i n ) General 29 9.3 Robot safety guarding (SIP3) To safeguard the danger zone in the plant, a safety guard that contains a protection door for entering the danger zone has been attached to the machine. The hazard zone cannot be accessed at any time, as the safety gate is secured by a mechan- ical safety switch. The safety gate unlocks when the access demand button is pressed after the machine has come to a defined standstill. It is locked after the safety gate is closed and acknowledged. The protection door automatically unlocks in case of an emergency stop after a standstill of the machine and when the machine is switched off. With this safety guard, only vertical and lateral removal are possible. However, lateral removal is only possible in injection molding machines without tie bars when the rear safety gate of the clamping unit is open. (optionally also on operator side). The protection door in the safety guard takes on the function of the rear safety gate of the clamping unit. At Engel, this protection door is also named safety package 3 (SIP3) due to the technical design. WARNING! Danger of fatal injury due to moving components and high-pressure injection! The person inside the safeguard must always possess the key from the key- operated acknowledgement switch in order to prevent accidental acknowl- edgement of safeguards, which would cause the machine to restart. Do not acknowledge the safety guard until the danger area is clear of person- nel and foreign bodies. General 30 Operator Manual - Robot | Version G/11/401/2/21 Example: safety guarding with protection door [1] EMERGENCY STOP button inside [2] EMERGENCY STOP button outside [3] Access request key with lamp [4] Acknowledgement key with key-operated switch Entering the hazardous area 1. Actuate the access demand button to unlock the protection door (button flashes). Due to this, the robot interrupts automatic mode when the Stop when safety gate requested instruction is reached in the robot sequence. By default after the molded part has been removed. The injection molding machine stops at the end of the cycle. Do not open the safety gate during locking and/or unlocking as this can cause damage to the locking mechanism. The lit access request key indicates that the protection door has been unlocked and enabled for opening. 2. Remove the key on the acknowledgement key. 3. Opening safety gate and entering the hazard zone. Always take the key for the acknowl- edge button in with you. 4. When the protection door is open in set-up mode, users with access level 5 or higher can execute robot movements by simultaneously pressing the consent key and corre- sponding pushbutton. In this case, the servoaxes move slowly at the corresponding manual moving speed and pneumatic movements at full speed. 5. After leaving the danger area, the operator must acknowledge the protection door with the key-operated switch immediately (within 5 seconds) after closing the door, this then locks the protection door. 6. The plant continues processing the program after the start key is actuated. 1 4 2 3 General 31 Pluggable safety gate The safety guarding and protection door are connected to the injection molding machine via a male connector instead of the rear safety gate on the injection unit (optionally also operator side). Connect the safety gate of the clamping unit This disables the function of the protection door in the safety guarding. For example, the end of arm tooling can be changed while the injection molding machine is in production. 1. Disconnect safety guarding with protection door. 2. Attach and close the rear safety gate of the clamping unit. Connect safety guarding with protection door For the shared automatic mode of the injection molding machine and the robot. 1. Disconnect and open the rear safety gate of the clamping unit. 2. Connect the safety guarding with protection door and reactivate the Robot main switch program switch. Alarms and messages An acknowledgement must occur after switching on the control voltage The following message is displayed until you acknowledge the protection door: The acknowledgement must occur within 5 seconds of, but not within 0.05 seconds after clos- ing the protection door. You are not permitted to press the acknowledgement key for too long (maximum of 10 sec- onds). If these conditions are not fulfilled, the following message appears: Robot safety gate open Robot safety gate opening-closing-acknowledging Effect Robot movements can be executed in set-up mode by users with access level 5 or higher by simultaneously pressing the consent key and the corresponding pushbutton. In this case, the servoaxes move slowly at the corresponding manual moving speed and pneumatic movements at full speed. Remedy Open - close protection door and acknowledge within 5 seconds using the key-operated switch. Robot safety gate x: acknowledgement key pressed too early Cause The acknowledgement key was actuated before the protection door was closed. Effect The robot motors are switched off. Remedy Open and then close protection door again and acknowledge (not within 0.05 seconds) using the key-operated switch. General 32 Operator Manual - Robot | Version G/11/401/2/21 If the rear safety gate of the clamping unit is closed when the safety guard of the robot is attached, the following messages appear: Robot safety gate: Acknowledgement key too long not actuated Cause Protection door has not been acknowledged within 5 seconds. Effect Protection door not acknowledged. Remedy Protection door must be opened/closed/acknowledged again. Robot safety gate: Acknowledgement key actuated too long Cause Acknowledgement key has been actuated longer than 10 seconds. Effect Protection door not acknowledged. Remedy Protection door must be opened/closed/acknowledged again. Robot safety gate: Acknowledgement key actuated too fast Cause A message appears if less than 0.05 seconds pass between closing and acknowledging the protection door. The acknowledgement key may have been actuated before the protection door was closed. Effect Protection door not acknowledged. Remedy Protection door must be opened/closed/acknowledged