OPERATIONS MANUAL

FOR THE INSPECTION WORKSTATION

PUBLICATIONS

By:

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Research Information Center

Aalional Bureau of Standards

Gaithersburg, Maryland 20899

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OPERATIONS MANUAL FOR THE INSPECTION WORKSTATION

Howard T. Moncarz

Stephen A. Osella

Bruce Borchardt

Ralph Veale

April 21, 1988

This publication was prepared by United States Government

employees as part of their official duties and is, therefore, a

work of the U. S. Government and not subject to copyright.

Certain commercial equipment, instruments, or materials are

identified in this paper in order to adequately specify the

experimental procedure. Such identification does not imply

recommendation or endorsement by the National Bureau of Standards,

nor does it imply that the materials or equipment identified are

necessarily the best available for the purpose.
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TABLE OF CONTENTS

Page

I. INTRODUCTION 1

1. WHAT THIS MANUAL IS ABOUT 1

2. AUDIENCE 1

3. OVERVIEW 1

II. GENERAL DESCRIPTION OF THE IWS 3

1. PHYSICAL LAYOUT 3

1.1. Coordinate Measuring Machine fCMM) 3

1.2. Surface Roughness Instrument (SRI) 6

1.3. Robot 6

1.4. Material Handling System (MHS) 9

2. MAIN MODES OF OPERATION 9

2.1. Integrated 12

2.2. Stand-Alone 12

- 3. THE IWS CONTROLLERS 12

3.1. What Is A Controller? 12

3.2. Types Of Controllers 12

3.2.1. Workstation Controller (WSC) 12

3.2.2. Equipment Controllers 14

3.3. How Controllers Are Connected 14

3.3.1. Physical Connections 14

3.3.2. Logical Connections 14

4. CONTROLLER COMMANDS 17

4.1. Workstation Controller (WSC^ 17

4.2. Equipment Controllers 18

4.2.1. CMMC Work Orders 18

4.2.2. SRIC Work Orders 18

4.2.3. IRC Work Orders 18

4. 2. 3.1. For Robot 18

4. 2. 3. 2. For SRIC 19

5. INSTALLATION 19

III. SAFETY CONSIDERATIONS 21

1. BEFORE OPERATING THE IWS 21

2. ROBOT SAFETY 21

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Page

IV. STARTING THE WORKSTATION 25

1. PROCEDURES FOR COMPUTER CONTROLLERS COLD START . . 25

1.1. Controller Cold Start Up 25

1.1.1. Turn Them On 25

1.1.2. Boot Up Pascal 25

1.1.3. Set The Date And Time 2 5

1.2.

CMM Computer Cold Start Up 26

2. PROCEDURES FOR EQUIPMENT COLD START 2 6

2.1. Cold Start For The CMM . 26

2.1.1. Turn It On . 26

2.1.2. Calibrate The PH9 Probe 2 6

2. 1.2.1. Execute The Calibration Program 26

2. 1.2. 2. Activate Pendant Joysticks 28

2. 1.2. 3. Move Probe Away From Table 28

2. 1.2. 4. Switch To Absolute Mode 28

2 0 1.2. 5. Probe Calibration Positions 28

2 .1.2. 6. Calibrate Zero Probe Position 28

2. 1.2. 7. Calibrate Remaining Probe Positions .... 30

2. 1.2. 8. Verify Probe Calibration 30

2. 1.2.9. Move To Zero Probe Orientation 3 0

2.2.

Cold Start For The Robot 30

2.2.1. Turn It On 31

2.2.2. Calibrate Robot Arm 31

2. 2. 2.1. Switch to Arm Mode 31

2. 2. 2. 2. Move Arm To Calibration Position If

Necessary 31

2. 2. 2. 3. Calibrate 35

2.2.3. Calibrate Robot Track . , 35

2. 2. 3.1. Switch To Track Mode 35

2. 2. 3. 2. Move Robot To Track Calibration Position . . 35

2. 2. 3. 3. Calibrate 35

2.2.4. Load Robot Program (am_robot) 35

2.3. Cold Start For The SRI 35

2.4. Cold Start For The ADI 35

2.5. Safety Fence 36

2.5.1. Experimental Operation 36

2.5.2. Unattended Operation 36

3. PROCEDURES FOR EQUIPMENT WARM START 3 6

3.1. Warm Start For The CMM 36

3.2. Warm Start For The Robot 38

3.2.1. Stop The Robot Program If Necessary 38

3.2.2. Move Robot To Arm Calibration Position If

Necessary 3 8

3.2.3. Clear Serial Port 38

3.2.4. Start The Robot Program 38

3.3. Warm Start For The SRI 38

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Page

3.4. Warm Start For The ADI 38

3.5. Warm Start For The Safety Fence 38

4. PROCEDURES FOR EQUIPMENT CONTROLLERS WARM

, START 39

4.1. Starting The CMM Controller 39

4.2. Starting The SRI Controller 39

4.3. Starting The Robot Controller 39

5. PROCEDURES FOR WORKSTATION CONTROLLER WARM

START 39

5.1. Integrated (Connected To Cell) 40

5.2. Stand Alone (User Interface) 40

5.2.1. Starting The Execution Control System . . , . 40

5.2.2. Workstation Synchronization 43

5.2.3. Workstation Warm Start Up 43

V. OPERATING INSTRUCTIONS IN READY STATE ‘ 45

1. INTEGRATED MODE 45

2. STAND ALONE . . .

' .45

2.1. Eguioment Controllers 45

2.2. Operating Instructions For The WSC 45

2.2.1. Work Orders . 45

2. 2. 1.1. Creating Work Orders 49

2.2.1.1.1. Automatic Creation Of Work Orders .... 49

2. 2. 1.1. 2. Manual Creation Of Work Orders . 49

2. 2. 1.2. Editing Work Orders 49

2. 2. 1.2.1. Editing Work Order Action Data 49

2. 2. 1.2. 2. Editing Work Order Parameter Data .... 49

2. 2. 1.3. Moving To Other Work Orders * . 50

2. 2. 1.4. Deleting A Work Order 50

2. 2. 1.5. Issuing Work Orders 50

2.2.2. Warm Shut Down 50

3e RESTARTING THE IWS 50

3.1. Restart Equipment 50

3.2. Restart Controllers 51

VI. SHUTTING DOWN THE WORKSTATION 53

1. SHUT DOWN STATES 53

1.1. Warm Shut Down 53

1.2. Extended Warm Shut Down 53

1.3. Cold Shut Down 53

1.4. Extended Cold Shut Down 53

2. PROCEDURES FOR WARM SHUT DOWN 53

2.1.

Workstation Controller 53

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Page 2.2.

Equipment Controllers 54

3.

PROCEDURES FOR EXTENDED WARM SHUT DOWN 54

3.1. Computer Controllers • 54

3.2. Coordinate Measuring Machine 54

4.

PROCEDURES FOR COLD SHUT DOWN 54

4.1. Workstation Controller 54

4.2. Equipment Controllers 54

4.3. Stop- The Execution Control System 54

4.4. Robot 55

4.4.1. Stop The Robot Program . 55

4.4.2. Move Robot To Arm Calibration Position . . i . 55

4.4.3. Move Robot To Track Calibration Position ... 55

4.5. CMM 55

5.

PROCEDURES FOR EXTENDED COLD SHUT DOWN 55

5.1. Computer Controllers 55

5.2. Robot 55

5.3. CMM 56

5.4. SRI 56

5.5. ADI 56

VII. ERROR HANDLING 57

1. TYPES OF ERRORS 57

2. CMM ERRORS 57

2.1. Missed Part 57

2.2. Unexpected Touch 57

2.3. Program Hangs 57

3.

SRI ERRORS 58

3.1. SRI Display Changes To F's 58

3.2. ADI Display Goes Off 58

3.3. Program Hangs 58

4.

ROBOT ERRORS 58

4.1. Move Error 58

4.2. Program Hangs 58

5.

WSC ERRORS 58

5.1. Process Plan Parsing Error 58

5.2. Equipment Controllers Indicate Error 59

6.

NETWORK ERRORS 59

6.1. Network Set Up Error 59

6.2. During Operations 59

7.

DATA SERVER ERRORS 59

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Page

7.1. Data Files Not Found . . 59

7.2. AMRF Data System Indicates Error 59

VIII. DATA PREPARATION ' 61

1. CREATING AND/OR EDITING DATA FILES 61

1.1. Who Should Do It - 61

1.2. The Editor 61

2. INTERNAL DATA STRUCTURES 62

GLOSSARY 63

APPENDICES 69

A. IWS DOCUMENTATION LIST 69

B. OPERATIONS REFERENCE GUIDE 71

1. STARTING THE INSPECTION WORKSTATION 71

2. OPERATING THE INSPECTION WORKSTATION STANDALONE 72

3. RESTARTING THE INSPECTION WORKSTATION 72

4. SHUTTING DOWN THE INSPECTION WORKSTATION 73

REFERENCES 75

READER COMMENT FORM 77

V
LIST OF FIGURES

Page

Figure 1 — Floor Plan of the AMRF 4

Figure 2 — Physical Layout of IWS 5

Figure 3 — Surface Roughness Instrument 7

Figure 4 — Automatic Dial Indicator 8

Figure 5 — Robot Teach Pendant 10

Figure 6 — Safety Fence . 11

Figure 7 — Controller Hierarchy 13

Figure 8 — Physical Architecture of the IWS 15

Figure 9 —> Logical Architecture of the IWS 16

Figure 10 — CMM Control Panel 27

Figure 11 — CMM Pendant 29

Figure 12 — Robot Control Locations 32

Figure 13 — Robot Control Panel 33

Figure 14 — Robot Display After System Software Loaded ... 34

Figure 15 — CMM Origin . .

' 37

Figure 16 — Robot Display When A Program Is Running 41

Figure 17 — WSC Operating Options 42

Figure 18 — Tray 510 46

Figure 19 — Tray 520 47

Figure 2 0 — Tray 530 48

vi
OPERATIONS MANUAL FOR THE INSPECTION WORKSTATION

I. INTRODUCTION

1. WHAT THIS MANUAL IS ABOUT

The main purpose of this manual is to explain how to operate the

Inspection Workstation (IWS)

.

The IWS inspects parts delivered to it by the AMRF Material

Handling System. The current equipment at the IWS allows two

types of part inspection: dimensional inspection and measurement

of surface finish.

2 . AUDIENCE

This manual is intended to be used by anyone who needs to operate

the IWS —whether the IWS is integrated to the AMRF and accepting

commands from the Cell, or whether it is in stand-alone mode and

accepting commands directly from the operator.

No specialized training in computers or automation is required.

The minimum requirement is that the operator be familiar with

machine shop operations.

