0S1R 88-3804

me 9, 1988

CLEANING AND DEBURRING WORKSTATION

OPERATIONS MANUAL ht

'' J - fit i $

By:

Karl fttotpfiy

Peter Tanguy

ftichard Norcross

Predertck Proctor

CLEANING AND DEBURRING WORKSTATION

OPERATIONS MANUAL

by

Karl Murphy

Richard Norcross

Peter Tanguy

Frederick Proctor

June, 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 is identified in this paper to adequately describe the systems under

development. Such identification does not imply recommendation or endorsement by the National

Bureau of Standards, nor does it imply that the equipment is the necessarily the best available for the

purpose.

CDWS Operations Manual

Table of Contents

I. Introduction 1

1. Workstation Description 1 2. How This Manual Is Organized 2

3. Who Should Use This Manual 3

4. Documentation Convention 3

II. Demonstration Instructions 5

1. Workstation Safety 5

2. Stand-alone Demonstration 6

3. AMRF Integrated Demonstration 7

4. Cell and Database Testing 7

III. Unimate 2000 9

1. Start-up Procedure 9

2. Shut-down Procedure 1

1

IV. PUMA 760 13

1. Start-up Procedure 14

2. Shut-down Procedure 14

3. General Information 14

4. Error Handling 15

V. Workstation Controller 17

1. Start-up Procedure 17

2. Terminal Inputs 17

3. Shut-down Procedure 18

4. Common Commands 18

VI. Part Placement 21

VII. Manual Vise Operation 23

VIII. Process Plan Generation 25

Appendix:

A. Workstation Floor Plan 29

List of References 31

CDWS Operations Manual

I. INTRODUCTION

This manual provides instructions for the operation of the Cleaning and Deburring Workstation

(CDWS) at the National Bureau of Standards' Automated Manufacturing Research Facility

(AMRF). The instruction sets are limited to the normal start-up and shut-down procedures of the

workstation enabling an operator to run basic demonstrations and tests.

This section gives a brief description of the workstation's operation, explains how the manual is organized, describes who should use this manual, and enumerates the documentation convention

used.

1. WORKSTATION DESCRIPTION

The CDWS cleans and deburrs the metal workpieces or parts that were machined at the AMRF.

Equipment at the workstation includes a PUMA 760 robot for deburring, a Unimate 2000 robot for

part handling and buffing, a washer/dryer system for cleaning, a buffing wheel system for buffing, a rotary vise for clamping parts, and two roller tray stations for receiving parts. The workstation

floor plan is shown in Appendix A.

Research at the workstation has focused on using computerized part geometry to generate accurate

robot paths for both part handling and for deburring. At a computer display of a part that requires

deburring, an operator selects the edges that the PUMA 760 robot must deburr along with various

deburring parameters such as tool speed and feed rate. The operator also specifies how the part is

to be gripped by the Unimate 2000 robot, how the part is to be clamped in the vise, and how the

part is to be placed in the washer/dryer. These instructions, called process plans, are translated into

the proper format and sent to the robots.

The machined parts enter and exit the workstation on part trays placed at the roller tray stations.

The Unimate 2000 robot, under command of the workstation controller, grasps a part as instructed

by the process plan and carries the part either to the rotary vise or to the washer/dryer system.

Normally the process plan specifies deburring, and the Unimate 2000 robot puts the part in the vise

where it is clamped. The PUMA 760 robot moves to the vise and begins to deburr the edges on the

top side of the part, changing its deburring tool as required. To account for part misplacement and

robot inaccuracies, the PUMA 760 robot adjusts the calculated locations of the edges specified in the

process plan by detecting the correct location of each point on the path with a wrist force sensor. The Unimate 2000 robot reorients the part and the PUMA 760 robot again locates and deburrs the

edges on the newly exposed face. If a part is to be cleaned, the Unimate 2000 places it on the

washer/dryer index table. From here the part cycles through the washer, where a hot water spray

cleans the part, and through the dryer, where hot air jets dry the part. The buffing wheel system

has not been integrated into the workstation operations. When it is, the Unimate 2000 robot will

hold parts into the spinning wheels, buffing the edges and faces of the part. When all cleaning and

deburring processes are complete, the Unimate 2000 robot transfers the part back to the tray

station.

The workstation uses a hierarchical control structure as shown in Figure 1. At the top is the

workstation controller (WSC) [1, 2]. The wSC accepts commands from either an operator at the

workstation or from a remote source, such as the AMRF cell controller. The WSC sends commands

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CDWS Operations Manual

and data to the two robots and to the washer/dryer system. The PUMA 760 robot is controlled by

an NBS developed system, the Real-time Control System (RCS) [3, 4]. The PUMA 760 RCS

controls the demurring tools and the quick change wrist. The Unimate 2000 robot is controlled by

VAL, the vendor supplied controller [5, 6]. The VAL controller sends commands to the tray stations

and to the buffing wheels. Both the PUMA 760 RCS and the Unimate 2000 VAL controller can send

commands to the rotary vise but only one system has control of the vise at a given time. Arbitration

is coordinated by the WSC. The wSC does not control the vise directly because the WSC control

delay is too large.

Figure 1. CDWS Control Hierarchy

2 . HOW THIS MANUAL IS ORGANIZED

This manual describes the power-up and operation procedures needed to demonstrate the CDWS.

There are three basic modes of operating the workstation, a stand-alone demonstration, an AMRF

integrated demonstration, and a cell and database test.

