Robot modes
SM1: Manual mode with reduced speed
In manual mode, the robot can be moved manually, taught robot programs can be executed at reduced speed, or the robot can be moved manually in hand-guided mode (hand-guided control, HGC).
Manual mode is activated by setting the key switch on the control unit or an external key switch to the Manual position.
In manual mode, only the safety functions SF1 (emergency stop button), SF4 (enable device) and SF5 (Cartesian speed limit SM1) (see Secure inputs/outputs) are active. Externally connected safety devices, as well as all configured safety positions and speed limits, are disabled to allow for different levels of user interaction. The Cartesian velocity of each robot joint and the end effector is limited to 250 mm/s.
The robot's movements can only be triggered with the enabling unit (consent switch in the middle position; see Enabling unit).
SM2: Automatic mode
In automatic mode, the robot executes programmed robot programs for automatic operation. All configurable safety functions are active in accordance with the configuration set by the integrator or operator.
Measures must be taken in accordance with the requirements of the risk assessment of the robot system to provide appropriate protective devices to prevent harm to persons and damage to property.
Automatic mode is activated by setting the key switch on the control unit or an external key switch to the Automatic position.
SM3: Position recovery mode (position verification)
Each robot drive is equipped with a redundant measurement system to determine the position of the drive at the required performance level.
To ensure redundant monitoring of the respective axis positions, it may be necessary to verify the zero position of one or more base or drive modules.
A verification that needs to be performed is indicated when the drive module status indicator flashes rapidly at 5 Hz (see Status indicator for the drive modules).
The procedure for restoring a position is described in Performing a position recovery.
Switching between operating modes
The operating modes of the robot system are activated using a key switch.
You can use either the key switch of the control unit or an external key switch for this purpose.
An external key switch must meet the requirements specified in the risk assessment of the robot system. When an external key switch is connected, the key switch function of the control unit is deactivated. The operating mode can then be switched only using the external key switch. The operating mode cannot be changed on a web interface.
Only authorized and trained personnel (see Definition of users) may have access to the key for the key switch.
Illustration 15: Key switch on the control unit
- Operating mode key switch
- "Safety Reset" button
Only authorized and trained personnel may have access to the key for the key switch.
Uncontrolled switching between operating modes can pose a risk to people.
Manual mode
The robot's movements can only be triggered with the enabling unit (consent switch in the middle position; see Enabling unit).
Viewing the robot's full range of motion in manual mode
In manual mode, the axes of the robot are moved. Collisions between people and the robot can result in serious injuries.
► In manual mode, the range of motion of the robot must be fully visible.
► Before initiating the movements, the operator must ensure that no one is in the danger zone.
► Depending on the situation, the danger zone must be cordoned off with a red-and-white chain during setup.
- ✓ The robot system is fully assembled, ready for operation and powered on.
- ✓ The enabling unit is connected to the control unit.
- ✓ The system is turned on.
- ► Set the key switch on the control unit or the external key switch to the Manual position.
- ⇨ The status indicators on the drive modules light up yellow/red.
- ► Press and hold the feed control button on the feed unit in the middle position.
- ⇨ The Safety Reset button on the control unit is flashing white.
- ► Press the Safety Reset button on the control unit.
- ⇨ The status indicators on the drive modules light up blue.
- ⇒ Manual mode is enabled.
Automatic mode
Do not enter the operating area of the robot while it is in automatic mode
In automatic mode, axis movements are performed at normal speed. Collisions between people and the robot can result in very serious injuries.
► In automatic mode, never reach into the work area of the robot or enter it.
- ✓ The robot system is fully assembled, ready for operation and powered on.
- ✓ The system is turned on.
- ► Set the key switch on the control unit or the external key switch to the Automatic
position.
- ⇨ The Safety Reset button on the control unit is flashing.
- ► Press the Safety Reset button on the control unit to confirm that the system is ready for
safe operation.
- ⇨ The status indicators on the drive modules light up white.
- ⇒ Automatic mode is on.
See also
Status indicator for the drive modules
The status indicator lights up when the EtherCAT connection is established. The status indicator shows the current operating mode using different colors and flashing patterns.
Illustration 16: Status indicator on the drive module
- Status indicator
| Operating mode | Pattern | Color |
|---|---|---|
| Automatic mode | Continuous light | White |
| Manual mode | Continuous light | Blue |
| Manual node – hand-guided control (HGC) | Pulsating light at 0.65 Hz | |
| Position recovery | Continuous light: Zero position detected (or not lost) Flashing at 5 Hz: The drive requires verification of the zero position | |
| Position recovery – free movement enabled | Pulsating light at 0.65 Hz: Zero position detected (or not lost) Flashing at 5 Hz: The drive needs to return to its zero position | |
| Safe stop 1 | Continuous light | Red |
| Safe stop 1 – ready for reset | Flashes at 1 Hz | |
| Invalid mode (key switch in automatic mode, but at least one drive has lost its safe position) | Continuous light: Zero position detected (or not lost) Flashing at 5 Hz: The drive needs to return to its zero position | |
| Safe stop 1 – ready to reset (position recovery) | Flashes at 1 Hz: Zero position detected (or not lost) Flashing at 5 Hz: The drive needs to return to its zero position | |
| Safe stop 2 | Continuous light | Yellow |
| Safe stop 2 – ready to reset | Flashes at 1 Hz | |
| Error | Continuous light | Purple |
| Profinet identification | 3 flashes at 1 Hz, followed by a 1-second pause | Green |
Table 6: Indication of operating modes on drive modules
Performing a position recovery
Position recovery must be performed for each affected drive, starting with the base module.
- ✓ The robot system is fully assembled, ready for operation and powered on.
- ✓ The enabling unit is connected to the control unit.
- ► Set the key switch on the control unit to the Manual position.
- ► Press and hold the feed control button on the feed unit in the middle position.
- ► Press the Safety Reset button on the control unit.
- ⇨ Manual mode is enabled.
- ⇨ The sum of the absolute values of all angular velocities of the drives may not exceed 4 degrees/s so that a Cartesian velocity of 250 mm/s is not exceeded, regardless of the robot's configuration.
- ► Use the RobCo Studio control software to trigger the movement of the drive module to the zero position.
- ► Check to see if the zero-position markings on the housing and the output flange of the drive module are aligned with each other (see the following figure).
Illustration 17: Markings for the zero positions on a drive module
- Zero position marking on output flange
- Zero position marking on housing
- ⇨ The zero-position markers are not aligned with each other: The drive is defective and needs to be replaced. Please contact RobCo Service.
- ⇨ The zero-position markers are aligned with one another: The position of the drive has been verified.
- ► Press and hold the Safety Reset button on the control unit for at least 3 seconds until the drive module status indicator stops flashing at 5 Hz.
- ⇒ Position recovery for the drive module is complete.
If additional drive modules indicate that a verification is required, perform the verification as described above.
Once the positions of all drive modules have been successfully restored, normal operation can resume.