37640-E0 Automationandrobotics MG Ed1 pr1

Tech-Design
Automation & Robotics

Beginning, Advanced, Comprehensive Levels
Module Guide
Edition 1
37640-E0
HIS PAGE IS SUPPOSE TO BE BLANK
FIRST EDITION
First Printing, September 2009
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Automation & Robotics Table of Contents
Introduction ................................................................................................................... 1
Directions....................................................................................................................... 3
Beginning Level ......................................................................................................... 3

Lesson 2, Saving Your Program........................................................................... 3
Lesson 4, Loading Your Program ......................................................................... 5
Advanced Level ......................................................................................................... 7
Lesson 2, Using RoboCIM.................................................................................... 7
Lesson 3, Introduction to Programming.............................................................. 12
Lesson 4, Program Editing ................................................................................. 21
Lesson 5, Industrial Application .......................................................................... 26
Lesson 6, Gravity Feeder ................................................................................... 29
Lesson 7, Rotary Carousel ................................................................................. 31
Comprehensive Level .............................................................................................. 33
Lesson 2, Saving Your Program......................................................................... 33
Lesson 4, Loading Your Program ....................................................................... 35
Lesson 5, Using RoboCIM.................................................................................. 36
Lesson 6, Introduction to Programming.............................................................. 41
Lesson 7, Program Editing ................................................................................. 50
Lesson 8, Industrial Application .......................................................................... 55
Lesson 9, Gravity Feeder ................................................................................... 58
Lesson 10, Rotary Carousel ............................................................................... 60
Module Guide i
Automation & Robotics Table of Contents
ii Module Guide
Automation & Robotics Introduction
INTRODUCTION
This Module Guide contains the directions that you will use when you are completing
lesson activities. The multimedia curriculum will direct you to this guide and a specific
activity. The directions are titled and are organized by Lesson. The table of contents will
guide you to the appropriate page.
Module Guide 1
Automation & Robotics Directions
2 Module Guide
DIRECTIONS
Beginning Level
Lesson 2, Saving Your Program
5100/5150 File Server Application
The 5100/5150 File Server Application is designed to save the programs you make with
the Teach Pendant on a computer. It is used solely for use with the Teach Pendant.
1. Open the 5100/5150 File Server Application by clicking on the icon in the toolbar.
The 5100/5150 File Server window appears.
2. The I/O Menu of the Teach Pendant allows you to load and save programs to and
from the host computer. Go to the Main Menu of the Teach Pendant and select the
I/O Menu.
When the Teach Pendant and the server connect, the following screen appears:
File I/O Menu

1 Load
2 Save
The 5100/5150 File Server window should open and a “Hello” message should appear
in the Last Request text field.
3. To save your program, press 2 on the Teach Pendant. The following appears:
4. Press 1 on the Teach Pendant to save your new file.
Module Guide 3
5. The 5100/5150 File Server application will display the Save Remote Data…window.
6. Enter a filename for your program that includes your initials, for example, Les2js.
You can use a maximum of eight characters. Click OK.
7. After the program is saved, the 5100/5150 File Server window appears with EOT
(end of transmission) displayed in the Last Request field. Minimize the window.
8. On the Teach Pendant, press the Esc key twice to return to the Main Menu.
Go to the next section in the presentation.
4 Module Guide
Lesson 4, Loading Your Program
I/O Menu.
File I/O Menu

1 Load
2 Save
3. Navigate to the Load (1) option. This option is used to load an existing program into
the Teach Pendant memory. To load a saved program, enter the number beside its
name. Any program in the Teach Pendant memory will be erased. You can scroll
trhough the list of saved programs using the up and down arrow keys.
4. The message “recv” is displayed while the file is loading. When this message
disappears, press the ESC key twice to return to the Main Menu.
If you have previously saved a program made in the task mode and then later load that
program while in process mode, the Teach Pendant will switch to the task mode
automatically.
When you are finished, go to the next section in the presentation.
Module Guide 5
6 Module Guide
Advanced Level
Lesson 2, Using RoboCIM

In this activity, you will use the RoboCIM software in Simulation mode and in Control
mode. You will first change the coordinates of each articulation and observe the motions
performed by the robot displayed in the View Display area. You will then observe the
motions of the actual robot when you change the articulation coordinates when in
Control mode.
Setting up the System

On the work surface, position the robot as indicated below (position R0, C7). Do not
position the accessories yet.
Module Guide 7
The equipment should be connected for all the activities in this module, as shown
below. If it is not, please ask your instructor for help.
You are now ready to control the robot using RoboCIM in the Simulation Mode.
1. Click the Application Launch button and select RoboCIM.
2. From the Welcome screen, select Create a new RoboCIM workspace. The RoboCIM
main window appears.
3. You will be working in the Simulation mode first, so make sure you are in Simulation
mode.
8 Module Guide
4. Select the Motion tab from the Tabbed Dialog Section. The Motion window appears.
5. Experiment with rotation of the robot

shoulder in the clockwise and
counterclockwise direction by clicking the
arrows for the Base articulation in the
Articular Coordinates section. (Note: the
single arrows provide a slower speed; the
double arrows provide a fast speed for
long moves.)
6. Observe the rotation of the robot

shoulder in the view display area. Then
return the shoulder to its initial location.
7. To move the upper arm of the robot up

and down, use the arrows for the
Shoulder articulation.
8. Observe the motion of the upper arm in

the view display area, the return the
upper arm to its initial position.
9. Experiment with moving the forearm of

the robot up and down by using the
arrows for the Elbow articulation. Then
return the forearm to its initial position.
10. To move the gripper of the robot up and down, use the arrows for the Wrist Pitch
articulation. Once again, return the gripper to its initial position. Experiment with the
arrows for the Wrist Roll articulation too.
11. To open and close the robot gripper, click and hold the Close button in the Gripper
section. Then click and hold the Open button.
You will now move the robot in the Control Mode.
1. Turn on the power supply of the robot and wait until the green LED at the rear of the
robot base stops flashing and the red LED turns off.
2. Change the mode to Control. If a dialog box appears indicating