Chapter II, Demonstration Instructions, is the normal entry point to this manual and provides

instructions for the three demonstration modes, stand alone, integrated, and cell/ database test. This chapter leads the operator through the remainder of the manual in the sequence needed for the

different demonstrations. The stand-alone demonstration includes the two robots and edge

selection but does not require the AMRF cell controller nor the AMRF database to be running. In

this mode, the workstation is under the direct control of the operator. See Section II.2. The AMRF

integrated demonstration includes both robots and requires that both the AMRF cell controller and

the AMRF database are running but does not include edge selections. In this mode, the workstation

is under the control of the AMRF cell. See Section II.3. The cell and database test requires that the

cell and database are running but does not require the robots. This mode is used when the cell and

database operators want to test their systems' interfaces to CDWS (see Section II.4). Safety

procedures for running the workstation are provided in Section ILL

Chapter III, Unimate 2000 Robot, lists in detail the start-up and shut-down procedures for the

Unimate 2000 robot. This includes the Unimate 2000 VAL controller and the controllers for the

associated equipment.

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CDWS Operations Manual

Chapter IV, PUMA 760 Robot, lists the start-up and shut-down procedure for the PUMA 760 Robot.

This chapter also includes general information about the PUMA 760 RCS and certain error handling

procedures.

Chapter V, Workstation Controller, lists the start-up and shut-down procedure for the WSC. The

commands which can be entered by the operator in the stand-alone mode are also enumerated.

Chapter VI, Part Placement, explains how to manually position parts into the part trays at the roller

tray stations.

Chapter VII, Manual Vise Operation, explains how to manually open and close the vise.

Chapter VIII, Process Plan Generation, covers the operator interface to process planning at the

workstation. The operator can graphically specify deburring plans by selecting edges on a part

along with deburring parameters. Process plans are generated during the stand-alone

demonstration mode.

3 . WHO SHOULD USE THIS MANUAL

This manual is intended for NBS personnel and for government, industry, and university

researchers who need to power-up, operate, and shut-down the CDWS or any of its subsystems. It provides step by step instructions that are to be followed at the workstation during power-up,

operation, and shut-down. The internal workings and interfaces of the CDWS subsystems are covered in other documents [1, 2, 3, 4, 5, 6]. This manual assumes that the operator only has

minimal experience with computers. Terms such as computer terminal, keyboard, and mouse

should be understood.

The Cleaning and Deburring Workstation is an ongoing research effort. Several aspects of

operation will change without notice. If the operator encounters an error that can not be resolved,

he should contact one of the principle operators for assistance. This manual contains more

information than is immediately needed by an operator. A suitably trained operator may utilize any

aspect of this manual with which he feels comfortable.

4. DOCUMENTATION CONVENTION

This manual uses the following conventions:

• The name of each keyboard key mentioned in the text appears in uppercase courier letters.

For example, the carriage-return key appears as RETURN

.

• In a control-key sequence, a caret ( A

) represents the CONTROL key. For example, control-C

appears as

A C, and is accomplished by holding the CONTROL key down, pressing C, and

releasing the CONTROL key.

• Information that appears on the terminal screen appears in bold courier print. For example,

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CDWS Operations Manual

the : R rsl> prompt appears on the 760 RCS terminal when the RCS system is awaiting

input from the keyboard.

Information that you must enter exactly as it appears in the manual is in plain courier print.

For example, "Enter 3 LOAD" means to type 3 LOAD and press RETURN.

Variable data that you must enter is in italics courier print. The instruction "Enter block #

LOAD" indicates that you are to replace block # with a specific block number when you

enter the load command. For example, you might type 3 LOAD and press RETURN .

Optional data that you may omit is represented within curly brackets ({ }). Most optional

data is also variable data and appears in italics courier print within curly brackets. The

instruction "Enter RECE I VE_TRAY { ( Tray_serial_#) }" indicates that you may

either omit the serial # or specify a desired serial #. For example, you might type

RECE I VE__TRAY and press RETURN or you might type RECE I VE_TRAY (123) and

press RETURN.

When input is to be typed in a specific window or on a specific board, the actual prompt is

included in the command string. For example, on the 760 RCS system the instruction

"Enter: R Mst> Halt" means to type Halt and press RETURN on the master board.

The name of a button to be pressed or the label of a switch setting is in double quotes. For

example: Flip the power switch to "ON".

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CDWS Operations Manual

II. DEMONSTRATION INSTRUCTIONS

This chapter provides instructions for operating the workstation and leads the operator throughout

the remainder of the manual in the proper sequence. Before running any equipment, the operator

should read Section 1, Workstation Safety.

There are three basic modes of operating the workstation, a stand-alone demonstration, an AMRF

integrated demonstration, and cell and database test. A stand-alone demonstration includes both

robots and graphic edge selection (see Section 1.1) but does not require that the AMRF cell

controller nor the AMRF database, IMDAS, is running. In this mode, the workstation is under direct

control of the operator. See Section II.2. An AMRF integrated demonstration includes both robots

and requires that both the AMRF cell controller and the AMRF database, IMDAS, are running but

does not include edge selections. In this mode, the workstation is under the control of the AMRF

cell. See Section n.3. A cell and database test requires that the cell and database are running but

does not require that the robots and equipment are running. This mode is used when the cell and

database operators want to test their systems and the interfaces to workstation controller but do not

need to actually process parts. See Section II.4.

