UR Controller and Forge/Ctrl
READY Robotics do NOT constitute safety advice. Products sold through READY Robotics are not by themselves a fully integrated workcell. As
required in ISO 10218-2, READY Robotics strongly recommends performing
a complete risk assessment of the integrated workcell per ISO 12100. You
may wish to use the methodology found in the ANSI/RIA TR R15.306 Task-
based Risk Assessment Methodology.
Contents
Introduction . . . 5
Overview of the system . . . 5
Forge/Ctrl components . . . 6
Technical specifications . . . 9
Mounting the Forge/Ctrl . . . 12
Connect your UR Controller to the Forge/Ctrl . . . 13
Forge/Ctrl Setup . . . 22
Setting Up Forge/OS on UR . . . 28
Forge/OS . . . 42
Hardware configuration . . . 44
Turning OFF the Forge/Ctrl . . . 46
Introduction
The Forge/Ctrl is an industrial, IP54-rated computer running Forge/OS. This product allows you to interface with multiple brands of robots, machine tools, PLCs, vision systems, force sensors and other peripherals using a standard set of I/O interfaces including pneumatics and fieldbus connectors.
This guide will begin by outlining an overview of the system, Forge/Ctrl components, and technical specifications. Then, this guide will walk you through the following setup procedure:
1. Mount the Forge/Ctrl
2. Connect the UR Controller to the Forge/Ctrl 3. Connect the Forge/ Ctrl to power and air
4. Complete Initial Configuration on the READY Pendant 5. Complete Hardware Configuration on the READY Pendant
After you finish this process, you will be ready to start programming your system with Forge/OS!
Overview of the system
Forge/Ctrl READY Pendant
Element Description
Forge/Ctrl The hardware which has an industrial computer with the necessary interfaces to automate a workcell.
Forge/OS The operating system designed by READY which runs applications that assist in automating the workcell.
READY Pendant The Human-Machine Interface (HMI) for Forge/OS and Task Canvas.
Task Canvas The application which assists the user in programming a robot for automation running on Forge/OS.
Forge/Ctrl components
Left Side
Interfaces of the Forge/Ctrl on the Left Side
Element Description
120V 15A Power NEMA 5-15r which supplies 120VAC at 15A and can be used to supply power to Universal Robot products.
Power Disconnect Switch to safely energize and de-energize the Forge/Ctrl and its peripherals.
Power Cable NEMA 5-15 Plug to supply power to the Forge/Ctrl and its connected peripherals.
Air Input Industrial Quick Disconnect Plug to supply air to the Forge/Ctrl.
Exhaust Push-to-Connect Fitting for the internal solenoids of the Forge/Ctrl.
Right Side
Interfaces on the Right Side of the Forge/Ctrl
Element Description
WAN, LAN 1, LAN 2 Ethernet Ports to connect the Forge/Ctrl to the internet.
Note: LAN 2 is located on the Top Side of the Forge/Ctrl
Power Button Push Button to turn ON or turn OFF the Forge/Ctrl. The button lights up to indicate the state of the Forge/Ctrl.
USB 1, USB 2 USB Type A Ports.
HDMI HDMI Port to connect to the READY Pendant.
PLC Module 26-Pin Amphenol Connector to connect to READY's PLC Breakout Box.
Air Out 4mm Push-to-Connect Fitting for 4mm air hose.
Air Out 6mm Push-to-Connect Fitting for 6mm air hose.
Top Side
Interfaces on Top of the Forge/Ctrl
Element Description
LAN 2 Ethernet port to connect the Forge/Ctrl to the internet.
Module 1, 2, 3 M12 Connectors customizable by READY.
Technical specifications
Power Requirements
Voltage Input 120VAC
Current 15A
Power Output
NEMA 5-15r 120VAC, 10A (READY Pendant or Universal Robot Power Only) Short Circuit and Overcurrent Protection: 10A Circuit Breaker 4-Pole M12 Connector 12VDC, 4A (READY Pendant Power Only)
Electronic Short Circuit and Overcurrent Protection PLC Module
(Through PLC Breakout Box ONLY)
24VDC, 2.5A Total. (Combined Between 24V Power Pins and All Outputs)
Electronic Short Circuit and Overcurrent Protection PLC Inputs (Through PLC Breakout Box ONLY)
Quantity, Type 8x, Sinking
Rated Voltage 24VDC at 4mA, nominal
Continuous Permissible Voltage 30VDC, max.
