power & force limiting (pfl) application...

May 12, 2017 | 1© 2017 YASKAWA CONFIDENTIAL INFORMATION ALL RIGHTS RESERVED | YEU_PPTX_Template_2017© 2017 YASKAWA CONFIDENTIAL INFORMATION ALL RIGHTS RESERVED | GLOBAL TEMPLATE

POWER & FORCE LIMITING (PFL)

APPLICATION GUIDE

HC10

May 12, 2017 | 2© 2017 YASKAWA CONFIDENTIAL INFORMATION ALL RIGHTS RESERVED | YEU_PPTX_Template_2017

APPLICATION SUMMARY

1. Power & Force Limiting (PFL) Function Example

○ Broadly describes what PFL is and how it can be used in a

simple Pick & Place application

2. Tool Setting

○ Describes how to properly configure a tool for a PFL-enabled

application

3. PFL Modules

○ Details each step for properly configuring a PFL-enabled

application with multiple zones

4. PFL Application with No Zones (Example)

○ Highlights the differences (configuration, settings) between a

PFL application with and without zones

5. Clamping Prevention

○ Describes how to configure a zone to stop the robot before

a clamping scenario occurs


CONTENTS

1. Power & Force Limiting (PFL) Function Example

2. Tool Setting

2.1 Basic Tool Setting (Manual & Automatic)

2.2 Tool Interference Setting

2.3 Tool Number – How To Program

3. PFL Modules

3.1 {SLC EXT. Signal Allocation}

3.2 {Robot Range Limit}

3.3 {External Force Limit}

3.3 {Speed Limit}

3.5 {Safety Logic Circuit}

4. PFL Application with No Zones (Example)

5. Clamping Prevention

Legend:

{Menu on Pendant}

[Membrane Button on Pendant]

Manual Reference Material

Important Note

“Term in Manual”


1. POWER & FORCE LIMITING (PFL) FUNCTION EXAMPLE

• The PFL Function detects external forces using embedded sensing in the robot

• If an externally detected force exceeds a user-defined limit, the PFL Function will stop the robot

• To successfully program a Pick & Place application, two conditions must be met:

1. The normal external force produced by part contact (gripping or releasing) should not stop the

robot

2. {External Force Limit} and {Speed Limit} in Zones 1 & 2 should be lowered to avoid clamping

dangers

Pick: Place:

Zone 1

Zone 2


1. PFL FUNCTION EXAMPLE

Pick:

Place:

Zone 1

Zone 2

PFL Setting Other Space Zone 1&2

External

Force

Limit

PFL Input Signal PFLIN01 PFLIN02

X (N) 100 50

Y (N) 100 50

Z (N) 100 50

Resultant (N) 100 50

Speed

Limit

Speed Input Signal MS-OUT01 MS-OUT02

Speed Limit (mm/s) 250 100

Part Contact & Impact Avoidance:

• Tool # Change (Example: MOVx Tool 0 -> MOVx Tool 1)

• A Tool # Change command will disable the PFL function for the

first 5mm of a programmed move to prevent a “pseudo-impact”

due to intended contact with a part (see more detail on Page 10)

External Force & Speed Limits:


2.1 BASIC TOOL SETTING – MANUAL INPUT

• For a simple Pick & Place application to work properly, two different tool states must be considered

1. Gripper without part (Tool 0) 2. Gripper with part (Tool 1)

• In the current implementation for PFL, these states are treated as separate tools on the YRC1000

pendant (each with their own set of properties)

• Therefore, the weight of Tool 1 above should be the sum of the gripper & the part

Tool 0

Reference Material: YRC Instructions (178642-1CD) 8.3.1 Tool Data Setting

Tool 1

1

6kg


2.

1.