again. Acknowledgement contactor x defective Cause Monitoring inputs of the protective equipment acknowledgement con- tactors were active or not active more than 1 second simultaneously. Effect Cycle interruption, motor stop, alarm lamp Remedy Contact ENGEL Service. General 33 If the safety guard of the robot is disconnected, the following message appears: The following message appears if you attempt to activate program switch Main robot switch when the safety guard of the robot is disconnected: Clamping unit safety gate disconnected but not completely open Effect The robot motor switches off. Automatic operation of the plant not possible. Remedy Completely open the rear safety gate of the clamping unit. Clamping unit safety gate 2 not entirely open Effect The robot motor switches off. Automatic operation of the plant not possible. Remedy Completely open the rear safety gate of the clamping unit. Robot safety gate not connected Cause The motors switch off or cannot be switched on. Program switch Main robot switch deactivates. Effect Connect the safety guard of the robot and activate program switch Main robot switch on Robot program switch screen. Remedy The motors switch off or cannot be switched on. Program switch Main robot switch deactivates. Clamp unit safety gate 2 not connected or not open Cause An attempt has been made to use robot functions although the safety gate of the robot is not connected. Effect Robot functionalities cannot be used. Remedy Connect the safety gate to the robot. General 34 Operator Manual - Robot | Version G/11/401/2/21 Operation 35 Operation The Operation chapter contains information on operating the robot. 1 Machine control panel A swiveling touchscreen color monitor, combined with foil and toggle keys, enables optimal ergonomic operation. Users need to log in to access settings and parameters. Text and graphics editors support fast and easy customization of the machine to match your injection molding process and free programming of the program sequence. Data storage is to the control unit, USB memory stick or a network drive. A help system with graphics supports operations and maintenance of the injection molding machine. You can install the optional VirtMould software to run the original machine visualization on a PC. This gives you the ability to change settings independently of the injection molding machine, and to store your changes on a Compact Flash card or USB memory stick to transfer them to the machine. Because the robot and injection molding machine are fully integrated it provides a convenient platform for operating both components. The common platform for the machine and the robot offers the same operating elements and sequences, for both. Control panel with side grips for two-handed swiveling (right with unlocking). Operation 36 Operator Manual - Robot | Version G/11/401/2/21 1.1 Overview Color touch screen display Touch keys for manual control of the individual machine movements. (Optional swivel keys) Sensor for the user authorization card (option) 2 USB interfaces. To connect to external devices (e.g.: memory stick, printer, keyboard, etc..) Safety button key Control voltage switch Emergency stop button Program interruption Start key Robot motor switch Configurable foil keys for the manual control of the individual system motions Operation 37 1.2 Configurable foil keys The control panel has 8 foil keys that the user can individually assign functions. The configured functions of the keys appear as symbols on the screen above the foil keys. [1] Assigned symbol field with a function [2] Unassigned symbol field [3] Foil keys for calling up functions Example: Procedure for assigning a function to a foil key. 1. Press the symbol field of a configurable foil key. A key menu with the functions that can be selected appears on the screen and the selected field turns red. 2. Press the desired symbol in the key menu to place it on the red field. Activate the asso- ciated function by pressing the foil key below it. 3. To delete a function or to replace it by a different one, either press an empty field or the desired symbol. 4. To close the key menu, press the red field. 1 2 3 Operation 38 Operator Manual - Robot | Version G/11/401/2/21 2 Hand control device KETOP C100E The hand control device (HCD) is a portable operating and display device with an 8.0" touch screen and the following functions: Setting and displaying parameters for the injection molding machine and robot. Robot operations. Sequence teach and programming function. CAUTION! Danger of damage to equipment! The hand control device is equipped with highly sensitive electronics. Handling tips Status LEDs Function Power Lit when the connection to the control unit is active. Motor Lit when the robot motors are switched on. RC2 Lit after switching to robot 2 with the toggle robot button. Emergency stop button Touch-sensitive keys 8.0" color touch screen Slot for Compact Flash Card (PC- Card Adapter required) Operation 39 Use only your finger or a stylus to operate the touch screen of the manual control device. Use only your finger to actuate the foil keys on the manual control device. Ensure no one can trip over the cable to avoid personnel injury and mechanical dam- age. Place the hand terminal into the designated fixture when it is not being used. It is important to check the proper function of safety features such as the EMERGENCY STOP button and consent key periodically. Never place the control device near a heat source. Do not expose the device to any mechanical vibrations, excessive dust, humidity or strong magnetic fields. To clean the control device use a soft cloth, slightly moistened with water or a mild cleaning material. Do not use any type of solvent. Operation 40 Operator Manual - Robot | Version G/11/401/2/21 2.1 Safety controls Emergency stop button When the EMERGENCY STOP button is activated the power of the entire system, including the robot and machine is immediately turned OFF. The control unit remains ON. To reset the EMERGENY STOP button turn it clockwise. Consent keys The hand control device has two consent keys located at both sides of the device. To consent, you