Logic 1 Signal (min) 15VDC at 2.5mA
Logic 0 Signal (max) 5VDC at 1mA
Max. Cable Length (meters) 500m Shielded, 300m unshielded PLC Outputs (Through PLC Breakout Box ONLY)
Quantity, Type 8x, Solid State - MOSFET (Sourcing)
Current (max.) 0.5 A
Surge Current 8A for 100ms
Inductive clamp voltage L+ -48 V DC, 1 W dissipation.
External Suppression must be used for most inductive coils Max. cable length (meters) 500m Shielded, 150m unshielded
Air Requirements
Main Air Input 90-100 psi
Installing an Air Filter is Highly Recommended to Increase System Life
Air Input Quality Dry air with a 5µm Particle Filter
Air Output 4mm 4x 4mm Push-to-Connect Fitting
Air Output 6mm 4x 6mm Push-to-Connect Fitting
Environmental
IP Classification IP 54
Max Operating Temperature 45 degrees C (113 F) Min Operating Temperature 0 degrees C (32 F)
Weight 19 kg (41.8 lbs)
Dimensions (enclosure only) 400 x 400 x 210 mm (15.75 x 15.75 x 8.25 in) Connectivity
Ethernet 2x LAN Ports
1x WAN Port
USB 2x USB Type A Ports
Mounting the Forge/Ctrl
The Forge/Ctrl may come equipped with a set of Mounting Feet. Use them to mount the Forge/Ctrl to your desired location.
Units: [in] mm
Connect your UR Controller to the Forge/Ctrl
IMPORTANT: This document assumes that you have mounted your robot in accordance with UR's guidelines. You can download their documentation athttps://www.universal-robots.com/download/. Enter SW 5.4 for your UR software version.
Link subject to change without notice. Current as of April 15, 2020
UR Robot UR Controller and Pendant Forge/Ctrl
Replacement Panel Ethernet Pass Through Dust Cover
UR Controller Box Key Ethernet Cable(s): 3ft, 15ft Bit Driver with T20 TORX Bit Ensure that your UR Controller is not plugged into a power source.
1
Open the UR Controller by inserting the controller key and turning it clockwise.
2
Use the T20 TORX bit to remove the screws for the UR Controller side plate.
Note: Keep the screws in a safe location, you will need them to attach the replacement plate.
3
Feed the wires for the replacement plate through the UR. These wires connect to terminal blocks that will eventually be attached to the UR controller.
4
Use the screws that you removed in step 3 to attach the replacement plate.
5
Connect the wires from the replacement plate to the terminal blocks according to the table and diagram below.
6
Locate the Ethernet Pass Through and remove the nut that’s on it. Do not lose the nut, as you will need it later.
7
Locate the Dust Cover and place its loop over the connector. Ensure that it is seated against the gasket.
8
At the bottom of the UR controller is a hole with a plug in it. Remove the plug and insert the silver side of the connector into the hole at the bottom of the UR controller.
9
Locate the nut that you removed from the Ethernet Pass Through. Screw the nut onto the Pass Through until it is hand-tight against the controller wall.
10
Locate the shorter Ethernet cable and plug one end of it into the Ethernet Pass Through.
11
Plug the other end of the cable into the port beneath the terminal blocks.
12
Close the UR Controller and turn the key counterclockwise to lock the door shut.
13
Locate the longer ethernet cable and plug one end of it into the Ethernet Pass Through.
14
Unscrew the dust cover on the LAN1 port on the Forge/Ctrl and plug the other end of the ethernet cable into it.
15
Plug your UR robot’s cable connector into the metal socket at the base of the UR Controller by pushing the cable against the socket firmly so that it’s seated in the port and then turning the collar clockwise.