a hard home positioning has not been done, click Do hard Home to accept and close
the box.
Module Guide 9
3. Now that RoboCIM is in the Control Mode, use the arrows of the five articulations in
the Motion window to move each articulation. Observe the motions performed by the
actual robot. Return each articulation to its initial location.
4. Once you are familiar with control of the robot articulations, return the robot arm to
its home position by performing a soft home position. To do this, select Soft Home
from the Motion menu of the RoboCIM menu bar.
5. On the work surface, put the objects shown in the figure below (square part, film
canister, and metallic can), making sure to position them as indicated in the figure.
(NOTE: the dashed lines in the figure indicate how the objects will be moved by the
robot in the steps that follow.)
10 Module Guide
6. In the Motion window of RoboCIM, use the arrows of the five articulations and the
Open/Close buttons of the gripper to make the robot grasp the film canister at
position (R7, C6) and move it right over the metallic can without colliding into it.
7. Once the film canister is over the can, open the gripper in order for the canister to be
dropped into the can.
8. Use the arrows of the five articulations and the Open/Close buttons for the gripper to
make the robot grasp the square part and move it to position (R2, C2) of the work
surface.
9. If you have time, continue experimenting with moving the robot articulations by
making the robot grasp the square part and moving it at several locations on the
work surface.
10. Exit RoboCIM. Do not save the workspace.
Shutdown Procedure
1. Make sure there is nothing inside of the robot gripper. If an object is in the gripper,
open it to release the object.
2. Clear the area around the robot.
3. Execute a soft home positioning by selecting Soft Home in the Motion menu of the
menu bar.
4. Set the mode to Simulation.
5. Turn off the power supply.
6. Ask your instructor if the equipment should be disconnected. If yes, disconnect the
system and return the equipment to its storage location.
Module Guide 11
Lesson 3, Introduction to Programming
In this activity, you will record points and use them to create a program that makes the
robot dip a part into a tank.
1. Click on the Application Launch button and select RoboCIM. From the Welcome
screen, select Create a new RoboCIM workspace.
2. Select Work Surfaces in the View menu of the RoboCIM menu bar. The Work
Surfaces dialog box appears. Set the R+ field to 2, and the C+ field to 1. Set the R-
and C- fields to 0. Click on Close to accept the new settings and close the box.
Two work surfaces now appear in the view display area.
3. Change the position of the robot as follows:

 Select the Object tab to display the Object window. Since the R and C
coordinates are currently set to R0, C4, the robot is at 0 row of perforations
from the R axis, and four rows of perforations from the C axis in the direction
pointed by this axis.
12 Module Guide
 Set the robot to position (R0, C7) by changing the C value to “7” in the
Position field. Leave the robot orientation set to 0 degrees. The robot position
is now as shown below:
4. You will now add a metallic can to the view display area:
 In the header section of the Object window, click on the New button. The New
Object selection box appears.
 Click on the icon of the metallic can (Model 77123) to select it. Leave the
default name in the dialog box that now appears. Click OK.
In the view display area, the newly added can now appears at position (R0, C0).
 In the basic parameters (bottom) section of the Object window, set the can to
position (R8, C9). Leave the can orientation set to 0 degrees. The can is now
positioned as shown is the figure above.
5. You will now add a film canister to the view display area:
 Click the New button. In the New Object selection box, click on the icon of the
film canister (Model 95183) to select it. Leave the default name and click OK
to close the dialog box that now appears.
In the view display area, the newly added film canister now appears in position (R0,
C0).
 In the basic parameters section of the Object window, set the position of the
film canister to (R8, C5). Leave the orientation of the film canister set to 0
degrees.
Module Guide 13
6. Save your work by selecting Save from the File menu. Enter Example and your last
name for the filename. For example, ExampleSmith. Then click the Save button.
You will now record four points that will establish the path the robot will go through to
perform its tasks without collisions.
 The starting (and arrival) point (point A)
 The height clearance point (point B)
 The point over the approximate center of the metallic can (point C)
 The point down to which the canister is lowered within the can (point D)
These points will then be used to edit a program for control of the robot motions.
In the view display area, note that the robot arm is at its soft home position, which is the
default arm position when a workspace is created.
1. Open the robot gripper fully by first selecting the Motion tab to display the Motion
window.
2. In the Gripper section, click on the Open button until the robot gripper becomes fully
open in the view display area.
3. Record point A by doing the following:
 Use the arrows of the five articulations of the robot to move and position the
gripper so that it is ready to grasp the film canister.
 Grip the film canister by clicking on the Close button.
14 Module Guide
In the header of the Point Recorder panel, click on the Record button .
Enter “A” as the name point and click OK.
4. Record point B (height clearance point) by following the steps below:
 Use the arrows of the five articulations of the robot to raise the canister 140
mm (5.5 in) approximately above the work surface, and over the top of the
metallic can.
 Click on the Record button and enter “B” as the point name. Click on OK.
5. Record point C (point over the metallic can):

 Use the arrows of the five articulations of the robot to move the canister over
the approximate center of the metallic can.
 Click on the Record button and enter “C” as the point name. Click OK.
Module Guide 15
6. Record point D (point down to which the canister is lowered within the can):
 Use the arrows of the five articulations of the robot to lower the bottom of the
canister down into the can (bottom quarter of the canister level with the top of
the can).
 Click on the Record button and enter “D” as the point name. Click OK.
7. Return the film canister to the starting point:

 In the Point recorder panel, double-click on the name of point A, which will
return the canister to point A (starting point).
 Release the canister by opening the robot gripper fully (click on the Open
button of the Gripper section).
8. Perform a soft home by selecting Soft Home in the Motion menu of the RoboCIM
menu bar.
Now that the points have been recorded, a program can be edited.
1. First create a new icon program:

 Select the Program tab to display the Program window.
 Click on the Icon Mode button to open the Icon program editing panel.
Below the menu bar and animation toolbar of the Program window, note that a tab
button is displayed, containing the letters “P0”, for the newly created program.
Below the program tab “P0” is a list of command icons, and the program editing
section where the program commands will be entered.
16 Module Guide
2. Enter the program shown by following these steps:
Module Guide 17
3. Save your new program by selecting File and then Save.
4. Before you can test the program in the Simulation Mode, you need to build (compile)
it.
 Click on the tab of program P0 to select it.
 Select Compile from the Build menu of the Program window to start the
compiling process. If errors are detected, correct them and start the compiling
process again.
5. Run the program in the Simulation Mode:
 Make sure you are in Simulation Mode.
In the animation toolbar of the Program window, click on the Execute button to start
execution of the program.
 Once execution of the program is completed, click several times on the
Execute step by step button , and observe the action performed by the
robot for each separate command.
 Finally, check the Run Continuously button , and click on the
Execute button, which will cause the program execution to repeat itself.
 Click on the Pause button and observe that this pauses the program.
Resume execution of the program by clicking on the Execute button.
 Stop program execution by clicking on the Stop button .
 Deselect the Run Continuously button.
You are now ready to test the program in the Control Mode.
18 Module Guide
On the work surface, position the robot, the film canister, and the metallic can as shown
below:
1. Turn on the power supply of the robot, and wait until the green LED at the rear of the
2. In the Toolbar of the RoboCIM main window, set the communication to Control.
3. Run the program by steps: click several times on the Execute step by step button
in the Program window.
4. Once the program is operational, you can run it continuously by clicking on the Run
Continuously button and then the Execute button in the animation toolbar of the
Program window.
5. When you are ready, stop the program by clicking on the Stop button.
6. Complete the Shutdown Procedure.
Shutdown Procedure
Module Guide 19
menu bar.
20 Module Guide
Lesson 4, Program Editing
In this activity you will edit the program you created in Lesson 3. You will first change
the position of the metallic can; then you will insert a delay in the program to simulate a
process in which a part must be dipped into a product container for 5 seconds. Finally,
you will reduce the speed at which the film canister is lowered into the metallic can.
1. On the work surface, place the robot and the objects as shown below.
2. Click on the Application Launch button and select RoboCIM. Open the RoboCIM
workspace/program that you created in Lesson 3 (Example and your last name).
The equipment shown in the RoboCIM view display whould be positioned like the actual
equipment.
3. Select the Program tab to display the program.
Module Guide 21
4. Before you edit the program, you need to verify that it operates properly.
 Build and compile the program by selecting Compile from the Build menu of
the Program window. If errors are detected, correct them and start the
compiling process again.

6. In the animation toolbar of the Program window, click on the Execute step by step
button , and observe the action performed by the robot for each separate
command:
 Starting from the home position, the end effector is lowered to point B, then
the gripper is fully opened.
 The end effector grasps the film canister at point A, raises it to point B, and
moves it in a straight path right over the metallic can at point C.
 The film canister is lowered a certain distance within the can (point D), and
then returned to point a through the reverse path (D>C>B>A).
 The gripper is opened, and then the end effector is returned to the home
position. A new cycle can begin.
7. Turn on the Power Supply of the robot and wait until the green LED at the rear of the
9. Once the hard home positioning has been performed, run Run the program by steps:
click several times on the Execute step by step button in the Program window.
Program window.
12. Place RoboCIM in the Simulation mode.
13. On the work surface, modify the position of the metallic can by placing it at (R5, C2).
14. Now modify the position of the metallic can displayed in RoboCIM to reflect the
change made by first selecting the Object tab. The Object window appears.
15. In the upper section of the Object window, click on the line of the metallic can to
display the parameters of the object at the bottom of the window.
22 Module Guide
16. Set the metallic can position to (R5, C2) by changing the R value to “5” and the C
value to “2”.
17. You will now modify the coordinates of the points that need correction (points C and
D), due to the change in the position of the metallic can.
For Point C:
 Make sure the end effector is at the home position.
 Fully open the gripper.
 Double click on the name of point B in the Point Recorder panel to make the
open gripper go right over the film canister.
 Double click on point A to make the gripper ready to grasp the canister.
 Fully close the gripper to grasp the canister.
 Double click on point B to raise the canister over the work surface.
 Using the arrows of the robot’s articulations in the Motion window, move the
canister over the approximate center of the metallic can.
 Save Point C with the new required coordinates by doing the following:
o In the Point Recorder panel, click on the Record button.
o Enter the name of the point being modified, as recorded in the Point
Recorder panel, using the same case (enter C). Click OK. You will be
asked if you want to replace the old point. Click on Replace.
For Point D:
 Using the arrows of the robot’s articulations in the Motion window, lower the
bottom of the canister down into the can (bottom quarter level with the top of
the can).
 Save Point D with the new coordinates by clicking on the Record button.
Enter “D” as the point name, then click OK to replace the old point with this
new one.
18. Return the film canister to the starting point by double-clicking on the name of point
A in the Point Recorder panel. Then, release the film canister by fully opening the
gripper.
19. Perform a soft home positioning.
20. Save the edited program in a new workspace in order to prevent overwriting the
original one you created in the last lesson. To do this, select File>Save As and enter
Lesson4 followed by your last name (for example, Lesson4Smith). Click Save.
21. Compile and Build the edited program like you did before and then test the program
in the Simulation mode.
22. Once the program runs properly, place RoboCIM in the Control mode and run the
program by steps.
Module Guide 23
Program window.
You will now edit the program in order to insert a delay. You will make the film canister
delay for 5 seconds after it is lowered into the metallic can.
1. Select the Program tab.
2. Click on program line 013 to highlight it. This will permit the insertion of a DELAY
command before this line.
3. In the list of command icons, click on the icon to insert a DELAY command in
program line 013.
4. Click on line 013 to highlight it. In the field DELAY(s) = , enter “5”. This will make the
film canister “hold” for 5 seconds when it reaches point D.
5. Save the newly edited program, then build and compile it.
6. Test this program in the Simulation mode. Verify that there is a 5 second delay when
the film canister is lowered within the can before it is withdrawn from the can.
7. Once the program operates properly, place RoboCIM in the Control mode and run
the program by steps. After that, you can run it continuously by checking the Run
Continuously button.
8. Stop program execution and then place RoboCIM in the Simulation mode.
9. Now you will edit the program to remove the DELAY command by first clicking on
program line 013 to highlight it. Then clicking on the Delete (X) button.
10. Save the newly edited program, then build and compile it. Test the program in the
Simulation mode and then in the Control mode.
You will now edit the program to modify the speed at which the film canister is lowered
and withdrawn within the metallic can, changing the speed to a very slow speed of 5.
24 Module Guide
2. Click on program line 011 to highlight it. In the field SPEED =, which is currently set
to 20, enter “5”. This will cause the speed associated with the next movements to be
reduced from 20 to 5.
3. Save the newly edited program, then build and compile it. Test this program by steps
in the Control mode. (NOTE: The reduction of the speed cannot be observed in the
RoboCIM software when this software is in the Simulation mode.)
4. Verify that when the film canister is lowered within the can, it is lowered at a very low
speed. When the film canister is withdrawn from the can, it is alsow withdrawn at a
very low speed.
5. Once the program has been found operational, you can run it without interruption.
6. Stop the program execution, and then place RoboCIM in the Simulation mode.
Shutdown Procedure
menu bar.
Module Guide 25
Lesson 5, Industrial Application
In this activity you will create a program that simulates the spot welding of a metallic
can. You will then edit your program in order to insert extra welding points. Finally, you
will create a program that simulates the continuous welding of a steel plate.
3. Simulate the spot welding of four points on the contour of the metallic can, as shown
in the graphic above. First, make four marks dividing the can circumference into four
quadrants (marks A, B, C, and D). These marks correspond to the four welding
points.
26 Module Guide
4. Now create a program that will make the robot perform the following tasks in
sequence:
 Starting from the home position, close the gripper. The extremity of the closed
gripper will simulate the electrode tip.
 Lower and position the tip to around 25 mm (1 in) right over mark A.
 Slowly move the tip close to mark A without touching it. (NOTE: do not touch
the can with the tip – keep a minimum distance of 3 mm (0.125 in).
 Move back the tip to around 25 mm (1 in) right over point B at a high speed.
Then, slowly move the tip close to mark B without touching it.
 Repeat steps d. and e. in order to point the two other marks (C and D).
 Return the end effector to the home position.
5. Once the program is complete, save it using the filename “Lesson5 your last name”.
6. Test and debug your program.
7. Now edit your program, adding four welding points, one between each of the four
current welding points. Save this program (File>Save As) using a different filename
“Lesson5 EDIT your last name”.
8. Test and debug your edited