only need to press one of the buttons. There are three possible positions for the consent key. Press lightly (in the center) to consent. Do not press, or press down hard (in situations of panic) to enable the Off function. Movements of the robot, and of the peripheral unit controlled by the robot, are possible in set- up mode when the safety gate is open by simultaneously pressing the consent key and the respective pushbutton. In this case, the servoaxes move slowly at the corresponding manual moving speed and pneu- matic movements at full speed. Consent key Function Switch contact Not pressed Zero position Off (open) Pressed Consent On (closed) Pressed hard Panic Off (open) Consent key (on both sides) Emergency stop button Operation 41 Robot consent key pressed on automatic manual switchover Cause Consent key on manual control device was pressed during switcho- ver from automatic to manual mode. The consent key may be stuck without authorization or an electric defect is present. Effect The robot motors are switched off or cannot be switched on. Remedy Ensure that the consent key is not actuated and that electric function is present. Acknowledge the error message. Switch on robot motors. Robot consent key pressed on starting up the control unit Cause Consent key on manual control device was pressed while the control unit was booting. The consent key may be stuck without authorization or an electric defect is present. Effect Robot motors cannot be switched on. Remedy Ensure that the consent key is not actuated and that electric function is present. Acknowledge the error message. Switch on robot motors. Operation 42 Operator Manual - Robot | Version G/11/401/2/21 2.2 Foil keys on the KETOP C100E hand control device The manual control device has 34 function keys which are implemented as foil keys. You can select other function keys directly via the screen. You can modify the default key mappings in the Manual Control Device Editor or robot setup. The functions of the green foil keys can always be used for the active robot. The remaining keys have generic functions and apply to both robots. Key symbol: Key description Function description Motor switch Switch servomotors on and/or off. A slowly flashing LED indicates that the motors are ready to be switched on. Fast flashing indicates an error preventing switching on. Error acknowledge- ment Deleting the error messages displayed. The display automatically switches to the Alarm screen. Movement to Home position Starts the normal position run in the manual and/or set-up mode. The key must remain pressed until reaching the normal position, otherwise the sequence stops. The movement to home position is only possible with the motors switched on. Referencing The pushbutton is for autoaxis measure- ment. Step acknowledge- ment Serves the stepwise passing of the instruc- tions in the sequence. With switched-on test mode the consent and step acknowledge- ment key must be pressed at the same time in order to process the instructions. Test mode Switching test mode on/off. Take over Teach instruction Select Teach special instructions Press the button to open a dialog with spe- cial teach instructions in the Sequence Edi- tor and on the hand control device display. Freely configurable keys The key function is configured to reflect the requirements for the current machine. Operation 43 Freely configurable keys The key function is configured to reflect the requirements for the current machine. Freely configurable keys The key function is configured to reflect the requirements for the current machine. Freely configurable keys The key function is configured to reflect the requirements for the current machine. Freely configurable keys The key function is configured to reflect the requirements for the current machine. Freely configurable keys The key function is configured to reflect the requirements for the current machine. C100 Dialog Toggles between the standard screens and the screen for preselecting the function keys. Start action Execute the action for the selected function key on screen. Toggle robot Toggles between robot 1 and robot 2 func- tion keys. The RC2 LED is lit when you tog- gle to robot 2. The functions of the green foil keys can always be used for the active robot. The remaining keys have generic functions and apply to both robots. Move X axis in [+] and [-] direction Movement only possible in manual or setup mode. Move Y axis in [+] and [-] direction Movement only possible in manual or setup mode. Move Z axis in [+] and [-] direction Movement only possible in manual or setup mode. Rotate A axis right [+] and left [-] Movement only possible in manual or setup mode. Key symbol: Key description Function description Y A Operation 44 Operator Manual - Robot | Version G/11/401/2/21 Rotate B axis right [+] and left [-] Movement only possible in manual or setup mode. Swivel C axis down [+] and up [-] Movement only possible in manual or setup mode. Freely configurable keys The key functions are configured to reflect the requirements for the current machine. e.g. for an additional servoaxis. Quick position Robot axes move directly to preset quick position. The quick position pushbutton only works while the consent key is pressed for safety reasons. You must press both keys, otherwise movements will stop. Decrease override Reduces the current speeds for all ser- voaxes by a percentage factor. In manual mode, the manual moving speeds of the respective axes represent the maximum (100%). In automatic mode, the speeds set on the screens represent the maximum (100%). Increase override Increases the current speeds for all ser- voaxes by a percentage factor. In manual mode, the manual moving speeds of the respective axes represent the maximum (100%). In automatic mode, the speeds set on the screens represent the maximum (100%). Key symbol: Key description Function description B C Operation 45 2.3 Screen keys on the KETOP C100E hand control device Screen function keys for machine control are also configured on the hand control device. Press the C100 Dialog foil key to display the keys on screen. Note! Depending on the number of keys, this