R1C / R1C-4

Control Unit

PickAPP application

CR00758136_en-05/2018.04

Instruction Handbook
The information contained in this manual is the property of COMAU S.p.A.

Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.

COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.

Copyright © 2008-2013 by COMAU - Date of publication 04/2018

 Comau Robotics Product Instruction

SUMMARY

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Modification History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1. GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Fundamental Requirements Applied and Respected . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Basic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Basic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3. INSTALLATION AND ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...22

Safety issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Bypass circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Basic issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Insertion procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4. USAGE AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...29

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Main Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Create . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Top Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Open the Navigation Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Current environment name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Program Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Points commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

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Comau Robotics Product Instruction

SUMMARY

Jog type command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Alarm notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
DRIVEs status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Handling the PATH Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Step by step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Common buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
JPAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Cartesian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Inserting a new point in the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Teach SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Top Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Open the Navigation Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Current environment name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Program Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Alarm notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Turn motors ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Choose single/loop execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Play / Pause / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Navigation Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
General settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
FRAMES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Actions on the individual port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Adding/removing User I/Os. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Vision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Alarm Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Warning messages (yellow notification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Alarms (red notification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Latched alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Usage procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Changing the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Creating a new program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Modifying an already existing program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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 Comau Robotics Product Instruction

SUMMARY

Step by step executing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Running a program in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Adding a new User Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Executing an existing Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Control Unit restart and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5. INTEGRATED VISION SYSTEM (OPTIONAL FEATURE) . . . . . . . . . . . . . . . . . . . . ...75

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Not Connected Vision System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Not Configured Vision System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Configured Vision System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Target. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Activate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Go Live . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Manual adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Autofocus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

6. INTEGRATED CONVEYOR TRACKING (OPTIONAL FEATURE). . . . . . . . . . . . . . ...89

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cards handling menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Creating/modifying a configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Params. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Teach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
FIXED MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
VISION MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

7. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...102
Calibration Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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Comau Robotics Product Instruction

PREFACE

PREFACE
– Symbols used in the manual
– Reference documents
– Modification History.

Symbols used in the manual

The symbols for WARNING, CAUTION and NOTES are indicated below together with
their significance.

This symbol indicates operating procedures, technical information and precautions that
if ignored and/or are not performed correctly could cause injuries.

This symbol indicates operating procedures, technical information and precautions that
if ignored and/or are not performed correctly could cause damage to the equipment.

This symbol indicates operating procedures, technical information and precautions that
it are important to highlight.

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 Comau Robotics Product Instruction

PREFACE

Reference documents
This document refers to PickAPP software application for R1C/R1C-4 Control Unit.
In addition to the current manual, the complete manuals set for R1C/R1C-4 consists of:

Comau Control Unit – Technical Specifications

– Transport and installation
– Control Unit Use.

These manuals are to be integrated with the following documents:

Comau Robot – Technical Specifications

– Transport and installation
– Maintenance
Programming – Motion programming
Applications – According to the required type of
application.

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Comau Robotics Product Instruction

PREFACE

Modification History
– In the current manual version 02/2017.11, compared to previous version, the
following important modifications have been made:
– description of Integrated Vision System (optional feature).
– In the current manual version 03/2018.01, compared to previous version, the
following important modifications have been made:
• description of the new Card environment which improves the usage of the Jog
motion, which allows to quickly record special positions and orientations, and
the associated procedures
• Adding a new User Card
• Executing an existing Card
• description of the new button to handle Restart Cold and Shutdown
commands (par. 4.5.8 Control Unit restart and shutdown on page 73)
• description of Activate command, available in the user interface of the Vision
System
• description of the Autofocus functionality, available in the Go Live
environment of the Vision System.
– In the current manual version 04/2018.03, compared to previous version, the
following modification have been made:
• added needed information for the camera user profile creation (Camera
settings note).
– In the current manual version 05/2018.04, compared to previous version, the
following modification have been made:
• added the description of Integrated Conveyor Tracking (optional feature)
• modified the description of the Input environment, now called I/O
environment: it allows handling user output ports too and selecting I/Os by
Ports and by Devices.

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Comau Robotics Product Instruction

PREFACE

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1. GENERAL SAFETY REQUIREMENTS

This chapter deals with general specifications that apply to the whole Robot System.
Considering its significance, this chapter is referred unreservedly in each system
instructions handbook.

This chapter deals with the following topics:

– Responsibilities
– Safety Requirements.

1.1 Responsibilities

– The system integrator is responsible for ensuring that the Robotic System (Robot
and Control Unit) is installed and handled in accordance with the Safety Standards
in in the country where the installation takes place. The application and use of the
necessary protection and safety devices, the issuing of declaration of conformity
and any EC marking of the system are the responsibility of the Integrator.

– COMAU refuses any responsibility for accidents caused by incorrect or improper

use of the Robotic System (Robot and Control Unit), by tampering with circuits,
components, software and with the use of spare parts that are not included in the
spare parts list.
– The application of these Safety Requirements is the responsibility of the persons
assigned to direct / supervise the activities indicated in the section Applicability,
which should make sure that the Authorised Personnel is aware of and
scrupulously follow the requirements contained in this document in addition to the
general Safety Standards applicable to Robotic System (Robot and Control Unit)
in in the Country where the system is installed.
– The non-observance of the Safety Standards may cause to the operators
permanent injuries or death and can damage the Robotic System (Robot and
Control Unit).

The installation shall be carried out by qualified Personnel and must conform to all
National and Local standards.

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1.1.1 Safety Fundamental Requirements Applied and

Respected
The robotic system is composed of Control Unit and Robot series SMART 5 considers
as applied and respected the following Safety Fundamental Requirements, Annex 1 of
Directive on Machinery 2006/42/CE: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 – 1.2.4.3 – 1.2.5
– 1.2.6 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 – 1.5.9 – 1.5.10 –
1.5.11 – 1.5.13 – 1.6.3 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.
In case it is provided only the Robot series SMART 5 are to be considered as applied
the following requirements: 1.1.3 – 1.1.5 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4
– 1.5.6 – 1.5.8 – 1.5.9 – 1.5.10 – 1.5.11 – 1.5.13 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2
– 1.7.4.

1.2 Safety Requirements

1.2.1 Purpose
These safety requirements are aimed to define the behaviour and obligations to be
observed when performing the activities listed in the Applicabilitysection.

1.2.2 Definitions
Robotic System (Robot and Control Unit)
Robotic system is the workable assembly composed of: Robot, Control Unit, Teach
Pendant and other possible options.

Protected Area
The protected area is the zone confined by the protection barriers and intended to be
used for the installation and operation of the Robot.

Authorised Personnel
Authorised personnel defines the group of persons who have been appropriately trained
and assigned to carry out the activities listed in the section Applicability.

Staff in Charge
The staff in charge defines the personnel who manage or supervise the activities of the
employed persons defined in the preceding point.

Installation and Startup

The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
Robot axes, in compliance with the safety requirements of the Country where the
System is installed.

Functioning in Programming Mode

Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual movement of Robot axes and programming
of work cycles at low speed, programmed cycle testing at low speed and, when allowed,

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GENERAL SAFETY REQUIREMENTS

at working speed.

Functioning in Auto / Remote Mode

Operating mode in which the Robot autonomously executes the programmed cycle at
work speed, with the operators outside the protected area, with the protection barriers
closed and included in the safety circuit, with local (located outside the protected area)
or remote start/stop.

Maintenance and Repair

Maintenance and repair are activities that involve periodical checking and / or
replacement of Robot and Control System (mechanical, electrical, software) parts or
components, and trouble shooting, that ends when the Robot and Control System has
been reset to its original project functional conditions.

Decommissioning and Dismantling

Decommissioning defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.

Integrator
The integrator is the professional expert responsible for the Robot and Control System
installation and startup.

Misuse
Misuse is defined as the use of the system outside the limits specified in the Technical
Documentation.

Action Area
The Robot action area is the enveloping volume of the area occupied by the Robot and
its equipment during movement in the area.

1.2.3 Applicability
These requirements must be applied when carrying out the following activities:
– Installation and Startup
– Functioning in Programming Mode
– Functioning in Auto / Remote Mode
– Robot Axes Brake Release (if present)
– Maintenance and Repair
– Decommissioning and Dismantling.

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GENERAL SAFETY REQUIREMENTS

1.2.4 Operating Modes

Installation and Startup
– The startup is only possible when the Robot and Control System has been correctly
and completely installed.
– The system installation and startup is exclusively the task of the authorised
personnel.
– The system installation and startup is only permitted exclusively inside a protected
area of an adequate size to house the Robot and the equipment it is outfitted with,
without passing beyond the protection barriers. It is also necessary to check that in
normal Robot movement conditions there is no collision with parts inside the
protected area ( e.g structural columns, power supply lines, etc.) or with the
barriers. If necessary, limit the Robot work area using mechanical hard stop (see
optional units).
– Any fixed Robot control stations must be located outside the protected area and in
a point such as to permit a full view of the Robot movements.
– The Robot installation area must be as free as possible from materials that could
impede or limit the visibility.
– During installation the Robot and the Control Unit must be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Fix the Robot to mount holder, with all the provided bolts and pins, tightened to the
tightening torque indicated in the product Technical Documentation.
– If present, remove the fixing brackets of the axes and verify the proper fixing of the
equipment the Robot is outfitted with.
– Check that the Robot guards are correctly fixed and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– Install the Control Unit outside the protected area: the Control Unit should not be
used as part of the fencing.
– Check that the voltage value of the power mains is consistent with that indicated
on the nameplate of the Control Unit.
– Before electrically connect the Control Unit, check that the circuit breaker on the
power mains is locked in open position.
– Connection between the Control Unit and the supply mains at the works, is to be
with a cable dimensioned appropriately for the power installed on the Control Unit
(for further details see the Control Unit “Transport and Installation” manual).
– Connect the ground cable (PE) then connect the power conductors to the main
switch.
– Connect the power supply cable, first connecting the ground cable to the circuit
breaker on the power mains line, after checking with a tester that the circuit breaker
terminals are not powered. It is recommended to connect the cable armouring to
the earth.
– Connect the signals and power cables between the Control Unit and the Robot.