program.
You will now create a new program

that will simulate the continuous
welding of a steel plate.
1. On the work surface, place the

robot and the objects as shown:
2. You will now simulate the welding

of continuous lines along a
rectangular steel plate. The plate
will be simulated by two square
parts placed side-by-side on the
work surface. Create a program
that will make the robot perform the
following tasks in sequence:
 Starting at the home

position, close the griper.
The extremity of the closed
gripper will simulate the
electrode tip.
Module Guide 27
 Lower and position the tip to an approach point about 25 mm (1 in) over the
starting point shown in the figure.
 Slowly move the tip close to the starting point without touching it.
 Move the tip along all four edges, through step points of equal height [3 mm
(0.125) in above the edges] spaced about 13 mm (0.5 in) apart, simulating the
continuous welding of lines. The distance between two contiguous rows of
perforations of a work surface is 50 mm (2 in).
 Once points have been recorded along all edges and the staring point is
reached, return the end effector to the home position.
 Save the program using the filename “Lesson5 Plate your last name”.
 Test and debug your program.
 When you are finished, complete the Shutdown Procedure.
Shutdown Procedure
menu bar.
28 Module Guide
Lesson 6, Gravity Feeder
In this activity, you will create a program that makes the robot pick up parts from a
feeder and drop them into a metallic can. When the feeder becomes empty, the robot
will remain at the home position until parts are placed in the feeder.
1. On the work surface, place the objects as shown below:
2. Connect the normally-open contact (yellow and black jacks) of the feeder
microswitch TTL input 1 of the robot base. The microswitch will prevent the robot
from trying to grasp a part when the feeder becomes empty.
Module Guide 29
4. Create a program that will make the robot perform the following tasks in sequence:
 Check the status of TTL input 1 to see if a part is available in feeder by

using the text command INPUT(1) OFF or the command icon
INPUT1=0 to make the program verify that parts are available in the
feeder. The RoboCIM Controller Status panel indicates the status [LOW
(red) or HIGH (green)] of the signal present at TTL input 1. In the
Simulation mode, a LOW (OFF) level is simulated at TTL input 1 as long
as the number of parts in the feeder (as set in the Object window for the
feeder) is not 0. In the Control mode, the program will execute as long as
parts are detected in the feeder, that is, even if the number of parts
simulated by the program becomes null, because in that case, the
program reads the actual signal provided by the microswitch feeder.
 If a part is available in the feeder, lower and position the open gripper near
this part.
 Close the gripper to grasp the part.
 Slowly withdraw the part from the feeder, taking care that the part does
not rub against or collide with the feeder.
 Move the part over the metallic can, then drop it into the can.
 Return the end effector to the home position. A new cycle can begin.
 Restart from the beginning and run the program until the feeder becomes
empty.
 Once the program is complete, save it as filename “Lesson6 your last
name”.
5. When you are finished, complete the Shutdown Procedure.
Shutdown Procedure
menu bar.
30 Module Guide
Lesson 7, Rotary Carousel
In this activity you will experiment with the operation of the Lab-Volt Rotary Carousel.
You will then create a program that simulates a galvanizing process where the surface
of an iron or steel workpiece is dipped into a bath of molten zinc.
1. On the work surface, place the robot and the Rotary Carousel as shown below. Do
NOT add the metallic can and the film canister yet. This will be done later.
2. Connect the cable of the Rotary Carousel to the ACCESSORY output on the base of
the robot.
3. Experiment with rotation of the carousel:
 Click on the Application Launch button and select RoboCIM. From the
Welcome screen, select Create a new RoboCIM workspace.
 Display the Object window for the carousel. Set the field “Port” to “CH 1”.
Module Guide 31
 Display the Motion window and using the single (low-speed) or double
(high-speed) arrows of the Carousel, make the displayed carousel rotate
in both directions.
4. Create a program that will make the platter of the carousel rotate 180 in the
clockwise direction, and then return to the initial (home) position and stop.
 Use the command icons CHANNEL and RCHANNEL to make
the carousel rotate.
5. Save the program as “Lesson 7 your last name”. Test and debug your program.
6. On the work surface, now place the metallic can and the film canister, as shown on
the previous page.
You will now simulate a galvanizing process where the surface of an iron or steel
workpiece is dipped into a bath of molten zinc to prevent corrosion, then moved to a
carousel workstation, rotated, and finally returned to its initial location.
 Grasp the film canister placed at the starting point (R9, C10).
 Raise it above the work surface and move it over the metallic can.
 Lower the film canister a certain distance within the can, then withdraw it
and move it over the starting point on the carousel platter.
 Place the film canister on the carousel platter, and then rotate the platter
by 270 clockwise (in front of the microswitch). Use the command icon
.
 Grasp the film canister and return it to the starting point.
 Save the program as “Lesson 7 GALV your last name”.
Shutdown Procedure
menu bar.
32 Module Guide
Comprehensive Level
Lesson 2, Saving Your Program
5100/5150 File Server Application
I/O Menu.
File I/O Menu

