Practical No.1: Introduction to industrial automation lab and safety.

Robotics lab comprises of 4 industrial robots with application like spray painting, pick and place,
sorting, machine tending and welding.
Overview of the robot:
The robot comprises the following components: 1. Robotic arm 2. Teach pendant 3. Robot controller

Robotic arm:
The robotic arm is an electro-mechanical mechanism that can move about the following five axes
(J1, J2, J3, J4 and J5):

Name Movement Maximum

range speed
J1 Waist axis ±180° 110°/s
J2 Shoulder axis ±130° 110°/s
J3 Arm axis ±150° 110°/s
J4 Wrist tilting axis ±180° 150°/s
J5 Wrist rotational axis 360° 150°/s

1. Base plate
2. Mechanical limit indicator for J1-axis
3. Robot flange

The movement of the robotic arm about the different axes are achieved through the respective
motor drives. Encoders monitor the actual position of the different axes. Home position sensors
monitor the home position of the different axes. A mechanical limit indicator (2) on the base plate
(1) indicates the limit of the robotic arm movement about the J1-axis. For safety of personnel and
equipment, software axis limits are defined to restrict the movement range of the robotic arm about
the different axes. The tool or end-effector is mounted on the robot flange (3) to perform specific
tasks such as cutting, welding, gripping, etc.

Teach pendant
The teach pendant consists of a touchscreen and two buttons. The teach pendant is used to create/edit
programs and operate the robot by means of the teach pendant application. Following is an overview
of the teach pendant:
1

5
3
4
Teach pendant

7 6
 No. Element Function
1 Power ON indicator Indicates that the teach pendant is powered ON.
2 Emergency stop button Stops the robot immediately.
3 Mode selector switch Switches between Auto, Manual, and Idle modes of
operation.
4 Touchscreen Allows the user to set up and operate the robot.
5 USB port (Rear) Allows the user to transfer data between the teach pendant
and a USB drive.
6 Slave micro-USB slot (Rear) Allows the user to connect a micro-USB device to the
teach pendant.
7 RJ45 port (Rear) Allows the user to connect the teach pendant to a network
for TCP/IP communication with other devices.
-- Stylus Allows the user to operate the teach pendant.

Robot controller
The robot controller controls the robotic arm. The robot controller consists of a cabinet for
housing the CPU, power supply, drive controllers, I/O and data storage modules. The robot
controller cabinet has connection points for power supply, encoders, teach pendant, and
optional spare points for connecting other auxiliary components. The different components of
the robot controller are as follows:

Main components outside the robot controller

5
4 6
3 7

2 8

1 9

16 11 10
12 13

14 15

Main components of the robot controller

Sr.
Name Function
No.
1 Robot controller Controls the robotic arm.
Turns ON or OFF the power supply to the robot
2 Main switch
controller.
Glows when the power supply to the robot controller
3 POWER ON lamp
is ON.
Glows when there is a fault and stops glowing after
4 FAULT lamp
the fault is reset.
Turns ON the robot controller. Glows to indicate
5 CONTROL ON button
that the controller is ON.
 6 RESET button Resets the robot controller after a fault.

7 Emergency stop button Stops the robotic arm immediately, when pressed.

8 Spare communication port 1 --

9 Spare communication port 2 --
Port for connecting a computer for troubleshooting
10 Ethernet (RJ45) port
and analysis.
Power socket for connecting auxiliary equipment
11 230V utility socket
or external devices.
Socket for connecting the power cable from the
12 Power socket (X1)
robot controller to the robotic arm.
Socket for connecting the encoder cable from
13 Encoder socket (X2)
the robot controller to the robotic arm.

14 Power supply connection Supplies power to the robot controller.

15 Earthing screw Point for connecting the earthing wire.

Socket for connecting the teach pendant cable to
16 Teach pendant socket (X3)
the robot controller.

Main components inside the robot controller

Main components inside the robot controller

Sr. No. Name Function

Controls and co-ordinates the movements of the robotic
1 Central Processing Unit (CPU) arm, and communicates with I/O devices connected to the
CPU.
2 Drive controllers (Axes 1, 2, and 3) Controls the stepper drives for axes J1, J2, and J3.
3 Drive controllers (Axes 5 and 6) Controls the stepper drives for axes J4 and J5.
Regulates the power supply from the Mains to power the
4 SMPS (Switched-Mode Power Supply)
drives and various components of the robot controller.
Cuts the power supply to the different components of the robot
5 MCB (Miniature Circuit Breakers) controller to prevent damage to the electrical circuits in case of
power surges or short circuits.
Turns OFF the power supply to the robot controller when the
6 Temperature cut-out unit
temperature inside the robot controller exceeds a set value.
Sets the cut-out value for the temperature inside the robot
7 Cut-out temperature setting switch
controller.
8 Inlet fan Blows air into the robot controller to cool the robot controller.
 Evacuates the hot air from the robot controller to cool the robot
9 Exhaust fan
controller.