1. WORKSTATION SAFETY

Before operating workstation equipment, the operator should be fully trained in the workstation's

safety procedures. Two of the more important procedures are:

• WEAR SAFETY GOGGLES or safety glasses with side shields at all times while at the

workstation or on the shop floor. Safety goggles are available at all entrances to the

shop floor. Ensure that all visitors wear the proper eye protection.

• NEVER ENTER A ROBOT'S WORK VOLUME when the arm power is on, signaled

by red lights mounted on each robot. The robots' work volumes are marked by red

painted floors and are delineated by black and yellow safety tape. Although the robots

may appear to move in a predictable manor, a malfunctioning servo valve, for example,

could cause the robot to move unexpectedly and at high speed.

EMERGENCY STOP There are two ways to stop the equipment in the workstation: HOLD and

E-STOP. HOLD is a soft stop, used to temporarily stop the motion of one or both of the robots.

When the HOLD is reset, the robot(s) continues the task as normal. E-STOP is a hard stop, used in

emergency situations to turn off the power to all of the workstation equipment and apply brakes to

the robot arms. When E-STOP is reset, the controllers will need to be initialized. An E-STOP is

more difficult to recover from but provides a quicker and more reliable method of stopping the

robots than HOLD does.

There are several stop boxes (shown in Figure 2) spread about the workstation. Each has a large

"E-STOP" button, which stops all workstation equipment; two "HOLD" buttons, one for the PUMA

760 Robot and one for the Unimate 2000 Robot; and three "RESET" buttons, one for the E-STOP,

one for the PUMA HOLD and one for the Unimate HOLD. The stop boxes are wired in series so you

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CDWS Operations Manual

can press "HOLD" on one stop box and "RESET" on another. There are also "HOLD" and "E-STOP"

buttons on the PUMA 760 joystick but they only stop the PUMA 760 and do not stop any other

equipment.

To 'HOLD' a robot, press the appropriate "HOLD" button on the stop box. It is a good idea to keep

your hand near the "HOLD" button when you are issuing new commands. To recover from a "HOLD", press the appropriate "RESET" button, and the robot will continue to move.

To 'E-STOP* the equipment, press the palm-sized red "EMRG STOP" button. This turns off both

robots' arm power, the pneumatic debarring tools, the rotary vise, the washer/dryer index table, the

water pump, the heater, the buffing wheels, the dust collector, and the roller tray stations.

2. STAND-ALONE DEMONSTRATION

1) Clear parts from vise.

See Section VII.

2) Position part in tray, (tray 1, sector 1 is the default).

See Section VI.

3) Power Up Unimate 2000 Robot.

See Section HI. 1.

4) Power Up PUMA 760 Robot.

See Section IV. 2.

5) Power Up the workstation controller (WSC).

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CDWS Operations Manual

See Section V. 1, select "standalone" in step 4 of that section.

6) At WSC enter "WSC> teach part" where part is from step 2 above.

See Section V. 2.

7) Select edges and deburring parameters.

See Section VIH.

8) The robots will move and deburr your part.

9) Answer "n" to: WSC> j# Save Process Plan? <n/number>

j# n

wso

10) Repeat steps 6 through 9 as required.

11) Shut down the workstation.

See Sections III. 2, IV. 3, and V. 3.

3. AMRF INTEGRATED DEMONSTRATION

1) Clear parts from vise.

See Section VII.

2) Power Up Unimate 2000 Robot

See Section III. 1.

3) Power Up PUMA 760 Robot

See Section IV. 2.

4) Power Up the workstation controller

See Section V. 1, select "fully config" in step 4.

5) Commands for the Workstation are remotely generated.

6) At demonstration conclusion, shut down the workstation

See Sections III. 2, IV. 3, and V. 3.

4. . CELL AND DATABASE TESTING

1) Start-up the workstation controller

See Section V. 2, select "cell test" or "dbase test" in step 4.

2) At testing conclusion, shut down the workstation controller

See Section V. 3.

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CDWS Operations Manual
„CDWS Operations Manual

III. UNIMATE 2000 ROBOT

This chapter lists in detail the start-up and shut-down procedure for the Unimate 2000 robot. This

includes the Unimate 2000 VAL controller and the controllers for the associated equipment.

1. START-UP PROCEDURE

1) Between base of Unimate 2000 robot and green/glass partition, lift red-handled circuit

breaker to "ON" position to connect power to Unimate 2000 robot controller.

2) At air valves between load/unload tables and base of Unimate 2000 robot, make sure both air

valves are turned counter-clockwise to supply air to Unimate 2000 robot gripper and

load/unload tables.

3) At air valve next to rotary vise, make sure air valve is turned counter-clockwise to supply air

to rotary vise.

4) At Unimate 2000 robot controller TV950 terminal, turn switch on black switch box next to

terminal to "2000CRT" mode.

5) At Unimate 2000 Robot Controller Rack:

a) On front of rack, flip power switch to "ON" position to engage fan and CRT.

b) Open front door to rack. The words UNIM 25B 4-23-82 will appear on the terminal

screen and the orange "ATTENTION" light will be on.

c) Pull the red stop button out if necessary and push in button marked "CONSOLE

POWER" to connect power to controller console and green button light will come on. Also,

the orange/red "HOLD/ERROR" light will come on and the following will be displayed on

the terminal screen:

* VAL-I I BOOT B2K6.2.0 19JUL85 *

LOAD VAL- I I FROM FLOPPY (Y/N)

?

d) Enter N. The following will appear on the screen:

VAL- 1 1 2670.2.0 P/N-935F25 H/W-0 S/N-0 20MAR85 23KW

COPYRIGHT 1981 - UNIMATION, INC.