3 . OVERVIEW

Chapter II gives an overall description of the IWS. The material

covered in this chapter is not required to start up and run this

workstation. However, the operator is encouraged to read this

chapter to gain a better understanding of the IWS —in order to

make fuller use of its capabilities.

Chapter III is a short tutorial on safety considerations in

operating the IWS. All operators should read and understand this

chapter before starting up the IWS.

Chapters IV, V, and VI explain the operation of the IWS —starting

it up, operating it, and finally, shutting it down. Under normal

operation, these chapters contain all the information necessary to

operate the IWS.

Chapter VII describes possible errors that can occur during

operation, and explains how to deal with each one.

Finally, Chapter VIII explains data preparation. Currently, data

preparation or editing should not be done by IWS operators.

However, this chapter is included for completeness; to give a

flavor of the type of data that the IWS uses.

1
IWS Operations Manual

The information in the Glossary, Appendices, and References is not

required to operate the IWS. However, the operator may find this

information useful.

The glossary defines terminology used in this manual.

Appendix A lists all the documents included in the complete IWS

documentation. For an understanding of the IWS beyond the

material covered in this manual, refer to the proper document

listed in this appendix.

In addition to the IWS documentation, other documents (e.g. the

equipment user manuals) that could be helpful to the IWS operator

are listed in the References section.

Appendix B consists of three condensed reference guides of the

starting, ready state, and shut down procedures.

Finally, an error report/reader comment form is provided for the

operator to give feedback on the manual, so that improvements can

be made in the future.

2
IWS Operations Manual

II. GENERAL DESCRIPTION OF THE IWS

The information contained in this chapter is necessary for the

operator who wants to gain a general understanding of the IWS

architecture and equipment configuration in order to make full use

of its capabilities. This chapter can be skipped, however, if the

operator only wants to run the workstation in its simplest mode of

operation.

1. PHYSICAL LAYOUT

The Inspection Workstation is located in the temperature

controlled room in the southwest corner of the AMRF shop floor.

Figure 1 is a diagram of the entire AMRF. The IWS is located in

the bottom left of this figure.

The physical layout of the IWS is shown in Figure 2 . A cart

carrying a tray of parts to be inspected comes into the IWS along

the track shown in this figure. The tray is automatically

delivered to the tray transfer station that is located under the

robot. (The robot is mounted on a gantry above the IWS.)

There are three major pieces of equipment in the IWS: the

Coordinate Measuring Machine (CMM) , the Surface Roughness

Instrument (SRI) , and the Robot. (Note that in this document, the

'R' in 'Robot' is capitalized when referring to the IWS Robot.)

The equipment at the IWS is described below.

1.1. Coordinate Measuring Machine (CMM)

The CMM is used to measure the dimensional tolerances of a part.

To enable very accurate measurements, the temperature within the

IWS is maintained at twenty degrees Celsius. The particular CMM

used is known as a horizontal am CMM, since it consists of a

horizontal am that moves vertically.

The part to be measured is placed on the table of the CMM. This

table has three degrees of freedom in the horizontal plane—two

translational degrees of freedom perpendicular to each other and

one rotational degree of freedom about an axis through the center

’ of the table. A probe is mounted on the end of the am. The

particular probe used for the IWS is a PH9 type probe. This probe

has an additional two rotational degrees of freedom about the am.

The probe is a force sensitive mechanism that registers a touch if

its synthetic ruby tip encounters a small force. This force is

adjustable and is held at about five grams for nomal IWS

operation. At this force level, most parts can be accurately

measured while the part is secured on the table by its own

3
IWS Operations Manual

To

Material Loading TURNING WORKSTATION

VERTICAL WORKSTATION

HORIZONTAL WORKSTATION

Figure 1. Floor Plan of the AMRF

4

[
IWS Operations Manual

Figure 2. Physical Layout of IWS

5
IWS Operations Manual

force due to gravity. If the part is very light, it can still be

measured if it can be mounted on a fixture and the combination of

fixture and part placed on the table.

The CMM has direct computer control capability (DCC) and can be

operated in either manual or automatic mode. In the IWS, it works

in automatic mode except when positioning the probe to the CMM

Origin (see Chapter IV, Section 3.1) and during the initial

calibration of the probe.

1.2. Surface Roughness Instrument (SRI)

The SRI is used to determine the surface roughness of a part by

measuring the light scattered off the surface in question.

The SRI consists of two main components: an electronic controller

mounted in a box and an infrared light source and detectors

mounted in a tube (called the head of the SRI). (See Figure 3.)

The light is shined in a narrow beam on the surface of a part.

The light scattered back is measured by a line of twenty

detectors. Based on empirical analysis, a roughness average is

estimated.

Additionally, an automatic dial indicator (ADI) is used along with

the SRI to enable the Robot to position a part at a precise

distance away from the head of the SRI. The dial indicator

consists of a spring loaded plunger, that when depressed will

record the distance it is depressed, and the electronics to

control and monitor it. (See Figure 4.) When the Robot presses a

part against this indicator, a reading of how far the plunger has

been depressed is recorded, and later used for positioning the

part in front of the SRI.

1.3. Robot

The IWS Robot is used to transfer parts from one place in the

workstation to another, and to work as a unit with the SRI to

position a part in front of it as required.

The IWS Robot is a standard robot that is custom mounted upside

down on a gantry to permit it to reach any place in the IWS that

is required. The Robot system consists of the Robot itself, the

Robot computer, the teach pendant, and the monitor. The Robot has

two modes of movement; position and track. In position mode, the

Robot can be moved at six joints —the waist, shoulder, elbow,

wrist roll, wrist flex, and hand roll. In track mode, the Robot

can be moved along the gantry track. The Robot cannot move in

both modes simultaneously.

6
IWS Operations Manual

To SRI Controller

Front View Side View

Figure 3. Surface Roughness Instrument

7
IWS Operations Manual

Figure 4. Automatic Dial indicator

8
IWS Operations Manual

The arm is capable of lifting up to 50 pounds, and has a span of

40 inches. The gantry axis is 72 inches long. The gripper has a

maximum span of 6 inches and the gripper pads move in straight

lines maintaining parallelism. The force applied to the gripper

is determined by the air pressure available; at 60 psi it's about

40 pounds. It is not adjustable under automated control, so that

any fragile parts will be crushed.

The robot has its own computer built into it that is considered

part of the Robot itself. This computer contains two floppy disk

drives; one is used for the AR Smart system required for Robot

operation. The other is for user programs. In particular, this

drive contains the program that allows the HP computer to control

the Robot and interface it to the IWS.

A teach pendant (Figure 5) is used to operate the Robot when it is

not hooked up to the IWS. The pendant includes a 20 key keypad,

with 4 color-coded modes, giving 80 different commands available.

On the same pendant is a joystick control for the Robot, with

three degrees of freedom available at any one time. That is, the

joystick can do x, y, and z in 'position' mode, or it can do roll,

pitch, and yaw in 'orientation' mode. Position or orientation

mode is chosen by a switch. There is also a motor on/off button

and a program run/stop rocker switch.

Surrounding the Robot is an electric safety fence that can detect

if anyone comes into the space that the Robot can reach. If so,

the controls can be set to sound an alarm or to immediately turn

off the Robot. (See Figure 6.)

1.4. Material Handling System fMHS)

The function of the AMRF Material Handling System is to deliver

parts throughout the AMRF as needed. The components of the MHS

used by the IWS include the tray table, an interlock mechanism,

and a cart used to transport the parts. The only part of this

system under the control of the IWS is the interlock mechanism.

The IWS sends a command to this mechanism which either allows or

prevents the MHS from taking control over the tray. (For further

details of the MHS, see Reference 8.)

2. MAIN MODES OF OPERATION

The IWS operates in two main modes of operation—either integrated

or stand-alone. These are described below.

9
IWS Operations Manual

Figure 5. Robot Teach Pendant

10
IWS Operations Manual

WSC and

Robot

Controllers

CMM

Controller

o

X

Electric eye fence shown by

Figure 6. Safety Fence.

11
IWS Operations Manual

2.1.

Integrated

In integrated mode, the IWS receives its commands from the AMRF

Cell, and continually reports its status back to the Cell. Once

the IWS is started in this mode, no further operator action is

required.

2.2.

Stand-Alone

In stand-alone mode, the IWS is not connected to the rest of the

AMRF. All commands to the IWS are entered by the operator. . The

IWS can operate in stand-alone mode even when the rest of the AMRF

is not operating.

3. THE IWS CONTROLLERS

3.1. What Is A Controller?

The purpose of a controller is to supervise the operation of a

mechanism, another controller, or both. The thing that the

controller supervises is known as its subordinate. The

controller, itself, is supervised by another controller called its

supervisor. (See Figure 7.)

A controller accomplishes its "mission by communicating to its

subordinates in a language that each subordinate understands.

This language consists of commands from a controller to its

subordinate of what the subordinate is supposed to accomplish and

statuses back from the subordinate of the progress towards

accomplishing its tasks. In the IWS, each controller is on a

separate HP computer and communication between controllers takes

place through a local workstation network.

3.2. Types Of Controllers

Controllers are used in the IWS to regulate and monitor the

activity of the equipment and equipment controllers. There are

four controllers at the IWS; one for each of the equipment systems

(Sections 1.1 to 1.3) and one for the overall workstation

controller.

3.2.1. Workstation Controller (WSC)

The WSC supervises the IWS. It receives commands in integrated

mode from the Cell Controller and in stand-alone mode from an

operator. The WSC is in charge of coordinating the activity of

the IWS by sending commands to the equipment controllers and

monitoring their return statuses.

12
IWS Operations Manual

Figure 7. Controller Hierarchy

13
IWS Operations Manual

3.2.2. Equipment Controllers

Each machine has a dedicated controller. The controller is in

charge of interfacing with the WSC, executing an equipment work

order command, and controlling and monitoring the assigned device.

The controllers are directly connected to the equipment and

communicate with it in the language understood by the device. The

only difference between the equipment and workstation controllers

is that the feedback from the machines is in the form of sensory

data instead of status messages.

3.3. How Controllers Are Connected

3.3.1. Physical Connections

All the controllers communicate with each other (and the rest of

the AMRF) by means of RS232 serial connections. As can be seen in

Figure 8, the WSC is directly connected to the AMRF Cell

Controller and to each of the equipment controllers.

3.3.2. Logical Connections

The logical architecture of the IWS specifies how controllers are

connected to each other by the flow of commands. As can be seen

in Figure 9, the WSC is the top most level of the IWS hierarchy

and receives its commands from the AMRF Cell. The CMM and Robot

Controllers are subordinate controllers to the WSC. The CMM is

directly below the CMM Controller. Under the Inspection Robot

Controller (IRC) is the Robot and the SRI Controller. The SRI and

the ADI are directed by the SRI Controller.