• The “Automatic Measurement” function can be used to automatically calculate tool

settings

• On the Top Menu, select {UTILITY} -> {W.GRAV.POS MEASURE} to use the function

Reference Material: YRC Instructions (179531-1CD)

8.3.3

2.1 BASIC TOOL SETTING – AUTOMATIC MEASUREMENT

*Note – At this time, YII

recommends manually

configuring tool

settings using accurate

CAD data for a given

end effector


2.2 TOOL INTERFERENCE SETTING

• PFL function uses the {Robot Range Limit} module to

detect whether the entire robot body, including tool

interference (not the TCP position) enter a user-defined

zone

• These zones can be used to slow down or stop the robot

• Tool Interference must be defined to use the {Robot

Range Limit} module

• To enter the function:

{Main Menu} -> {ROBOT} -> {TOOL INTERFERE}


2.2 TOOL INTERFERENCE SETTING

Reference Material: YRC1000 Options - Arm Interference with Specified Cubic Area Check Function (178679-1CD) 1.2.2 Tool

Interfere File

Window Details

1. Up to 5 models (cylinders & spheres) combined as the tool shape

2. “Point1” and “Point2” coordinate values: the position of the ends of each cylinder

3. “Radius”: radius of the cylinder and the sphere


2.3 TOOL NUMBER – HOW TO PROGRAM

Pick:

Place:

MOVL P001 V=100 (Tool 0)


DOUT OT#(x) ON


Update the tool information on controller (same

position)

Turn the gripper ON

PFL is OFF during the first 5 mm move5mm

Notes:

• Tool No. information can only be updated during a motion command

(MOVx)

• “MOVx (Tool Update)” and “DOUT” are currently always used in

conjunction to achieve the Tool # change for the controller and the

gripper

• A Tool No. Change command (MOVx Tool 0 -> MOVx Tool 1) will disable

the PFL function for the first 5mm of a programmed move to prevent a

“pseudo-impact” due to intended contact with a part (*this is TUV

approved)

Use Together



1. Press [SHIFT] + [TOOL SEL] to open the tool list

2. Jog the cursor to the desired used Tool No.

3. Press [SHIFT] + [TOOL SEL] again to finalize the

selection

Tool No. Select Window

Currently Selected Tool No.How to change Tool #:



01

• Check all commands with Tool No. before executing the program

• The Tool No. for a selected line in the INFORM Editor can be read from the job header (see left)

• An easier way to check Tool No. for the entire job is to display the “Tool No. Column” (see right)

• How to Enable: {Top Menu} -> {DISPLAY} -> {ENABLE TOOL NO}

• If a Tool No. is wrong, jog the cursor to a specific line, select the intended Tool No., and overwrite the line ( [MODIFY] +

[ENTER] )

Tool No. for the Selected Line

Tool No. Column


3. PFL MODULES

PFL Modules in {Safety Func.} Menu

1. {SLC EXT. Signal Allocation}

2. {Robot Range Limit}

3. {External Force Limit}

4. {Speed Limit}

5. {Safety Logic Circuit}

Reference Material: YRC1000 Options Instructions for Functional Safety Function (178949-1CD) for Details of Functional

Safety Function


3. PFL MODULE SUMMARY CHART

Robot Range Limit External Force Limit

Signal: FS-OUTxx Signal: PFLINxx

Link

Safety Logic CircuitSLC EXT. Signal Allocation

Robot

Position

Output Input

PFL Force

Limit

Allocate

Signal: MS-OUTxx

Speed Limit

Input

PFL Speed

Limit


NOT USED -> F-SAFE #1

FS-OUT01 Zone 1

FS-OUT02 Zone 2

• The {F-Safety Signal Allocation} module is used to

designate a signal “FS-OUTxx” as the output signal

of the {Robot Range Limit} module (this alerts the

system when the robot enters a zone)

• {Main Menu} -> {SAFETY FUNC.} -> {F-SAFETY

SIGNAL ALLOC}

• Jog cursor to the specific FS-OUTxx signal, and

press “select” to choose F-SAFE #1

For an application with 2 zones, define 2 FS-OUTxx signals:

3.1 {SLC EXT. SIGNAL ALLOCATION}


3.2 {ROBOT RANGE LIMIT}

Robot Range

Signal X (mm) Y (mm) Z (mm)

Zone 1 FS-OUT01 400/600 -600/-300 0/300

Zone 2 FS-OUT01 400/600 400/600 -100/0

Note• The definition of inside the cube is not the TCP, but the

“robot body” and “tool interference”

• This example is based on ROBOT coordinates

Choose any 2 files (pg. 16) to save robot range limit data:

X

Z

Zone 1

Zone 2

Y

Origin

{Robot Range Limit} can be used to define a 3-dimensional area as a specific zone, where

the user can customize PFL settings (speeds, allowable forces, etc.)


