks)

Move the robot in JOINT mode to the approximate block locations and switch to
XYZ mode to teach exact positions. Teach position 6 first. Then move the robot
slightly in the X direction to teach position 3. Then move the robot slightly more in
the X direction to teach position 2. Switch back to JOINT mode and swing axis 1
only to the drop location. Switch to XYZ mode and teach the positions in this order
4 then 7 then 5.

You should be able to rapidly teach the positions using this method.

Scorbot Project 2 Instructor Notes

Approximate Line 1-20 = Blocks over from Scorbot 1

Approximate Line 21-40 = Bring blocks back to original location

24
3 Times = 40 x 3 = 120 Lines. This is a long program.

Or:

Use Counters:

1. Set Variable A = 0
2. GP #1 Speed Fast
3. Label: Loop
4. GP #2 Speed Fast
5. Wait 10 (1 sec)
6. GP #3 Fast
7. Set Variable A = A+1
8. If A < 4 Jump to Loop

Labels must have the same case and spacing. LOOP1 is not the same as LOOP 1.

Be sure you have selected Level 3 or Pro for additional programming commands.

Don’t forget to use JOINT mode to get close. And then use XYZ mode to move in the Z direction
to make block placements on top of each other perfect. If block placement is not perfect, the blocks
will get misplaced over the course of 3 runs back and forth and will no longer sit on top of each
other.

Use the Goto Position Linear (GL) to increase accuracy when approaching and departing.

Create the Flow Chart, Diagram of Positions and write the program first. Once this is signed off by
the instructor, utilize you partner to quickly code the program into the computer and teach the
positions.

Add REMARKS to your program after you have entered it into the computer.

25
26
Scorbot 2 – Final Project
Student Name
Date

Project 3 – Robot Inputs

27
An industrial robot controller utilizes a variety of sensors to make itself “smart”. Just as you have
eyes, ears, a nose, touch, etc. to send information to your brain about your environment, robots can
also be configured with different sensors. These sensors are referred to as inputs and fall into three
categories.

Contact sensors require physical contact to activate the sensor. The most common contact sensor is
a limit switch that must be pushed to activate. The doors on your car have limit switches that turn
off the interior lights depending on if the door is open or closed.

Non-contact sensors activate if something comes within a range of the robot. The most common is
proximity sensors that might sense an object if it comes within an inch of the sensor. Optical
sensors, magnetic sensors and sound sensors are also non-contact sensors. The door to a hardware
store has an optical sensor on it that senses your presence and opens or closes the door depending
on if you have entered the doorway threshold.

Process monitoring sensors may be either contact or non-contact and return information about the
status of the robot. Temperature, pressure and vision systems are examples of process monitoring
sensors. A door to a secure building might have a vision system that scans your face, retina or
fingerprints to determine if you are someone who should be allowed access to the building.

Below is a comparison of some types of sensors that provide information to a robot controller or the
human brain.

Sensor Type Robot Example Human Example

Vision System Process Monitoring Camera that identifies Your eyes identify
different colored items different colors.
for packaging.
Temperature Process Monitoring A sensor verifies that a Waving your hand
liquid is the correct over boiling water on
temperature before the stove.
processing it.
Ultra-Sonic Non-Contact A robot uses sound to Your ears can hear
measure the distance thunder, which allows
the source is away you to determine how
from an object. far away a storm is.
Touch Sensor Contact A robot can touch an You can touch an
object to determine if object to determine if
it is soft or hard. is soft or hard
Mass Spectrometer Non-Contact A robot can determine Your nose can smell
what type and the different types of odors
chemical composition so you can determine
of a gas. what they are.

Sensors can further be classified as digital or analog. Digital or Discrete sensors only have two
states which are typically ON or OFF. Engineers classify these states at HIGH or LOW and robots
analyze the state in a binary sense as 1 or 0. Analog sensors have an infinite number of values or
28
states and usually categorized as transducers. A thermometer is a good example of an analog device
as today the temperature might be 78 and tomorrow it might be 76. The resolution is also important
when defining an analog sensor. The thermometer might record a temperature of 76, 76.15 or even
76.1578 degrees depending on the resolution. Changes in temperature with a high resolution
thermometer will provide infinite values or states.

Sensor Type Classification

Pushbutton used on a control Contact Digital
panel
Inductive proximity switch that Non-Contact Digital
senses metal
Vision system that looks for Process Monitoring Analog as the size of the cracks
cracks in a casting might vary

Scorbot inputs 1-8 on the ER4 controller and inputs 1-16 on the ER5 controller are digital and are
configured as sourcing. This means that one side of the digital input must be sunk to ground.
Directly jumping the input terminal to the ground terminal will activate the input.