16
Next, plug your UR’s power cable into the port at the base of the UR Controller.
17
Forge/Ctrl Setup
This section assumes that you have completed the instructions from "Connect your UR Controller to the Forge/
Ctrl".
Forge/Ctrl UR Controller and Pendant READY Teach Pendant
Connect the READY Pendant to the Forge/Ctrl. The READY Pendant has 4 connectors: HDMI, USB, 4-Pin M12 circular connector, and a 12-pin M12 circular connector. The 4-Pin M12 circular connector is the 12V power cable, and the 12-pin M12 circular connector is the safety connector.
Note: The cables that connect to the Forge/Ctrl must be plugged in by pushing the cable against the socket firmly so that it's seated in the port, and then turning the collar clockwise to secure it.
1
Plug the Pendant HDMI into the HDMI port on the Forge/Ctrl.
1
Plug the Pendant USB into one of the two USB ports on the Forge/Ctrl.
2
Plug the Pendant 4-pin M12 power cable in the 12V Power port on the Forge/Ctrl.
3
Plug the Pendant 12-pin M12 Safety connector into the UR Controller Replacement Plate that was installed during the “Connect your UR Controller to the Forge/Ctrl” subsection.
4
Locate the gray NEMA 5-15 power cable connected to the left side of the Forge/Ctrl. Plug the cable into a 120V power outlet.
2
Power Requirements
Voltage 120VAC
Current 15A
Typical Consumption
5
Plug the black power cable from the UR Controller into a power source.
3
Turn on the Forge/Ctrl by turning the Power Disconnect Switch to the ON position.
4
If the green power button light on the Forge/Ctrl does not turn on, press it to turn the Forge/Ctrl on.
Press the power button on the UR Teach Pendant to turn it on (it will turn green).
5
Connect the Forge/Ctrl to an air supply.
There is a Quick Disconnect Plug on the left side of the Forge/Ctrl that is connected to the internal solenoids.
6
Air Requirements
Main Air Input 90-100 psi
Installing an Air Filter is Highly Recommended to Increase System Life Air Input Quality Dry air with a 5µm Particle Filter
Connectivity Industrial Quick Disconnect
Coupling Size 1/4
Plug Tip Length 3/16"
Plug Tip Diameter 5/16"
To connect shop air to the system, pull back on the outer cylinder of the socket.
1
Connect the quick disconnects together and then release the outer cylinder to secure the connection.
Note: Do not disconnect the air supply while the system is on. Removing air from the system will prevent certain peripherals and end effectors from working properly.
2
Setting Up Forge/OS on UR
After the power is turned on on your Forge/Ctrl and UR teach pendant, your pendant should show a sequence of screens and then arrive at the End User License Agreement (EULA).
1
Please read and accept the EULA.
2
If your system boots to the Hardware Configuration screen, then Initial Config is already configured and you can skip to step 16. Otherwise, continue to step 4.
3
Next, you will see the network selection screen. Select the type of network that you would like to use or tap SKIP if you do not want to configure a network at this time. You can revisit and change your network settings at any point after your system is configured.
Cellular Your Forge/Ctrl comes with an internal cellular modem. If you do not know your facility’s wireless settings and want to connect to a network, select CELLULAR.
Wireless If you select WIRELESS, you will need to enter the wireless network name (SSID) and password.
Wired If you select ETHERNET, you can connect your Forge/Ctrl to the internet by using the WAN Ethernet port on the Forge/Ctrl.
4
Next, you may wish to set up Administrative (Admin) PIN. Forge/OS offers two roles, an Operator and an Administrator.
▪ Operator: limited to loading existing tasks/setups and executing tasks.
▪ Administrator: full access to all the features and functionality in Forge/OS.
For a full list of permissions, see the "User Roles" subsection of "The Control Suite" chapter in the user manual.
5
Note: If you choose not to create a PIN during initial configuration, you can create one at any time after your system is configured.
IMPORTANT: If you set up an Admin PIN right now, then your system will start in the limited Operator role each time the system is reset. To switch to Admin mode, you must tap the menu labeled READY ROBOTICS in the bottom left corner of the screen and then tap USER ROLES and select
Administrator.