Additionally, all four controllers can directly access (in logical

terns) the AMRF IMDAS, to get whatever data each separate

controller needs. IMDAS (Integrated Manufacturing Data

Administration System) is the distributed data system which

provides common interfaces to the AMRF's user programs and

underlying databases [B.9, B.IO]. In the current implementation,

only the WSC can access the IMDAS.

Even though the logical architecture of the IWS is different from

its physical architecture, the network communications system takes

care of transferring commands and data along the paths shown in

the figure for the logical architecture. For instance, to

transfer a command from the Inspection Robot Controller (IRC) to

the SRI Controller (SRIC) , the command is transferred from the IRC

to the WSC computer to the SRIC. Effectively, the command is

transferred from- the IRC to the SRIC, even though in actuality it

is relayed by the WSC computer. The roundabout path is chosen by

the network communications system, and can be ignored by the

14
IWS Operations Manual

Figure 8. Physical Architecture of the IWS

15
IWS Operations Manual

Figure 9. Logical Architecture of the IWS

16
IWS Operations Manual

operator. The operator should think in terms of the logical

architecture to understand the system.

Even though the physical architecture may change in a future

implementation to improve the efficiency of the data transfers,

the logical architecture can remain the same if so chosen by the

designer. In the current logical architecture, the SRI Controller

is directly connected to the Robot Controller because the two

operate together, as if they were a single mechanism, when

inspecting a part with the SRI. To connect these two controllers

together, rather than have them both subordinate to the WSC, is a

more natural implementation and results in a considerably simpler

programming task.

4. CONTROLLER COMMANDS

4.1. Workstation Controller (VISC)

As indicated above. Cell commands can be issued to the WSC from

the Cell Controller in integrated mode or from the user in

stand-alone mode. The WSC initiates operation of the workstation

from a state called cold shutdown by issuing a sequence of

commands to its subordinate controllers. This is required to put

the IWS into the proper state (the ready state) , so that the WSC

can accept inspection commands from the Cell (or user)

.

There is a set of transition commands used to set up and shut down

the WSC and a set of work order commands that are permissible once

the WSC is ready. The transition commands utilized to set up the

WSC are SYNCHRONIZE and WARM_STARTUP, and WARM_SHUTDOWN and

COLD_SHUTDOWN are used to shut down the WSC. The current work

orders are RECEIVE_TRAY, SHIP_TRAY, and INSPECT_LOT.

The RECEIVE_TRAY and SHIP_TRAY commands prepare the IWS to receive

or ship a tray of parts, respectively. The INSPECT_LOT work order

is the input command from the Cell Controller directing the WSC to

inspect a tray of parts. It is the objective of the WSC to

decompose that command into a set of equipment level work order

commands. The resulting group of machine work orders constitutes

the process plan at the workstation level, referred to as the

operation sheet. The individual work orders will be discussed in

the next section. Usually, each work order has arguments - (parameters) associated with it; however, they will not be

discussed in this document.

17
IWS Operations Manual

4.2.

Ecruipment Controllers

The CMM, SRI, and Robot each have their own controller—the CMMC,

SRIC, and IRC, respectively. The CMMC and IRC receive orders from

the Workstation Controller and supervise the operation of their

appointed machine. The SRIC receives its orders from the IRC and

commands the SRI and ADI. Following is a description of the work

orders that are currently supported by the IWS equipment

controllers. It is not necessary to be familiar with this set of

commands unless the operator is interested in generating new

operation sheets.

4.2.1. CMMC Work Orders

There are two work orders that can be sent to the CMMC: LOAD_DATA

and INSPECT. The LOAD_DATA order is used to direct the CMMC to

retrieve the required part and inspection plan data. The function

of the INSPECT order is to command the CMMC to measure the

dimensional tolerances of the given part.

4.2.2. SRIC Work Orders

In the present IWS configuration, the SRIC is under the control of

the IRC; therefore, the SRIC work orders are issued by the IRC and

not by the WSC. These work orders are LOAD_DATA, READ_DIAL, and

INSPECT_PART. LOAD_DATA directs the SRIC to retrieve the required

part and inspection plan data. READ_DIAL obtains a dial reading

from the ADI. INSPECT tells the SRIC to begin the SRI inspection.

4.2.3. IRC Work Orders

WSC work orders to the IRC contain commands specific to the Robot,

commands that are executed by the IRC and the SRIC together, and

commands that are passed on by the IRC to be executed by the SRIC

itself. Commands executed by the Robot itself are discussed in

the next section. Commands that are executed by both the IRC and

SRIC or the SRIC alone are discussed in the section following that

one.

4. 2. 3.1. For Robot

The first work order that the IRC must receive is LOAD_DATA—to

command the IRC to retrieve the data that it requires to operate.

The other Robot specific work orders are ACQUIRE, CLEAR, MOVE,

RELEASE, and TRANSFER. These commands were originally defined for

the Horizontal Workstation [7] and were adapted for the IWS. The

ACQUIRE command is used to direct the Robot to grasp a part at a

given location. Conversely, the function of the RELEASE order is

18
IWS Operations Manual

to instruct the Robot to release the part and end up at a given

point. The CLEAR command is similar to the RELEASE command,

except that the Robot is first directed to go to a particular

point before it releases the part. The MOVE order commands the

Robot to move the part from its current location to a specified

destination, but not release it. The TRANSFER work order is a

higher level combination of ACQUIRE, MOVE, and RELEASE. If the

Robot is holding the part to be transferred, the ACQUIRE portion

is ignored.

4. 2. 3. 2. For SRIC

The work orders employed to operate the SRI through the IRC are

LOAD_SRI_DATA, GET_DIAL_READING, and INSPECT_WITH_SRI . These

three work orders are sent from the WSC to the IRC. The first,

LOAD_SRI_DATA is passed on to the SRIC. (The command to the SRIC

is LOAD__DATA.) The latter two commands require both Robot move

commands and commands to the SRIC. The GET_DIAL_READING command

is used to determine the part offset relative to the Robot

grippers so that the part can be positioned correctly in front of

the SRI head. This command requires the Robot to move the part

surface up to the ADI, and then issue the READ_DIAL work order to

the SRIC. The INSPECT_WITH_SRI command directs the Robot to move

the part surface up to the SRI and then issue the command,

INSPECT^PART, to the SRIC.

5 . INSTALLATION

The IWS controllers and equipment are currently installed and

configured. Note that the configuration and switch settings

should not be changed under normal operating conditions.

19
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IWS Operations Manual

III. SAFETY CONSIDERATIONS

1. BEFORE OPERATING THE IWS

Before operating the IWS you must first complete an orientation

course given by a qualified IWS staff member that includes safety

information and instruction for operating the IWS.

2. - ROBOT SAFETY

If you will be operating the IWS Robot you must thoroughly

understand the information presented here. People who are

incidentally in the area can be governed by a simple rule; stay

behind the light fence.

The problem of safety around a robot is not a simple one. It will

be necessary to get close to the IWS Robot at times and especially

during the teaching and calibration phases. Particular attention

has to be taken when operating the Robot, even when you have the

teach pendant in your hand and have your fingers over the

emergency motors off button. You need to understand the system

and how it will react to your inputs. Only with experience can

you develop the skill required to be comfortable in handling the

Robot

.

The rest of this section applies specifically to the "American

Robot" (now American Cynflex) Merlin robot on the gantry frame in

the Inspection Workstation.

This Robot has several modes of operation. The choices include:

machine 0 or 1, elbow mode 0 or 1, move mode 0 or 1, position or

orientation, and the three axes.

Machine 0 is the 6-axis Robot, and machine 1 is the gantry, which

has just one axis. These are changed by the green shift of the

key labeled MVM (it has no green label)

.

Elbow mode is selected by the ELM key, followed by a 0 or 1

argument. It can also be included in a program. Elbow mode 0 is

elbow down for our system; it is never used. Unfortunately, elbow

mode 0 is the default of the system. Elbow mode is the nastiest

trick that this Robot can play on you. The trouble is that the

Robot we have is hung upside down from the gantry. This means

that we usually work in the non-default elbow mode, mode 1, which

keeps our elbow up. The canned programs all have a declaration of

ELM 1 near the beginning, so when they are run the Robot will work

properly. However, ELM is cleared when you Clear Program, so you

can get an unexpected elbow shift, which is a thrust of the hand

forward like the lunge of a fencer. Note that elbow mode only

21
IWS Operations Manual

applies when the machine is in move mode 1, the straight line

motion. This is a good reason to use move mode 0 as often as

possible.

Move mode is selected by the key MVM, and a 0 or 1 argument. Move

mode 0 is "joint-coordinated" motion, where each joint moves

separately. From the pendant, this means that each joystick

direction controls an axis independently. In a program, it means

that the arm "swings" through motions smoothly, but not on a

precise path. Move mode 0 is less likely to produce move errors

in a program, since it is less likely to go through a "forbidden"

zone, e.g. the Robot's own base. For teaching points, move mode 1

is more commonly used, since it gives moves that are definitely

predictable in a right-angle coordinate system. For example, when

a part is being placed on a table, a single joystick move can move

the point closer to the table without changing the orientation of

the part.

Position or orientation is a choice that only applies to joystick

motions. In move mode 0 (joint-coordinated), "Position" means

that the joystick moves are related to the first three axes

(waist, shoulder and elbow) , and "Orientation" means that they are

related to the three final axes (wrist roll, wrist flex, and hand

roll) . In move mode 1, "Position" means that the joystick moves

are straight lines at right angles to each other. "Orientation"

should mean that the joystick= controls three rotations, one about

each orthogonal axis. It doesn't seem to work quite that simply;

the axes of rotation are all different, but not orthogonal.

The common teaching mode is machine 0, elbow mode 1, move mode 1.

In this circumstance, the position movements labeled X, Y and Z

are the absolute directions: X is East-West, Y is North-South,

and Z is Up-Down. (This is if frame 0 and tool 0 are set.)

The problem relating to safety is primarily how to predict what

will happen when you issue a command. ("Command" can mean either

a keyboard or joystick action.) Practice with the joystick is the

best way of learning what it does. Unexpected moves from keyboard

commands are best avoided by learning the combinations likely to

cause them. These combinations are primarily: move mode 1 with

elbow mode 1, moving through the wrist straight orientation in

move mode 1, forgetting that a frame or tool is set and going the

wrong way with the joystick (i.e. Down instead of North) , clearing

a program in move mode 1, moving to a point relatively instead of

absolutely ( on either machine) , and moving the wrong machine.

Other guidelines which should be followed:

1. Only one person inside the fence at a time (when the Robot is

22
IWS Operations Manual

active) ; that person should be using the pendant and be in

complete charge of the Robot's actions.