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– Connect the Robot to earth through the Control Unit or by means of specific ground
terminal blocks, depending on the predispositions available on the Robot and/or on
the Control Unit.
– If present, check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors may cause permanent damage to the
Control Unit components.
– The Control Unit manages internally the main safety interlocks (gates, enabling
pushbuttons, etc.). Connect the Control Unit safety interlocks to the line safety
circuits, taking care to connect them as required by the Safety standards. The
safety of the interlock signals coming from the transfer line (emergency stop, gates
safety devices etc.) i.e. the realisation of correct and safe circuits, is the
responsibility of the Robot and Control System integrator.

In the cell/line emergency stop circuit it is necessary to include the contacts of the
Control Unit emergency stop push-buttons, available on X30. The push-buttons are not
interlocked inside the emergency stop circuit of the Control Unit.

– The safety of the system cannot be guaranteed in case of interlocks erroneous,

incomplete or missing execution.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic mode; in Programming mode the power is disabled
immediately.
– When preparing protection barriers, especially light curtains and access doors,
take into consideration the Robot stopping times and distances according to the
stop category (0 or 1) and the weight of the Robot.

If present, on the Control Unit, make sure that the setting of the stop circuit timer is
consistent with the type of Robot connected (for further details see the Control Unit
“Transport and Installation” manual)

– Check that the environmental and operating conditions do not exceed the limits
specified in the Technical Documentation of the specific product.
– The calibration operations must be carried out with great care, as indicated in the
Technical Documentation of the specific product, and should be concluded by
checking the correct position of the machine.

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– To load or update the system software (for example after boards replacing), use
only the original software handed over by COMAU. Scrupulously follow the system
software loading procedure described in the Technical Documentation supplied
with the specific product. After loading, always make some Robot moving tests at
low speed remaining outside the protected area.
– Check that the barriers of the protected area are correctly positioned.

Functioning in Programming Mode

– The programming of the Robot is exclusively the task of the authorized personnel.
– Before starting to program, the operator must check the Robotic System (Robot
and Control Unit) to make sure that there are no potentially dangerous irregular
conditions, and that there is nobody inside the protected area.
– The programming should be controlled from outside the protected area whenever
possible.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the Teach Pendant is working properly (low
speed, emergency stop device, enabling device, etc.).
– During the programming phases, only the operator with the Teach Pendant is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (DRIVE ON) always must be controlled from a position
outside the operating range of the Robot, after checking that there is nobody in the
area involved. The Drive On operation is considered complete when the relevant
machine status indication is shown.
– When programming, the operator must remain at an appropriate distance from the
Robot to be able to avoid any irregular machine movements, and in any case in a
suitable position to avoid the risk of being trapped between the Robot and
structural parts (columns, barriers, etc.), or between movable parts of the Robot.
– When programming, the operator must avoid to remain in a position where parts of
the Robot, pulled by gravity, could move downwards, upwards or sideways (when
installed on a inclined plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at low speed has been carried out. The
test must be controlled from a safe distance.
– Special attention is to be paid when programming using the Teach Pendant: in this
situation, although all the hardware and software safety devices are active, the
Robot movement depends on the operator.
– During the first running of a new program, the Robot may move along a path that
is not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the Robot position
out of the path that links two steps of the program), could give rise to movements
not envisaged by the operator when testing the program.

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GENERAL SAFETY REQUIREMENTS

– In both cases operate cautiously, always remaining out of the Robot range of action
and test the cycle at low speed.

Functioning in Auto / Remote Mode

– The activation of the automatic operation (AUTO and REMOTE states) is permitted
only with the Robotic System (Robot and Control Unit) integrated inside an area
with protection barriers properly interlocked, as required by the Safety Standards
currently in in the Country where the installation takes place.
– Before starting the automatic mode the operator must check the Robot and Control
System and the protected area to make sure there are no potentially dangerous
irregular conditions.
– The operator can activate automatic operation only after having checked:
• that the Robot and Control System is not in maintenance or repair status;
• that the protection barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked with the appropriate key;
• that the safety devices (emergency stop, protection barrier safety devices)
are functioning;
– Special attention is to be paid when selecting the remote mode, in which the line
PLC can perform automatic operations of motors power up and program starting.

Robot Axes Brake Release (if present)

– In the absence of motive power, the Robot axes repositioning is possible by means
of optional brake release devices and suitable lifting devices. Such devices only
allow the brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enabling push-button) are disabled; also the
Robot axes can move upwards or downwards because of the s generated by the
balancing system or by the gravity .

Before using the manual brake release devices, it is recommended to sling the Robot,
or hook it to an overhead travelling crane.

– The use of brake releasing device may cause the axes falling due to gravity, as well
as possible impacts due to an incorrect reset, after applying the brake releasing
module. The procedure for the correct usage of the brake releasing device (both
for the integrated one and module one) is to be found in the maintenance
handbooks.

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– When after the interruption of an unfinished MOVE the motion is enabled again, the
typical function of trajectory recuperation may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next restart of the
automatic cycle. Avoid moving the Robot in positions that are distant from the ones
required for the motion restarting; alternatively disable the outstanding MOVE
programmes and/or instructions.

Maintenance and Repair

– When assembled in COMAU the Robot is supplied with lubricants that do not
contain any harmful to health substances, however, in some cases, repeated and
prolonged exposure to the product may cause skin irritation, or if swallowed,
sickness.
First Aid Measures. In case of contact with the eyes or skin: rinse the affected
areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; consult a
doctor as soon as possible.
– Maintenance, trouble-shooting and repair are only to be carried out by authorised
personnel.
– When carrying out maintenance and repair operations, the specific warning sign
stating the maintenance status must be placed on the control panel of the Control
Unit, until the end of the operation, even if it should be temporarily suspended.
– Maintenance and components or Control Unit replacement operations must be
carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages deriving from connection to peripheral units or external
power sources (e.g. 24 Vdc input/output). Power off the external sources when
operating on involved system parts.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Defective components must be replaced with others having the same Part
Number, or equivalent components defined by COMAU.

If present, the safety components, in case of replacement, must be configured using the
same parameters of the components just removed.

– Trouble-shooting and maintenance activities must be carried out, whenever

possible, outside the protected area.
– Trouble-shooting executed on the control is to be carried out, whenever possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards must be observed
when operating in presence of dangerous voltages.
– Trouble-shooting on the Robot must be carried out with the power supply turned
off (DRIVE OFF).
– At the end of the maintenance and trouble-shooting operations, all the deactivated
safeties must be reset (panels, protection shields, interlocks, etc.).

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– Maintenance, repair and trouble-shooting operations must be concluded with the

check of the correct functioning of the Robotic System (Robot and Control Unit)
and all the safety devices, executed from outside the protected area.
– During the software loading phases (for example after replacement of electronic
boards) use only the original software handed over by COMAU. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading, to be sure, always run a test cycle,
remaining outside the protected area
– Disassembly of Robot components (e.g. motors, balancing cylinders, etc.) may
cause uncontrolled movements of the axes in any direction: before starting a
disassembly procedure, consult the warning plates applied on the Robot and the
Technical Documentation supplied.
– If present, always restore the protective covering where previously installed.

Decommissioning and Dismantling

– The decommissioning and removal of the Robot and Control System is exclusively
the task of Authorised Personnel.
– Move the Robot in transport position and assemble the axes locking brackets
(when required) following the instructions on the plate on the Robot and its
Technical Documents.
– Before decommissioning initiation, the mains voltage at the Control Unit inlet must
be powered off (switch off the circuit breaker on the power mains and lock it in open
position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the power mains,
first disconnecting the power conductors, then the earth one. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the Robot and the Control Unit,
then the ground cable.
– If present, disconnect the Robot pneumatic system from the air distribution mains.
– Check that the Robot is properly balanced and if necessary sling it correctly, then
remove the Robot securing bolts from the mount holder.
– Remove the Robot and Control Unit from the work area, following all the
requirements indicated in the products Technical Documents; if lifting is necessary,
check the eyebolts proper fixing and use only suitable slinging devices and
equipment.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU, or one of its
branches, who will indicate, according to the type of Robot and Control Unit, the
operating methods in accordance with safety principles and environment
safeguarding.

Disposal operations must be carried out in accordance with the legislation of the country
where the Robot System is installed; dispose the batteries, oils and other chemical
liquids respecting the environment and in accordance with the legislative standarts in ,
transfering them to the appropriate waste collection sites.

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– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.

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Comau Robotics Product Instruction

GENERAL DESCRIPTION

2. GENERAL DESCRIPTION

2.1 Introduction
Current manual describes the use of Comau PickAPP application software, available
on a mobile device which is an Android Tablet.
It allows moving a robot in order to implement a Pick and Place process without
knowing the robot programming language.
The following topics are dealt with:
– Basic System
– Basic Functions.