The ER4 digital inputs 1-8 are shown above with the ground connection directly below them.
Shown below is the electrical schematic for connecting a pushbutton to Scorbot input 3.

It is often useful to use an input common if components such as pushbuttons are located in close
proximity to one another. Incorporating a common saves wire and time because a single wire acts
as the sink for every input. Show below is the electrical schematic for connecting 3 pushbuttons to
Scorbot inputs 1, 4 and 7. Schematics created using free software at digikey.com.
29
The construction of a pushbutton input / output board is recommended in order to complete the
Scorbot labs included in the book. The plans for such a board are shown below using the following
wiring color scheme where Blue is -VDC and Red is +VDC.

Input Ground = Blue, Inputs = Yellow, Output Common = Red, Outputs = Green

The I/O field devices (lights and switches) are drilled at 1” spacing. A 8” x 4” x ¾” plywood based,
which is wood screwed to a 8” x 3” x ¼” plywood panel works good and is easy for the students to
make. A 10 slot contact block is mounted and wired as shown.

An I/O board similar to the one described above and pictured here can be purchased from this
vendor for $30.

30
Robot - Scorbot Project 3

Purpose To use an input device as an operator start.

Instructions:
Complete the lab using the following grading criteria.

31
 C = correctly running program with: hand written program + printed
program with diagram of positions and program remarks + properly wired
(labeled, clean, no exposed copper)
B = Include Flow Chart using Inspiration
A = Include Flow Chart using Inspiration and incorporate master control
relay circuit for I/O board.
Process:

1. Move robot to a Safe pallet location.

2. Robot to approach and pickup Part #1 on operator start input #1.
3. Robot to move Part #1 to Pallet location and waits for input #2 to drop.
4. Repeat this procedure for Part #2 with inputs at Pickup and Pallet.
5. Use a 1-second delay after the robot closes the gripper. And a 1-second delay each time after
the robot opens the gripper.
6. Use slower approach speed.
7. Use fast on depart speed and for movements in the cell space.

Complete the preliminary diagram of positions, flow chart, program and I/O legend and schematics
prior to beginning in the lab.

Scorbot Project 3 Instructor Notes

A conditional jump is when the program will move to the specified line if the
condition is met. In Scorbot 2, you used a conditional jump IF A < 3 then JUMP to
Label LOOP.

32
A lot of industrial robots us GOTO instead of JUMP but the meaning is the same. An
unconditional jump does not need to satisfy a condition and will move to the
specified line. An example is JUMP to Label END.

An input is programmed as a conditional jump. An example of an operator start is

shown below:

If Input 1 is not pushed, it will be OFF, which makes line 3 true, triggering a
conditional jump to line 2 which is label BEGIN. Once Input 1 is pushed, line 3 is
not longer true, and therefore the robot will not jump and will execute line 4.

Input – A signal received by the controller. This usually means a switch has been
closed. If inputs are already wired into your controller, check you input assignment
before beginning the lab.

Symbols: Normally Open Pushbutton: NO PB:

Normally Open Limit Switch: NO LS

Normally Closed Pushbutton: NCPB:

Fuse Block – Controller is equipped with a fuse block. (Input light indicates switch
has been closed)
Print to Screen is important to alert operator he/she must act.

33
34
35
Input Type Describe
1 NO PB Pick Blocks
2 NO PB Drop Blocks
Project 4 – Emergency Stops
36
An industrial robot features several levels of E-stops. The highest level of E-stop is the circuit
breakers that control the electricity to the robot controller, computer and field devices. Hitting the
main “lab” E-stop will turn off all power to the lab or room and turn off all power to the circuits
controlling the workcell. This E-stop is absolute with regards to electrical safety but requires the
time consuming restart and boot of all computer and robot systems in order to get the workcell
functioning. The second level of E-stop is the normally closed robot arm power port on the robot
controller. Hitting this E-stop will halt operation of the robot but does not remove power to the
robot controller. The robot motors remain energized so a complete restart of the workcell is not
necessary. A third level of E-stop is the interruptible program state. Hitting this E-stop causes the
robot program to halt the robot. The robot system remains completely energized and the robot
remains in run mode. A safety program begins running instead of the main program. This type of
E-stop can be dangerous because the entire workcells remains running even though the robot is not
moving. The benefit is that the workcell operation can be immediately returned to the run state. A
final safety procedure is a Master Control Relay. Hitting the stop on the MCR removes all AC and
DC electrical power to the field devices. It is also good practice to have the MCR close the robot
arm power port which means that the MCR must be latched in order to operate the robot arm.