INITIALIZE (Y/N)?

e) Enter N. The prompt "

. " will then be displayed on the screen. The orange "HOLD" light

will go off, but the red "ERROR" light will remain on.

6) At RCS Rack for Unimate 2000 Robot:

a) On front of rack, flip power switch to "ON" position to connect power to rack.

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CDWS Operations Manual

b) Open front door to rack. On top side and behind the front panel of Bucket2 interface box,

flip switch to "COMP" mode to enable computer interface to equipment

7) At RCS Terminal for Unimate 2000 Robot:

a) Flip power switch on back of terminal to "ON" position.

b) On reset box on top of terminal, press momentarily the reset button labelled "System

Reset" to reset RCS's computer system. The words pF86-l . 4 R4 5-1 . 2 up will

appear on the screen.

C) Enter HEX F7 C9 OUTPUT 2 6F0 30 ERASE 0 CBOOT 0 MBOOT init-cm 2

D>M. If while entering this command string you make a mistake, use the DEL key to

backspace and then re-enter the command correctly. After a short time, the system will

initialize itself and the workstation status will appear on the screen. The RCS program is

now running.

8) At RCS Rack for Unimate 2000 Robot, open front door to rack and look at front panel of

Lord F/T Sensor Controller box. If green light marked "SENSOR HEALTH" is off and

"FAILURE ALARM" is sounding, press button marked "INITIALIZE" momentarily to reset

controller. Make sure the lower toggle switch of the Acme Interface Box has been turned to

the "ON" position, then switch the upper toggle switch to the "ON" position to engage the

relays.

9) At the Acme Power Panel behind the RCS racks, pull the red and black power lever up to the

"ON" position. At the Acme Pushbutton Panel by the buffing wheels, pull the lit red

"STOP" button out, and push the green "CONTROL POWER ON" button in. Power will

now be supplied to the Acme equipment.

10) At Unimate 2000 Robot Controller Rack:

a) *** Important: Clear Unimate 2000 Robot's work volume of all personnel. The

maximum reach of robot is delineated on the floor using safety tape.

b) Turn switch marked "ARM POWER" to "ON" position to provide power to robot and

corresponding orange light will come on. After a short time, the red "ERROR" light will go

out. Also, the red safety light towards the end of the Unimate 2000 Robot's boom will come

on.

11) At Unimate 2000 Robot Controller TV950 terminal:

a) Flip power switch at back of terminal to "ON" position.

b) Turn switch on black switch box next to terminal to "TV950" mode.

c) Enter EX POWER . UP. Place your hand over the red EMERG STOP button in case of

error. The gripper should open and the robot should raise slightly, move to its rest position

near the trays, and execute its warm-up motions for seven cycles.

d) At the conclusion of the power-up routine, the robot should return to its rest position at

the vise, and the message The 2000 has been reset should appear on the screen.

e) To run part handling system under control of workstation controller, turn switch on black

switch box next to terminal to "SUN" mode. The Unimate 2000 is now running.

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CDWS Operations Manual

2. SHUT-DOWN PROCEDURE

1) At Unimate 2000 Robot Controller TV950 terminal, Enter DO MOVE REST. VISE. Place

your hand over the red EMERG STOP button in case of possible malfunction or operator

error. If robot was resting at the load/unload tables, the robot will swing to assigned rest

point. If robot was resting at the vise, the robot will stay at assigned rest point. Robot is

now at power down position.

2) At Unimate 2000 Robot Controller Rack, turn switch marked "ARM POWER" to "OFF"

position to disable power to robot and corresponding orange light will go out. Also, the red

safety light towards the end of the Unimate 2000 Robot's boom will go out. Push the red

stop button to turn off the controller, shut the rack, and turn the rack switch to the "OFF"

position to disable the fan and CRT.

3) At RCS Terminal for Unimate 2000 Robot:

a) Press the space bar to abort the status program. Enter HALT.

b) Enter BYE to shutdown the RCS's storage disk. Blinking stars should fill the screen,

indicating the system has been halted.

c) On back of terminal, flip power switch to "OFF" position.

4) At RCS Rack for Unimate 2000 Robot, turn the top toggle switch of the Acme Interface Box

to the "OFF" position, then turn the power switch on front of rack to "OFF" position to

disconnect power to rack.

5) At Base of Unimate 2000 Robot, push red-handled circuit breaker to "OFF" position to

disconnect power to Unimate 2000 Robot controller.

6) At Acme Pushbutton Panel, push the red "STOP" button in to cut power to the equipment.

At the Acme Power Panel, throw the power lever down to the "OFF" position.

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CDWS Operations Manual
CDWS Operations Manual

IV. PUMA 760 ROBOT

This chapter lists the start-up and shut-down procedure for the PUMA 760 Robot and includes

general information about the PUMA 760 RCS and certain error handling procedures.

1. START-UP PROCEDURE

*** Warning: Do not initialize the PUMA 760 at power-up. That is, if you see the question:

INITIALIZE (Y/N) ? on the terminal in the PUMA 706 robot controller rack, enter N. If

you enter Y and initialize the controller, you will erase all programs and locations stored in

VAL. If this happens, see Section 4, Error Handling.