1 Load
2 Save
The 5100/5150 File Server window should open and a
“Hello” message should appear in the Last Request text field.
3. To save your program, press 2 on the Teach Pendant. The following appears:
4. Press 1 on the Teach Pendant to save your new file.
Module Guide 33
5. The 5100/5150 File Server application will display the Save Remote Data…window.
6. Enter a filename for your program that includes your initials, for example, Les2js.
You can use a maximum of eight characters. Click OK.
7. After the program is saved, the 5100/5150 File Server window appears with EOT
(end of transmission) displayed in the Last Request field. Minimize the window.
8. On the Teach Pendant, press the Esc key twice to return to the Main Menu.
34 Module Guide
Lesson 4, Loading Your Program
I/O Menu.
File I/O Menu

1 Load
2 Save
3. Navigate to the Load (1) option. This option is used to load an existing program into
the Teach Pendant memory. To load a saved program, enter the number beside its
name. Any program in the Teach Pendant memory will be erased. You can scroll
trhough the list of saved programs using the up and down arrow keys.
4. The message “recv” is displayed while the file is loading. When this message
disappears, press the ESC key twice to return to the Main Menu.
If you have previously saved a program made in the task mode and then later load that
program while in process mode, the Teach Pendant will switch to the task mode
automatically.
When you are finished, go to the next section in the presentation.
Module Guide 35
Lesson 5, Using RoboCIM
In this activity, you will use the RoboCIM software in Simulation mode and in Control
mode. You will first change the coordinates of each articulation and observe the motions
performed by the robot displayed in the View Display area. You will then observe the
motions of the actual robot when you change the articulation coordinates when in
Control mode.
Setting up the System

On the work surface, position the robot as indicated below (position R0, C7). Do not
position the accessories yet.
36 Module Guide
The equipment should be connected for all the activities in this module, as shown
below. If it is not, please ask your instructor for help.
You are now ready to control the robot using RoboCIM in the Simulation Mode.
1. Click the Application Launch button and select RoboCIM.
2. From the Welcome screen, select Create a new RoboCIM workspace. The RoboCIM
main window appears.
3. You will be working in the Simulation mode first, so make sure you are in Simulation
mode.
Module Guide 37
4. Select the Motion tab from the Tabbed Dialog Section. The Motion window appears.
5. Experiment with rotation of the robot

shoulder in the clockwise and
counterclockwise direction by clicking
the arrows for the Base articulation in
the Articular Coordinates section.
(Note: the single arrows provide a
slower speed; the double arrows
provide a fast speed for long moves.)
6. Observe the rotation of the robot

shoulder in the view display area.
Then return the shoulder to its initial
location.
7. To move the upper arm of the robot

up and down, use the arrows for the
Shoulder articulation.
8. Observe the motion of the upper arm

in the view display area, the return the
upper arm to its initial position.
9. Experiment with moving the forearm

of the robot up and down by using the
arrows for the Elbow articulation.
Then return the forearm to its initial position.
10. To move the gripper of the robot up and down, use the arrows for the Wrist Pitch
articulation. Once again, return the gripper to its initial position. Experiment with the
arrows for the Wrist Roll articulation too.
11. To open and close the robot gripper, click and hold the Close button in the Gripper
section. Then click and hold the Open button.
You will now move the robot in the Control Mode.
12. Turn on the power supply of the robot and wait until the green LED at the rear of the
38 Module Guide
13. Change the mode to Control. If a dialog box appears indicating

a hard home positioning has not been done, click Do hard Home to accept and close
the box.
14. Now that RoboCIM is in the Control Mode, use the arrows of the five articulations in
the Motion window to move each articulation. Observe the motions performed by the
actual robot. Return each articulation to its initial location.
15. Once you are familiar with control of the robot articulations, return the robot arm to
its home position by performing a soft home position. To do this, select Soft Home
from the Motion menu of the RoboCIM menu bar.
16. On the work surface, put the objects shown in the figure below (square part, film
canister, and metallic can), making sure to position them as indicated in the figure.
(NOTE: the dashed lines in the figure indicate how the objects will be moved by the
robot in the steps that follow.)
Module Guide 39
17. In the Motion window of RoboCIM, use the arrows of the five articulations and the
Open/Close buttons of the gripper to make the robot grasp the film canister at
position (R7, C6) and move it right over the metallic can without colliding into it.
18. Once the film canister is over the can, open the gripper in order for the canister to be
dropped into the can.
19. Use the arrows of the five articulations and the Open/Close buttons for the gripper to
make the robot grasp the square part and move it to position (R2, C2) of the work
surface.
20. If you have time, continue experimenting with moving the robot articulations by
making the robot grasp the square part and moving it at several locations on the
work surface.
21. Exit RoboCIM. Do not save the workspace.
Shutdown Procedure
menu bar.
40 Module Guide
Lesson 6, Introduction to Programming
In this activity, you will record points and use them to create a program that makes the
robot dip a part into a tank.
2. Select Work Surfaces in the View menu of the RoboCIM menu bar. The Work
Surfaces dialog box appears. Set the R+ field to 2, and the C+ field to 1. Set the R-
and C- fields to 0. Click on Close to accept the new settings and close the box.
Two work surfaces now appear in the view display area.
3. Change the position of the robot as follows:

 Select the Object tab to display the Object window. Since the R and C
coordinates are currently set to R0, C4, the robot is at 0 row of perforations
from the R axis, and four rows of perforations from the C axis in the direction
pointed by this axis.
Module Guide 41
 Set the robot to position (R0, C7) by changing the C value to “7” in the
Position field. Leave the robot orientation set to 0 degrees. The robot position
is now as shown below:
4. You will now add a metallic can to the view display area:
 In the header section of the Object window, click on the New button. The New
Object selection box appears.
 Click on the icon of the metallic can (Model 77123) to select it. Leave the
default name in the dialog box that now appears. Click OK.
In the view display area, the newly added can now appears at position (R0, C0).
 In the basic parameters (bottom) section of the Object window, set the can to
position (R8, C9). Leave the can orientation set to 0 degrees. The can is now
positioned as shown is the figure above.
5. You will now add a film canister to the view display area:
 Click the New button. In the New Object selection box, click on the icon of the
film canister (Model 95183) to select it. Leave the default name and click OK
to close the dialog box that now appears.
In the view display area, the newly added film canister now appears in position (R0,
C0).
 In the basic parameters section of the Object window, set the position of the
film canister to (R8, C5). Leave the orientation of the film canister set to 0
degrees.
42 Module Guide
6. Save your work by selecting Save from the File menu. Enter Example and your last
name for the filename. For example, ExampleSmith. Then click the Save button.
You will now record four points that will establish the path the robot will go through to
perform its tasks without collisions.
 The starting (and arrival) point (point A)
 The height clearance point (point B)
 The point over the approximate center of the metallic can (point C)
 The point down to which the canister is lowered within the can (point D)
These points will then be used to edit a program for control of the robot motions.
In the view display area, note that the robot arm is at its soft home position, which is the
default arm position when a workspace is created.
7. Open the robot gripper fully by first selecting the Motion tab to display the Motion
window.
8. In the Gripper section, click on the Open button until the robot gripper becomes fully
open in the view display area.
9. Record point A by doing the following:
 Use the arrows of the five articulations of the robot to move and position the
gripper so that it is ready to grasp the film canister.
 Grip the film canister by clicking on the Close button.
 In the header of the Point Recorder panel, click on the Record button .
Enter “A” as the name point and click OK.
Module Guide 43
10. Record point B (height clearance point) by following the steps below:
 Use the arrows of the five articulations of the robot to raise the canister 140
mm (5.5 in) approximately above the work surface, and over the top of the
metallic can.
 Click on the Record button and enter “B” as the point name. Click on OK.
11. Record point C (point over the metallic can):

 Use the arrows of the five articulations of the robot to move the canister over
the approximate center of the metallic can.
 Click on the Record button and enter “C” as the point name. Click OK.
44 Module Guide
12. Record point D (point down to which the canister is lowered within the can):
 Use the arrows of the five articulations of the robot to lower the bottom of the
canister down into the can (bottom quarter of the canister level with the top of
the can).
 Click on the Record button and enter “D” as the point name. Click OK.
13. Return the film canister to the starting point:

 In the Point recorder panel, double-click on the name of point A, which will
return the canister to point A (starting point).
 Release the canister by opening the robot gripper fully (click on the Open
button of the Gripper section).
14. Perform a soft home by selecting Soft Home in the Motion menu of the RoboCIM
menu bar.
Now that the points have been recorded, a program can be edited.
1. First create a new icon program:

 Select the Program tab to display the Program window.
 Click on the Icon Mode button to open the Icon program editing panel.
Below the menu bar and animation toolbar of the Program window, note that a tab
button is displayed, containing the letters “P0”, for the newly created program.
Below the program tab “P0” is a list of command icons, and the program editing
section where the program commands will be entered.
Module Guide 45
2. Enter the program shown by following these steps:
46 Module Guide
3. Save your new program by selecting File and then Save.
4. Before you can test the program in the Simulation Mode, you need to build (compile)
it.
 Click on the tab of program P0 to select it.
 Select Compile from the Build menu of the Program window to start the
compiling process. If errors are detected, correct them and start the compiling
process again.
In the animation toolbar of the Program window, click on the Execute button to start
execution of the program.
 Once execution of the program is completed, click several times on the
Execute step by step button , and observe the action performed by the
robot for each separate command.
 Finally, check the Run Continuously button , and click on the
Execute button, which will cause the program execution to repeat itself.
 Click on the Pause button and observe that this pauses the program.
Resume execution of the program by clicking on the Execute button.
 Stop program execution by clicking on the Stop button .
 Deselect the Run Continuously button.
You are now ready to test the program in the Control Mode.
Module Guide 47
On the work surface, position the robot, the film canister, and the metallic can as shown
below:
1. Turn on the power supply of the robot, and wait until the green LED at the rear of the
3. Run the program by steps: click several times on the Execute step by step button
in the Program window.
Program window.
Shutdown Procedure
menu bar.
48 Module Guide

Module Guide 49
Lesson 7, Program Editing
In this activity you will edit the program you created in Lesson 3. You will first change
the position of the metallic can; then you will insert a delay in the program to simulate a
process in which a part must be dipped into a product container for 5 seconds. Finally,
you will reduce the speed at which the film canister is lowered into the metallic can.
2. Click on the Application Launch button and select RoboCIM. Open the RoboCIM
workspace/program that you created in Lesson 3 (Example and your last name).
The equipment shown in the RoboCIM view display whould be positioned like the actual
equipment.
3. Select the Program tab to display the program.
50 Module Guide
4. Before you edit the program, you need to verify that it operates properly.
 Build and compile the program by selecting Compile from the Build menu of
the Program window. If errors are detected, correct them and start the
compiling process again.