3.2 {ROBOT RANGE LIMIT}

Settings (bottom-left)• File Valid Cond: VALID

• Alarm: OFF (Only Output Signal, Does Not Stop Robot)

• Monitor Target: OUTSIDE (Keep Normal Working Under Monitor)

• Coordinate: ROBOT (Suggested for This Example)

• Shape Type: CUBOID

• Point1 / Point2: Coordinates (mm) of Cube Vertex for Zone 1 & Zone 2

• Output Signal: FS-OUT01 for Zone 1, FS-OUT02 for Zone 2

Note

• Output Signal FS-OUTxx should be defined in the {F-Safety Signal Allocation}

module before it is used. Otherwise, the signal will not be available for selection


External Force

Signal Situations X (N) Y (N) Z (N) Resultant (N)

PFLIN01 Factory Default 100 100 100 100

PFLIN02 Lower in Zone 1&2 50 50 50 50

• PFLIN01 is the factory default setting of PFL Function

• PFLIN02 are the settings to lower the limits in Zones 1 & 2

Note

• The maximum external force allowed for setting is 300N

{External Force Limit} is the module used to define and save

force limit settings

Choose any 2 files to save external force limit data:

3.3 {EXTERNAL FORCE LIMIT}


Settings(top-left)

• File Valid Condition: SIGNAL (gets signal from {Safety Logic Circuit})

• Control Group: R1

• Limit (Each Axis): INVALID for all

(bottom-left)

• External Force Limit: Force Threshold in XYZ Direction & Resultant

• Input Signal bit0: “PFLIN01”, “ON” (bit 1,2,3,4 leave blank) for undefined zones

“PFLIN02”, “ON” (bit 1,2,3,4 leave blank) for Zone 1 & 2

• Output Signal: *Leave blank*

Note• In File No. 1, the factory default setting for FILE VALID COND is “VALID”. This

field must be changed to “SIGNAL” for this example. Otherwise, a file with

“VALID” will override all other files.

3.3 {EXTERNAL FORCE LIMIT}


Speed Limit Signal Situations Speed (mm/s)

MS-OUT01 Factory Default 250

MS-OUT02 Lower in Zone 1&2 100

Note• PFLIN01 is the factory default setting of PFL Function

• PFLIN02 are the settings to lower the limits in Zones 1 & 2

3.4 {SPEED LIMIT}

{Speed Limit} is the module used to define

and save speed limit settings

Choose any 2 files to save speed limit data:


Settings(top-left)

• File Valid Condition: SIGNAL (Get signal in Safety Logic Circuit)

• Control Group: R1

• Limit Speed: *Enter the desired speed limit*

• Detection Delay Time: 0 (+1) sec

(bottom-left)

• Input Signal bit0: “MS-OUT01”, “ON” (bit 1,2,3,4 leave blank) for undefined zones

“MS-OUT02”, “ON” (bit 1,2,3,4 leave blank) for Zone 1 & 2


Note• The {Speed Limit} module will slow the robot down to a user-defined speed limit (if

active speed is higher). If the robot speed is still higher than the limit after the user-

defined delay time, the PFL function will stop the robot. Minimum delay time is 0 (+1)

seconds.

3.4 {SPEED LIMIT}


• The {Safety Logic Circuit} module is used to define

the logic relation between signals from different PFL

function modules

• Each line has 2 Inputs & 1 Output

• Input1 and Input2 can be Positive or Negative (NOT)

• AND / OR logic can be inserted between Input1 and

Input2

3.5 {SAFETY LOGIC CIRCUIT}


3.5 {SAFETY LOGIC CIRCUIT} EXPLANATION

Safety Input PFL Function

Force 1 Speed 1

Force 2 Speed 2

Zone 1 Zone 2 Force 1

Graphic Description (just for explanation):