2. Before issuing commands which may cause large motions (e.g.,

MOV, ELM, MVM) step back from the Robot; preferably outside the

fence.

3 . Keep the speed low—this means both the wheel on the pendant

and the programmed SPD; they are independent. You can't keep the

MOV slow by turning down the rheostat.

4. THINK before you move: At least mentally check the frame set,

the tool set, the move mode setting, the elbow mode setting, and

the speed. It doesn't hurt to issue a redundant command to be

sure of these settings. (As long as it's into MVM 0; the change

to MVM 1 or ELM 1 can be very hazardous.)

The Robot shouldn't be impossible to stop; there is a collision

sensor which monitors the Robot's arm. If sufficient force is

applied' to the arm, the programmed position and the present

position will be unacceptably far apart and the Robot will shut

down. Punching the arm with a fist seems to be the most effective

way to activate the collision detector. Warning: the detector is

quite tough to activate;. DO NOT depend on this to avoid injury.

The quickest way to stop a disastrous move is to shut down the

motors. The pendant's red button will usually be closest to the

main operator; another button is on the front panel. Turning on

the fence (which will often be off during teach operations) and

running your hand through the light fence is the quickest way to

shut down the Robot from the side of the room away from the

control panel. Please note that pressing the red button on the

front panel or activating the fence stops the robot's motion

immediately by applying a brake to it. Pressing the stop button

on the pendant merely' turns the robot motor off, and the arm will

drift slightly before coming to a stop.

For a more comprehensive description of operating the Robot, see

the Merlin Robot System Operators and User Guide [ 3 ]

.

23
IWS Operations Manual
IWS Operations Manual

IV. STARTING THE WORKSTATION

A number of procedures must be done in the correct order to start

up the IWS. When all of the IWS equipment and computers have been

shut down for an extended period of time, all of the cold start up

procedures described in this chapter must be done. First the

computer controllers must be started and then the equipment itself

must be brought to a cold start. When the IWS has to be restarted

or when cold start is completed, the equipment controllers and

equipment must be warm started. Finally, after the Workstation

Controller has completed warn start up, the IWS is ready for

operation.

This chapter describes the required start up procedures and the

equipment calibration procedures in detail. Refer to Appendix

B.l. for a quick reference guide on starting the IWS.

1. PROCEDURES FOR COMPUTER CONTROLLERS COLD START

Cold start up for a computer controller is necessary if the

computer is powered down or is not working under the Pascal

operating system.

1.1.

Controller Cold Start Up

All of the computers except the CMM computer have the same cold

start up procedure. Start up for the CMM computer is discussed in

Section 1.2.

1.1.1. Turn Them On

Each of the computer systems consists of a hard disk, a central

processing unit, a keyboard, and a monitor. Each component of the

system is connected to a power outlet which is located next to the

monitor screen. To turn on a system, simply flip the red switch

so that the light turns on.

1.1.2. Boot Up Pascal

Upon power up, the computer system will attempt to boot up. When

you hear a tone you must press ENTER, then Ip to select Pascal as

the working operating system. After Pascal is chosen, the

computer will complete boot up and will come up in the correct

directory for the most up to date version of the IWS software.

1.1.3. Set The Date And Time

To set the date in the correct format, for example September 13,

25
IWS Operations Manual

1987, type 13-SEP-87 [ENTER]. ([ENTER] refers to the key labeled

'ENTER'.) To set the time for 9:36 am type 9:36 [ENTER].

1.2. CMM Computer Cold Start Up

Before starting the CMM computer, be sure the start up disk is in

the right hand disk drive. Then, simply press the "AC LINE button

on the front right of the keyboard to turn on the power. The

computer will boot up off of the diskette and will come up in the

correct directory for the most up to date version of the CMM

software. Enter the correct date and time and proceed with start

up.

2. PROCEDURES FOR EQUIPMENT COLD START

This section contains specific procedures for starting up the IWS

equipment from an extended cold shut down state. If these

instructions fail to start the equipment, refer to Chapter VII of

this document for trouble-shooting directions.

2.1. Cold Start For The CMM

2.1.1. Turn It On

Two steps have to be taken to turn on the CMM. First, shift the

Power On lever to the right. This lever should always be left

turned on. Next, press the Ready/Servo On button. (See Figure

10 .

)

2.1.2. Calibrate The PH9 Probe

The PH9 Probe has to be recalibrated only if the main power to the

CMM has been off for more than 24 hours. This could occur due to

a power outage or if the main power to the CMM was turned off.

(Normally, the main power to the CMM is always left on. The 24

hour leeway is due to a battery backup.) If the power has not

been interrupted for over 24 hours, you can skip the calibration

procedure and go to Section 2.2. Otherwise, the PH9 Probe must be

calibrated prior to operation. To calibrate the probe, follow

these instructions.

2.

1.2.1.

Execute The Calibration Program

At the CMM Controller computer, execute the calibration program by

entering xcordaxiruncmm. Choose 1 as the debug string from the

first menu and then press enter when asked to do so. Subsequently,

enter k from the second menu to enable keyboard input. It will

now be possible to issue FLB commands to the CMM.

26
IWS Operations Manual

[=1

EMERG/ A POWER POWER

SERVO READY

STOpV ) OFF 1

1 ON

OFF

SERVO ON

Figure 10. CMM Control Panel

27
IWS Operations Manual

2. 1.2. 2. Activate Pendant Joysticks

If the servos are not on, turn them on by pressing the Servo On

button (Figure 10) . Next, activate the joysticks on the hand

pendant by pressing MAN to go to manual mode, JOY to select

joystick mode, and SLOW to reduce the motion speed (Figure 11)

.

2 . 1 . 2 . 3 . Move Probe Away From Table

The right joystick on the pendant is used to maneuver the probe

north and south and up and down. The left joystick moves the

table east and west. Very carefully move the probe so that it is

positioned about six inches above the gage block.

2 . 1 . 2 . 4 . Switch To Absolute Mode

Switch from incremental to absolute mode (if it is not already in

that mode) by pressing the ABS button on the pendant.

2. 1.2.5. Probe Calibration Positions

The PH9 probe must be set to the seven different positions listed

below.

Probe Axis A Axis B

0 90 -90

1 90 -110

2 90 -180

3 70 -90

4 100 -120

5 0 -90

6

“ 105 -70

The procedure to set these is described in the following sections.

2. 1.2.

6.

Calibrate Zero Probe Position

Push Probe Axis A button on the pendant and enter 90. Then push

Probe Axis B button and enter -90. To enter a minus number, first

enter the number and then press the +/- button. The probe will be

oriented vertically and pointing downward. Using the pendant

joysticks, carefully move the probe so that it is positioned over

the center of the steel ball (located at the southeast corner of

the table, and called the calibration sphere) and about six inches

above it. Make sure the speed is set to slow before moving the

probe.

28
IWS Operations Manual

joystick

ZLOCK

JOG JOY

PART MACH

FAST SLOW

ABS INCR

MAN AUTO

PROBE PROBE

AXIS AXIS TABLE

B A

SffVO

PAUSE POWER DRIVE

OFF

CALCULATOR/MENU KEYPAD + * *

SELECT

/ EXIT X

7

Y

8

Z.9

MENU

FCTN CALC

R

4

A

5

DIA6

PRINT

REPORT

DISPLAY OFF

UNE

YES

1 2

PROBE

3

NOM

ENTRY

TOL

ENTRY

NO

0

• +/-

TIP SELTIP CAL

- RECORD CLEAR z= ENTER

FUNCTION

Figure 11. CMM Pendant

29
IWS Operations Manual

At the computer keyboard, enter the FLB command calfxtr sp,1.5,p6.

Subsequently, enter ah and follow the instructions given on the

monitor of the hand pendant or the computer screen. You will be

asked to move the probe to specific positions. After each

positioning, press the RECORD button to register the point.

Lastly, press the AUTO button to let the machine automatically

calibrate the zero probe position.

2. 1.2. 7. Calibrate Remaining Probe Positions

For each of the six remaining probe positions comply with the

following instructions.

Press MAN, SLOW, and then JOY to go back to manual mode.

Carefully move the probe about six inches above the calibration

sphere. Enter the A and B axis probe orientation values specified

in Section 2. 1.2.5. for the current probe position.

At the computer keyboard, enter the command at 1 (through at 6

depending on the probe position) . As specified by the

instructions on the hand pendant and on the computer screen, move

the probe so that it is pointing toward the center of the ball and

is about six inches from the surface of the ball and then push the

RECORD button on the pendant. Subsequently, move the probe 0.25

inches away from the ball, but again make sure the probe is still

pointing towards the center, and press the RECORD button. Press

the AUTO button to allow the CMM to calibrate the probe position.

Repeat the steps in this section to complete the calibration for

the remaining probe positions.

2. 1.2. 8. Verify Probe Calibration

Move the probe to a safe position away from any objects. Verify

the calibration by issuing a gt 0 through gt 6 command. For each

probe position, the probe will automatically orient itself as

specified in Section 2. 1.2. 5.

2. 1.2. 9. Move To Zero Probe Orientation

Issue the gt 0 command to orient the probe vertically and pointing

downward. Stop the calibration program by pressing the HP Shift

and Stop keys together.

2.2. Cold Start For The Robot

It is recommended that the operator be familiar with the Robot

operating procedures before attempting to handle the Robot.

30
IWS Operations Manual

2.2.1.

Turn It On

The power must be turned on at the wall circuit switch. It is not

usually turned off there. Then turn on the switch on the box on

the east column of the Robot gantry (Figure 12)

.

Push the power on button on the control box on the west column

(Figure 13) . This button will not work if the red power off

button is not released. To release the power off button, turn it

clockwise and let it pop out.

Push the battery low button on the control panel. This closes a

relay which would otherwise hold the power supplied to the control

boards a little too low and cause extraneous move errors.

Wait about three minutes for the system to load. When the display

on the teach pendant is the same as in Figure 14 , the American

Robot Operating System has been loaded and the Robot is

operational

.

2.2.2.

Calibrate Robot Arm

2 . 2 . 2 . 1 . Switch to Arm Mode

Press MVM 0 [ENTER] and then Machine 0 [ENTER] from the pendant to

put the Robot in arm mode. The Machine key is the green shift of

the MVM key. This key is not explicitly labelled.

2. 2. 2. 2. Move Arm To Calibration Position If Necessary

If the Robot arm is not in the calibration position, you must use

the teach pendant to move it there. The arm calibration position

is roughly in the middle of the gantry track with the Robot arm

completely horizontal. For more infomation about the correct arm

calibration position, consult the Merlin Robot System Operators

and User Guide [3 ]

.

With the Robot arm pointing east, set the position/orientation

switch on the pendant to position and straighten the elbow using

the joystick so that it is horizontal. Then, flip the switch to

orientation and use the joystick to align the wrist and hand

joints so that the blue markers match up. Lastly, set the switch

back to position and turn the waist of the Robot so that it is in

the calibration position.