screen can contain several tabs. Before you can execute a movement, e.g. move barrel out, first select the key for this move- ment on screen. This does not perform an action. The movement occurs when you press the Execute foil key. C100 Dialog key on manual mode device Robot Peripheral unit Info Panel - robot actual values All motors switched on Home position reached Execute key on manual mode device Operation 46 Operator Manual - Robot | Version G/11/401/2/21 2.4 Hand Terminal Function keys KETOP C100E Symbol Key explanation Quality control part request At activated test depositing a depositing of a test part on the test part depositing position occurs. Alarm Change to the alarm page on the C100 display. Suction/Gripper 1 Switching-on and/or -off of the vacuum/compressed air circuit in the manual and/or set-up mode. Suction/Gripper 2 Switching-on and/or -off of the vacuum/compressed air circuit in the manual and/or set-up mode. Switch off -axis Switching-on and/or -off of the demolding axis (X- or Z-axis) for the manual displacement of the axis. Softservo Switching-on and/or -off of the softservo function for the take-off axis. Parking position robot The robot axes move directly to the pre-set park position for end of arm tooling change. The movements will stop if you do not hold the button down. Operation 47 Conveyor-belt Steps the conveyor-belt in the manual and/or set-up mode. Symbol Key explanation Operation 48 Operator Manual - Robot | Version G/11/401/2/21 3 Free pushbuttons Free pushbuttons F1 to F8 can be configured on the machine's control panel or the robot's manual control device. Pressing a pushbutton sets the corresponding marker; repeated press- ing resets it. Example: Free pushbuttons F1 and F2 on the machine's control panel configured In the robot sequence you can query whether the pushbutton has been pressed or the push- button marker has been set. In addition, you can set the marker of the free pushbutton with the Assign structure instruction. Additional parameters for the free pushbuttons are available in the robot setup. Example: Set the Free pushbutton 1 - marker to TRUE withthe Assignment structure instruction. 1. In the Instructions selection window, select the Assignment structure instruction and insert this into the sequence at the desired position. 2. The Assignment dialog box will appear. 3. Press Selection. Cancel Execute Help variable value Assignment Choice: No condition Operation 49 4. The following dialog box appears. 5. Select the desired marker and accept with Execute. 6. Click on No condition and set the condition TRUE. 7. Use the Execute menu button to insert the assignment into the sequence. Example: Query the condition of the marker of free pushbutton 1 with the IF structure instruction. 1. In the Instructions selection window, select the IF structure instruction and insert this into the sequence at the desired position. Cancel Execute Help variable Create Free pushbutton Marker Robot Peripheral unit Free pushbutton 1 - marker Free pushbutton 2 - marker Free pushbutton 3 - marker Free pushbutton 4 - marker Free pushbutton 5 - marker Choice: Free pushbutton 6 - marker Free pushbutton 7 - marker Free pushbutton 8 - marker Cancel Execute Help variable value Assignment Choice: No condition Cancel Execute Help variable value Assignment Free pushbutton 1 - TRUE Operation 50 Operator Manual - Robot | Version G/11/401/2/21 2. The Condition editor dialog box will appear. 3. Set the type to User marker. 4. Choose the Element selection box. 5. The following dialog box appears. Display on screen page Condition editor - If Cancel Execute Help Type Element Choice DEL. CLR TRUE FALSE Number Selection of type Linkage (optional) Selection of vari- Text Cancel Execute Help variable Create actuated Free pushbutton Free pushbutton 1 Marker Free pushbutton 2 Free pushbutton 3 Free pushbutton 4 Free pushbutton 5 Choice: Free pushbutton 6 Free pushbutton 7 Free pushbutton 8 Peripheral unit Robot sequence Operation 51 6. Select the marker of free pushbutton 1 and accept with Execute. 7. Use the Execute menu button to insert the condition into the sequence. Display on screen page Condition editor - If Cancel Execute Help Type Element DEL. CLR TRUE FALSE Number Selection of type Linkage (optional) Selection of vari- Text Free pushbutton 1 - marker Operation 52 Operator Manual - Robot | Version G/11/401/2/21 4 Screen structure The clearly laid out touchscreen of the control unit enables simple and fast setting of the plant. 4.1 Top line [1] Machine number [2] Page title [3] User name [4] User accesss authorization [5] Date/time 4.2 Screen page selection and function keys For user-friendly operation, the following screen page selections and function keys are avail- able: Note! In the following description, note that the screen selection keys in the screenshots may differ from the screens on your control unit. Info Panel - robot actual values 1 2 3 4 5 Quick Setup Quick Setup, General settings, Status page, ... Sprue separation Sprue deposit Intermediate layers, Previous entry, ... Grid editor, work area setup, robot setup, ... Integrated robot interface Screen Switchover between robot and machine Take-off Depositing, Grid Reject deposit Quality Control part depositing Robot program switches, ... Back to a previous selection Machine and robot sequence Setup Help Alarm page Scroll keys (faded if not required) Mold parameters, notepad Data dialog Print Mask editor Cycle time analysis, Weekly time switch Operation 53 4.3 Status display The first line shows current messages, warnings and alarms during operation. The number to the right of the message indicates the total number of current messages. All the messages are also displayed on the alarms screen. The second line shows possible operating states. Colored symbols are active, dimmed ones are inactive. [1] Line for messages and alarms [2] Machine motor status symbol [3] Robot motor status symbol [4] Heater status symbol [5] Data set active; read data set [6] Final backup (not active) [7] Printer (inactive) [8] Network access (inactive) [9] operating modes A colored highlight indicates the current mode of operation. Depending on the access level, different modes of operation can be displayed by clicking on a field. 