8.1 RPL Robot DCS Setup

Each Haas Robot is provided with FANUC's DCS System. This allows the user to define speed and positional limits to the robot. If the robot goes outside of these limits, DCS will stop the robot and remove power to the motors.

This guide will show how to configure a simple Cartesian Position Check limits for your robot. The Cartesian Position Check Function allows a user to define a work zone and a restricted zone for the robot. If the robot exits a defined work zone then DCS will stop the robot.

The Robot Package comes pre-configured with Cartesian Speed Check limits for RUN and SETUP mode.

Note: For more general information on DCS refer to the HRP - Fanuc DCS Setup chapter in the Haas Robot Package Manual.

Note: Verify proper setup of the DCS zones at the time of RPL installation.

The DCS zone is setup by 2 points that form the diagonal as shown in the image. Point 1 [1] and Point 2 [2] form the box that the robot needs to stay inside of. 

If the robot leave the designed box, DCS alarms will be generated that will prevent the robot from being moved.

The default coordinate system for the HRP is shown in the image. 

The X-axis is pointed out of the base in the direction shown, and the Y-axis points 90 degrees from there.

Note: The User Frame will be rotated in a later step so that the measurements taken in this step match the orientation of the pallet and machine.

It's helpful to write out your measurements as they are made. The measurements need to be in mm. Convert from inches to mm by multiplying the inch value by 25.4.

The signs for the dimensions will be as shown in the image.

Measure the following distances for the Point 2 X, Y, and Z values.

• X-Value: Measure the distance from the middle of joint 2 [1] to just before fence/light curtain [2]. This will be the value for Point 2 X-coordinate.
• Y-Value: Measure the distance from the middle of joint 2 [2] to the shelf [4]. This distance is shown by the arrow going from [3] to [4].
• Z-Value: Measure the distance from the middle of joint 2 [1] to the floor of the pallet [3]. This distance is shown by the arrow going from [2] to [3].

Record the values for each measurement. Make sure to put the right sign for the value. Refer to the previous step for whether each measurement should be positive or negative.

Measure the following distances for the Point 1 X, Y, and Z values.

• X-Value: Measure the distance from the middle of joint 2 [1] to just before the end of the Zero Point receiver in the machine [2]. This will be the value for Point 2 X-coordinate.
• Y-Value: Measure the distance from the middle of joint 2 [1] to just passed the zero point receiver in the load station [3].
• Z-Value: Measure the distance from the middle of joint 2 [1] to the above the top of the shelf [4].

Note: Record the values for each measurement. Make sure to put the right sign for the value. Refer to the previous step for whether each measurement should be positive or negative.

These coordinates will represent the point [5] shown in the image. The DCS zone will be a box drawn from Point 1 to Point 2.

To setup a DCS User Frame, a computer with internet access will need to be connected to the Robot Control Box with a RJ-45 cable. Open the front door of your robot controller and unplug the RJ-45 cable from Port 1 [1]. Plug in a new RJ-45 cable that is connected to a computer that has internet access.

Note: Port 1 is labeled CD38A inside the robot control box.

Follow the video above to setup the adapter settings on your computer to match the robot IP address.

Note: When finished setting up the DCS User frame, disconnect the RJ-45 cable from the computer and robot and plug the RJ-45 back into the Port 1.

Login to the HMI Jogging Pendant from your web browser.

Navigate to the User Frame Setup view.

Click on [Frame 9] then click [DETAIL].

When on User frame 9 [1] select R and enter -35.000 [2] as shown in the image,  and then hit enter on your keyboard.

This number adds a negative amount of rotation (in degrees) about the Z-Axis to the world frame. This cancels out the rotation of the robot base.

Note: The image shows an R rotation value that should be added to all RPL machines

Navigate to DCS Menu.

Enable the pendant by hitting the ON/OFF button on the top right.

Enter user frame section (10).

Select the second zero in the list under No. column and press 9. Confirmation question will show at the bottom, press [YES]. Change that value to 9 after confirmation.

You should see P or R populate with the same value from the previous step.

Go back to DCS menu.

Go into Cart. Position Check (5).

Go into No. 1.

Enable the position check No. 1 by selecting then pressing [CHOICE] at the bottom.

Change the Method type to Work Zone (Diagonal) by clicking the row then selecting [CHOICE] at the bottom.

Target Model 1 should say Robot Model, Target model 2 and 3 should be disabled.

Set Base Frame: User Frame: to 9 by selecting then entering 9.

In Point 1 and 2, enter in the values that were recorded from the Measure DCS Points section above. This is where we define the two points for the work space diagonal box.

Note: The values for point 1 and 2 in the image do not represent what the points will be. The Point 1 and 2 values will depend on the location of the fence/light curtain as well as the type of machine being paired with the RPL.

For Stop Type, click the row then select [CHOICE] at the bottom and change to Speed Check(1).

Make sure Stop Prediction is Yes.

Click on <DETAIL> under Speed Check then hit [ENTER] on your keyboard.

Set Limit 1 to 20.0, Delay Time to 0, and Permissible distance to 0.0, Speed Control to DISABLE.

Press [PREV] 3 times to get back to the Main DCS screen.

Now we will apply the all the changes we made in the DCS menu. Any DCS section that was changed since last APPLY will show a RED CHGD next to it. Press APPLY at the bottom.

Enter 1111 for the Master Code.

This will take you to another menu that will show you the changes made in the DCS menu since last apply. Press OK if all changes are correct.

Close the HMI Pendant Window.

Cycle power on the robot controller by turning the power switch OFF, waiting 5 seconds then back ON.

Setup is complete. There is now a work zone setup around the robot. If any part of the robot leaves the work zone at a speed greater than 20mm/s, it will alarm. If this alarm is triggered, it is possible to reset the alarm and jog back into the zone at a rate less than 20mm/s. The next section covers how to visualize the zone that was just created.

With the Work Zone setup, we want a way to visualize the zone in relation to the robot.

Access the Jogging HMI Pendant and navigate to MENU > NEXT > 4D Graphics.

You will see the robot virtually on the HMI pendant along with its current orientation.

To see the DCS zone, click on [VISIBLE] at the bottom bar, if it is not there, press the > arrow on the bar.

A new menu will display in the top left of the 4D display. Click on 4D DCS Display, it will turn a shade of blue to signify that it is ON. You will see a box appear if your DCS zone is enabled and setup.

Verify that the work zone that appears is surrounding your robot. If the zone is a shade of red, that means a part of the robot is outside of the zone. If the zone is green that means your robot is within the zone.

This display will update in real time, you can have this open on your laptop/computer while you jog the robot with the HAAS machine.

Note: The DCS zone set for the RPL should look different from the zone in the image. This is only a reference of what the 4D DCS Display looks like on the laptop.