6. In the animation toolbar of the Program window, click on the Execute step by step
button , and observe the action performed by the robot for each separate
command:
 Starting from the home position, the end effector is lowered to point B, then
the gripper is fully opened.
 The end effector grasps the film canister at point A, raises it to point B, and
moves it in a straight path right over the metallic can at point C.
 The film canister is lowered a certain distance within the can (point D), and
then returned to point a through the reverse path (D>C>B>A).
 The gripper is opened, and then the end effector is returned to the home
position. A new cycle can begin.
7. Turn on the Power Supply of the robot and wait until the green LED at the rear of the
9. Once the hard home positioning has been performed, run Run the program by steps:
click several times on the Execute step by step button in the Program window.
Program window.
13. On the work surface, modify the position of the metallic can by placing it at (R5, C2).
14. Now modify the position of the metallic can displayed in RoboCIM to reflect the
change made by first selecting the Object tab. The Object window appears.
15. In the upper section of the Object window, click on the line of the metallic can to
display the parameters of the object at the bottom of the window.
Module Guide 51
16. Set the metallic can position to (R5, C2) by changing the R value to “5” and the C
value to “2”.
17. You will now modify the coordinates of the points that need correction (points C and
D), due to the change in the position of the metallic can.
For Point C:
 Make sure the end effector is at the home position.
 Fully open the gripper.
 Double click on the name of point B in the Point Recorder panel to make the
open gripper go right over the film canister.
 Double click on point A to make the gripper ready to grasp the canister.
 Fully close the gripper to grasp the canister.
 Double click on point B to raise the canister over the work surface.
 Using the arrows of the robot’s articulations in the Motion window, move the
canister over the approximate center of the metallic can.
 Save Point C with the new required coordinates by doing the following:
o In the Point Recorder panel, click on the Record button.
o Enter the name of the point being modified, as recorded in the Point
Recorder panel, using the same case (enter C). Click OK. You will be
asked if you want to replace the old point. Click on Replace.
For Point D:
 Using the arrows of the robot’s articulations in the Motion window, lower the
bottom of the canister down into the can (bottom quarter level with the top of
the can).
 Save Point D with the new coordinates by clicking on the Record button.
Enter “D” as the point name, then click OK to replace the old point with this
new one.
18. Return the film canister to the starting point by double-clicking on the name of point
A in the Point Recorder panel. Then, release the film canister by fully opening the
gripper.
19. Perform a soft home positioning.
20. Save the edited program in a new workspace in order to prevent overwriting the
original one you created in the last lesson. To do this, select File>Save As and enter
Lesson4 followed by your last name (for example, Lesson4Smith). Click Save.
21. Compile and Build the edited program like you did before and then test the program
in the Simulation mode.
22. Once the program runs properly, place RoboCIM in the Control mode and run the
program by steps.
52 Module Guide
Program window.
You will now edit the program in order to insert a delay. You will make the film canister
delay for 5 seconds after it is lowered into the metallic can.
2. Click on program line 013 to highlight it. This will permit the insertion of a DELAY
command before this line.
3. In the list of command icons, click on the icon to insert a DELAY command in
program line 013.
4. Click on line 013 to highlight it. In the field DELAY(s) = , enter “5”. This will make the
film canister “hold” for 5 seconds when it reaches point D.
5. Save the newly edited program, then build and compile it.
6. Test this program in the Simulation mode. Verify that there is a 5 second delay when
the film canister is lowered within the can before it is withdrawn from the can.
7. Once the program operates properly, place RoboCIM in the Control mode and run
the program by steps. After that, you can run it continuously by checking the Run
Continuously button.
8. Stop program execution and then place RoboCIM in the Simulation mode.
9. Now you will edit the program to remove the DELAY command by first clicking on
program line 013 to highlight it. Then clicking on the Delete (X) button.
10. Save the newly edited program, then build and compile it. Test the program in the
Simulation mode and then in the Control mode.
You will now edit the program to modify the speed at which the film canister is lowered
and withdrawn within the metallic can, changing the speed to a very slow speed of 5.
Module Guide 53
2. Click on program line 011 to highlight it. In the field SPEED =, which is currently set
to 20, enter “5”. This will cause the speed associated with the next movements to be
reduced from 20 to 5.
3. Save the newly edited program, then build and compile it. Test this program by steps
in the Control mode. (NOTE: The reduction of the speed cannot be observed in the
RoboCIM software when this software is in the Simulation mode.)
4. Verify that when the film canister is lowered within the can, it is lowered at a very low
speed. When the film canister is withdrawn from the can, it is alsow withdrawn at a
very low speed.
5. Once the program has been found operational, you can run it without interruption.
6. Stop the program execution, and then place RoboCIM in the Simulation mode.
Shutdown Procedure
menu bar.
54 Module Guide
Lesson 8, Industrial Application
In this activity you will create a program that simulates the spot welding of a metallic
can. You will then edit your program in order to insert extra welding points. Finally, you
will create a program that simulates the continuous welding of a steel plate.
3. Simulate the spot welding of four points on the contour of the metallic can, as shown
in the graphic above. First, make four marks dividing the can circumference into four
quadrants (marks A, B, C, and D). These marks correspond to the four welding
points.
Module Guide 55
4. Now create a program that will make the robot perform the following tasks in
sequence:
 Starting from the home position, close the gripper. The extremity of the closed
gripper will simulate the electrode tip.
 Lower and position the tip to around 25 mm (1 in) right over mark A.
 Slowly move the tip close to mark A without touching it. (NOTE: do not touch
the can with the tip – keep a minimum distance of 3 mm (0.125 in).
 Move back the tip to around 25 mm (1 in) right over point B at a high speed.
Then, slowly move the tip close to mark B without touching it.
 Repeat steps d. and e. in order to point the two other marks (C and D).
 Return the end effector to the home position.
5. Once the program is complete, save it using the filename “Lesson5 your last name”.
6. Test and debug your program.
7. Now edit your program, adding four welding points, one between each of the four
current welding points. Save this program (File>Save As) using a different filename
“Lesson5 EDIT your last name”.
8. Test and debug your edited

program.
You will now create a new program

that will simulate the continuous
welding of a steel plate.
1. On the work surface, place the

robot and the objects as shown:
2. You will now simulate the welding

of continuous lines along a
rectangular steel plate. The plate
will be simulated by two square
parts placed side-by-side on the
work surface. Create a program
that will make the robot perform the
following tasks in sequence:
 Starting at the home