4.4 Screens The screen pages comprise individual tabs that group related parameters. To give the operator a better overview of the screen pages, the individual tabs on the screen pages can be compacted as follows. Program interruption key 2 4 5 6 7 8 3 9 1 9 9 9 Operation 54 Operator Manual - Robot | Version G/11/401/2/21 Note! In the following description, note that the screen pages in the screenshots may differ from the screens on your control unit. 4.4.1 Info Panel The following tab is always at the top of every screen page. [1] Buttons for switching over between the info panel of the injection molding machine, robot and optional additional robot. With several robots (e.g. tandem rise systems), the control unit also switches when tog- gling between the Info Panels the screen pages Grid editor and Work area setup for the applicable robot. [2] Actual values of the axes The positions of the servoaxes are displayed in millimeters (mm) or degrees (). The status [ - ] or [ + ] is displayed for the final position of pneumatic rotary and swivel- ing axes. While an axis is moving, [ - ] start or [ + ] start is displayed. If no final posi- tion is reached, [ 0 ] start is displayed. [3] Override speed The display appears graphically with a bar and as a percentage. Robot main switch Home position movement with parts Equipment type ERC SIP1 or 2 Vertical Robot Robot Info Panel - robot actual values 1 2 3 Data dialog All motors switched on Axes referenced Home position Operation 55 4.4.2 Input field Input fields enable entering or modifying parameters. For example: Changing the value of a parameter 1. Select the parameter input field. 2. The following dialog box appears. 3. Enter the required value and press the enter key to accept. 4.4.3 Program switch Program switches allow you to switch programs and functional units on and off. For example: Deactivating a program switch 1. Selecting program switches. 2. The following dialog box appears. 3. Press the enter key in the preview to accept the switch position shown. Override speed at automatic start active Override at automatic start Speed limitation intermediate deposit Set value Override speed at automatic start active Override at automatic start Speed limitation Preview Switch position OFF Override speed at automatic start active Operation 56 Operator Manual - Robot | Version G/11/401/2/21 4.4.4 Selection field The select fields contain defined settings for selection. Example: Changing the type in the Vacuum/compressed air 1 tab 1. Selecting a selection box. 2. All setting options for the type are displayed. The currently selected type is highlighted in blue. 3. Select the required type. The control unit then applies your setting. 4.4.5 Link in robot sequence The tabs that are allocated to a variant have a Sequence button besides a title. Pressing the button tells the control unit to go to the corresponding variant in the robot sequence. Activated Deactivated in the sequence Vacuum/compressed air 1 Type Part monitoring Analog vacuum monitoring Calibration OFF Vacuum Signal 10 and Activated Deactivated in the sequence Vacuum/compressed air 1 Type Part monitoring Analog vacuum monitoring Calibration OFF Vacuum Vacuum Compressed air barrel Se- Program switch Quality Control depositing Quality Control deposit - 1 Operation 57 4.4.6 Dialog window Separate dialog boxes are available to interact with menu functions that require additional que- ries or entries. The content of the dialog box depends on the menu function and can require various entries; on the other hand, their setup is standardized. Example: Write data 4.4.7 Input keyboard The following input keyboard appears for numeric parameter value input: The Enter key saves the value of the input field if it lies within the range of possible entries. If this is not the case, the input field is highlighted in red and yellow. A virtual keyboard is displayed when parameters are selected that require alphanumeric input. Write active parts data on Available drives Name Description Free memory Required memory C:\5632 C:\231 Cancel Write Help Standard Title Contents Dialog message Instruction keys Includes standard parts data Input field (current value) Display of possible input values (plausibility) Cancel key Cancel Help key Copy key, copies the value from the previous entry to the input field intermediate deposit Set value Increment key (increase value) Decrement key (reduce value) Previous value entered Enter key Operation 58 Operator Manual - Robot | Version G/11/401/2/21 Special keys Parameter input process 1. Log in to the control unit with your user level. 2. Select the desired screen. 3. Press the set value to be changed. 4. Type the value using the input keyboard; the value is displayed in the input field. Check whether your entry is plausible. 5. If you made an error while typing, press the Delete key. You can then enter the correct value. 6. To store the value press the enter key. If the entered value is nevertheless too high or too low, the colors of the plausibility dis- play in the input field change to yellow/red (see the figure below). The control unit dis- cards the value. You need to enter a correct value. 