1) Turn on the PUMA 760 Robot Controller Rack; move the large red switch in back to "ON”.

2) If the controller is off, hold "AUTO START" button in while you turn on the controller chassis.

Continue holding the "AUTO START" button until you hear a click, about 3 sec. Continue with

step 3.

If the controller is already on, a) press the "ARM POWER OFF" button and then b) hold the

"AUTO START" button in while you toggle the "LSI INIT" switch (on the top of the chassis).

Continue holding the "AUTO START" button until you hear a click, about 3 sec.

3) Clear people from the robot work volume.

4) Press "ARM POWER" button.

5) Press the "JOINT" button on the PUMA joystick and move the robot to the vise-safe location.

(The tool is vertical, the tool tip is midway between the quick change rack and the robot base,

and the tool tip is slightly higher than the top of the quick change rack. See Figure 3.)

*** Warning: The robot joints will move about 10 degrees during the following step. Keep a hand

near the "ARM POWER OFF" or "E-STOP" button.

6) Press the "COMP" button on the PUMA joystick. The robot will move as it calibrates itself.

7) Set the terminal switchbox to "RCS", if not already there.

Figure 3. Vise-Safe Location

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CDWS Operations Manual

8) Turn on: the 760 RCS rack, all the chassis in the rack, and the RCS terminal.

9) Press the black "SYS Reset" button on the terminal switch box. If not already set, switch the

black rotary switch to "MST", and set the toggle switch to "TERM".

*** Warning: The robot will move to the vise-safe location during the following step. Make sure

it is free to move, or keep your hand on the HOLD SET button.

10) Press function keys f 9 then f 10. Or, if the terminal was off, enter:

HEX F7 C9 OUTPUT 26F0 30 ERASE 0 CBOOT 0 MBOOT 4 D>M

If you make a typing mistake while entering this command, use the DEL key to backspace and

re-enter the command correctly.

After the disk spins up, the computer will begin to print messages from the various boards.

The robot will move to the vise safe location. The tip of the robot tool should be higher than

the top of the quick change rack. If not see errors below. You should end up on Mst> with

the message: *** System Running *** DONE.

The 760 RCS system is now running and ready to receive commands from the SUN.

2. SHUT-DOWN PROCEDURE

1) Move arm to a safe location and press the ARM POWER OFF button.

2) Enter Mst> BYE. This stops the RCS controller, unloads the disk, and starts "snake" (the screen saver program).

3) Turn off all equipment that you turned on.

3. GENERAL INFORMATION

MOVING FROM BOARD TO BOARD: The RCS system has 7 levels running on a separate

computer boards. There is a master board, Mst> , and 6 slave boards, rcs>, task>,

path>, prim>, joint> and comm>. Although there are 7 boards, there is only one

terminal which "talks" to all 7 boards.

To move from board to board use the terminal function keys. The RCS terminal has 11

function keys labeled f 1 thru f 11. Each has a separate function as labled on the duct tape.

For example, f 3 will move you to the Mst> board. You can move back and forth between

any two boards.

To operate the RCS system you must enter different things on different boards. In this manual,

the prompt tells you the board to enter data on. For example: Mst> GO. means type a G, an

O, and RETURN on the Mst> board. On the computer screen, the prompt shows the name of

the board you are on. Some commands entered on the master board will automatically send

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CDWS Operations Manual

commands to slave boards, ex: Mst> GO.

JOYSTICK: Enter either Mst> JOYSTICK or task> 912 LOAD. These commands clear

certain errors and enable the joystick. To move the robot, flip the enable switch up and set the

velocity to a low value. (Rotate clockwise.) The most common motions are tool X, tool Y and

tool Z. See Figure 4.

E-STOP

Enable

Velocity

X-Y Tool Point

Z Tool Point

Hold

Figure 4. PUMA 760 Robot Joystick

STATUS: Enter Mst> STAT, task> STAT, or path> STAT. The status of the robot will be

displayed. The task and path status are different and the master status is the combination of

both task and path status.

COMMAND DIRECTORIES: task> 910 LIST and task> 920 LIST. These blocks list different commands to the robot. For example, entering: task> 924 LOAD will command

the robot to move to VISE-SAFE.

SUN COMMANDS: task> ENABLE- SUN-CMD and task> D I SABLE- SUN-CMD tells

TASK level to accept/ignore commands from the workstation controller.

VISE: path> GET-VISE locks the 2000 out of the vise volume. path> DROP -VISE drops

the vise volume request. The 2000 can now get the vise. The vise volume arbitration is

handled by the RCS for the Unimate 2000.

RSL: At start-up, the RSL board is told to accept robot paths from the SUN. This program is

called: rsl> BGO. If RSL is to ignore the paths from the SUN enter: Mst> ABT_RSL

rsl> DGO. You will not get a prompt back. To abort these processes, BGO or DGO, enter:

Mst> ABT RSL.

4 . ERROR HANDLING

Most errors can be corrected by doing step (a) below. If the joystick is needed, see Section 3,

General Information.

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CDWS Operations Manual

a) General error recovory:

• Enter Mst> GO. Then, if there is no error:

• Enable joystick and move the robot near the vise safe location.

• Enter: t&p> 924 LOAD. The robot will move to the vise safe location. The tip of the robot

tool should be higher than the top of the quick-change rack. If not see error (d) below.

b) Force sensor is down.

• comm> INIT-FORCE.