2.2 Basic System

The basic system consists of the following basic components (see the figure below):
– R1C / R1C-4 Control Unit (1)
– Bypass circuit to be inserted in the X124 connector (2)
– Racer3, Racer5 or Rebel families robot (3)
– Tablet (minimum size 8", maximum size 10.1") based on Android OS (minimum
required version is Lollipop 5.1 and above) (4)
– Access point Wi-Fi (5)
– System software - version 1.11.008 installed on R1C / R1C-4 Control Unit
– Software option CR17926410 - “PickAPP Android application”
– PickAPP application manual.

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GENERAL DESCRIPTION

2.2.1 Options
The currently available options are as follows:
– Cognex Vision System - integrated vision system into Comau systems,
supporting models compatible with Cognex FindPatMaxPattern objects
identification algorithm.

Refer to Chap.5. - Integrated Vision System (optional feature) on page 75 for a detailed
description.

– Integrated Conveyor Tracking - handling integrated Comau standard Conveyor

kits, with or without the integrated Vision System.

Refer to Chap.6. - Integrated Conveyor Tracking (optional feature) on page 89 for

further details.

2.3 Basic Functions

A Graphical User Interface is provided composed of dedicated environments allowing
the use of the following functions:
– connecting the tablet to R1C / R1C-4 Control Unit
– jogging the robot, teaching the wished positions, showing the trajectory path,
modifying the robot movements characteristics
– turning on/off motors (DRIVE ON/OFF), starting/pausing/stopping programs
– modifying the positions setup
– navigation menu to handle
• programs
• robot speed
• system states
• grippers
• reference frames
• I/O signals
• integrated Vision System (optional)
• integrated Conveyor Tracking (optional).

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INSTALLATION AND ACTIVATION

3. INSTALLATION AND ACTIVATION

– Safety issues
– Bypass circuit
– Installation
– Activation

3.1 Safety issues

Since in the PickAPP application scenario (refer to par. 2.2 Basic System on page 20)
a mobile device is meant to substitute the Teach Pendant on Pick and Place processes
programming and configuration, the related security issues are transferred at the cell
level, due to the fact that commercial tablets do not contain neither the Emergency Stop
button nor the Enabling Device.

For the described above reasons, in order to guarantee the operator’s safety, robot
manual movements (JOG), motors power on, START/STOP cycle commands, may
come from the tablet but will take effect only if the cell gates are CLOSED; furthermore,
the Emergency Stop button must be available at cell level.

For further details about the safety issues, refer to Chap.6 - Virtual TP5 Teach Pendant
in R1C - R1C-4 Control Unit Use manual.

3.2 Bypass circuit

– Basic issues
– Insertion procedure.

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INSTALLATION AND ACTIVATION

3.2.1 Basic issues

To obtain a system configuration without any Teach Pendant devices (e.g. with a mobile
device), for Pick & Place processes, it is needed to insert a hardware circuit called the
bypass circuit (see the previous figure) which performs the following operations:
– bypass the Emergency Stop button contacts
– bypass the Enabling Device contacts
– set the modal selector switch status to AUTO-REMOTE.
Irrespective of whether R1C or R1C-4, the bypass circuit must be inserted into the X124
connector, according to the following Insertion procedure.

3.2.2 Insertion procedure

To insert the bypass circuit into the X124 connector (see the previous figure) and then
to control R1C / R1C-4 Control Unit by means of the tablet, the following operations are
needed:

a. switch OFF R1C / R1C-4 Control Unit

b. disconnect TP5 Teach Pendant, if any

c. insert the bypass circuit into the X124 connector (which bypasses both Emergency
Stop and Enabling Device contacts of the Teach Pendant)

d. switch R1C / R1C-4 Control Unit ON again.

It is now able to accept the connection with the tablet, when required.

CAUTION!!
Remember that in this configuration the Emergency Stop button, available on the
disconnected Teach Pendant, DOES NOT work, neither do the Enabling Device
buttons.
Therefore, in order not to meet with potentially dangerous situations, it is strongly
recommended to remove (hide) any existing physical Teach Pendants, from the Control
Unit and the cell proximity.

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INSTALLATION AND ACTIVATION

3.3 Installation
The application software is provided by COMAU web site:

http://comau.com/en/our-competences/robotics/software/pickapp .
In order to install it into the mobile device, the following steps are to be executed:

a. copy the application software to the mobile device (tablet) in the wished folder (e.g.
Download folder);

b. in the folder where the application has been copied, touch the application icon to
start its installation.

a. Two scenarios may occur:

a.1 the Unknown sources flag is NOT enabled in the tablet settings.

a.2 Choose SETTINGS

a.3 enable the Unknown sources flag (as shown in the figure above)

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INSTALLATION AND ACTIVATION

a.4 touch OK to confirm the operation

b. the Unknown sources flag is enabled. In the displayed window, choose INSTALL
to actually start the application installation

NOTE that whenever the Unknown sources flag is enabled, the only required step after
touching twice on the filename, is b.

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INSTALLATION AND ACTIVATION

3.4 Activation

IP addresses requirements
All the involved devices (Tablet, Access Point, Control Unit, optional Vision System
Camera) must be configured and connected to the same network.
The figure below shows an example of connections and IP addresses.

The following steps are needed to activate PickAPP application:

a. touch PickAPP icon on the tablet desktop

b. in the displayed Connection Page (figure above), the user is asked to insert the
Control Unit IP address. It can be either directly typed in or inserted by means of
the Control Unit QR code.

WARNING
Wait at least 5 seconds between a disconnection and the subsequent connection.

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INSTALLATION AND ACTIVATION

c. Touch Next command.

NOTE that if the Control Unit software version is not fully compatible, an alarm message
occurs at the application startup, informing the user that the application behavior can be
unexpected and therefore it is recommended to update the Control Unit software version
to the specified one.

As far as already connected applications, the following conflict scenarios may occur:
– VirtualTP5 already connected,
– PickAPP already connected.
In both scenarios (see figures below), an informational page is displayed and the
connection attempt is refused by the Control Unit.

d. If no conflicts occur, the wireless connection between PickAPP and Control Unit is
established and the application is active and ready to be used.

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INSTALLATION AND ACTIVATION

The system status is automatically switched to AUTO-REMOTE. Since then, the user is
allowed to change the system state as wished.
Upon a disconnection, the system state is forced to AUTO-REMOTE again.
The only exception is the case in which the previous state was AUTO-LOCAL and
DRIVEs were ON. In such a way, the running program continues to run.

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USAGE AND PROCEDURES

4. USAGE AND PROCEDURES

4.1 Introduction
Upon the application activation, the system status is set to AUTO-REMOTE and the
application Main Page is displayed on the tablet.

NOTE - Upon a disconnection, the system state is forced to AUTO-REMOTE again. The
only exception is the case in which the previous state was AUTO-LOCAL and DRIVEs
were ON.

The purpose of the PickAPP application is to create/modify/run programs to execute

Pick and Place processes.
– Main Page
– Navigation Menu
– Alarm Page
– Usage procedures.

4.2 Main Page

In the Main Page, two subpages are available:
– Create
– Run.

4.2.1 Create

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USAGE AND PROCEDURES

This environment allows the user to handle programs: create, modify and save them.
The core of Pick and Place processes is the path, which means a sequence of
positional data associated to input ports, override, tool, frame, vision or conveyor
configurations, etc. (referred to as points, in the current manual) chosen by the user. So
the main goal of PickAPP is to setup all the points features, to move the robot to the
wished position and then insert such points into the current path.
The Create Page is divided into four parts (see previous figure):
– Top Menu (1)
– PATH (2)
– JOG (3)
– Function buttons (4).

4.2.1.1 Top Menu

– Open the Navigation Menu
– Current environment name
– Program Save
– Points commands
– Jog type command
– Alarm notification

4.2.1.1.1 Open the Navigation Menu

Touching the shown below symbol, causes the Navigation Menu to be open.

4.2.1.1.2 Current environment name

The name of the current environment is displayed as shown in the figure below.

4.2.1.1.3 Program Save

Touching the Program Save icon causes the current program to be saved with the
same name.
If it was never saved before, it is added to the available programs list, with the name
specified by the user.

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4.2.1.1.4 Points commands

Touching this icon causes a menu to be displayed, providing the following commands
related to the path points:
– Renumber - irrespective of their current naming and/or numbering, this command
renumbers the path points in ascending order, naming them “Point”.
See the example shown in the following figures.

– Reverse - this command copies the existing points in reverse sequence, until the
second one. This allows to move along the path backward, and restart the cycle
from the beginning.
See the example in the figures below.

4.2.1.1.5 Jog type command

This icon activates the Jog type command, allowing to select the wished Jog type to be
used while jogging in the Create environment.

The available Jog types are:

– Joint
– JPAD
– Cartesian.
For further information see par. 4.2.1.3 JOG on page 36.

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4.2.1.1.6 Alarm notification

The bell icon indicates whether or not an alarm occurred. The notification can be either
red or yellow, depending on the severity. For further information see Alarm Page.

4.2.1.1.7 DRIVEs status

A coloured bar shows the DRIVEs current status (following figures):
– grey means DRIVE OFF
– green means DRIVE ON

4.2.1.2 PATH
– Handling the PATH Points
– Step by step.

4.2.1.2.1 Handling the PATH Points

This section displays the points belonging to the program. The user is allowed to view
the points details and edit them, if wished.