7. To copy an existing value: Select the next set value. Press the copy key in the input dialogue (takes over the previously typed value from the previous entry). Press the enter key to store the value. Highlights the entire text Highlights a portion of the text by activating this key and moving the cursor with the arrow keys Copies the selected text Pastes the copied text Mold number Position intermediate deposit Indicates the plausible range of values. In this example, the range of values lies between 0.0 and 100,0. Position intermediate deposit Operation 59 4.4.8 Tool tip Tapping on short designations, screen flags or actual value displays opens up a tool tip with the corresponding designation or complete text. From user level 11, the control unit copies the internal variable names of the selected screen element into the intermediate storage. Reject deposit - 1 position Program switch reject depositing Reject deposit Speed in depositing area Speed to depositing position Reject depositing posi- Rejects signal Rejects vacuum/compressed air circuits Info Panel Se- Eject reject moldings Reject depositing position Operation 60 Operator Manual - Robot | Version G/11/401/2/21 5 User settings The basic user settings are configured on the Set-up screen page. Settings In the settings, you can specify your desired language, change the date and time, and select the display mode of the units. Language Switching to another screen language. Date/time Use the +or - key to change the setting. Screensaver Time setting after which the screen switches off. Logout when screensaver is active When switched on, log-off also occurs when the user authorization card is inserted. Changes are permitted as of user level 11. Log out when screensaver is active Changes permitted as of user level 11. Units Switching over display format of units. ISO Displays units in metric system Imperial Displays units in imperial system Absolute Displays absolute values Relative Displays relative values (percent) Settings Date/time Language Setup German ISO Absolute Imperial Relative Unit Info Panel Log out when screensaver is active Screensaver 20 min Year 2005 Second: 5 Day: 25 Minute 0 Month 6 Hour: 11 Operation 61 5.1 User login In order to enter or change parameters or settings on the machine, the user must first log in with his/her user authorization. Every user is assigned a language, user name, user level and unit type. The higher the user level, the more access rights the user has. The control unit automatically saves every change made to the machine in the infolog together with the date, time and user name. Logging in and out with the user authorization card on the plant The user data are stored on the user access authorization card. A sensor for logging in with the authorization card is integrated into the control panel. If you hold your authorization card in front of the sensor, you will be logged in. After a time that is set in the control unit, the user is automatically logged out if the control unit is not put into opera- tion. There is also a slot for inserting the authorization card to the left of the sensor. The user is then logged in until the authorization card is removed. [1] User access authorization card slot [2] Sensor Category ISO unit Imperial unit Conversion factors Stroke 100 mm 3,94 in 100 mm x 0.0394 =3.94 in Absolute tempera- ture 100 C 212 F 100 C x 1.8 +32 =212 F Pressure 100 bar 1450.3 psi 100 bar x 14.503 =1450.3 psi Weight 100 g 3.53 oz 100 g x 0.0353 =3.53 oz Weight 100 kg 220.5 lb 100 kg x 2.205 =220.5 lb Force 100 kN 11.24 tf 100 kN x 0.1124 =11.24 tf Volume 100 cm 6.10 in 100 cm x 0.061 =6.10 in Volume 100 l 26.4 gal 100 l x 0.264 =26.4 gal Torque 100 Nm 73.756 lbf ft 100 Nm x 0.7375 =73.75 lbf ft 2 1 Operation 62 Operator Manual - Robot | Version G/11/401/2/21 Log-in by entering password on the Set-up screen page. (Option) To login from the machine using a password: 1. Access the Setup screen page. 2. Select the user from the User drop-down menu. 3. Enter the correct password in the Password field. 4. Login is successful once the user name and number appear in the top-right corner of the screen. 5. Log-off with the [Logoff] key. User level Level Target group Applications 0 Production personnel Operating a preset plant without the ability to modify parameters. 3 Set-up engineer, retooling engineer Additionally parameter changes for stan- dard programs, load and write parts data, Micrograph, 5 Supervisor Additionally parameters and programs, pro- cess data package, Minicam, set value graphics profile points, data dialog, heating optimization. 7 Advanced setup personnel Additionally sequence programming, freely programmable inputs/outputs 9 Technician customer Heating configuration, control parameters, robot sequence with extended condition editor 10 Customer service techni- cian Additional parameters for maintenance pur- poses and service tools for troubleshooting 11 Customer service techni- cian Additionally user administration, machine setup, robot setup, calibration programs, variable changes, read/write machine data, backup flash card, software update from 12 ENGEL service technician Additional functions and settings User login User Password Logout Logout 2 3 Operation 63 On delivery of the device, the following users are created by default: Administrator rights enable the administrator to modify these users and add new users. 5.2 User administration Engel delivers the machine with predefined users. Additional access levels can be created and existing access levels modified. A higher or equal authorization with administrator rights is required for creating and modifying users (right to create further users). 5.2.1 Creating, changing or deleting users User name User level Pass- word Optimization L1 5 p Optimization L2 6 p Teach_L1 7 p Teach_L2 9 p Service_Customer 11 p Administration Logged on Log on New Delete User Local Remote Language Change Cancel Help Unit German German German German German German ISO abso- ISO absolute ISO absolute ISO absolute ISO absolute ISO abso- > User > Administration Configuration Log on Operation 64 Operator Manual - Robot | Version G/11/401/2/21 Press [OK] and close the log-in dialog window with [Cancel]. Changing users Tap on the desired user line and press [Change]. Now you can modify the settings for this user. To accept the settings, the password must be confirmed. Close the log-in dialog window with [Cancel]. Delete user Tap on the desired user line and press [Delete]. Confirm the deletion with [OK]. Close the log-in dialog window with [Cancel]. User Password Confirmation Local Remote Language Unit Administrator Cancel Help Name Password Password Access level on the machine Access level from network to machine Language selection Unit of measurement selection Administrator rights for creating additional us- ers New German ISO absolute New Settings for the new user > OK User > > Administration User > > Administration Delete? Cancel Operation 65 5.2.2 Creating a user authorization card Tap