Safety devices are wired Normally Closed because if there was an electrical fault in the wiring or
solid state safety devices, it is probable that the circuit would become fused open. Level two and
level three E-stops also need to be wired Normally Closed, as the controller and programs will be
looking for a change of state from high to low indicating the E-stop circuit has been activated
(opened).

The interruptible input command is different than the normal conditional input. The normal IF
INPUT command examines the state of a specific input at only one specific instance. An if input #1
command inserted at line 38 of a robot program only examines the state of input #1 at line 38.
Pushing input #1 when the robot program is executing line 56 has no effect. The Scorbots’ On
Input Interrupt command is different because is examines that state of the specific input at every
line of the program. On Input Interrupt #1 command would cause the same conditional response if
input #1 was pushed at line 38 or line 56 or any other line.

The next program will incorporate SUBROUTINES. A subroutine is a program that is run out of
the main program. When a subroutine is called, it will run and dictate the primary operation of the
robot, but the main program will continue to run in the background. Returning from the subroutine
will end the subroutine operation and main the program will again take over operation of the robot.

A good way to understand subroutines is to draw analogies to several Hollywood movies. The first
movie to watch is The Matrix which is a story about a large computer program. This program is
similar to the main program the affects the movements of the Scorbot. Mr. Smith is an “agent” in
the movie and is another computer program. The computer program, Mr. Smith, is a subroutine and
is designed to run within the larger Matrix program when something goes wrong. You will have a
main program named Scorbot 4, which will have a subroutine program called Safety. The Safety
program will not run, unless the E-stop is pressed, indicating something has gone wrong.

Robot - Scorbot Project 4

37
Purpose To use a variety of inputs. To use a safety gate and subroutine.

Instructions:
Complete the lab using the following grading criteria.
C = correctly running program with: hand written program + printed program
with diagram of positions and program remarks + e-stop wired + I/O legend and
schematics
B = Include Flow Chart using Inspiration
A = Include Flow Chart using Inspiration and include correct light scheme.

Process:

1. Move robot to a safe location.

2. Robot to move 4 parts from the pickup to the pallet.
3. Robot to pickup part #1 on input #1.
4. Robot to pickup part #2 on input #2.
5. Robot to pickup part #3 on input #1.
6. Robot to pickup part #4 on input #2.
7. If at any time the E-stop, input #3 is opened, the robot will stop and wait for a
reset signal, input #4, to begin operating again.

Safety Gate

Pickup Pallet

Complete the preliminary diagram of positions, flow chart, program and I/O legend and schematics
prior to beginning in the lab.

Scorbot Project 4 Instructor Notes

OI – On input interrupt (Whenever the input is hit, it reacts the safety gate)

38
NC switch – If signal if OFF something has occurred.
NO switch – If signal is ON something has occurred.

Safety Sub:

1 On interrupt #3 off, call Sub Safety

2 GP1, s7
3 GP2, s3
4 ….the rest of your program.

37 …the last line of your program.

38 SET sub Safety
39 Print to Screen: “Safety situation. Push button #4 when Clear.”
40 Label: RESET
41 If input #4 off, jump to RESET
42 RETURN Sub

Interruptible Input #3 stops the main program and starts the subroutine. Input #4
allows the subroutine to complete so that it may return to the main program.

Subroutines need to be added at the very end of the program. You cannot have main
programming code after you have started coding the subroutines.

Subroutines need to be called. Subroutines need a Set and a Return.

Add remarks after program is complete.

Use wire scheme:

Red = +12 VDC

Blue = -12 VDC (ground)
Yellow = Inputs
Green = Outputs

39
Project 4 Diagram of Positions Project 4 Flow Chart

40
 I/O Legend and Schematics

Input Type Describe

1 NO PB Pick up Block
2 NO PB Drop Block
3 NC PB Program E-stop
4 NO PB Safety Reset

41
Project 5 – Outputs
42
There are 3 different type of power systems used in industrial robots. The most common is electric.
Electricity is used because it is readily available and because of commonality and availability of
electronic components. Common electrical voltages are 12 volts direct current (DC), 24 VDC, 120
volts alternating current (AC) and 240 VAC. 240 VAC and 480 VAC 3-phase are also common
electrical sources in manufacturing facilities but are much more dangerous that 120 VAC single
phase. Other advantages of the electrical power source, is that it is clean and does not contaminate
the work area, it provides direct control of the drive systems and it provides quiet operation. A
drawback is that payload may be limited as compared to a hydraulic system and that the feedback
control system is more complicated and expensive.