position, close the griper.
The extremity of the closed
gripper will simulate the
electrode tip.
56 Module Guide
 Lower and position the tip to an approach point about 25 mm (1 in) over the
starting point shown in the figure.
 Slowly move the tip close to the starting point without touching it.
 Move the tip along all four edges, through step points of equal height [3 mm
(0.125) in above the edges] spaced about 13 mm (0.5 in) apart, simulating the
continuous welding of lines. The distance between two contiguous rows of
perforations of a work surface is 50 mm (2 in).
 Once points have been recorded along all edges and the staring point is
reached, return the end effector to the home position.
 Save the program using the filename “Lesson5 Plate your last name”.
 When you are finished, complete the Shutdown Procedure.
Shutdown Procedure
menu bar.
Module Guide 57
Lesson 9, Gravity Feeder
In this activity, you will create a program that makes the robot pick up parts from a
feeder and drop them into a metallic can. When the feeder becomes empty, the robot
will remain at the home position until parts are placed in the feeder.
1. On the work surface, place the objects as shown below:
2. Connect the normally-open contact (yellow and black jacks) of the feeder
microswitch TTL input 1 of the robot base. The microswitch will prevent the robot
from trying to grasp a part when the feeder becomes empty.
58 Module Guide
 Check the status of TTL input 1 to see if a part is available in feeder by

using the text command INPUT(1) OFF or the command icon
INPUT1=0 to make the program verify that parts are available in the
feeder. The RoboCIM Controller Status panel indicates the status [LOW
(red) or HIGH (green)] of the signal present at TTL input 1. In the
Simulation mode, a LOW (OFF) level is simulated at TTL input 1 as long
as the number of parts in the feeder (as set in the Object window for the
feeder) is not 0. In the Control mode, the program will execute as long as
parts are detected in the feeder, that is, even if the number of parts
simulated by the program becomes null, because in that case, the
program reads the actual signal provided by the microswitch feeder.
 If a part is available in the feeder, lower and position the open gripper near
this part.
 Close the gripper to grasp the part.
 Slowly withdraw the part from the feeder, taking care that the part does
not rub against or collide with the feeder.
 Move the part over the metallic can, then drop it into the can.
 Return the end effector to the home position. A new cycle can begin.
 Restart from the beginning and run the program until the feeder becomes
empty.
 Once the program is complete, save it as filename “Lesson6 your last
name”.
Shutdown Procedure
menu bar.
Module Guide 59
Lesson 10, Rotary Carousel
In this activity you will experiment with the operation of the Lab-Volt Rotary Carousel.
You will then create a program that simulates a galvanizing process where the surface
of an iron or steel workpiece is dipped into a bath of molten zinc.
1. On the work surface, place the robot and the Rotary Carousel as shown below. Do
NOT add the metallic can and the film canister yet. This will be done later.
2. Connect the cable of the Rotary Carousel to the ACCESSORY output on the base of
the robot.
3. Experiment with rotation of the carousel:
 Click on the Application Launch button and select RoboCIM. From the
Welcome screen, select Create a new RoboCIM workspace.
 Display the Object window for the carousel. Set the field “Port” to “CH 1”.
60 Module Guide
 Display the Motion window and using the single (low-speed) or double
(high-speed) arrows of the Carousel, make the displayed carousel rotate
in both directions.
4. Create a program that will make the platter of the carousel rotate 180 in the
clockwise direction, and then return to the initial (home) position and stop.
 Use the command icons CHANNEL and RCHANNEL to make
the carousel rotate.
5. Save the program as “Lesson 7 your last name”. Test and debug your program.
6. On the work surface, now place the metallic can and the film canister, as shown on
the previous page.
You will now simulate a galvanizing process where the surface of an iron or steel
workpiece is dipped into a bath of molten zinc to prevent corrosion, then moved to a
carousel workstation, rotated, and finally returned to its initial location.
 Grasp the film canister placed at the starting point (R9, C10).
 Raise it above the work surface and move it over the metallic can.
 Lower the film canister a certain distance within the can, then withdraw it
and move it over the starting point on the carousel platter.
 Place the film canister on the carousel platter, and then rotate the platter
by 270 clockwise (in front of the microswitch). Use the command icon
.
 Grasp the film canister and return it to the starting point.
 Save the program as “Lesson 7 GALV your last name”.
Shutdown Procedure
menu bar.
Module Guide 61

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Tech-Design

Automation & Robotics

First Printing, September 2009

Copyright 2009 Lab-Volt Systems, Inc.

Lab-Volt and Tech-Design are registered trademarks of Lab-Volt Systems, Inc.

All other trademarks belong to their respective owners.

Beginning Level ......................................................................................................... 3

5100/5150 File Server Application

File I/O Menu

4. Press 1 on the Teach Pendant to save your new file.

Go to the next section in the presentation.

Lesson 4, Loading Your Program

File I/O Menu

When you are finished, go to the next section in the presentation.

Lesson 2, Using RoboCIM

Setting up the System

1. Click the Application Launch button and select RoboCIM.

5. Experiment with rotation of the robot

6. Observe the rotation of the robot

7. To move the upper arm of the robot up

8. Observe the motion of the upper arm in

9. Experiment with moving the forearm of

You will now move the robot in the Control Mode.

2. Change the mode to Control. If a dialog box appears indicating

10. Exit RoboCIM. Do not save the workspace.

Go to the next section in the presentation.

Lesson 3, Introduction to Programming

Two work surfaces now appear in the view display area.

3. Change the position of the robot as follows:

3. Record point A by doing the following:

 Grip the film canister by clicking on the Close button.

5. Record point C (point over the metallic can):

7. Return the film canister to the starting point:

1. First create a new icon program:

2. Enter the program shown by following these steps:

3. Save your new program by selecting File and then Save.

Go to the next section in the presentation.

Lesson 4, Program Editing

3. Select the Program tab to display the program.

5. Run the program in the Simulation Mode:

12. Place RoboCIM in the Simulation mode.

19. Perform a soft home positioning.

25. Place RoboCIM in the Simulation mode.

1. Select the Program tab.

1. Select the Program tab.

7. Complete the Shutdown Procedure.

Go to the next section in the presentation.

Lesson 5, Industrial Application

6. Test and debug your program.

8. Test and debug your edited

You will now create a new program

1. On the work surface, place the

2. You will now simulate the welding

 Starting at the home

Go to the next section in the presentation.

Lesson 6, Gravity Feeder

1. On the work surface, place the objects as shown below:

 Check the status of TTL input 1 to see if a part is available in feeder by