• Check power to sensor chassis, cable connections, etc.

c) The robot does not move

• It may already be at vise-safe. Try t&p> 922 LOAD. The robot should move to qc-gate.

• Press the HOLD CLEAR button on the RCS joystick.

• See General errors

d) The robot does not move to vise-safe location, the tool is lower than the top of the quick

change. This generally means that the robot does not know that it has a tool.

• t&p> 911 LOAD, commands reset, then t&p> 924 LOAD.

• Check power to bucket- 1 interface chassis, cable connections, etc.

e) Quick Change Error:

If the robot has an error over the quick change and stops moving:

t&p> X-UNLOCK Unlock quick change? Y

t&p> 911 LOAD. This restarts RCS. t&p> 912 LOAD. This activates the joystick

f) No air: tools don't work, quick change doesn’t work

• Turn on air valve feeding the PUMA 760 robot.

g) No Auto Start program on VAL.

• Do not initialize!

• Do steps 1-5 in Section 1, START-UP PROCEDURE above without pressing the "AUTO START"

button. The robot will not move.

• Flip the two toggle switches on the terminal switch box to "LOCAL" and "TERM".

• Enter cal. Answer Y. The robot will move.

• Continue on step 7 in Section 1, START-UP PROCEDURE above.

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CDWS Operations Manual

V . WORKSTATION CONTROLLER

This chapter lists the start-up and shut-down procedures for the WSC. The commands which can be

entered by the operator in the stand-alone mode are also enumerated. All commands in this chapter

are enter by using the SUN terminal, keyboard, and mouse.

1 . START-UP PROCEDURE

1) If SUN terminal is running "Game Of Life"; press any key and go to step #4.

2) Otherwise, turn the SUN computer on via the three main power switches located on the SUN

disk pedestal, the SUN base pedestal, and the back of the SUN terminal screen.

3) Log into the system with: cdws login: rjn

4) Start the controller program by:

open rootmenu,

position the mouse arrow over the gray background area, hold down the right mouse button.

open "WSC" submenu,

with right button depressed, move mouse to the "=>" to the right of "WSC"

highlight appropriate configuration with mouse arrow.

w/ prompts

fully config

CELL test dBase test standalone

760 only

cmm

controller prompts for CMM & robot status CMM at "demo", database & both robots running

CMM at "demo", database & robots not running

CMM at "demo", database running, robots not running no CMM, both robots running no CMM, Unimate 2000 not running

(ignore)

5) Wait. The system takes about three minutes to initiate and run. The prompt WSC> will appear in the terminal window.

2. TERMINAL INPUTS

To enter data into the terminal window the mouse arrow must be in that window.

If the prompt, WSC>, is missing the system may still accept inputs. However a prompt can be

generated by entering: (

)

Commands are entered by typing the command followed by its parameters. E.g.:

WSO teach block_fh 110

When the system asks a question it will provide an identifier which must be the first element of

17
CDWS Operations Manual

your response. Also, the system generally gives a guide to the acceptable responses. For example:

WSO j5 Save this Process Plan? <n/number>

WSO j5 n

3. SHUT-DOWN PROCEDURE

1) Enter: WSO quit

2) Wait. "Game of Life" will appear on the screen.

3) If desired, turn off the three power switches.

4. COMMON COMMANDS

The following is a list of common commands to the WSC. These are listed as a reference and are not needed by a novice user. Commands to the workstation can come from the cell or can be typed

into the workstation control window. The first three commands are the standard sequence from the

cell.

RECEIVE TRAY { TRAY_SER__NR} { TRANSFER POINT}

locks the transfer point tray station and fetches theTray Contents Report from the database

IMDASTRAY_SER_NR is the "tray serial number" and defaults to "mttray".

TRANSFERPOINT is the AMRF name for the tray station and defaults to "CDWS_TP1".

DEBURR LOT LOT_ID { OPERATION_SHEET} { LOT_TYPE}

deburrs the lot of parts as specified by the instruction_set declared in the operation_sheet.

LOT_ID is the lot's identification number and is a required entry.

OPERATIONSHEET defaults to the standard instruction_set numbers.

LOTTYPE is the part description and defaults to "MIXED" which means "do all parts".

SHXP__TRAY { TRANSFERJPOINT

}

releases the transfer point tray station and clears those parts from the internal database.

teach part-type {sector} {tray} {location}

develops and tests a process plan for the specified type of part.

part-type is the part description and is a required entry.

sector is the tray sector where the part is placed and defaults to "1".

tray is the tray station where the part is placed and defaults to "1".

location is the current "vise" position of the practice part and defaults to "TRAY".

move-part part goal

moves the named part to the goal position. The part must be in the internal database,

part is the name of the part and is required.

goal is either "TRAY" or a vise-grip location where the part is to be placed and is required.

18
CDWS Operations Manual

add-part part part-type tray-station {location}

adds a part to the internal database.

part is the name of the part and is required.

part-type is the part description and is a required entry.

tray-station is the buffer position of the part (e.g. TRAY1 1,TRAY24) and is required,

location is the current position of the part and defaults to the buffer position.

set-location part location

changes the part's location in the internal database (w/o part movement),

part is the name of the part and is a required entry,

location is the part's new position.

RCS command-string

sends the command to the task level of the RCS controller controlling the PUMA 760.

command-string is the command to be sent and must be enclosed in double quotes (" ").