A hydraulic system uses a high pressure fluid (oil) to move actuators and provides high power. The
hydraulic system utilizes a pump, tank, valves and linear and rotary actuators to pressurized oil up
to 2000 psi. The drawbacks of this power source are that fluid leaks and is messy increasing the
risk of injury and fire. Additionally, the equipment is expensive and load. Hydraulic control is
often simpler as components are either on or off, and speed of actuation is controlled with flow
control valves rather than electrical feedback. Electric robots have improved significantly in their
ability to move large payloads, but hydraulics remains prevalent in industry to accomplish the
largest tasks.

A pneumatic system uses compressed air to move rotary and linear actuators. Pneumatic systems
are similar to hydraulic systems, but have substantially less power as compressed air operates at
approximately 100 psi. Pneumatic systems are popular for clamping, grippers and blow off as most
manufacturing facilities have a central compressed air system. The cost of the compressed and
equipment is less than hydraulics. Pneumatics is a well developed power source and system leaks
are not an issue. Pneumatic control systems are also usually very simple utilizing some type of
programmable controller to activate valves states (on or off).

A final type of power incorporated in robot systems is spring force. The above power systems may
work opposite a spring in order to store residual power in a system. Turning off the power source
will result in the spring force actuating a valve or fixture to the opposite state.

A controller output is an electrical voltage that originates by turning on a specific controller

terminal. Outputs may come prewired internal to the controller to be sinking or sourcing, or they
may be wired externally to source or sink. The Scorbot ER5+ controller has relay type outputs 1–4
that may be wired sourcing or sinking and can be wired to accommodate a specific voltage.
Outputs 5-16 are transistor outputs that are internally wired as sinking which means the output
common needs to be returned to 12 VDC. The internal power supply of the ER5+ controller can be
used for outputs 5-16 as long as the amp loads of the outputs are limited. The Scorbot ER4
controller has relay type outputs 1-4 which can be wired sourcing or sinking and can accommodate
a specific voltage. Therefore, the ER4 outputs will utilize an external power supply. The ER4
controllers have an internal power supply and a voltage tap on the front of the controller, but just
about any small load will cause the controller to drop out due to excessive amp draw.

Since the ER5 controller outputs are internally sinking, and because the ER4 inputs are internally
sourcing, it might be useful to wire the ER5 and ER4 relay outputs as sinking. This allows the
output field device common to be 12VDC (red) and the input field device common to be ground
(blue).
The wiring of the relay type outputs of the ER 4 and ER5 is shown below:

43
The wiring of the transistor outputs on the ER5 is shown below:

The wire color scheme that has been adopted to this point is:
Red = 12 VDC, Blue = Ground, Yellow = Inputs, Green = Outputs

Robot - Scorbot Project 5

Purpose To use inputs and outputs.

44
Instructions:
1. Complete the lab using the following grading criteria.
1. C = correctly running program with: hand written program + printed
program with diagram of positions and program remarks + outputs
wired + I/O legend and schematics
2. B = Include Flow Chart using Inspiration
3. A = Include Flow Chart using Inspiration and use variable
positioning.

2. Move the robot to a safe location.

3. The program will not start until the safety is closed. Assume it is open at the start –
OPERATOR START.
4. Move each part to the drilling location at “A” and delay 2 seconds. (1 block height above
the table)
5. At location “A” turn on the drill (output #3) for 3 seconds and then turn it off.
6. Move to location “B” for a “buffing operation” and delay 2 seconds.
7. At location “B” turn on buffer (output #4) for 3 seconds and then turn it off.
8. Move each part from pickup to pallet repeating the drilling and buffing steps. (Use a
subroutine)
9. Incorporate a safety routine that turns on a Green light (output #1) when the robot is running
and turns on a Red light (output #2) when the safety gate is broken.

Safety Gate

Drill

Pickup Buffer Pallet

Complete the preliminary diagram of positions, flow chart, program and I/O legend and schematics
prior to beginning in the lab.
Scorbot Project 5 Instructor Notes

On Output #1 – Changes state of Normally Open (NO) and Normally Closed (NC)
contacts.

Off Output #1 – Returns states for normal

45
Wire small 12 VDC computer fans to simulate drilling and buffing or use indicator
lights.

The Pickup and Pallet locations vary, but the buffing and drilling sequence is the
same for each part.

Use a subroutine drill and buff in order to reduce the amount of programming.

Use print to screens to signal drilling and buffing.

Incorporate and operator start and safety subroutine.

Remember to place subroutines after main program.

Positions do not have to be sequential.

Project 5 diagram of positions Flow Chart

46
I/O Legend and Schematics

Input Type Describe

1 NO PB Operator Start Output Type Describe
2 NO PB Safety Reset 1 Green Light Robot Operate
3 NC PB Program E-stop 2 Red Light Safety Indicator
3 Motor Drill
4 Motor Buffer

47
Recommended projects:

48