Central Processing Unit (CPU)

The CPU controls and co-ordinates the movements of the robotic arm, and communicates with I/O
devices connected to the CPU. Following is an overview of the CPU:

Sr. No. Name Function

To connect a computer to the CPU through an
1 Ethernet port Ethernet cable for communication with the CPU
and programming of the CPU.
To connect a computer to the CPU through an RS
2 Serial connection port 232 or RS 485 cable for communication and data
transmission.
3 Flexible axis port To connect additional encoders to the CPU.
To connect the different drives to the CPU through
4 Ether CAT port
an Ether CAT connector.
Displays the status (ON or OFF) of the different
I/O devices connected to the onboard I/O ports.
5 Backlit display
Also displays the errors in the drives, axes, I/O
devices and connections.
6 Power ON LED Glows when the CPU is powered ON.
7 Enable status LED Glows when the CPU is enabled.
To connect 8 inputs (Input channels 0 to 7) and
8 I/O channels 8 inputs/ outputs (Bi-directional I/O channels 8
to 15) to the CPU.
To connect an additional CAN 16 I/O module for
9 CAN Bus port
connecting additional I/O devices to the CPU.
To connect an SD card to the CPU for transferring
10 SD card slot
data between the CPU and the SD card.

I/O channels on the CPU

The CPU has eight 24 V input channels (0 to 7) or connecting input devices and eight bi-directional
I/O channels (8 to 15) for connecting input or output devices.

1. Input channels
2. 2. Bi-directional I/O channels
I/O channels on the CPU
 Technical data
Parameter Value
Robot make AUTOFINA BRABO
Robot model TR10-5
Construction Articulated arm
Installed Floor and ceiling mounted
Ambient temperature of the robot 0 °C - 45 °C
workspace
Relative humidity of the robot workspace < 90%
Recommended area of fencing 2 m x 2 m = 4 m2
Recommended height of fencing 1.8 m
Number of axes 5
Axis movement range J1-axis: ±180°
J2-axis: ±130°
J3-axis: ±150°
J4-axis: ±180°
J5-axis: 360°
Maximum speed J1-axis: 110°/s
J2-axis: 110°/s
J3-axis: 110°/s
J4-axis: 150°/s
J5-axis: 150°/s
Maximum payload 10 Kg
Maximum reach 750 mm
Weight of robotic arm 95 Kg
Position repeatability (accuracy) ±0.2 mm
Main power supply 230V AC, Single phase,
Regulated power supply
Full load current 15 Amps
Maximum power consumption 4.5 kW
Operating temperature 0 °C - 45 °C
Acoustic level <70 dB
Robot controller dimensions 660 X 600 X 350 mm
Robot controller weight 45 Kg
Spare digital I/O 3 Input, 4 Output (Bi-
directional)
Communication protocol Ethernet, EtherCAT

VIII. General safety and precautions

 Turn OFF the main power switch on the robot controller and secure it with a padlock before
starting any maintenance or repair function. Do not enter the workspace of the robot or the enclosed area
when the robot is in switched ON condition.
 Strictly observe all mandatory safety regulations that are currently in force while performing
maintenance work.
 Allow only authorized and skilled personnel to carry out maintenance work on the machine.
 If the robot has been operational for a long time, wait for the motors and the robot controller
to cool down to normal temperature before starting any maintenance or repair tasks.
 Make sure that there is enough space and sufficient lighting in the maintenance area.
 After a maintenance function and before you connect the robot to the power supply, make sure that
all cables and the earthing wire are correctly connected.
 Make sure that all safety devices are connected before you switch ON the robot after a
maintenance function.
High voltage hazard.
Any contact with live parts leads to an immediate threat to life due to electric shock. Damage to the
insulation or individual components can be lethal.
Only a qualified and authorized electrician is allowed to work on electrical equipment.
Turn off the main power switch and secure it with a padlock to prevent any unintended restart
of the machine.
If there is damage to electrical insulation, immediately turn off the main power switch and repair
the insulation.
Before you start working on the electrical parts, make sure that the parts are free of electrical
power.
Cover or safeguard any other connected electrical parts.
Do not bridge any fuses.
Keep moisture away from live electrical parts. This may lead to short circuits.
Moving robotic arms.
Risk of severe injury or death.
Do not operate the robot without a safety enclosure or safety fence.
Do not touch the robotic arm or enter the robot workspace when the robot is switched ON.

Fire hazard.
Risk of severe burns due to fire.
Do not keep any flammable items in the robot workspace.
If any electrical insulation is damaged, repair the insulation or replace the parts.
Use a carbon dioxide extinguisher to extinguish the fire.

Hot surfaces.
Risk of burns to skin.
Do not touch the hot surfaces of the robot. Carry out maintenance activity only after the robot
components have cooled down to normal temperature.
Wear protective hand gloves.

Observation Table:
 Parameters Value
Type of robot
Number of axes
Payload
Reach
Weight of robotic arm

Conclusion:

1. The robot comprises the three components: ________________________ ,______________________ &

_____________________.

2. ____________________ is used to create/edit programs and operate the robot

Practical related Questions

1. State important components inside the robot controller.
2. State important components outside side the robot controller.

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