Tap NO to skip this step or tap YES if you would like to set up this feature.
1
If you tap YES, enter the 4-digit pin that you would like to use.
Enter the pin. Tap SAVE PIN. The pin is saved in the system.
IMPORTANT: If you lose or forget your PIN you will have to contact READY technical support to reset it. The READY support number is 1(833)732-3977.
2
Select the timezone in which your Forge/Station is located. Scroll in the list to locate your timezone. Tap the timezone listing that corresponds to your location. After selecting your timezone, tap NEXT.
6
On the next screen, select Universal Robots and then tap NEXT.
7
Select the model of your Universal Robots robot arm on the next screen.
8
The next screen provides selection for if your robot has an internal force sensor. If you are using a Universal Robots e-Series cobot, there is a built in force sensor , so tap YES.
The next screen asks if you have a READY TeachMate with your robot. TeachMate V1 and V2 are shown below. If you are not using either of these, tap NO and skip to step 12. If you have one of these, tap YES.
If you indicated that you do have a TeachMate, you will be asked which version of the Teachmate you are using and if the TeachMate is inline with your end effector. If the TeachMate is mounted onto wrist 3 like in the image below, tap YES.
9
The IP Address and other network information on this screen needs to be entered into the network settings of the UR Pendant.
Shift your attention to the UR teach pendant.
1
Tap the "hamburger" menu in the top right corner of the screen.
2
Tap on Settings from the drop down.
3
Tap on System in the left menu. This should open up a fly out menu, and in there tap on Network.
4 10
Tap the radio button next to Static Address.
5
Enter the IP address, Subnet mask, Default gateway, preferred DNS server, alternate DNS server as specified on the READY Pendant.
IMPORTANT: Make sure to hit the green check mark when entering values on the UR or the value will not be saved.
6
Once you have entered the information (the exact numbers may be different for your system), tap Apply.
7
You should see a green check mark next to Network is Connected if the settings are applied successfully.
8
Locate the provided USB thumb drive and plug it into the open USB port on the READY Forge/Ctrl.
11
IMPORTANT: If you were not provided with a USB thumb drive or cannot locate it, you can use any thumb drive that has 2GB or more of space; however, this step will will erase the files on it. Ensure that you back up any important data.
When the USB thumb drive is inserted, on the Forge Controller, a green check mark will show that the drive has been successfully connected.
Tap NEXT.
1
Forge/OS will copy files to your USB thumb drive, and you should see a couple screen changes . 2
12
Once the files are copied, tap OK to continue.
13
On this next screen, remove the USB Thumb Drive from the READY Forge/ Ctrl so that you can insert it into the UR teach pendant.
Locate the USB port on the top right of the pendant attached to the UR controller. Plug the USB thumb drive into this USB port. The pendant will say Uploading safety program and then Remove USB drive.
1
Remove the USB Thumb drive from the UR Pendant.
2 14
Now you must reset the UR controller from the UR pendant. Press the power button and then select Restart from the menu that pops up.
Note: If you accidentally power off the UR controller, just power it back on once it is completely off.
3
Wait for the UR controller to boot up again.
4
Once the UR controller is restarted, put the robot into "remote" mode by following these steps.
Tap the “hamburger” menu in the top right corner. Tap Settings to get to the settings screen, and tap System.
1
Tap Settings to get to the settings screen, and tap System.
2
Tap on the Remote Control from the System drop down menu.
3
Tap Enable. This will enable remote mode so that Forge/OS can control the UR robot arm.
4 15
Tap the pendant icon in the upper right hand corner of the screen that says Local under it. Then tap Remote Control.
5
Check that the Forge Pendant has updated to the following screen. Tap NEXT to continue.
6
Forge/OS
Forge/OS
Forge/OS is the READY operating system on which you can program and execute applications for a variety of robot and automation systems. Forge/OS includes applications for creating robot tasks, manually configuring and controlling attached devices, and communicating job information from an automated cell to help track productivity.
Applications
Double check your configuration settings on the next screen. Tap COMPLETE SETUP once the correct settings are recorded.