Remember that “point” means a general element of the PATH, i.e. a line of the program,
whether it is an individual position associated to an individual movement or a group of
movements and related positions, associated to a Vision or Conveyor Tracking
configuration.

Long touching a point, a window is displayed in which some standard commands are
made available to handle it:
– Rename - allows modifying the point name
– Move - allows modifying the point position within the PATH
– Copy - allows creating a new point by copying it from the selected one
– Remove - allows deleting the selected point.
Short touching a point, any information about it are displayed; the Point Details depend
on whether it is a
– Fixed point,
– Vision point
– Conveyor point.

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Fixed point

– POINT INFORMATION
• Point name - this is the name of the point, chosen either by the user or
automatically by the application. The name is preceeded by a symbol
meaning the point type (Fixed point in this case). It is editable by touching it.
• Input signal - allows selecting an input signal to be waiting on, before moving
to the Fixed point
• Trajectory - allows choosing a different trajectory for the current movement
(Joint, Joint fly, Linear, Linear fly)
• Speed override - allows modifying the speed, acceleration and deceleration
override for the current movement
• Gripper action - allows chosing a gripper and/or an action, associated to the
current point
• Tool and Frame - these are the tool and the frame associated to the current
point
• Point coordinates - these are the taught point coordinates.
– Current robot position - the coordinates of the current robot position are
displayed. They can be associated to the current point, by simply touching the
following symbol

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Vision point

– POINT INFORMATION
• Point name - this is the name chosen either by the user or automatically by
the application. The name is preceeded by a symbol meaning the point type
(Vision point in this case). It is editable by touching it.
• Input signal - allows selecting an input signal to be waiting on, before
executing the Vision point
• Trajectory - allows choosing a different trajectory for the current movement
towards the TARGET point; available choices are Joint, Joint fly, Linear,
Linear fly
• Speed override - allows modifying the general override associated to the
TARGET point
• Gripper action - allows choosing a gripper and/or an action, associated to the
TARGET point
• Tool - this is the tool associated to the TARGET point.
– APPROACH
• Speed override - allows modifying the speed override when moving to the
APPROACH point
• Trajectory - allows choosing a different trajectory for the current movement
towards the APPROACH point; available choices are Joint and Linear
– DEPART
• Speed override - allows modifying the speed override when moving to the
DEPART point
• Trajectory - allows choosing a different trajectory for the current movement
towards the DEPART point; available choices are Joint and Linear.

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Conveyor point

– POINT INFORMATION
• Point name - this is the name chosen either by the user or automatically by
the application. The name is preceeded by a symbol meaning the point type
(Conveyor point in this case). It is editable by touching it.
• Configuration - it is allowed to select a Conveyor Tracking configuration
• Trajectory - the Conveyor point trajectory is always Linear only
• Speed override - allows modifying the general override associated to the
TARGET point
• Gripper action - allows choosing a gripper and/or an action, associated to the
TARGET point
• Tool - this is the tool associated to the TARGET point.
– INITIAL WAIT - allows specifying the distance [mm] the Conveyor should cover,
before starting tracking.
– TRACKING LAG - allows specifying a positive or negative distance [mm], along
the X axis of conveyor movement direction, to be used as an offset for the TARGET
point.
A positive value means the operation is performed AFTER the TARGET point,
while a negative means the operation is performed BEFORE the TARGET point.
– APPROACH / DEPART
• Speed override - allows modifying the speed override when moving to the
selected point (APPROACH or DEPART)
• Trajectory - the trajectory type when moving to the selected point
(APPROACH or DEPART) cannot be modified because it is always Linear for
a Conveyor point.
– CONFIGURATION DESCRIPTION - this is a short description which summarizes
the Configuration associated to the Conveyor point.

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4.2.1.2.2 Step by step

This execution mode allows step by step checking the program, before executing it in
automatic mode (par. 4.5.5 Running a program in automatic mode on page 70).
It is activated by means of the switch highlighted in the left figure below.

When activated, Play, Backward and Forward buttons are displayed; the only available
one is Play. In the next steps, depending on whether a subsequent and/or preceding
point exists which can be executed, Backward and/or Forward buttons are made
available too, as shown in the previous right figure.

Note that the motors must be ON (par. Turn motors ON/OFF on page 38) to be able to
start the execution!

WARNING
With integrated Vision System, any existing Vision points are NOT executed in
Step-by-step modality.
The same applies for any existing Conveyor points, in case of integrated Conveyor
Tracking option.

Refer to par. 4.5.4 Step by step executing a program on page 69 for any forther
information.

4.2.1.3 JOG
This section displays all data related to set the robot movements and the gripper data,
as well as the keys to jog the robot.

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The Jog type is selected in the Top Menu by means of the Jog type command..

There are some common buttons, available for any Jog types, and someone else,
dedicated to the cosen Jog type:
– Common buttons
– Joint
– JPAD
– Cartesian.
In addition, an environment is available which allows creating objects called “Cards”,
referred to special positions (both system and user), to be executed whenever required
by programs’ needs:
– Card.

4.2.1.3.1 Common buttons

– Gripper buttons
– General Speed
– Turn motors ON/OFF.

Gripper buttons
– Select gripper
– Open/Close gripper.

Select gripper

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Open/Close gripper
These buttons (figure below) are just available when drives are ON. They, respectively,
open and close the gripper.

General Speed
Allows displaying and modifying the general speed, if wished. This speed refers to all
the robot movements, both for Step by step execution and automatic Run cycle.

Turn motors ON/OFF

Touching this button causes the motors to be switched to the

opposite state: OFF to ON, ON to OFF.

See also par. 4.2.1.1.7 DRIVEs status on page 32.

NOTE
Switching on/off any existing Conveyor, is NOT controlled by this button: the Conveyor
motors must have their own autonomous control, which is the user’s care.

4.2.1.3.2 Joint

The following information is displayed (refer to the previous figure):

– Jog data:

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• Joint coordinates
• Jog keys.

Joint coordinates
Robot current position coordinates

Jog keys
The + and - keys (see the figure above) allow jogging the individual robot axes

4.2.1.3.3 JPAD

The following information is displayed (refer to the figure above):

– Robot position
– Jog buttons
• JPAD - translation
• JPAD - rotation.

Robot position
It allows modifying the relative position between the tablet and the robot. A window is
opened in which the user is allowed to rotate the robot position until it matches the actual
one.

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JPAD - translation

To select either translation or rotation, touch the highlighted button in the following
figure. The application opens a menu in which the user can choose the wished item
(Linear).

The robot moves referred to the user position.

– The group of two arrow buttons are for moving along Z axis
– The group of four arrow buttons are for moving along X axis (up and down) and Y
axis (left and right).

JPAD - rotation

To select either translation or rotation, touch the highlighted button in the following
figure. The application opens a menu in which the user can choose the wished item
(Angular).

These arrow buttons allow to rotate around the cartesian axes.

In the figure above the example refer to a Rebel robot, which only has the possibility of
rotating around Z axis.

4.2.1.3.4 Cartesian

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The following information is displayed (refer to the previous figure):

– Reference frame
– Jog data:
• Cartesian coordinates
• Jog keys.

Reference frame

Touch the highlighted button (figure above). The application opens a suitable selection
menu (Base, Tool and UFrame) for the cartesian trajectory.

Cartesian coordinates

These are the cartesian coordinates of the robot current position (X, Y, Z, Euler angles).

Jog keys
The + and - keys (see the figure above) allow jogging the robot according to the
individual cartesian coordinates (X, Y, Z, Euler angles).

4.2.1.3.5 Card
This is an environment which improves the usage of the JOG motion, which allows
quickly recording peculiar Positions and Orientations. This special way of recording is
associated to an object called a Card.

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Executing a Card means moving the robot to the Position or Orientation previously
saved to such a Card (par. 4.5.7 Executing an existing Card on page 72 describes the
corresponding procedure).
Two types of Cards are provided:
– System Card
– User Card.

System Card

These are three remarkable positions:

– Calibration - robot calibration position ($CAL_SYS)
– Orthogonal - TCP orthogonal to the declared frame
– Parallel - TCP parallel to the declared frame.

When executing the last two Cards, the robot remains on the current position, and the
TCP orientation changes according to what specified by the Card (Orthogonal or
Parallel).

User Card
These are user defined Cards, to save wished Positions or Orientations.
To add a new Card, refer to par. 4.5.6 Adding a new User Card on page 71 which
describes the corresponding procedure.
– Position

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Adds a new Card saving a Position. Available choices are:

• Joint - saves the robot current position, in joint coordinates
• Cartesian - saves the cartesian coordinates of the robot current position,
referred to the active Tool and UFrame at the Card creation time.

Anyway, note that when a cartesian Card is executed, the saved position is referred to
the active Tool and UFrame at the Card execution time.

– Orientation
Adds a new Card saving an Orientation, likewise Parallel and Orthogonal System
Cards.

This means that saving is performed for the current TCP orientation ONLY, NOT for the
whole position.
When executing such a Card, the robot remains on the current position, and the TCP
orientation is applied.

4.2.1.4 Function buttons

This section makes some special “buttons” available, dedicated to configure and insert
the points of the program:
– Inserting a new point in the program
– Teach SETUP.

4.2.1.4.1 Inserting a new point in the program

Each time this button is touched, a new point is added to the

displayed PATH, according to the current Teach SETUP.