31
IWS Operations Manual

Wall Mounted

Power Breaker^

WSC and

Robot

Controllers

CMM

Controller

3

X

I

f

Figure 12. Robot Control Locations,

32
IWS Operations Manual

Figure 13. Robot Control Panel
IWS Operations Manual

Figure 14. Robot Display After

System Software Loaded

34
IWS Operations Manual

2. 2. 2. 3. Calibrate

Press CLB (red shift CLB) on the pendant. Answer 1 [ENTER] to the

first prompt which means a power on calibration. Lastly, Press

ENTER when prompted to confirm the calibration. The arm will move

around a little, and the pendant will display CAL PROC 1 when

finished.

2.2.3. Calibrate Robot Track

2 . 2 . 3 . 1 . Switch To Track Mode

Press Machine 1 [ENTER] on the pendant to choose the gantry track

machine mode. Again, the Machine key is the Green shift MVM key.

2. 2. 3. 2. Move Robot To Track Calibration Position

Using the joystick on the pendant, move the gantry (towards the

IWS entrance) to a position about an inch south (to the back of

the room) of the calibration position (marked by a red line on the

gantry) by moving the joystick to the right.

2. 2. 3. 3. Calibrate

Press CLB 1 [ENTER] , and lastly push the yes button when asked Cal

Machine 1?. The gantry will search and then stop when calibrated

and will respond with CAL PROC 1.

Next, press Machine 0 [ENTER] which makes the arm active.

2.2.4. Load Robot Program (am_robot)

Press LPG 400 [ENTER] to load the program that will communicate

with the HP computer. Wait for the prompt: I>lpg 400 which will

indicate that the Robot program is loaded into memory.

2.3. Cold Start For The SRI

The Surface Roughness Instrument power lines are connected to the

SRI computer outlets. Therefore, by turning on the SRI computer

system you are also activating the Surface Roughness Instrument.

2.4. Cold Start For The ADI

The Automatic Dial Indicator is also connected to the SRI computer

outlets; therefore, same as above, the ADI is started by turning

on the SRI system. The display on the ADI should be on and should

be all zeroes. If it is not on, press the button on the ADI

labeled O (see Figure 4)

.

35
IWS Operations Manual

2.5. Safety Fence

The Safety Fence console consists of a fence power on/off switch,

a fence reset button, an audio on/off switch, and various light

indicators. (See Figure 6.) The instructions for operating these

are presented in the following sections.

2.5.1. Experimental Operation

During experimental operation, the safety fence is generally left

turned off. However, if you decide to keep it off, be very

careful of safety.

2.5.2. Unattended Operation

Before turning on the safety fence, first press the reset button

until the fence light indicator stops- flashing. Then, flip the

fence switch to on. If you want to turn on the alarm in the event

that the fence is triggered, flip the audio switch to on.

3. PROCEDURES FOR EQUIPMENT WARM START

Warm start is necessary to synchronize the IWS equipment with the

IWS Controllers. This is required when the IWS is initially

started up, or when it is restarted after an error has crashed the

system.

3.1. Warm Start For The CMM

iPrior to warm starting the CMM, the CMM probe tip must be

positioned at the CMM Origin. This position is defined by the top

center of a gage block which is located at the southwest corner of

the CMM table. This gage block has a hemispherical hole cut in

its top, so that the center of the probe tip may be positioned at

the correct location. (See Figure 15.)

To activate the joysticks, press the following pendant buttons:

MAN, JOY, and SLOW. The Probe can now be moved by manipulating

the two joysticks on the pendant. Very carefully position the red

probe tip to the CMM Origin.
IWS Operations Manual

NORTH

Figure 15. CMM Origin

37
IWS Operations Manual

3.2.

Warm Start For The Robot

3.2.1. Stop The Robot Program If Necessary

If the Robot program is running, you must first stop the program

execution. Do this by flipping the rocker switch on the pendant

to STOP briefly, and putting it back to RUN position. Then press

IMM to go back to manual mode. Lastly, press Machine 0 [ENTER]

MVM 0 [ENTER] to enable arm movement mode.

3.2.2. Move Robot To Arm Calibration Position If

Necessary

If the Robot is not at the arm calibration position, move the

Robot to that position by pressing MOV 199 [ENTER] . The Robot

will move to a vertical position.

3.2.3. Clear Serial Port

Next, clear the serial port by pressing IN 801 [ENTER]. Then,

again toggle the rocker switch on the pendant to STOP and then put

it back to RUN position. You should see the sp rd aborted message

flashing on the teach pendant.

3.2.4. Start The Robot Program

Lastly, to start the Robot program, press RUN (red shift RUN) on

the teach pendant. You should see the running ... message on the

pendant

.

3.3. Warm Start For The SRI

After Cold Start Up, the Surface Roughness Instrument is ready for

operation. Therefore, no extra set up is necessary. If the IWS

is to be restarted, toggle the SRI off and on.

3.4. Warm Start For The ADI

After Cold Start Up, the ADI is ready for operation. Therefore,

no extra set up is necessary. If the IWS is to be restarted,

toggle the ADI off and on.

3.5. Warm Start For The Safety Fence

The Safety Fence can be turned on at any time; however, the fence

reset button must be pressed before the fence is activated.

38
IWS Operations Manual

4. PROCEDURES FOR EQUIPMENT CONTROLLERS WARM START

To begin operations, a program called the execution control system

(ECS) must first be started on each of the equipment controllers.

Note that all entries to the HP computers must be entered exactly

as specified here. (I.e. 'a' is not the same as 'A'.)

4.1. Starting The CMM Controller

Start the execution control system by first pressing s to "stream"

a file. Then press ECS [ENTER] when prompted for the file you

want to stream. The appropriate files will be loaded into memory

and then the servo power will be deactivated and the CMM will be

reset.

When the message Press Execute to Continue appears on the CMM

monitor, finish the CMM start up by pressing the servo on button

on the CMM console, the AUTO button on the hand pendant, and

finally the EXECUTE key on the CMM Controller computer.

4.2. Starting The SRI Controller

Start the execution control system by first pressing s to "stream"

a file. Then press ECS [ENTER] when prompted for the file you

want to stream. The appropriate files will be loaded into memory

and the SRI and ADI will be reset.

When the controller displays the Press M button prompt, wait 5

seconds, then press the M button on the ADI. If the SRI screen

shows WORKING in the top right corner, then the SRI Controller has

been started successfully.

4.3. Starting The Robot Controller

Start the execution control system by first pressing s to "stream"

a file. Then press ECS [ENTER] when prompted for the file you

want to stream. The appropriate files will be loaded into memory

and the IRC will be ready for operations. After about one minute,

the message 0.00000 will be displayed on the teach pendant. (See

Figure 16)

.

5. PROCEDURES FOR WORKSTATION CONTROLLER WARM START

The Workstation Controller can be operated in integrated mode,

where commands are received from the AMRF Cell Controller, or in

stand-alone mode, where commands are received from the user

interface. Be sure your keyboard entries are exactly what is

specified here. (Remember, 'a' is not the same as 'A'.)

39
IWS Operations Manual

Various Workstation Controller operation options have been set by

default. To change the Workstation Controller operating options

prior to operation, edit the file wsc_31: debug. To change the

Data Seirver operating options, edit the file ds_31: debug. The

editing must be done before warm starting the Workstation

Controller. Look at Figure 17 for the list and effects of the

operating options.

5.1. Integrated (Connected To Cell^

Start the execution control system by first pressing s to "stream”

a file. Then press ECS [ENTER] when prompted for the file you

want to stream. The Workstation Controller will now be activated

and the operation will be run by the Cell Controller.

5.2. Stand Alone (User Interface)

5.2.1. Starting The Execution Control System

Start the execution control system by first pressing s to "stream"

a file. Then press ECS2 [ENTER] when prompted for the file you

want to stream. The appropriate files will be loaded into memory

and the system will attempt to set up the Workstation Local

Network.

Wait for the message network established to be displayed before

proceeding. When you see the message, press the ENTER key. If

the message does not appear after an inordinate amount of time,

refer to Chapter VII on network set up errors.

You will then be shown the list of permissible Workstation

Controller commands. Press 1 [ENTER] to change the Workstation

Controller operating options or 2 [ENTER] to change the Data

Server operating options. These options can be set at any time

with no effect to the operation of the controller.

Before inspection work orders can be issued, the workstation has

to be set up.

40
IWS Operations Manual

sPr d aborted

I > 0. 00000

Figure 16. Robot Display When

A Program is. Running

41
IWS Operations Manual

Option Effect

d Turn on the Workstation status display

e Turn on Error Message Display in case of error

f Use SCRIPT1 by default for Order Action retrieval

1 Inspect a Tray Continuously

m Write Operation History to File

Figure 17. WSC Operating Options

42
IWS Operations Manual

5.2.2. Workstation Synchronization

You must first synchronize the Workstation Controller with the

other equipment controllers; therefore, press 3 [ENTER] to issue

the Synchronize command. It takes about 15 seconds to synchronize

the Inspection Workstation controllers.

5.2.3. Workstation Warm Start Up

You can now either warm start up to complete set up or cold shut

down to turn off the system. You have to send a Warm Start up

command before you can issue work orders. Press 3 [ENTER] to

issue a Warm Start up command. Refer to Chapter VI, Section 4.1.

to perform cold shut down of the Inspection Workstation.

It takes about one minute for the Workstation Controller to warm

start the system.

43
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IWS Operations Manual

V. OPERATING INSTRUCTIONS IN READY STATE

Once the IWS is started up, it is in an operational state called

the Ready State. From this state the IWS can receive trays of

parts, inspect those parts, and ship them off. The IWS remains in

this state until a shut down is ordered, or an error crashes the

system.

Without the benefit of a vision system, it becomes the duty of the

operator to inspect the position of each part in the tray

container and to reposition the parts if necessary. This is

required for both integrated and stand alone operations. If any

part is too far off its correct position, it can crash the entire

workstation.

There are three trays of parts that are currently being used in

the IWS for testing and demonstrations. These trays are

designated 510, 520, and 530. The locations of parts on these

trays are shown in Figures 18 to 20.

1 . INTEGRATED MODE

Under Cell control, there is nothing further required for the

operator unless there is an error. In the event of an error,

refer to Chapter VII for error recovery instructions.

2. STAND ALONE

2.1. Equipment Controllers

Unless there is an error, the only interaction allowed by the

operator is through the Workstation Controller.

2.2. Operating Instructions For The WSC

In Ready State, you can either issue work order commands to

perform the inspection process or a warm shut down command to shut

down the Inspection Workstation.