on the desired user line and press [Save]. Cards supplied by ENGEL do not need to be formatted. After confirmation of the dialog, the following message appears: Now touch the card against the sensor. The programming will now start. Close the log-in dialog window with [Cancel]. User > > Administration Log on Log on Logged on Administra- Configurator User Local Remote Language Unit German ISO absolute save to card Format board? Cancel ISO absolute ISO absolute ISO absolute ISO absolute ISO absolute New Delete Change Save Hold card in front of sen- Cancel Operation 66 Operator Manual - Robot | Version G/11/401/2/21 5.2.3 Importing/exporting user data All created user data can be exported and imported into other machines. There is thus no need for the administrator to recreate users on each machine. Insert a USB stick into the port on the control panel. Select the displayed USB drive. Note! To import user data the control unit must be restarted. Switch the plant to manual mode. Insert the USB stick with the saved user data. Same procedure as for Export . However, tap on [Import user data]. Then switch the control voltage off and on. Setup > Export user data > > Operation 67 6 Data dialog The data dialog box is used to save and load data sets on the plant or on external storage media (Compact Flash, USB stick, network). The screen page appears after switching on the control unit and/or after pressing the screen page selection key. [1] Selecting a medium Press the down arrow key to access all possible drive selections. hard disk0 System Flash card usbmassstorage plugged-in USB stick harddisknet Network drive connection [2] Dialog box with settings data sets (project selection) Touch the required selection to display the data attributes on the right side of the screen. [3] Status information Displays status (symbol) and the name of the active set (selection key to display the attributes and the mold image). [4] Data set attributes Displays all the data from the selected project in the selection window. Can be modified depending on user privileges. Name Selectable project file name =file name in selection list Author Name of the creator Production date Change date, author Date and name of the user making the latest changes. \harddisk 0 Author Name Production date Change author Change date Description \harddisk 0 2 Data dialog Active parts data set: 3 Data set attributes 4 ENGEL_ROBOTPART Machine number STANDARD+ROBOT- MASCHINEDATA Info Panel 1 Mold image 5 Parts data Edit Setup 6 View Operation 68 Operator Manual - Robot | Version G/11/401/2/21 Description user defined descriptive text [5] Mold image The image that was saved along with the parts data set is displayed here. Using instruc- tion menu buttons Edit and Mold image , you can load an image with the format *.jpg or *.png and then save it along with the parts data set. [6] Instruction menu keys Parts data using the instructions: Sequence preview, Read, Write, Copy, Copy all, Delete and Injection protocol. Edit using the instructions Delete message and Load mold image. Setup using the instructions: Export user data, Import user data, System flashcard, Software update, License update, Read machine data, Write machine data and Dis- play active machine data. View with the instructiions: Selection window on/off, message window on/off, maxi- mizing/minimizing 6.1 Storage media The following memory cards and adapters have been tested by Engel and are thus guaran- teed to work. Note! Problems may occur if you use other USB devices that have not been tested. If you select a data carrier with insufficient free storage space, the program will cancel the save operation and display a message. The message shows which data carrier is full, along with the last file that was completely stored on the data carrier. USB device Manufacturer Type floppy drive Mitsumi D353GUE Memory stick SanDisk Cruzer Mini USB 2.0 256 MB, Cruzer Micro USB 2.0 512 MB, Cruzer crossfire 1 GB, 2 GB Memory stick Memory Corp Memory Corp MC512USB9 Memory stick PNY Technologies PNY USB 2.0 Flash Drive 1 GB Memory stick E.T. Technologies HUSSAR E.T. Technologies Memory stick Xmore Xmore USB Stick 2 GB Xmore USB Stick 4 GB CF Card devices Manufacturer Type Compact Flash Card Toshiba THNCF1G02DG PC-Card Adapter SanDisk SDCF-03 Operation 69 6.2 Read parts data set A parts data set comprises the sequence data and settings for the machine and robot. The sequence data and machine settings of a parts data set are only visible to access level 11 and above. You can either load the whole parts data set or import only certain data. If you import only a certain part of the parts data, only these will be modified. The other data will remain unchanged. Sequence data In the sequence data only the machine or robot sequence is stored. When you only read in the sequence data, only the sequence changes. Parameters such as speeds, pressures, posi- tions,... do not change. Set values In the setting data all parameters such as speeds, pressures, positions,... are stored. When you only read in the setting data, only these parameters change. The sequence does not change. Procedure for importing a parts data set from a storage medium. 1. Switch the plant to manual mode. 2. Change to the Data dialog screen. 3. Select the storage medium. usbmassstorage.0.0.0\ is a USB memory stick, harddisk0\ is the control unit's internal memory. 