4.2.1.4.2 Teach SETUP

The following buttons are used to set the characteristics of the being taught point:
– Edit point name
– Select input signal
– Select Conveyor configuration
– Choose trajectory
– Set speed

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– Choose gripper action

– Select Tool and Uframe references
– Select Fixed/Vision/Conveyor.

Edit point name

A touch-keyboard is displayed in order to allow modifying the point

name.

Select input signal

Touching this symbol causes a window to be opened (see the

following figure) to allow selecting an input signal to be waiting on,
before executing the movement towards such a point.
In case of Vision points, waiting on the input signal is referred to the
first movement (the one towards the approach point).

Select Conveyor configuration

Touching this symbol causes a window to be opened (see the following

figure) to allow selecting the wished Conveyor configuration.

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Choose trajectory

A window is displayed to choose the being taught point trajectory.

WARNING
In case of Conveyor point, the only allowed trajectory is Linear.

– Joint - all robot axes start and stop together. The TCP trajectory and orientation is
unpredictable
– Joint Fly - continuous joint motion, without stopping the robot on the taught position
– Linear - the TCP moves in a straight line from the initial position to the final position.
The orientation of the tool also changes from the initial position to the final position
according to what is specified
– Linear Fly - continuous linear motion, without stopping the robot on the taught
position.

Set speed

A window is displayed (see the following figures) to set the speed override
for the being taught point.
Advanced setting is also provided for acceleration and deceleration ramps.
Speed settings for both Vision point and Conveyor point are referred to the
TARGET point.

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Choose gripper action

A window is displayed (figure below) to choose the associated gripper

action for the being taught point.
Gripper settings for both Vision point and Conveyor point are referred to
the TARGET point.

– Pick - is the action of taking the object

– Place - is the action of releasing the object
– No action - neither pick nor place actions are associated to this point.

NOTE that the gripper action associated to the being taught point, can also be affected
by the Open/Close Gripper buttons.

Select Tool and Uframe references

A window is displayed (figure below) to select Tool and Uframe

references for the being taught point. The displayed numbers, with the
icon, respectively refer to the active Tool and UFrame: tool[10] and
frame[0], in the example beside.
In the following figure the Tool and Uframe selection window is shown.

In case of Vision point and Conveyor point, the icon is different because
the Tool only is specified. The displayed number indicates the active
Tool. In the example beside, it is tool[10].
In the following figure the Tool selection window is shown, in which a
different Tool can be chosen.

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Select Fixed/Vision/Conveyor
Touching the three vertical dots, a menu is displayed which allows specifying whether
the being taught point is
– a fixed point - Fixed point
– a point coming from the Vision System - Vision point
– a point related to an integrated Conveyor - Conveyor point .
The default is Fixed point.

Fixed point
It is related to a standard destination, including a robot position, input port if required,
trajectory type, speed override, gripper action if required, tool and frame.

Vision point
It is a “composite point” including the Vision System active configuration, i.e. its
calibration, an object identification model, a search and identification area for such an
object, APPROACH, TARGET and DEPART positions.

Vision points are dynamically calculated. This means that if the object is moved, the
camera looks for it and the taught point is the one where the object was found.
For further details refer to Chap.5. - Integrated Vision System (optional feature) on
page 75.

Conveyor point
It is a “composite point” associated to a specific Conveyor Tracking configuration
including settings such as tracking window, Conveyor Base frame, Start and End
tracking events, APPROACH, TARGET and DEPART positions.

For further details refer to Chap.6. - Integrated Conveyor Tracking (optional feature) on
page 89.

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4.2.2 Run
This environment allows the user to run the current program.

The Run page is divided into the following parts (see previous figure):
– Top Menu (1)
– Program (2)
– Speed (3)
– Function buttons (4).

4.2.2.1 Top Menu

– Open the Navigation Menu
– Current environment name
– Program Save
– Alarm notification

4.2.2.1.1 Open the Navigation Menu

Touching the shown below symbol, causes the Navigation Menu to be open.

4.2.2.1.2 Current environment name

The name of the current environment is displayed as shown in the figure below.

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4.2.2.1.3 Program Save

Touching the Program Save icon causes the current program to be saved with the
same name.

4.2.2.1.4 Alarm notification

The bell icon indicates whether or not an alarm occurred. For further information see
Alarm Page.

4.2.2.2 Program
This section displays points belonging to the current program (the currently executed
point is marked when the program is running, as shown in the figure above).

The program current status is displayed in the top left corner.

4.2.2.3 Speed

This section displays the General Speed percentage and allows modifying it.

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4.2.2.4 Function buttons

This section makes some “buttons” available, dedicated to the program execution:
– Turn motors ON/OFF
– Choose single/loop execution
– Play / Pause / Stop

WARNING
If the integrated Vision System is present, the user can specify whether executing the
Vision point is wished, if any, acting on the camera symbol, as shown in the next figures.

4.2.2.4.1 Turn motors ON/OFF

Touching this button causes the motors to be switched

to the opposite state: OFF to ON or ON to OFF.

See also par. 4.2.1.1.7 DRIVEs status on page 32.

NOTE
Switching on/off any existing Conveyor, is NOT controlled by this button: the Conveyor
motors must have their own autonomous control, which is the user’s care.

4.2.2.4.2 Choose single/loop execution

The user must choose whether to execute the program just once
(Single) or to continuously execute it (Loop).

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4.2.2.4.3 Play / Pause / Stop

These buttons are available to act on the program execution:

– at the beginning, the only available button is Play, to start
program execution; this button is also enabled when the
program is Paused/Stopped, to continue/restart execution.
– While program is running, two buttons are enabled, Pause to
temporarily pause the program and (Stop) to finally stop it.

NOTE that, when Play button is touched, if any modifications have been made to the
not yet saved program, a message is displayed asking the user to save it.

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4.3 Navigation Menu

This menu is available from the Main Page by either swiping the screen or touching the
corresponding symbol (see figure below).

The following menu is displayed, as shown below.

The available commands refer to

– Programs
– General settings.

4.3.1 Programs
– New
– Open.

4.3.1.1 New
Create a new program. Touching this command, the Create subpage is open in which
the PATH section is empty (as shown in the figure below), ready to receive the new
program points.

If, when the New command is activated, a program is already open in Create subpage,
the user is allowed to save all changings, if any, before the new program is opened.

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4.3.1.2 Open
Open an already existing program.
Touching this command, the application displays the existing programs list, to allow the
user choosing the wished one.
The Create subpage is opened to handle the chosen program: view, edit, check, save
and execute it, as described in the previous sections.

If, when Open command is activated, a program is already open in the Create subpage,
the user is allowed to save all changings, if any, before the newly chosen program is
opened.

4.3.2 General settings

– State
– Gripper
– Frames
– I/O
– Vision
– Conveyor
– Info.

4.3.2.1 State
Select the system state (Programming, Auto local, Auto remote).

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4.3.2.2 Gripper
Gripper configuration: one page is available for each existing gripper.

The following data can be set:

– Working mode
• disabled - the gripper is not operational
• single - one output line configuration
• doppia - two output lines configuration
• custom - configuration in which the user specifies a program and two
customized routines (written by the user) for gripper open/close. To make the
configuration operational, act as follows:
• create folder Gripper in
UD:/SYS/APPS/PICKAPP/SETTINGS/
• copy .pdl files (including the customized routines) to handle the gripper,
to such a folder
• insert the name of the wished gripper program to Program Name field,

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• go to Create page and select the gripper buttons (open and close) to
check whether they work properly.
– Time for the action - duration of the specified gripper action
– Use output output port(s) to be used.

4.3.2.3 Frames
Select, modify and activate the Base, Tool and UFrame reference frames, at system
level.
Touching this command opens a subpage divided into three sections (figure below):
– FRAMES (green) - existing elements
– ACTIVE (yellow) - active frames
– VALUES (blue) - values corresponding to the selected element.

Choosing the wished frame type (BASE, TOOL, UFRAME), as shown in the figure
below, all the available information for such a frame type is displayed in the subpage. If
any information is required about a different frame type, change the selection.

In the shown above example, the TOOL frame type has been chosen, so all the
information in the subpage is corresponding to TOOL frame type: elements list, active
frame, selected element values.

4.3.2.3.1 FRAMES
After choosing the wished frame type (BASE, TOOL, UFRAME), the user can select an

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element from the displayed list, in order to view/modify it. The associated data are
displayed in the VALUES section (as shown in the next figure).

4.3.2.3.2 ACTIVE
This section displays the currently active frames (BASE, TOOL, UFRAME).

The Select button allows selecting the wished active frame.

As shown in the figures above, Tool and UFrame are always selected together.
Whereas the Base frame is selected by itself.
Touching the Select button, a window is displayed allowing to choose the frames to be
activated.
The example in the figure below, shows the Tool and UFrame selection.

4.3.2.3.3 VALUES
This section displays the values corresponding to the selected element of the list.
To modify them, open the lock in the top leftmost corner. All fields become editable.

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Closing the lock again, the inserted data are acquired by the system.
If, before closing the lock, deleting the modifications and loading the previous data again
is wished, touch the reload button (see figure below).

CAUTION!
If some changings are made to an ACTIVE frame, it is needed to activate it again, by
means of Select base and Select toolframe buttons, in order to make such
modifications operational, as described in par. 4.3.2.3.2 ACTIVE on page 56.

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4.3.2.4 I/O
Touching this command, the application displays the currently selected User I/Os and
allows handling them.

The following topics are described below:

– Actions on the individual port
– Adding/removing User I/Os.