2.2.1. Work Orders

To create, edit, manage, and dispatch work orders press 3 [ENTER]

at the main Workstation Controller menu. This will put you in the

work order menu.

A work order consists of a fixed order action data section and a

variable order parameter data section. The fixed section - specifies the work order identification number, work element.

45
NORTH

IWS Operations Manual

figure 18. Tray 510

CART

DEUVERY

FROM

THIS

SIDE
NORTH

IWS Operations Manual

Figure 19. Tray 520

47

CART

DELIVERY

FROM

THIS

SIDE
IWS Operations Manual

Figure 20. Tray 530

CART

DEUVERY

FROM

THIS

SIDE
IWS Operations Manual

update number, and order action. The variable section consists of

data pertinent to the particular work order.

The AMRF architecture specification stipulates that more than one

work order can be sent per cell command. This section is written

as if you can enter multiple work orders. However, the current

implementation will not allow you to do that—the WSC will only

accept one work order per command.

2. 2. 1.1. Creating Work Orders

Before entering or editing the work order data, you must first

create a work order "worksheet". This worksheet, displayed on the

screen, specifies the work order data necessary and initially

contains default values.

2.2. 1.1.1. Automatic Creation Of Work Orders

Option 9 of the work order menu automatically creates a new

worksheet if none exists and then retrieves the data from a script

file and enters it in the worksheet. If a worksheet does exist,

then the worksheet's data is overwritten.

If you choose this option you can then skip directly to issue the

work order if you do not wish to edit the data. Notice, however,

that you can edit the data even if you have retrieved the work

order data from a script file.

2. 2. 1.1. 2. Manual Creation Of Work Orders

You can either append a work order worksheet to the list of work

orders or you can insert a worksheet before another specified work

order worksheet in the list. To append a worksheet, enter 2 at

the work order menu. To insert a worksheet before the current

one, enter 3.

2. 2.

1.2.

Editing Work Orders

2.2. 1.2.1. Editing Work Order Action Data

To edit the work order action data, enter 7 at the work order

menu. Subsequently, enter the appropriate number for the work

order action datum you wish to edit and respond accordingly.

Enter 1 to get out of the work order action data menu.

2 . 2 . 1 . 2 . 2 . Editing Work Order Parameter Data

To edit the work order parameter data, enter 8 at the work order

menu. As with the work order, you must also create a parameter

49
IWS Operations Manual

worksheet before you can enter the data. Enter 2 or 3 to either

append or insert a parameter data worksheet.

After doing so, you can proceed to enter the data by selecting

option 7 of the work order parameter data menu. Enter the

appropriate number for the work order parameter datum you wish to

edit and respond accordingly. Enter 1 to exit the edit parameter

data menu.

You can create new work order parameters by entering either 2 or

3, or you can enter 1 if you are finished editing parameter . data

and wish to leave the order parameter data menu.

2. 2. 1.3. Moving To Other Work Orders

You can either go to the next or previous work order in the list

if it exists. To go to the next work order, enter 4. To go to

the previous work order, enter 5.

2.2. 1.4. Deleting A Work Order

Enter 6 at the work order menu to delete the current work order.

The work order after the one to be deleted will become the new

current work order.

2.2. 1.5. Issuing Work Orders

Finally, after you have created and edited the work orders, you

can either issue the work orders or you can quit without issuing

the command. To issue the work orders enter 10 from the work

order menu. If on the other hand you do not want to issue the

work order, enter 1 instead.

Note that the work orders that were created will remain in the

system until they are deleted or the execution control system is

terminated. Every time the work order menu is entered, the first

work order in the list will be displayed on the screen.

2.2.2. Warm Shut Down

Refer to Chapter VI, Section 2.1. for workstation warm shut down

instructions.

3. RESTARTING THE IWS

3.1. Restart Ecruioment

Refer to Chapter IV, Section 3, to restart the IWS equipment.

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IWS Operations Manual

3.2. Restart Controllers

Refer to Chapter IV, Section 4, to restart the IWS equipment

controllers and to Chapter IV, Section 5, to restart the

Workstation Controller.

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IWS Operations Manual
IWS Operations Manual

VI. SHUTTING DOWN THE WORKSTATION

1. SHUT DOWN STATES

As defined in the AMRF architecture specification, there are two

types of shut down: warm shut down and cold shut down. Two other

states were added at the Inspection Workstation to account for

more varied circumstances. Therefore, there are now four levels

of shut down defined: warmi shut down, extended warm shut down,

cold shut down, and extended cold shut down. The two new states

pertain only to the workstation equipment.

1.1. Warm Shut Down

Warm shut down is performed when the workstation is in the ready

state and the operator wants to discontinue operations but leave

the workstation enabled.

1.2. Extended Warm Shut Down

Extended warm shut down is executed after warm shut down and is

meant to disable some of the workstation equipment if operations

are suspended temporarily.

1.3. Cold Shut Down

Cold shut down is performed when the workstation is in the warm

shut down state and the operator wants to terminate the execution

control system on the computer controllers and disable, but not

power down, all of the workstation equipment.

1.4. Extended Cold Shut Down

Extended cold shut down is executed after cold shut down and is

used to power down all of the workstation controllers and

equipment when operations are halted indefinitely.

2. PROCEDURES FOR WARM SHUT 'DOWN

2.1. Workstation Controller

To issue a warm shut down command, press 4 [ENTER] from the main

Workstation Controller menu. The warm shut down command causes

the Workstation Controller to transition from a ready state to a

warm shut down state. However, before warm shut down, the

Workstation Controller will complete all of the pending work

orders

.

53
IWS Operations Manual

After warm shut down, the operator can either get back to ready

state by warm starting the workstation using the instructions of

Chapter IV, Section 5.2.3. or cold shut down the system by

referring to Section 4.1. of this chapter. 2.2.

Ecfuipment Controllers

The warm shut down commands to the equipment controllers are

issued automatically from the Workstation Controller. There are

therefore no procedures for equipment controller warm shut down.

3. PROCEDURES FOR EXTENDED WARM SHUT DOWN

3.1. Computer Controllers

To protect the computer's monitor screens, turn down the

brightness intensity of the monitors. However, leave the

execution control system running on the computer controllers.

3.2. Coordinate Measuring Machine

To warm shut down the CMM for an extended period of time, turn off

the servo motors by pressing the Ready/Servo On button on the CMM

console.

4. PROCEDURES FOR COLD SHUT DOWN

4.1. Workstation Controller

To cold shut down the IWS, press 4 [ENTER] at the main Workstation

Controller menu. Cold shut down takes about one minute.

4.2. Ecmipment Controllers

The cold shut down commands to the equipment controllers are

issued from the Workstation Controller.

4.3. Stop The Execution Control System

After the workstation has been shut down, press the Shift and Stop

(printed in blue) keys together to stop the execution control

system. Then press the I key to initialize the computer.

To restart the equipment controllers, use the procedures of

Chapter IV, Section 4. To restart the Workstation Controller, use

the procedures of Chapter IV, Section 5.

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IWS Operations Manual

4.4. Robot

4.4.1. Stop The Robot Program

Stop the Robot program by flipping the switch on the pendant to

STOP briefly, and putting it back to RUN position. Then enter IMM

to go back to manual mode.

4.4.2. Move Robot To Arm Calibration Position

Press Machine 0 [ENTER] and then MVM 0 [ENTER] to make the Robot

arm movement active. Press MOV 199 [ENTER] to move the arm into

calibration position.

4.4.3. Move Robot To Track Calibration Position

Press Machine 1 [ENTER] to activate the Robot track movement.

Press MOV 950 [ENTER] to move the gantry into calibration

position.

4.5. CMM

If the CMM Controller was shut down normally, the probe tip will

be properly positioned at the CMM Origin, and nothing further need

be done.

Otherwise, press MAN, JOY, and SLOW on the hand pendant to

activate the joysticks. Then use the joysticks to position the

probe back in the CMM Origin.

5. PROCEDURES FOR EXTENDED COLD SHUT DOWN

5.1. Computer Controllers

All of the computer system components are connected to the main

power outlet located near the monitor screen. Turn off each of

the computer systems by flipping the outlet's red switch so that

the light goes off.

5.2. Robot

Power down the Robot by turning off the switch on the box on the

east column of the Robot gantry. Then push the red power off

button on the control box on the west column so that it locks on

•the catch.

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IWS Operations Manual

5.3. CMM

Turn off the CMM by pressing the Servo Off button. Leave the

power on lever switched to the right.

5.4. SRI

The SRI power cables are connected to the SRI Controller computer

system; therefore, in turning off the SRI computer you also turn

off the SRI.

5.5. ADI

The ADI is also connected to the SRI Controller computer system.

The ADI is powered down by turning off the SRI Controller.

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IWS Operations 'Manual

VII. ERROR HANDLING

Currently, most errors that happen at the IWS are nonrecoverable.

Therefore, if an error does occur, the workstation usually has to

be restarted from a Warm Start.

1. TYPES OF ERRORS

Equipment errors and Controller errors are the two types- of errors

that take place at the IWS. Equipment errors arise from faults in

the inspection operation. Controller errors occur when the

execution control system on any of the controllers locks up.

Discussion on specific errors follows in the succeeding sections.

2 . CMM ERRORS

2.1. Missed Part

If the CMM probe tip does not contact the part within a travel

specified by data, the CMM reports an error and kicks over into

manual operation. The main reasons for this error are: the Robot

placed the part on the CMM too far out of position for the CMM to

find it; the wrong part was put on the CMM; or the data specifying

the part conflicts with the actual part being inspected. The

latter could occur, for example, if a hole was machined where an

inspection point was specified. This error is nonrecoverable.

The IWS must be restarted.

2.2. Unexpected Touch

A CMM error also occurs if the probe tip contacts the part (or any

object) when it is attempting to simply move to a new location.

The same reasons causing the missed part error could cause this

error. Again the CMM is kicked into manual operation, and the IWS

must be restarted.

2.3. Program Hangs

There are a number of reasons why the CMM Controller will become

'locked up' and not be able to continue its operations. This

could occur if the communication between the HP computer and the

CMM becomes garbled. Another reason is that the program reaches

an illegal state from which it cannot recover.

Whatever the circumstance that caused the lock up, the result and

corrective measures required are the same. The controller must be

stopped (by pressing the shift and stop keys simultaneously on the

HP keyboard) and the IWS must be restarted.

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IWS Operations Manual

3

.

SRI ERRORS

3.1. SRI Display Changes To F's

If the SRI Display changes to a series of F's, this indicates that

an SRI error has occurred. There is no way to recover from this

error; therefore, the IWS must be restarted.

It is possible that this error indicates a malfunction with the

SRI, which must be repaired before the SRI will operate.