VAL command

sends the command to the VAL+ controller controlling the Unimate 2000.

command can be multiple words and doesn't require quotes (e.g. VAL do depart

150).

re-initialize_VAL

re-establishes the command/status handshake with the Unimate 2000. This command

should be executed when the 2000 is returned to the WSC's control after being in local

mode.

deburr-part part { instruction_set }

deburrs the specified part based on the instruction_set.

part is the name of the part and is a required entry

instruction_set is the process plan to be used and defaults based on the part type

deburr-loops part-type loops

commands the PUMA 760 to deburr the specified loops. A workpiece of the given type

must be properly positioned in the vise and the appropriate RSL file downloaded to the

PUMA's RCS controller. E.g. deburr-loops pipeclamp_fv (0 1 2)

part-type is the workpiece description and is a required entry

loops is the list of loop numbers which correlate to the RSL file

RCS__status

returns the most recent status from the RCS controller controlling the PUMA 760.

initialize__dbase

generates the UVA protocol for establishing communications with the AMRF database.

set db-flag nil

shifts the controller to look at local copies of data rather than the AMRF database, IMDAS.

19
CDWS Operations Manual

initialize CELL

establishes communications with the CMM and in turn with the remote command source,

set CMM nil

causes the controller to ignore the remote command source. initialize_RCS

establishes communications with the RCS controlling the PUMA 760.

initialize VAL

establishes communications with the VAL+ controller controlling the Unimate 2000.

set VAL-flag nil

breaks the communications with the VAL+ controller controlling the Unimate 2000.

20
CDWS Operations Manual

VI. PART PLACEMENT

The Cleaning and Deburring Workstation is designed to receive parts at two tray transfer stations.

Parts arrive on predefined trays with the parts in preset locations. The workstation does not have

the capability to acquire randomly placed parts. Therefore, to operate the workstation in a stand-alone mode, an operator must position parts accurately by using the part positioning guides.

The first step in positioning parts is to identify the tray and sector number. Figure 5 shows the

numbering convention used at the CDWS. Sectors "1" through "4" reference the comers of the

trays. Since sector "5" has no such reference, it should be avoided when possible.

TRAY STATION

Unimate 2000 Robot

#2 TRAY STATION #1

Figure 5. Tray Numbering Convention

To assist proper part positioning in a sector, positioning guides are provided for the operator.

Each part has a unique positioning guide, as shown in Figure 6. The guides are kept under the tray

stations. To use the guides:

1) Turn off the Unimate 2000 arm power. See Section III. 2.

2) Orient the guide in accordance with the instructions on the guide.

3) Place the guide in the reference comer for the desired sector.

4) Place the part in the hole in the guide.

21
CDWS Operations Manual

5) Carefully lift the guide over the part.

The robot can capture the part when it is less then roughly one-half inch off the true position.

Therefore, the guide may nudge the part when being removed. Also, if the guides are missing, a educated guess will probably suffice.

dog pipeclamp_fv block__fh Iclevis

Figure 6. Part Positioning Guides

The basic demonstration at the CDWS involves the teaching and deburring of a single part. The

command for this demonstration contains default parameters for tray "1", sector "1". Figure 7

shows the proper location of the default position.

Figure 7. Default Part Position For WSC "teach" Command

22
CDWS Operations Manual

VII. MANUAL VISE OPERATION

During initialization and during some error recoveries the part fixturing vise requires manual

operation. The location of the vise controls is the "Bucket 2 Interface" box. This control box is in

the "RCS RACK for UNIMATE 2000". See Workstation Floor Plan. Figure 8 shows the vise

control logic. The vise must be returned to computer control before continuing a demonstration

(i.e. the "comp/man" switch, see Figure 8, must be in the "comp" position).

CONDITION SWITCH #0 SWITCH #1 SWITCH #2

VISE @ 0 DOWN DOWN DON’T CARE

VISE @ 90 DON’T CARE UP DON'T CARE

VISE @ 180 UP DOWN DON’T CARE

VISE OPEN DON'T CARE DONT CARE DOWN j VISE CLOSE DON’T CARE DONT CARE UP

Figure 8. Manual Vise Controls

To clear a part from the vise:

1) Turn off the Unimate 2000 arm power. See Section HI. 2.

23
CDWS Operations Manual

2) Turn off the PUMA 760 arm power. See Section IV. 3.

3) Make sure air is supplied to the rotary vise by turning the air valve next to the vise

counter-clockwise.

4) Turn on the RCS Rack for Unimate 2000 Robot.

5) Put "comp/man" switch to "man" position. See Figure 8.

6) Put switch #2 in the down position to open the vise.

7) Remove part from the vise.

8) Return "comp/man" switch to the "comp" position.

24
CDWS Operations Manual

VIII. PROCESS PLAN GENERATION

This chapter covers the operator interface to process planning at the workstation. The operator can

graphically specify deburring plans by selecting edges on a part along with deburring parameters.

During the execution of the "teach" command (See Chapter V.) the workstation's process plan

generator is automatically initiated. The user interface to the plan generator is a set of graphic

window displays. The master window, shown in Figure 9, will appear on the screen. Using the

jnouse, open the command menu (by pressing the far right mouse button) and select "select

deburring". The other menu selections such as "add vise grip" and "add robot grip" are beyond the

scope of this document. See [2] for explanation.

When the edge selection window appears, shown in Figure 10, select the edges to be deburred (by

pressing the left mouse button) along with the desired tools, tool parameters, and views. In this

25
CDWS Operations Manual

window, the mouse locator is the "printer's fist" which initially appears in the middle of the

window display.