4.3.2.4.1 Actions on the individual port

The user can act on each individual port belonging to the list, either by means of
available commands in the list page or short/long touching the wished port:
– Comment
– Short touch
– Long touch.

Comment
Just touch symbol to associate a comment to the corresponding port.
The application opens the field in which the comment can be typed in. Touch OK when
finished.
An example is provided in the following figures.

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Short touch
Short touching an I/O in the list, the application shows specific values, if any, of such
port, its native values in binary, decimal, octal and hexadecimal (Native Port Values)
and allows inserting/modifying a customized comment (Comments). See also par.
Comment on page 58.

Long touch

Long touching one of the listed I/Os, the dedicated command menu is displayed (as
shown in the following figure on the right). The dedicated commands depend on the
selected I/O type.
The previous figures show an example of long touching commands related to a DIN type
port.

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4.3.2.4.2 Adding/removing User I/Os

Touching key, in the right bottom corner, the user is allowed to add and/or
remove I/O ports from the list, selecting and/or deselecting the wished elements, among
the displayed ones.
Touching such a key, the user should first choose whether handling Ports or I/Os
belonging to specific Devices.

Ports
The application displays the list of all the I/O ports types.

The user can select the wished ports, in one of the following modalities:

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– select the checkbox associated to one or more types, in order to select ALL the
existing ports of such a types; ALL the DIN type ports and ALL the DOUT type ports
have been selected in the example shown in the following figure on the left; or
– open the list of a specific I/O type, by touching button and select the
checkbox associated to the wished ones only; the DOUT type ports list has been
opened and dout[3], dout[4] and dout[16]
– nell’esempio della seguente figura a destra, l’utente ha aperto l’elenco delle porte
di tipo DOUT ed ha selezionato solo dout[3], dout[4] and dout[16] have been
selected in the example shown in the following figure on the right. Note that the
DOUT type checkbox is not selected since just some of them have been selected,
not all of them.

Devices
The application displays the list of all the available devices.

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The user is allowed to select the wished ports, in one of the following modalities:
– select the checkbox corresponding to one or more devices, to select ALL of their
associated ports; in the example shown in the following figure, note that selecting
the CONVEYOR_2 device checkbox, ALL of its associated I/Os are selected; or

– open the list of the wished device, by means of button and select the
checkbox of the wished I/Os only.

4.3.2.5 Vision
Allows handling both the integrated Vision System connection and configuration, if
existing in the current robotic system.

Refer to Chap.5. - Integrated Vision System (optional feature) on page 75 for a detailed
description.

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4.3.2.6 Conveyor
Allows handling integrated Conveyor Tracking configurations.

For further details refer to Chap.6. - Integrated Conveyor Tracking (optional feature) on
page 89.

4.3.2.7 Info
Provides information about
– Application (APPLICATION INFO)
• application version code (Version code)
• application version name (Version name)
• minimum allowed system software version (Min. controller version)
– Control Unit (CONTROLLER INFO)
• system software version (Controller version)
• robot name (Robot name)
• Control Unit IP address (IP address)
• detailed information, such as
• CONFIGURATION
• HARDWARE
• SOFTWARE VERSIONS
• COMMUNICATION
• SOFTWARE OPTIONS.
Touching the listed above items, detailed information is displayed about it
(following figure, on the right).

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In the Control Unit area, a button is available (highlighted in the previous figure, on the
left) which allows to access the following commands:
– Restart Cold
– Shutdown.
Refer to par. 4.5.8 Control Unit restart and shutdown on page 73, for a detailed
description of such commands usage.

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4.4 Alarm Page

Touching the bell icon, causes to open the Alarm page, displaying the messages.
– Warning messages (yellow notification)
– Alarms (red notification)
– Latched alarms.

4.4.1 Warning messages (yellow notification)

These messages are automatically confirmed when exiting from the Alarm page.

4.4.2 Alarms (red notification)

The symbol in the rightmost top corner is provided to Reset all the occurred alarms with
red notification, exactly like pressing the Teach Pendant RESET button.

4.4.3 Latched alarms

If the occurring alarm is a LATCHED type alarm, using the reset button does not cancel
it: so, swipe each active alarm from right to left and touch the “confirm” symbol to confirm
it, as shown in the following figure.

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4.5 Usage procedures

– Changing the environment
– Creating a new program
– Modifying an already existing program
– Step by step executing a program
– Running a program in automatic mode
– Adding a new User Card
– Executing an existing Card
– Control Unit restart and shutdown.

4.5.1 Changing the environment

To choose the wished environment (Create / Run), act as follows:

a. touch the wished environment as shown in the next figure

b. Change to the required system status, as suggested by the application. In the

displayed example, changing from Create to Run is shown.

4.5.2 Creating a new program

a. Be sure that the current environment is Create. Otherwise switch to it as described
in par. 4.5.1 Changing the environment on page 67.

b. If there is an already open program, open the Navigation Menu and choose New
command. Save the current program, if needed.

c. The application displays an empty program

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d. Turn motors ON (par. Turn motors ON/OFF on page 38)

e. Jog the robot to the wished point (par. 4.2.1.3 JOG on page 36)

f. Select the wished point type to be inserted in the program (par. Select
Fixed/Vision/Conveyor on page 47). The default is Fixed point.

CAUTION
In case of Conveyor point, the user must be completely aware of the associated
Conveyor Configuration, to be able to place the robot into suitable positions both before
and after the configured tracking, approach, pick/place, depart operations.

g. Check the current configuration for the being taught point, in order to verify whether
it is as wished:

• point name (par. Edit point name on page 44),

• input signal (par. Select input signal on page 44),
• select Conveyor tracking Configuration name, if needed (par. Select
Conveyor configuration on page 44)
• trajectory (par. Choose trajectory on page 45),
• speed (par. Set speed on page 45),
• gripper action (par. Choose gripper action on page 46),
• tool and uframe (par. Select Tool and Uframe references on page 46)
• fixed/vision (par. Select Fixed/Vision/Conveyor on page 47).

h. Modify it, if needed, acting on the listed above point characteristics.

i. Touch the Inserting a new point in the program button to add the new point to the
PATH.

j. Repeat steps e. to i. for each needed point.

k. Save the newly created program (par. 4.2.1.1.3 Program Save on page 30).

l. A window is displayed to insert the program name.

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m. Type the program name and touch OK to confirm. The newly created program is
then inserted into the available programs list.

4.5.3 Modifying an already existing program

a. Be sure that the current environment is Create. Otherwise switch to it as described
in par. 4.5.1 Changing the environment on page 67.

b. Open the Navigation Menu and choose Open command.

c. The available programs list is displayed.

d. Touch the wished program

e. The application software opens it.

From this situation, execute the same steps of par. 4.5.2 Creating a new program on
page 67, from step d. to the procedure end.

4.5.4 Step by step executing a program

a. Be sure that the current environment is Create. Otherwise switch to it as described
in par. 4.5.1 Changing the environment on page 67.

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b. Touch Step by step switch (par. 4.2.1.2.2 Step by step on page 36) to activate the
associated functionality.

c. Turn motors ON (par. Turn motors ON/OFF on page 38).

WARNING
In case of integrated Vision System, Vision points, if any, are NOT executed, in
Step-by-step mode.
The same applies for Conveyor points belonging to the integrated Conveyor tracking
option.
For further details refer to par. Select Fixed/Vision/Conveyor on page 47.

d. Touch Play button to execute the first selected movement in the current program.

e. Touch Backward and/or Forward buttons, depending on the program check

requirements.

f. Turn the Step by step switch OFF when checking is accomplished.

g. If any modifications have been made, save the program (par. 4.2.1.1.3 Program
Save on page 30)

4.5.5 Running a program in automatic mode

a. Be sure that the current environment is Run. Otherwise switch to it as described in
par. 4.5.1 Changing the environment on page 67.

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b. Modify the General Speed override if needed (par. 4.2.2.3 Speed on page 49).

c. Select the wished execution type: Single or Loop (see par. 4.2.2.4.2 Choose
single/loop execution on page 50).

WARNING
Iin case of integrated Vision System, the user can specify whether executing Vision
points, if any, or not, acting on the camera symbol, as described in par. 4.2.2.4 Function
buttons on page 50.

d. Turn motors ON (par. Turn motors ON/OFF on page 38).

e. Touch PLAY button to start the execution (par. 4.2.2.4.3 Play / Pause / Stop on
page 51).

f. Touch PAUSE button if temporarily pause the program execution is wished

(par. 4.2.2.4.3 Play / Pause / Stop on page 51).

g. Touch STOP button to terminate the program execution (par. 4.2.2.4.3 Play /
Pause / Stop on page 51).

NOTE that before running a program in Automatic status, it is suggested to check it in

Step by step mode, in PROGR status.

4.5.6 Adding a new User Card

a. Access the Card environment, touching the corresponding button (highlighted in
the figure below)

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b. Touch one of the symbols related to the User Cards, in the displayed page.

c. The application opens a dedicated window. The user should

c.1 insert the new Card Name and an associated Description

c.2 choose the wished Card type (either Position or Orientation).

c.2.1 If Position, specify whther Joint or Cartesian

c.2.2 if Orientation, nothing more to do.

d. Touch OK to finish.