3.2. ADI Display Goes Off

If this happens, the ADI will not return a reading to the SRI

Controller, and the controller will stop operations. The power on

the ADI should be turned off and on again, and the IWS must be

restarted.

3.3.

Program Hangs

It is possible for the program to lock up for the same reasons as

described for the CMM (Section 2.3 above).

4. ROBOT ERRORS

4.1. Move Error

A move error is detected when the Robot no longer seems to be

moving and move error is displayed on the hand pendant. It is

possible to recover from a move error which occurs during

execution. On the teach pendant, enter IMM to get out of program

mode. Issue GTS 19., including the decimal point, to begin

execution at step 19 of the program. Enter PGM to get back into

program mode. Lastly, enter RUN to start the program. The Robot

will continue with the last command issued to it.

4.2. Program Hangs

It is possible for the program to lock up for the same reasons as

described for the CMM (Section 2.3 above).

5. WSC ERRORS

5.1. Process Plan Parsing Error

After the Workstation Controller retrieves the Inspection Process

Plan from the IMDAS, it parses it into a local data structure. If

an error occurs while parsing the process plan, the Workstation

Controller will shut down and the workstation must be restarted.

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IWS Operations Manual

5.2.

Ecfuipitient Controllers Indicate Error

If the Workstation Controller detects an error from one of the

equipment controllers, the workstation will shut down and must be

restarted.

6. NETWORK ERRORS

6.1. Network Set Up Error

If an error occurs while the communication network is being

established, the workstation must be restarted. If the error

persists, make note of the error message which appears on the

monitor of the computer signalling the error and report it to one

of the workstation system staff.

6.2. During Operations . If an error occurs after the network has been established and is

running, a network error message will be printed on the screen.

This should be reported to the workstation system staff.

7. DATA SERVER ERRORS

Data Server errors themselves do not cause the system to shut

down. The response to a data server error depends on the module

making use of it.

7.1. Data Files Not Found

If the a request is made to the Data Server which necessitates the

access of a local data file and that file does not exist, the Data

Server will return a request status of error. The Data Server

does not initiate shut down.

7.2. AMRF Data System Indicates Error

If the AMRF Data System returns an error to a transaction request,

the Data Server will simply pass along the error message.

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IWS Operations Manual
IWS Operations Manual

VIII. DATA PREPARATION

Data preparation is beyond the scope of this manual. In general,

the operator will not create new data or modify existing data.

This chapter is provided to give a general understanding of the

data required and how it is provided.

Each controller is data driven. This means that the control

program that performs the controller functions is fixed, and that

data is provided to allow each controller to perform its specific

tasks. For example, the CMM Controller uses data to inspect a

particular part with a particular inspection plan. To inspect a

different part, different data is provided.

Eventually, all data that each controller needs will be retrieved

from the IMDAS. (Some data will be provided as parameters of Cell

commands.) After the data is retrieved, it has to be translated,

to the format required by the controller itself.

Currently, the only data retrieved from the IMDAS is the tray

contents report, which specifies which parts are in the tray to be

inspected and where they are located in the tray. All other data

resides in data files that are stored in the hard disks on each

controller.

1. CREATING AND/OR EDITING DATA FILES

1.1. Who Should Do It

Creating and editing data files should only be done by someone

with computer experience. Additionally, that person requires a

thorough knowledge of the IWS —more so than is presented in this

manual

.

1.2. The Editor

Editing IWS data files can be done with any editor that can create

ASCII data files. The user should consult the manual that is

provided with the particular editor used for exact instructions on

using it. It is assumed that anyone using an editor to create

data files has experience with using one.

Eventually, these files will not be created by a standard editor.

Instead, they will be created automatically by an off-line

programming system that will allow an operator with little (or no)

computer experience as well as only a minimal knowledge of the IWS

to create the data required for the IWS.

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IWS Operations Manual

2. INTERNAL DATA STRUCTURES

As discussed above, each controller uses data structures that are

specific to its particular functions. These are stored in ASCII

data files located on the hard disk of each controller. There is

a naming convention used for all data files that should be grouped

together. The last three letters of any data file belonging to a

particular group is the same for all data files in that group.

For example, all CMM data files that describe the pipe clamp are

given the suffix of 'clp' in the file name (i.e. pts_clp) . The

letters before the suffix (i.e. 'pts' in this example) are used to

define a particular set of data (points to be inspected in this

case)

.

Each line of a data file is called a record. Each record is made

up of fields, each field representing a different piece of data.

The fields are distinguished by one or more spaces between them.

One or more fields is defined as the key (or keys) . These are

used to find a particular record in the file. The remaining

fields are data fields, and are retrieved when a data file is

searched.

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IWS Operations Manual

GLOSSARY

ADI Abbreviation for the Automatic Dial Indicator,

automatic dial indicator

Instrument used to measure the distance that a spring

mounted stem is depressed.

CMM Abbreviation for the Coordinate Measuring Machine.

CMMC Abbreviation for the CMM Controller.

CMM Origin

Top center of the gage block that is located at the SW

corner of the CMM table. The probe tip is positioned here

when the CMM is initialized, consequently establishing

this location as the zero position for the CMM.

cold shut down

Performed when the workstation is in the warm shut down

state and the operator wants to tenninate the execution

control system on the computer controllers and disable,

but not power down, all of the workstation equipment.

continuous mode

Robot mode in which the Robot does not pause at the point

it is moving to before proceeding on to the next point.

The opposite is point mode in which the Robot stops when

it reaches the point to which it is moving, where it waits

for its next command.

controller

Supervises the operation of a mechanism, another

controller, or both.

coordinate measuring machine

Machine used to measure the dimensions of a part.

data server

Software module that interfaces the controller it resides

on to the data it requires.

ECS Abbreviation for the execution control system,

elbow mode

Robot mode in which the elbow is specified to be either up

or down.

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IWS Operations Manual

execution control system

Computer program that runs on each controller computer and

implements the AMRF design principles. This program loads

and executes those modules which determine which

controller is actually being run.

extended cold shut down

Executed after cold shut down and is used to power down

all of the workstation controllers and equipment when

operations are halted indefinitely.

extended warm shut down

Executed after warm shut down and is meant to disable some

of the workstation equipment if operations are suspended

temporarily.

FLB Function library for the .CMM. The functions and

procedures contained here interface the HP computer that

this module is running on to the Sheffield CMM. This

module is a Pascal translation of the BASIC FLB that

Sheffield provides with its CMM.

gage block

For the purpose of the IWS, the gage block used is a block

of metal with a hemispherical hole in the center of its

top, and glued onto the CMM at its SW corner to provide a

zero position for the CMM.

gantry

A track mounted above the IWS that supports the Robot

(mounted upside down) , and allows the Robot to glide along

it. This track gives the Robot one more dimension (along

the track) than is normally provided with this Robot.

inspection workstation

AMRF workstation that inspects parts for dimensional

tolerance and surface finish.

integrated mode

Mode of operation of the IWS in which the IWS is

integrated to the AMRF—receiving commands from the AMRF

Cell, and obtaining data from the IMDAS.

IRC Abbreviation for the Inspection Robot Controller.

IWS Abbreviation for the Inspection Workstation.

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IWS Operations Manual

joint coordinated mode

A Robot mode which allows the Robot hand to move between

two points in its most efficient manner. The alternative

mode is straight line mode.

logical architecture

Specifies the direction of commands and statuses between

controllers and between controllers and equipment.

machine mode

Robot mode that specifies what robot degrees of freedom

are currently active. If machine mode is 1 (track mode )

,

the robot can move along the gantry track. Machine mode

of 0 (arm mode) allows the robot arm to move in all of its

six joints.

move mode

Robot mode that specifies whether the robot arm will move

in straight line mode or joint coordinated mode. Move

mode 0 is the joint coordinated mode; move mode 1 is the

straight line mode.

network

The connections (both hardware and software) that connects

the IWS controllers together and to the rest of the AliRF.

Local network refers to the former only.

operation sheet

A process plan at the workstation level —i.e. that

coordinates the activity of the controllers in the

workstation.

orientation mode

Robot mode (under teach pendant control) in which the

Robot can move in yaw, pitch, and roll.

parallel port

Refers to a computer I/O interface in which data are

transferred in groups of bits at a time.

pendant

Usually referred to as a teach pendant, it is a hand held

device with keyboard and display, used by an operator to

communicate with a mechanism. In the IWS, a pendant is

included with the CliM, and is considered a part of it.

Likewise, the IWS Robot has a teach pendant.

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IWS Operations Manual

PH9 probe

A motorized probe used on the CMM. This probe can be

oriented automatically under computer command. This

allows the CMM to measure more part surfaces without

reorienting the part than would be normally possible.

physical architecture

Specifies the physical connections among the controllers

and equipment.

position mode

Robot mode (under teach pendant control) in which the

Robot can move in x, y, and z directions.

process plan

Data file that contains a sequence of steps to perform a

manufacturing task.

ready state

The state in which a controller is ready to accept work

order commands. This is the normal state of the

controller during its operation.

RS232 An interface that specifies the electrical and mechanical

connection between two points.

safety fence

An electric eye that surrounds the Robot at the IWS and

detects if an object moves into the Robot's workspace, and

reacts according to its settings (either by audible alarm,

blinking light, or shutting down the Robot)

.

serial port

Refers to a computer I/O interface in which pieces of data

are transferred one bit at a time.

SRI Abbreviation for the Surface Roughness Instrument.

SRIC Abbreviation for the SRI Controller.

stand-alone mode

Mode of operation of the IWS in which an operator commands

the IWS, and the data used by the IWS is stored in local

data files.

straight line mode

A Robot mode which forces the Robot hand to move between

two points in a straight line. The alternative mode is

joint coordinated mode.

66
IWS Operations Manual

subordinate controller

Controller that is controlled by the subject controller,

supervisory controller

Controller that is the supervisor of the subject

controller.

surface roughness instrument

Machine that measures the optical scattering off the

surface of a part that can be correlated with its surface

roughness

.

transition commands

Commands used to transfer the IWS to a new state

(specified by the UVA protocol [4]).

warm shut down

Performed when the workstation is in the ready state and

the operator wants to discontinue operations but leave the

workstation enabled.

work order commands

A command accepted by a controller when it is in ready

state, and used to performi one of its main functions.

WSC Abbreviation for the Workstation Controller.

67
IWS Operations Manual
IWS Operations Manual

APPENDICES

A. IWS DOCUMENTATION LIST

1. H. T. Moncarz, Architecture and Principles of the

Inspection Workstation , to be published as an

NBSIR.

2. H. T. Moncarz, Implementation of the Execution

Control System of the Inspection Workstation , to

be published as an NBSIR.

3. H. T. Moncarz and T. H. Hopp, Implementation of

the CMM Controller , to be published as an NBSIR.