CDWS Graphs Edge Selection:

QUIT

DRAW

SAVE

VIEW:

TOP

bottom

left

right

front

back

TOOL:

END BRUSH RATE SPEED OFFnormal FORCE OFFcenter

i

| 0.58

|

Ops)

fl

9000

(RPM)

7.6

(deg)

10.0

(oz)

J

0.00

j (in) ^

Figure 10. Process Plan Generator's Graphic Display Window

The workstation controller continues to function during process plan generation. To perform other

tasks the user moves the mouse back to the terminal interface window and enters the command.

The graphic window will not automatically redraw itself. If the graphic display is obscured by

another window, bring the graphic display back to the top by pressing the function key L5 and

26
CDWS Operations Manual

select one of the views with the mouse.

View Selection:

To select a view, place the mouse pointer (the "printer’s fist") over the name of the desired views,

and click the left mouse button. Only views with "word" names can be fixtured by the

workstation. Other views (e.g. x=l) can be displayed on the screen but are meaningless to the

robots.

Tool Selection:

To select a different tool, point the mouse at the current tool and click the left mouse button. The

system toggles through the available tools in a round robin. The current suite of tools is; a 120 grit

aluminum oxide end brush, a 320 grit aluminum oxide hole brush with 5/8 inch outside diameter,

and a carbide chamfering tool which is listed as a spindle.

Parameter Selection:

Each tool has unique parameters and default settings. When a new tool is selected the parameters

and their current values are shown at the bottom of the display. Parameter values are changed via

the thermometer graphs at the left of each value. The values change with a single click of the left

mouse button.

Edge Selection:

Edges are selected with the same point and click procedure described above. An edge may be

unselected in the same manner in which it was selected. Figure 10 shows sample edge selections.

The Save Command:

In the upper left comer of the display are three commands, the bottom command saves the users

selections in a temporary file. Currently there is no way to correct selections once they are saved, so caution is advised. A "SAVE" selection only saves the edge selections visible at that time,

though there may be more then one "SAVE" on each side. The tool and parameters are saved with

the edges selected.

The Draw Command:

The "DRAW" command is only used when generating local geometry files and should be ignored.

The Quit Command:

The "QUIT" command terminates the session with the plan generator. Upon termination the

Process Plan Generator writes an AMRF-formatted process plan based on the saved edge selections.

When completed, the display is automatically erased and the workstation controller is advised of the

completion. The "teach" command then resumes its normal execution.

27
CDWS Operations Manual
CDWS Operations Manual

APPENDIX A

WORKSTATION FLOOR PLAN

29
CDWS Operations Manual
CDWS Operations Manual

LIST OF REFERENCES

[1] Norcross, R.,"CDWS Workstation Control Structure", IEEE International Conference on

Robotics and Automation, Philadelphia, PA, 1988.

[2] Norcross, R., "CDWS Workstation Controller Reference Manual", National Bureau of

Standards, to be published.

[3] "The NBS Real-time Control System / User Reference Manual". Editors: Kilmer, R. and

Leake, S. To be published 1988.

[4] Murphy, K., "RCS on the CDWS PUMA 760", National Bureau of Standards, to be

published.

[5] Programming Manual. User's Guide to VAL-II. Version 2.0. 398AG1, Unimation,

December 1986.

[6] Proctor, F., "CAD Directed Automatic Part Handling", National Bureau of Standards, to be

published.

31

READER COMMENT FORM

CLEANING AND DEBURRING WORKSTATION - OPERATIONS MANUAL

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.

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contribute suggested editorial changes.

If you wish a reply, give your name, company, and complete mailing address:

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Note: This form may not be used to order additional copies of this document or other documents in

the series. Copies of AMRF documents are available from NTIS.

Please mail your comments to: AMRF Program Manager

National Bureau of Standards

Building 220, Room B-l 1

1

Gaithersburg, MD 20899

>-l 14A (REV. 2.80

U.S. DEPT. OF COMM. 1. PUBLICATION OR 2. Performing Organ. Report No. 3. Publication Date

BIBLIOGRAPHIC DATA

SHEET (See instructions)

REPORT NO.

NBS IR 88-3804 JUNE 1983

TITLE AND SUBTITLE

Cleaning and Deburring Workstation Operations Manual

AUTHOR(S)

Karl Murphy, Richard Norcross, Peter Tanguy, and Frederick Proctor

PERFORMING ORGANIZATION (If joint or other than NBS, see in stru ction s) 7 . Contract/Grant No.

national bureau of standards

DEPARTMENT OF COMMERCE 8. Type of Report & Period Covered

WASHINGTON, D.C. 20234

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

, SUPPLEMENTARY NOTES

1

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

ABSTRACT (A 200-word or less factual summary of most significant information. If document includes a significant

bibliography or literature survey, mention it here)

This manual provides instruction for the operation of the Cleaning and Deburring

Workstation at the National Bureau of Standards’ Automated Manufacturing Research

Facility. The instruction sets are limited to the normal start-up and shut-down

procedures of the workstation enabling an operator to run basic demonstrations and

tests

KEY WORDS (Six to twelve entries; alphabetical order; capitalize only proper names; and separate key words by semicolon s) AMRF; Cleaning and Deburring Workstation; deburring; operating instructions;

RCS; real-time control; workstation control

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