4.5.7 Executing an existing Card

a. Access the Card environment, touching the corresponding button (highlighted in
the figure below)

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b. Touch the being executed wished Card, in the displayed page.

c. Regardless whether the chosen Card is a System Card or a User Card, the
application displays a suitable window allowing to execute it.

d. Turn motors ON, by means of the dispalyed button

e. Touch the enabled Play button and keep it pressed until a “MOVE finished...”
message is displayed together with a tablet vibration.

f. The robot is now to the position or with the orientation associated to the executed
Card. Touch CLOSE button.

4.5.8 Control Unit restart and shutdown

a. Select Info environment in the Navigation Menu.

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b. The application opens the selected environment.

c. A button is available (highlighted in the figure above) in the Control Unit section,
which allows accessing some commands. Touch it.

d. The application opens the available commands menu.

e. Touch the wished command to execute it.

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5. INTEGRATED VISION SYSTEM (OPTIONAL

FEATURE)

To be able to use the integrated Vision System, the related option is required.
Comau option code is CR17926411.

5.1 Introduction
COMAU system supports models compatible with Cognex objects identification
algorithm FindPatMaxPattern.
The only goal of integrating such a Vision System is to handle a subpattern of
parameters which helps implementing a Pick and Place type process. Knowledge
about the objects identification algorithm is absolutely not needed.

As already stated in IP addresses requirements note, please remember that all the
involved devices (Tablet, Access Point, Control Unit, Vision System Camera) must be
both connected and configured on the same network.
An example of connections and IP addresses is shown in the figure below.

Suggestions for inserting the smart camera in the Comau System:

– mount the camera perpendicularly to the plane in which objects will be identified
– use a continuous flow light source (LED type).

Camera settings
The following settings must be executed, by means of the Cognex software:
– insert the camera IP address (according to IP addresses requirements note)
– create a User for the camera, indicating a Username and a Password, selecting
Full option from Access menu and checking Allow Online Job Save checkbox
– switch the camera status to ON LINE.

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Programming the camera is made by means of PickAPP application.

Open the Navigation Menu and choose Vision item to handle the integrated Vision
System Connection and Configuration.

The following commands are available:

– Connect
– Configure
– Activate
– Go Live.

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5.2 Connect
The Vision environment provides the Vision page, in which the following scenarios may
occur:
– Not Connected Vision System
– Not Configured Vision System
– Configured Vision System.

5.2.1 Not Connected Vision System

Insert the required data (Camera Parameters):

– camera IP address
– camera Telnet port
– Username and Password belonging to the User created by means of Cognex
In-sight Explorer software (refer to Camera settings note for further details).

A symbol is available that, when touched, allows to show/hide the Password (see figure
above, on the left).

Touch CONNECT key.

The user is asked for confirmation.
Upon connection, Configure and Activate buttons are enabled in order to be able to
access the corresponding Configuration or Activation process (par. 5.2.2 Not
Configured Vision System on page 78).

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5.2.2 Not Configured Vision System

Touch the wished button: Configure or Activate.

The user is asked for confirmation.
Continue as described in par. 5.3 Configure on page 79 or in par. 5.4 Activate on
page 86, depending on the user’s choices.

5.2.3 Configured Vision System

A connected and configured Vision System is ready to be used. Therefore exit the
Vision environment and proceed to create/execute programs (Create and Run
environments) using it.
On the contrary, if the Vision System is already configured but it is wished to modify the
current configuration, touch the wished button (Configure or Activate) and act like if it
was a Not Configured Vision System.

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5.3 Configure
This command always creates a NEW configuration for the Vision System, making it
ready to be used.
The Calibration (par. 5.3.1 Calibration on page 79) could be either NEW as well, or
IMPORTED from a previously saved Configuration.

WARNING
Note that even if only one of the camera physical parameters (focus and diaphragm) is
modified, the Configuration procedure must be repeated again.
Thus, before executing a Configuration process, it is suggested to use the Go Live
command, to check such parameters adjustment and to modify them, if needed.
Furthermore, note that the camera best performances can be obtained by using a
perfect focus and a proper lighting of the being identified object.

The Vision System Configuration is composed of 4 phases, displayed by a step bar, in

the top area of the Vision Wizard page (as shown in the figure above):
– Calibration
– Model
– Area
– Target.
The symbol associated to a specific phase, becomes green when it is to be executed
and it remains green also when it is done and the application switches to the next phase.
Switching to the next phase is automatic as soon as a phase is done.
PREVIOUS and NEXT keys allow moving among the phases, both back and forth.
The central area of the Vision Wizard page, belongs to the camera.
The image is not dynamic: it is a picture of what the camera focuses at the page opening.
If refreshing the image is wished, touch the camera symbol (highlighted in red in the
figure below) to take a new picture.

5.3.1 Calibration
The Calibration phase associates camera pixels to robot positions. Using more points
risults in a finer calibration precision.

Note that a new Calibration is needed just if the relative position between the camera
and the reference frame is changed (e.g. the camera has been moved with respect to
the UFRAME).

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Before accessing the Vision wizard, choose whether creating a completely new
Calibration or using a previously created and saved existing one, as shown in the figure
below.
The available choices are
– CALIBRATE
• specify the total amount of points to be used during the Calibration procedure.
More points will result in a finer precision
• touch CALIBRATE key.
– IMPORT
• touch IMPORT key
• the application displays a list of the saved Configurations, as shown in the
next figure on the left. Select the Configuration to be imported. The Calibration
only is imported, in fact.

Using an already existing configuration, the first step (Calibration) is automatically

skipped and Model step is directly accessed (see right figure above) to be executed.

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In order to help the user in the Calibration operation, an example of Calibration Sheet is
provided in Appendix - par. 7.1 Calibration Sheet on page 102.

Start the Calibration procedure executing the following preliminary operations:

– place the reference object (e.g. the Calibration Sheet) including the calibration
points, under the camera
– take a picture touching the camera symbol (highlighted in red in the figure above).

Execute the following steps for each point:

a. select the wished point on the tablet (a red little cross indicates the chosen
selection, as shown in the figure above)

b. move the robot to such a point

c. touch NEXT key.

5.3.2 Model

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This phase creates the reference (model), for the camera, of the object that will have to
be identified. Execute the following steps:

a. place the object under the camera

b. take a picture touching the camera symbol (highlighted in the previous figure)

c. carefully select the part of the object that will be used as the model to be identified,
by zooming in/out and moving the frame around it

Use one finger to zoom out, zoom in and move the selecting mask.
Use two fingers to act on the image (zooming and moving).

d. touch NEXT key.

5.3.3 Area

This phase defines the area inside which the object will be searched for and identified.
To do this, execute the following steps:

e. zoom in/out and move the frame around the object, so that it will include the whole
search area

Use one finger to zoom out, zoom in and move the selecting mask.
Use two fingers to act on the image (zooming and moving).

f. select the wished tolerances the Vision System should use during the object
identification:
• Threshold - tolerance percentage while matching model and object
• Start angle / End angle - tolerances about the object rotation, when
compared with the model

g. touch NEXT key.

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5.3.4 Target
This phase defines the object picking modality. It is composed of three steps.

NOTE THAT before starting this phase, the gripper to be used during the actual working
cycle must be mounted on the robot.

Touch NEXT key to move to the next step:

a. step 1/3 - place the object under the camera and touch NEXT key.

BE CAREFUL!
Absolutely DO NOT place the robot between the camera and the object. This would
cause the object not to be identified.

When the object is identified, some dashed lines are displayed (as indicated in the
figure below).

b. Step 2/3 - move the robot to the position that will be considered as the
approach/depart one and touch NEXT key.

– approach is the point the robot must reach before moving to pick the object
– depart is the point the robot must reach after picking the object.

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The user is asked to confirm the chosen approach/depart position, by touching

SAVE key.

Note that approach and depart points are the same.

c. Step 3/3 - move the robot to the target position, i.e. the pick position, and touch
NEXT key.

The user is asked to confirm the target position (previous figure, on the right) by
touching SAVE button.

At the procedure end, the user is asked whether saving the Configuration. If so, insert
the wished name and touch OK (as shown in the figures above).

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CAUTION
All Configuration data are lost, if not saved.

Note that the Calibration included in the saved Configuration, can be used later to be
imported (refer to par. 5.3.1 Calibration on page 79 for further details).
Then the user is asked whether the saved Configuration should be activated.

When the procedure is accomplished, the Vision System is ready to be used. Therefore
exit the Vision environment and proceed to create/execute programs (Create and Run
environments) using it.

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5.4 Activate
Unlike Configure command, this command simply activates an ALREADY EXISTING
Configuration.
It allows configuring the Vision System too, making it ready to be used.
Touching the Activate button, the application displays a list containing the available
configurations, as shown in the figure below.

Long touching a configuration name in the list, a window is displayed in which the
following operations can be chosen:
– Rename - to rename the touched Configuration
– Remove - to cancel the touched Configuration from the list.
By simply touching the name of a listed configuration, instead, the user chooses it for
activation.
The application asks for confirmation before proceeding. Answer yes to activate the
chosen configuration.

When the Activation procedure is accomplished (figure above, on the right), the Vision
System is ready to be used. Therefore, exit the Vision environment and proceed to
create/execute programs (Create and Run environments) using it.

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5.5 Go Live
Touching the Go Live command (as shown in the left figure below) the streaming
environment (Camera Live) is entered in which all the scenarios focused by the camera,
are displayed in real time.

Note that the camera best performances can be obtained by using a perfect focus and
a proper lighting of the being identified object.

From left to right, the figures below show examples of images

– too much lighted
– too few lighted
– out of focus
– ok.