Note: UR controller may not finish booting before you tap COMPLETE SETUP in the previous screen. Wait for the UR Teach Pendant to show that the UR Controller is running before tapping COMPLETE SETUP. It may take up to 2 minutes for the Forge/CTRL to configure properly.
7
The controller will display a loading screen, that will say WELCOME, TO, FORGE/OS. Then the
Hardware Configuration screen will load once the configuration is complete. Tap on the bell icon on the bottom right of the screen. Then tap FIX. Now the Forge/Station is configured and ready for automation.
16
Forge/OS has two native applications for configuring and controlling your automation equipment. Hardware Configuration enables you to select and modify attached devices and will open when you first power on your system. Task Canvas is where you can assemble the blocks and flowchart that create an executable task for all of the devices you configured in Hardware Configuration.
The first time you boot up a Forge/OS system you will go through the Initial Configuration process to set up basic system settings, the attached robot arm, and peripherals specific to the arm. For information about the Initial Configuration of your Forge/OS system, see the Initial Configuration chapter.
Whenever you start Forge/OS after completing Initial Configuration, you will begin at Hardware Configuration.
For information about setting up tools and devices, see the Hardware Configuration chapter.
Home Screen
The home screen is the landing screen outside of Forge/OS applications.
Tap Create Task to access TaskCanvas with a new task.
Tap Load Task to access the Current Tasks screen and view the saved tasks on your system.
The Status Bars on the left and right edges of the screen display the current mode of the Forge system.
The Control Suite across the bottom of the screen gives you access to System Settings and manual controls for the robot and attached devices.
System Modes
The current mode of the Forge system is indicated by the status bars on the left and right edges of the screen.
If you have a TeachMate, it will also indicate the current mode with the colored LED.
▪ Teach mode is for programming tasks and executing task actions at safe speed. In Teach mode, you can Step blocks on the Task Canvas and move the robot arm at a reduced speed. You can also manually control attached devices and pneumatic ports.
▪ Run mode is for executing Task Canvas tasks at full speed. Depending on your hardware and safety configuration, all safety devices must be active and functional to enter Run mode.
▪ Robot Warning mode is a programming mode during which you cannot move the robot arm. You can access manual controls for certain devices in robot warning mode and you can still program all block types in Task Canvas. On Universal Robots arm, Robot Warning is also triggered by the robot arm’s Protective Stop mode.
▪ Robot Error indicates that something is wrong with the Forge/OS system, robot arm, or attached devices.
You cannot execute any functions in Robot Error and will have limited functionality in some applications, such as Hardware Configuration.
▪ (Universal Robots arms only) Guide mode allows you to move the robot arm by hand. When the arm is in Guide mode, you will have the same motion control as when holding the Teach button on the back of the UR pendant.
Hardware configuration
The Hardware Configuration defines the tools and devices attached to your Forge system. Throughout Forge/
OS, different screens will present you with options for controlling only the tools and devices that are configured in the Hardware Configuration, limiting available controls to those relevant to your hardware and hiding those that are not. The options available in this application may differ depending on your robot manufacturer and model and the information you entered when configuring your Forge system for the first time.
Element Description
Device Selection Select pre-configured tooling and peripheral devices; create/modify and select custom Tool Center Points (TCPs) and Payloads to be used by Forge/OS.
3D Visual Rendering View the visualization for a loaded TCP and Payload (center of mass).
Save Save the current configuration to the Forge system. All parameters, including tools, devices, TCPs, and Payloads, will be saved to the configuration.
Load View, load, and delete existing configurations Accept Apply the configuration to the Forge system.
Cancel Cancel any changes and revert to the previous settings.
Turning OFF the Forge/Ctrl
To turn off power on the Forge/Ctrl, press the Power Button on the right side of the Forge/Ctrl.
1
On the READY Pendant, select SHUTDOWN.
2
Wait until the READY Pendant is powered down and the green light on the Power Button is OFF.
3
On the left side of the Forge/Ctrl, turn the Power Disconnect Switch counterclockwise.
4