• 4. H. T. Moncarz and T. V. Vorburger, Implementation

» of the SRI Controller , to be published as an

NBSIR.

5. H. T. Moncarz and B. Borchardt, Implementation of

the Inspection Robot Controller . NBSIR 88-3772,

April 21, 1988

6. S. A. Osella, Implementation of the Workstation

Controller , to be published as an NBSIR.

7. J. Zimmerman, Inventory of Equipment in the

Inspection Workstation , to be published as an

NBSIR.

8. H. T. Mbncarz, S. A. Osella, B. Borchardt, and R.

Veale, Operations Manual for the Inspection

Workstation . NBSIR' 88-3766, April 21, 1988.

9. J, Z immeinnan , Recommended Technical Specifications

for Procurement of Commercially Available Systems

for the Inspection Workstation , to be published as

an NBSIR.

69
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IWS Operations Manual

B. OPERATIONS REFERENCE GUIDE

1. STARTING THE INSPECTION WORKSTATION

Turn on the Robot, SRI, and WSC computers by flipping the red main

circuit switch so that it is lit. Select the Pascal Operating

System for these computers. Enter the correct date and time.

[Chapter IV, §1.1]

Turn on the CMM computer by pressing the "AC LINE button on the

front of the computer keyboard. Enter the correct date and time.

[Chapter IV, §1.2]

Turn on the CMM by shifting the Power On lever to the right and

then pressing the Ready/Servo On button. [Chapter IV, §2.1.1]

Calibrate the PH9 Probe if necessary. [Chapter IV, §2.1.2]

Position the CMM probe tip in the gage block. [Chapter IV, §3.1]

Turn on the Robot System by turning the switch on the box on the

east gantry column to on, pressing the power on button on the

control box on the west column, and finally pressing the battery

low button also on the west control box. Wait for the AM Smart

Robot Operating System to load. [Chapter IV, §2.2.1]

Calibrate the Robot Arm. [Chapter IV, §2.2.2]

Calibrate the Robot Track. [Chapter IV, §2.2.3]

Load the Robot Program. [Chapter IV, §2.2.4]

Clear the Serial Port. [Chapter IV, §3.2.3]

Start the Robot Program. [Chapter IV, §3.2.4]

Press the O button on the Dial Indicator so that the display^ shows

all zeros. [Chapter IV, §2.4]

Start the Execution Control System on the CMM Controller. When

the message Press Execute to Continue appears on the CMM monitor,

press the servo on button on the CMM console, press the AUTO

button on the hand pendant, and finally press the EXECUTE button

on the computer keyboard. [Chapter IV, §4.1]

Start the Execution Control System on the SRI Controller. When

the message Press M Button appears on the SRI computer monitor,

press the M button on the Dial Indicator. [Chapter IV, §4.2]

71
IWS Operations Manual

Start the Execution Control System on the Robot Controller.

[Chapter IV, §4.3]

Start the Execution Control System on the WSC. Wait for the

Network Established message. [Chapter IV, §5.2.1]

Press 3 [ENTER] to Synchronize the Workstation. Wait about 30

seconds. [Chapter IV, §5.2.2]

Press 3 [ENTER] to warm start up the Workstation. [Chapter IV,

§5.2.3]

2. OPERATING THE INSPECTION WORKSTATION STAND-ALONE

At the Workstation Controller computer, select the Work Order

option in the main menu by pressing 3 [ENTER]. [Chapter V,

§ 2 . 2 . 1 ] Press 9 [ENTER] to read the work order data from a file. Enter

the name of the script file for the tray in the tray station. For

example, type SCRIPTl [ENTER] for Tray 510, etc. [Chapter V,

§ 2 . 2 . 1 . 1 . 1 ] Press 10 [ENTER] to issue the work order. [Chapter V, §2. 2. 1.5]

3. RESTARTING THE INSPECTION WORKSTATION

Stop the Execution control system on each of the computer

controllers by pressing the Shift and Stop (printed in blue) keys

together. Then press the I key to initialize the computer.

Oh the CMM hand pendant, press MAN, JOY, and SLOW and use the

joysticks to move the CMM probe tip to the gage block. [Chapter

IV, §3.1]

Using the Robot hand pendant, stop the Robot program by flipping

the rocker switch on the pendant to STOP briefly, and putting it

back to RUN position. Then press IMM to go back to manual mode.

Lastly, press Machine 0 [ENTER] MVM 0 [ENTER] to enable arm

movement mode. [Chapter IV, §3.2.1]

Move the Robot to the arm calibration position by pressing MOV 199

[ENTER]. [Chapter IV, §3.2.2]

Clear the Serial Port and start the Robot Program. [Chapter IV,

§3.2.3]

Start the Execution Control System on the CMM Controller. When

the message Press Execute to Continue appears on the CMM monitor.

72
IWS Operations Manual

press the servo on button on the CMM console, press the AUTO

button on the hand pendant, and finally press the EXECUTE button

on the computer keyboard. [Chapter IV, §4.1]

Start the Execution Control System on the SRI Controller. When

the message Press M Button appears on the SRI computer monitor,

press the M button on the Dial Indicator. [Chapter IV, §4.2]

Start the Execution Control System on the Robot Controller.

[Chapter IV, §4.3]

Start the Execution Control System on the WSC. Wait for the

Network Established message. [Chapter IV, §5.2.1]

Press 3 [ENTER] to Synchronize the Workstation. Wait about 30

seconds. [Chapter IV, §5.2.2]

Press 3 [ENTER] to warm start up the Workstation. [Chapter IV,

§5.2.3]

Go back to Appendix B.2. to operate the IWS.

4. SHUTTING DOWN THE INSPECTION WORKSTATION

At the Workstation Controller computer, select the Warm Shutdown

option by pressing 4 [ENTER] . Wait about one minute for the

Workstation to complete the warm shut down. [Chapter VI, §2.1]

Subsequently, also at the Workstation Controller computer, select

the Cold Shutdown option by pressing 4 [ENTER]. [Chapter VI,

§4.1]

Wait about one minute then press the Shift and Stop (printed in

blue) keys together to stop the execution control system. Then

press the I key to initialize the computer. [Chapter VI, §4.3]

Stop the Robot program by flipping the switch on the pendant to

STOP briefly, and putting it back to RUN position. Then enter TMM

to go back to manual mode. [Chapter VI, §4.4.1]

Press Machine 0 [ENTER] and then MVM 0 [ENTER] to make the Robot

arm movement active. Press MOV 199 [ENTER] to move the arm into

calibration position. [Chapter VI, §4.4.2]

Press Machine 1 [ENTER] to activate the Robot track movement.

Press MOV 950 [ENTER] to move the gantry into calibration

position. [Chapter VI, §4.4.3]

73
IWS Operations Manual

Turn off each of the computer systems by flipping the outlet's red

switch so that the light goes off. Turn off the CMM computer by

pushing the button in the front of the computer keyboard.

[Chapter VI, §5.1]

Power down the Robot by turning off the switch on the box on the

east column of the Robot gantry. Then push the red power off

button on the control box on the west column so that it locks on

the catch. [Chapter VI, §5.2]

Turn the CMM servos off by pressing the Servo Off button.

[Chapter VI, §5.3]

74
IWS Operations Manual

REFERENCES

1. American Robot Corporation, Merlin Robot System Operators

and User Guide . Revision 2.1, 15 February, 1984.

2. The Bendix Corporation, Cordax Coordinate Measuring

System, Reference Manual for the CORDAX Function Library . October, 1982.

3. The Bendix Corporation, User's Manual for the PH9 Probe

Head Expansion , May, 1982.

4. D. R. O'Halloran and P. F. Reynolds, Jr., "A Model for

AMRF Initialization, Restart, Reconfiguration, and

Shutdown", NBS/GCR 88/546, May 23, 1986.

5. Rodenstock Precision Optics, Inc., Operating Manual for

the Optical Surface Finish Measuring System RM400 , 1984.

6. R. Rybczynski, et al, AMRF Network Communications , to be

published as an NBSIR, 1988.

7. A. J. Wavering and J. C. Fiala, The Real-Time Control

System of the Horizontal Workstation Robot , NBSIR 8873692 , December 16, 1987.

8. C. E. Wenger, Material Handling System Implementation , to

be published as an NBSIR.

9. D. Libes and E. Barkmeyer, "The integrated manufacturing

data administration system (IMDAS) —an overview".

International Journal of Computer Integrated

Manufacturing, Vol. 1, No. 1, pp. 44-49.

10. C. Furlani, et al, "The Integrated Manufacturing Data

Administration System (IMDAS)", to be published as an

NBSIR, 1988.

75
IWS Operations Manual
READER COMMENT FORM

OPERATIONS MANUAL FOR THE INSPECTION WORKSTATION

This document is one in a series of publications which document

research done at the National Bureau of Standards' Automated

Manufacturing Research Facility from 1981 through March, 1987.

You may use this form to comment on the technical content or

organization of this document or to contribute suggested editorial

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BIBLIOGRAPHIC DATA

1. PUBLICATION OR

REPORT NO.

2. Performing Organ. Report No. 3. Publication Date

SHEET (See instruction s) NBSIR 88-3766 MAY 1988

4. TITLE AND SUBTITLE

"Operations Manual for the Inspection Workstation"

5. AUTHOR(S)

Howard T. Moncarz, Stephen A. Osella, Bruce Borchardt and Ralph Veale

6. PERFORMING ORGANIZATION (If joint or other than NBS, see in struction s) 7. Contract/Grant No. NATIONAL BUREAU OF STANDARDS -

U.S. DEPARTMENT OF COMMERCE

GAITHERSBURG, MD 20899

9.

SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS (Street, City, Stote. ZIP)

. Type of Report & Period Covered

10.

SUPPLEMENTARY NOTES

I I Document describes a computer program; SF-185, FIPS Software Summary, is attached,

11.

ABSTRACT (A 200~word or less factual summary of most si gn ificant in formation. If document includes a significant

bi bliography or literature survey, mention it here)

This document describes the operation of the Inspection Workstation (IWS) of the AMRP.

Tne IWS uses a coordinate measuring machine for dimensional metrology, an optical

rouglmess gage for surface finish inspection, and a robot for part handling within

the workstation. Each of these three pieces of equipment is supervised by a separate

controller, and a fourth controller (the workstation controller) coordinates these

equipment controllers.

Tae rWS can receive its commands either from the AMRF Cell Controller or from the

keyboard of the IWS workstation controller. The detailed instructions for starting

the IWS and maintaining its operation in either of these two modes are provided in

this document.

12.

KEY WORDS (Six to twelve entries; alphabetical order; capitalize only proper names; and separate key words by semicolon s) AMRF; coordinate measuring machine; dimensional tolerance; Inspection Workstation;

surface finish; surface roughness

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