From the camera physical parameters adjustment point of view, two different scenarios
are handled:
– Manual adjustment
– Autofocus.

5.5.1 Manual adjustment

This is the scenario in which the camera DOES NOT support Autofocus functionality.
This environment allows adjusting the camera physical parameters (focus and
diaphragm), manually acting on it.
In this case, the Camera Live environment does not allow using Autofocus button (as
shown in the figure below).

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5.5.2 Autofocus
This functionality, that can be enabled only for cameras supporting it, allows the focus
area automatic updating.

Before executing such an operation, select the focus area acting on the mask (using one
finger) and, if needed, on the image too (using two fingers).
Touch Focus switch to enable/disable the Autofocus functionality usage.
Then, activate the automatic focus update by using one of the following modalities:
– Manual focus - allows selecting the wished focus by swiping the bar with one
finger. The focus is adjusted by the system as soon as the finger is removed from
the bar
– Automatic focus - the focus is automatically adjusted by simply touching the
button.

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6. INTEGRATED CONVEYOR TRACKING

(OPTIONAL FEATURE)

To be able to use an integrated Conveyor Tracking, the related option is required.

Comau option code for Conveyor Tracking is CR17926206.

6.1 Introduction
COMAU provides some standard KITs to handle integrated Conveyor tracking, with
already mapped input ports.
PickAPP can support two Conveyor KITs at the same time.

Only COMAU standard Conveyors are supported.

The integration of the Conveyor Tracking option in PickAPP application, allows

implementing Pick and Place processes for objects on moving conveyors. Systems
including both Conveyor Tracking and Integrated Vision System (optional feature) can
be implemented.
The Conveyor tracking option must be CONFIGURED in order to be used in PickAPP
environment programs, i.e. the following data must be defined: general parameters,
tracking window, Conveyor Base, start/end tracking events, approach, target and
depart points.
A proper Configuration, allows inserting Conveyor points in the user programs.

CAUTION
In case of using Conveyor points, the programmer should be completely aware of the
associated Configuration, to be able to move the robot to compatible positions, both
before and after the tracking, approach, pick/place (i.e. target) and depart
operations.

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Open the Navigation Menu and choose Conveyor item (as shown in the previous figure
on the left) to handle the integrated Conveyor Configurations.
The application displays the Conveyor page (previous figure on the right) including 10
elements (card) meaning
– free cards, to add new configurations
– already existing configurations, editable if needed.

BE CAREFUL
The following requirements are to be complied with to be able to handle the Conveyor
configurations
– at least one conveyor KIT must be available in the system
– the system status must be Programming,
– no active configurations.

If the system status is not Programming, take care of Changing the environment.
If the Conveyor page specifies an active configuration (as shown in the following figure
on the left), open the indicated and deactivate it by means of OFF command (following
figure on the right).

Current chapter describes the following topics:

– Cards handling menu
– Creating/modifying a configuration.

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6.2 Cards handling menu

A menu can be opened in each card (figure above), whether free or already used,
providing the following commands:
– Import
– Delete
– Rename.

Import
Allows importing an already existing configuration and using it either to create a new one
or modifying the one from which importing is performed.
The application displays the existing configurations and asks the user to choose the
wished one to be imported.

To import a configuration means to acquire all its settings. It is up to the user to modify
them or to skip subsequent phases (touching the NEXT key) saving their already
existing settings.

Delete
Allows eliminating the selected configuration.

Rename
Allows renaming the selected configuration.

Note that the configuration is also renamed in any programs using Conveyor points
referring to it.

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6.3 Creating/modifying a configuration

There are three different ways of handling a configuration:
– touch a free card and create a completely new configuration;
– touch a free card and choose Import, to start from a previously saved configuration
and modify some of its values;
– touch a card associated to an already existing configuration, in order to modify it
(whether importing another one or not, the procedure is the same). The application
asks for confirmation before proceeding.

Irrespective of the chosen mode, the application opens a list in which the user should
select the Tool to be used for the Conveyor configuration.

CAUTION
Check that the selected tool and the one currently mounted on the robot flange do
match!

During the Configuration procedure, the user is helped by the Conveyor Wizard, as
shown in the following figure.

The Conveyor Configuration is composed of 4 phases, displayed by a step bar, in the

top area of the Wizard page (as shown in the figure above):
– Params
– Base
– Events
– Teach.

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During a certain phase execution, the corresponding symbol is white, with flashing
boundary; at the phase end, it becomes green and the execution switches to the next
phase.

When a phase is accomplished, switching to the next phase is automatic as soon as the
NEXT key is touched, corresponding to the latest step of the phase.
PREVIOUS and NEXT keys allow moving among the steps, both backward and forward.
Each phase can be composed of more than one step.

6.3.1 Params
This phase allows choosing the being configured Conveyor Kit and inserting some
important execution parameters.

If any values are displayed (either existing or imported configuration) and no changings
are wished, touch NEXT key to step to the following phase.

Select the wished Conveyor Kit; there are two choices:

– KIT 1
– KIT 2.
Then insert (or modify) the following functional parameters:
– Tx Rate - is the transmission rate, i.e. the ratio between distance covered by the
Conveyor and motor turns [mm/R]
– Tracking Window Start and Tracking Window End - these parameters allow
specifying start and end of the Tracking Window, beginning from Start Tracking
event, set in the Events phase.
Touch NEXT key.

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6.3.2 Base
This phase calculates the Conveyor Base reference frame.

If the Conveyor Base has already been calculated (either existing or imported
configuration), touch NEXT key. Use TEACH AGAIN key, instead, to calculate it again.
Refer to par. Import on page 91 for further details.
If the phase is skipped, saving the already existing values, Events phase is accessed.

Proceed with the following steps to allow the application to properly calculate the
Conveyor Base:

a. move the robot to the reference frame origin

b. teach the current position by touching CONFIRM POSITION key (previous figure)

c. move the robot to a X axis position, along the Conveyor movement direction

d. teach the current position by touching CONFIRM POSITION

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e. move the robot to a position in the XY plane

f. teach the current position by touching CONFIRM POSITION

g. continue with the Base calculation, by touching CALCULATE BASE (following

figure)

h. the application displays the Base calculated values; touch OK to confirm

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i. touch NEXT key to finish Base phase.

6.3.3 Events
This phase allows defining events to start (Start tracking) and stop (End tracking)
tracking.

If the configuration already exists or is imported and modifying Events settings is not
wished, touch NEXT key.

The start tracking event can be

– the end of the previous robot movement in the program (previous figure on the
left), or

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– an Input signal (previous figure on the right). In the displayed page, the shortcut
to I/O page is available. Furthermore, it is allowed accessing the Input
ports list of the currently selected type and also choosing the event type: rising
edge or falling edge.
The end tracking event can be
– the end of the last tracking movement, or
– a specified space [mm] covered by the conveyor from the tracking start.
Touch NEXT key after selecting the wished events and providing corresponding
information if needed, to complete the Events phase.

6.3.4 Teach
This phase allows teaching approach, target and depart poisitions.
If the configuration is already existing or imported and no changings have been made to
Base or Events, touch NEXT to skip this phase or TEACH AGAIN to execute it again.
If such a phase is skipped, answer YES to overwrite the configuration and finish

Before starting the Teach phase, check the selected tool and the currently mounted on
the robot flange do match.
Depnding on whether the Vision System is also involved or not, the Teach phase is
different. Thus the first choice to be made is related to the wished MOVE type:
– FIXED MOVE - procedure based on manual teaching
– VISION MOVE - procedure based on positions supplied by the Vision System.

6.3.4.1 FIXED MOVE

The procedure steps depend on whether the Start Tracking event type is
– Input signal associated to the sensor (following figure on the left), or
– end of previous movement of the robot (following figure on the right).

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In the FIXED MOVE mode, all movements are executed in jog.

a. Switch the robot motors on (DRIVE ON)

a.1 if the Start Tracking event comes from an Input, place the object on the Conveyor,
before the sensor position

a.2 touch NEXT key to start the procedure

a.3 power on the Conveyor and stop it when the object is near the robot.

b. move the robot to the approach position and touch NEXT to teach it

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c. move the robot to the target (pick or place) position and touch NEXT to teach it.

d. Insert the name of the new configuration

e. touch OK key to save the configuration and complete the procedure.

NOTE that if the Start Tracking event is end of previous movement, the procedure
starts at step b.

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6.3.4.2 VISION MOVE

NOTE
Check that the camera is properly mounted above the sensor.

In this modality, information from the camera is waited for, before executing movements.
No additional information or procedures are required from the user.
When the sensor triggers the object passing on the conveyor, the camera takes a picture
and the robot starts tracking.

CAUTION!
The robot should NEVER be placed between the camera and the object when the
camera has to take the picture in order to start searching and identifying it. It is then up
to the programmer to avoid such a situation.

The camera identifies the object and communicates its position.

NOTE
At RUN time, the tracking movements are the ones previously set in the camera
configuration.

Touch NEXT to insert the wished configuration name and then OK to save it and finish
the procedure.

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INTEGRATED CONVEYOR TRACKING (OPTIONAL FEATURE)

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APPENDIX

7. APPENDIX
– Calibration Sheet

7.1 Calibration Sheet

A sample Calibration Sheet is provided to help the user during the Calibration phase.
It is suggested to print the figure shown in the following page and to use it as described
in par. 5.3.1 Calibration on page 79.
The user can anyway decide to use his/her customized references, during the
Calibration operation.

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APPENDIX

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Made
in
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