When the target model number is -1, the robot model of the target motion group is checked in the zone check.
Tool model
Tool model is used when the Tool Change Function is used (refer to 3.8.1 Tool Change Function).
When the target model number is -2, the tool model of the target motion group is checked in the zone check. In this case, the tool model is the user model that is assigned to the DCS Tool Frame that is currently selected (refer to 3.8 DCS TOOL FRAME). When the Tool Change Function is not used, the target model should not be -2, the user model number of the tool shape should be set to the target model directly.
WARNING
If the target model number is set incorrectly, the safety function will not work, and serious personal injury could result. When the target model number is changed, the values must be verified and the function must be tested again.
3.4.2.4 Process time factor
The number of zones and models are limited to prevent processing time from becoming too long when too many zones and models are checked.
The following table shows the process time factor of each shape element. The process time factor is different for each method of safe zone to be checked.
Process time factor of shape elements
Shape of element
* In "2 spheres" case, each sphere is regarded as one Point if the size is not 0.
* When DeviceNet Safety, EtherNet/IP Safety or PROFINET Safety is used, 400 is added to the process time factor.
* When Safety function by FL-net is used ("Enable/Disable" in DCS Safety function by FL-net menu is "ENABLE"), 200 is added to the process time factor.
* When Safety PMC is used ("Safe I/O process" in DCS Safe I/O device menu is "Safety PMC"), 100 is added to the process time factor.
The process time factor of one safe zone is calculated as the total of all the elements in the target model.
The system total process time factor is the total of the process time factors of all enabled safe zones. If the system total process time factor is greater than 1000 and you apply DCS parameters, the message " Too many zone or models!" will be displayed. The number displayed with this message is the system total process time factor of the current setting parameters.
The system total process time factor is also displayed in the DCS Cartesian Position Check list menu.
The process time factor of Box is much greater than Point and Line-seg. To make the process time factor small, it is effective to replace the Box by combination of Point or Line-seg.
3.4.2.5 Recovery from alarm
When any shape model is outside of the defined safe zone, a DCS Cartesian Position Check alarm occurs and cannot be cleared. To move the robot to the safe zone, select T1 mode, and enable the Teach Pendant and press and hold the SHIFT and RESET keys, and jog the robot. If the SHIFT key is released while the shape model is still outside of the defined safe zone, the alarm occurs again and motor power is shut
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down. The frame position and orientation just before the DCS Cartesian Position Check alarm occurs is recorded. The robot can be jogged toward the recorded position and orientation, but if the robot moves away from the recorded position, the alarm occurs again and motor power is shut down.
When a DCS Cartesian Position Check alarm occurs because the DCS Cartesian Position Check is changed from disable to enable by a disabling input, the robot can only return to the position just before the alarm occurred by this operation. If this position is not in the safe zone, the alarm occurs again. To recover from the alarm, DCS Cartesian Position Check should be disabled by the disabling input. In this case, the robot can move as far as the stopping distance when the alarm occurred even out of the safe zone.
Please take care especially in the case where the stopping distance is large, for example when stop type is set to control stop.
When servo power is turned on, the robot moves slightly. To avoid DCS alarms by this motion, a very short motion is allowed even though the robot moves away from the recorded position. The robot can move slightly away from the recorded position, because the DCS alarm occurs when the moved distance of the robot exceeds the allowed short motion. If the payload setting of the robot is not correct, the motion at the servo power on becomes big, and the DCS alarm may occur. In this case, please check the payload setting or change the setting of the position check to disable temporarily.
The following describe the cases where the recorded position and orientation data are lost and cannot be recovered. To recover from the alarm in these cases, please temporarily disable the Cartesian Position Check.
- The motor or Pulsecoder is replaced, and the robot position becomes out of the safe zone.
(In this case, the position check temporary disable function that is explained later can be used.) - The Zone or shape model is changed and applied to DCS parameters, power to the controller is
cycled, and the current position becomes out of the safe zone.
- The controller power is turned off while the robot is moving, and the robot exits the safe area by momentum movement.
- The mastering parameters or robot setup data is changed and applied to DCS parameters, power to the controller is cycled, and the robot becomes out of the safe zone.