Note

• Line 1: #1 FSBIN01 is the Input on functional safety board (short

circuit from factory), and MS-OUT54 is PFL function status

• For monitor target of robot range limit is “Outside”, “NOT FS-OUTxx”

means robot enters Zone XX

• Lines 2 & 4: When the robot is outside of Zone 1 and Zone 2, the PFL

function will use the first external force and speed limit files

• Lines 3 & 5: When the robot is inside of Zone 1 or Zone 2, the PFL

function will use the second external force and speed limit files

Zone 1 Force 2

Zone 2


4. PFL APPLICATION WITH NO ZONES (EXAMPLE)

{SLC EXT. Signal Allocation}

{Robot Range Limit}

{External Force Limit}

{Speed Limit}

{Safety Logic Circuit}

If a JOB has no special zone requirements (meaning PFL settings will remain the same throughout the

duration of the application), then the {SLC EXT. Signal Allocation} & {Robot Range Limit} modules are

not used

{External Force Limit}

• Choose one file and enter the required external force limits

• File Valid Condition: Signal->VALID (overwrite other files)

• The “Input Signal” (pg. 19) field will no longer appear

{Speed Limit}

• Choose one file and enter the required speed limit

• File Valid Condition: Signal->VALID (overwrite other files)

• The “Input Signal” (pg. 21) field will no longer appear

{Safety Logic Circuit}

• Only keep the first line: #1FSBIN01 -> MS-OUT54

• (Ensure MS-OUT54 status is ON)


5. CLAMPING PREVENTION

Define a Zone to Prevent Clamping:

• Only {Robot Range Limit} module is needed

• Build a new {Robot Range Limit} file

Settings

• File Valid Cond: VALID

• Alarm: ON (Stop the Robot)

• Monitor Target: OUTSIDE

• Shape Type: CUBOID

• Point 1 / 2: Vertex of Cube



APPENDIX: TORQUE SENSOR CALIBRATION

PFL function takes use of the data from embedded sensors in the robot arm to calculate

and analyze the external force.

If the PFL function is not working properly or the user experiences alarms during

handguiding, a Torque Sensor Calibration process may be required.

1. Change security level to “YASKAWA” mode

2. Turn OFF PFL function

3. Jog robot back to Second Home Position

4. Correct the torque sensor data

Torque Sensor Calibration can only be conducted under YASKAWA mode (USB License Key

needed).

Four Steps to finish the Torque Sensor Calibration:



1. Change security level to “YASKAWA” mode (torque sensor data can only be read under YASKAWA

mode):

• Insert the USB License Key to the pendant

• Enter Security Mode window ( {Main Menu} -> {SYSTEM INFO} -> {SECURITY} )

• Press [INTERLOCK] + [SELECT] keys on keyboard

• Enter the Password, and press [ENTER]

Security Mode Window Enter Hided “YASKAWA” Mode



Enter Password YASKAWA Mode Display



2. Turn OFF PFL function (avoid singularity prevent during jogging robot back to Second

Home Position):

• Enter Safety Logic Circuit ( -> {SAFETY FUNC.} -> {SAFETY LOGIC CIRCUIT} )

• Add “NOT” logic before “#1 FSBIN01”

• Do not forget to turn PFL ON after calibration

Add “NOT” logic before “#1 FSBIN01” PFL is OFF



3. Jog robot back to {Second Home Position}:

• Enter Second Home Position Window ( -> {ROBOT} -> {SECOND HOME POS})

• Keep pressing “FWD” key until all differences in the positions are 0.0 deg.

Enter Window Second Home Position Window



4. Correct the torque sensor data

• Enter {PFL DIAGNOSIS} window (-> {SAFETY FUNC.} -> {PFL DIAGNOSIS})

• Change Input # to “9”, and record the data from 0 to 5, and from 10 to 15.

• Enter {TORQUE SENSOR ORG POS} window (-> {SAFETY FUNC.} -> {TORQUE SENSOR

ORG POS})

• Update the axis SLURBT data in CH1 (0 – 5) & CH2 (10 - 15)

Enter Window Change Input to “9”



The reading of Torque Sensor is sensitive and may change within a small range.

The user should approximate the average value, and enter data 0-5 into CH1 and

10-15 into CH2 respectively.

power & force limiting (pfl) application...

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