3.4.2.6 Position check temporary disable function
When the motor or Pulsecoder is replaced and the robot position becomes out of the safe zone, the robot sometimes cannot move far enough to recover from the situation by the above SHIFT and RESET operation. In this case, the operator needs to disable position check temporarily, then do some operation to recover from the situation such as mastering, then the setting of the position check is restored to enable.
The position check temporary disable function supports the operation to recover in this situation by changing the setting of the position check to DISABLE automatically when calibration is not completed (the calibration becomes not completed when the motor or Pulsecoder is replaced), and restoring the setting to ENABLE automatically when the calibration is completed.
This function is disabled by default. To enable this function, please set the system variable
$DCSS_SETUP.$CALMD_ENB to 1 (DISABLE is 0). When this function is enabled, the operation to recover the situation is the following.
1. When the calibration of the motion group that is used for the Cartesian position check or the Joint position check is not completed, the alarm "SYST-212 Need to apply to DCS param" occurs.
2. Do the operation to apply DCS parameter in DCS menu.
At this time, the setting of the all Cartesian position check and the all Joint position check that are setup for the motion group that the calibration is not completed are changed to DISABLE. Please check the setting displayed in the verify menu that is displayed after the code number is entered, and press F4(OK). (At this time, detail menu of the position check that is disabled automatically shows the message "Not calibrated! DISABLED temporarily!".)
If the local code number is defined, the required code number of this operation is "Base" code
B-83184EN/04
3.POSITION / SPEED CHECK FUNCTION
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number. (Because this operation is a part of mastering operation, and the same code number with the operation to change the mastering parameter is used.)
3. Cycle power to the robot controller.
4. The position check function is disabled now. Do the operation to recover the situation such as mastering.
5. When the calibration is completed, the alarm "SYST-212 Need to apply to DCS param" occurs.
6. Do the operation to apply DCS parameter in DCS menu.
At this time, the setting of the all Cartesian position checks and the all Joint position checks are restored to ENABLE. Please check the setting displayed in the verify menu that is displayed after the code number is entered, and press F4(OK). (At this time, detail menu of the position check that is restored to enable shows the message "Calibrated! Restored to ENABLE!".)
If the local code number is defined, the required code number of this operation is "Base" code number.
7. Cycle power to the robot controller.
CAUTION
- When this function is enabled, the alarm "SYST-212 Need to apply to DCS param" always occurs when the calibration of the motion group that is used for the Cartesian position check or the Joint position check is not completed, and the operation to apply DCS parameter is necessary.
- If any setting of Cartesian position check or Joint position check is changed such as the setting of safe zone, the position check temporary disable function is cancelled. For example, when the setting of the safe zone is changed during the operation of the above step 4, the operation will be the following.
1. The alarm "SYST-212 Need to apply to DCS param" occurs.
2. Do the operation to apply DCS parameter in DCS menu.
At this time, the new safe zone setting is applied, and the setting of the all Cartesian position check and the all Joint position check restored to ENABLE.
If the local code number is defined, the required code number of this operation is "Pos/Speed"
code number.
3. Cycle power the robot controller.
4. The alarm "SYST-212 Need to apply to DCS param" occurs. (Because the calibration of the motion group that is used for the Cartesian position check or the Joint position check is not completed.)
After that, go to step 2 in the above operation.
3.4.2.7 Approach warning signal output function
This function turns ON a DO signal when the shape model approaches the border of a safe zone in a DCS zone check function. When the distance from the border of the safe zone is less than the specified margin, the DO signal stays ON.
The index of the DO is set in $DCSS_SETUP.$DO_IDX.
The margin is set in $DCSS_SETUP.$DO_MGN. The unit is mm. The default value is 100 mm.
When the value is changed, cycle power is necessary to use the new value.
Please note the following about the approach warning signal output function.
- The approach is checked by the position relationship between the shape model and the safe zone.
The stop position prediction function and operation to recover from alarm does not affect this function.
- When the setting of DCS zone check function (safe zone, shape model, tool frame and so on) is invalid, the approach warning signal output is always set to OFF.
WARNING