4. Select the required parts data set from the list. Display of the information in the window Data set attributes 5. Press Parts data and Read. A window with a clock is displayed. The control unit loads the chosen parts data set and overwrites the current machine setting. The manual control keys of the machine are not active during loading. If the read values cannot be set (plausible), the following message appears: Flash card is full Effect Cancelling save to data carrier. Remedy Select a data carrier with more free space and try to save again. Parts data Set values Injection molding ma- Set values Robot Sequence data Sequence data Operation 70 Operator Manual - Robot | Version G/11/401/2/21 Note! If you read a parts data set from another plant, the following message is displayed: If the imported parts data set does not match the machine, the control unit will switch to Edit operating mode and the following message will appear: Now a message window with advice on troubleshooting will appear on the data dialog screen. If you click on the blue arrow of a message, the screen displaying the problem will appear. The next screen will display advice on how to remedy errors. In the robot sequence movements that are not possible due to the equipment on this machine are displayed with the following symbol. Changing to manual mode is not possible before these instructions are removed. Values corrected Effect Message only Remedy Open the corrected values dialog on the plausibility check screen, and check which values have been corrected. (See Operator Manual - Machine) Acknowledge the message in this window. Unable to load parts data set. Please check the sequence. () Effect Change to Manual mode not possible. Remedy Remedy the error displayed in the message window and change to Manual mode. Cancel Execute Help Test The data set has not been created with this machine Continue anyway? C:MOLD_1 data set not correctly launched Group configuration problem Correction due to missing equipment in the sequence editor Edit Setup View Parts data Unable to load parts data set. Please check the sequence. (project) Operation 71 6.3 Read sequence The sequence is stored as a parts data element. When you load a parts data set, you load the sequence at the same time. Sequence data loading is possible as of user access level 11. Note! Prior to loading a sequence the current parts data must be saved in order for the changes to become effective. Procedure for loading sequence data: 1. Switch the plant to manual mode. 2. Change to the Data dialog screen. 3. Select the sequence data set from the desired parts data set. 4. Press Parts data and Read. If you have modified the current parts data set, the following dialog window will appear. Cancel Cancels the parts data reading Execute Starts the parts data reading. Changes you made which were not saved are lost 5. Selecting Execute will cause a window to appear. When the window disappears, parts data import has been completed. 6.4 Write a parts data set When writing the parts data set, you can only save the entire parts data set. It is not possible to, for example, save only the settings data of the plant. Author Name Production date Change author Change date Data set attributes Active parts data set: Injection mold- Data dialog MOLD_3 System name Info Panel Sequence Set values MOLD_1 MOLD_1 User 11 User 11 MOLD_1 MOLD_3 Robot MOLD_2 Changed data will be lost! Execute Cancel Help STANDARD+COREFIX Read Process is running, please wait Operation 72 Operator Manual - Robot | Version G/11/401/2/21 Procedure for storing an active parts data set on a storage medium. 1. Select the active parts data set with the key at the top right of the screen. 2. Enter name and information in the Data set attributes window. 3. Select the storage medium. usbmassstorage.0.0.0\ is a USB memory stick, harddisk0\ is the control unit's internal memory. 4. Press Parts data and Write. The following window is displayed 5. Change the set attributes, when necessary, and confirm with Write. The control unit stores the parts data set on the selected drive. 6. If a data set with the same name already exists on the data carrier, the dialog window Overwrite ?? is displayed. If YES, press Execute. 6.5 Writing parts data sets with machine or robot data only As of access level 11 users can optionally write a parts data set that contains only the machine or robot data. Procedure for storing an active parts data set with robot data only: 1. Set access level 11. 2. Select the active parts data set with the key at the top right of the screen. 3. Enter name and information in the Data set attributes window. 4. Select the storage medium. usbmassstorage.0.0.0\ is a USB memory stick, harddisk0\ is the control unit's internal memory. 5. Press Parts data and Write. The following window is displayed Write active parts data on Available drives Name Description Free memory Required memory C:\5632 C:\231 Cancel Write Help Parts data Write active parts data on Available drives Name Description Free memory Required memory C:\5632 C:\231 Cancel Write Help Mold _1 Parts data injection molding machine Parts data robot Operation 73 6. SelectParts data robot 7. Change the set attributes, when necessary, and confirm with Write. The control unit stores the parts data set on the selected drive. 8. If a data set with the same name already exists on the data carrier, the dialog window Overwrite ?? is displayed. If YES, press Execute. 9. In the selection window, a parts data set containing just the robot data appears. 6.6 Copy parts data set Procedure when copying a parts data set to another data carrier. 1. Select the storage medium (usbmassstorage.0.0.0\ is a USB memory stick). 2. Press to select a Settings data set from the list. 3. Press the Parts data and Copy menu key. A window is displayed, with drive option, name proposal and description. 4. Choose a drive and enter requested changes. 5. Press Copy. 6.7 Parts data set - Copy all Procedure for copying all data sets on a storage medium to another storage medium 1. Press the Parts data and Copy all menu buttons The following dialog box appears. 2. Select the Source drive and the Aim drive to which you will be copying the data sets. 3. Press Execute to start the copying process. 4. The dialog box disappears once the copying process has been completed. If you attempt to copy a data set from the source drive that has the same name as an existing data set on the aim drive, the following message appears: MOLD_1 Robot Copy 1 of training 4 Parts data set for training Cancel Help Copy Name Available drives Description Copy chosen parts data on Free memory C:\5632 Copy all data sets Source drive Aim drive hard disk0 usbmassstorage.0.0.0 Cancel Execute Help Operation 74 Operator Manual - Robot | Version G/11/401/2/21 Cancel This data set will not be copied to the aim drive. Continuing copying other data sets. Execute The data set on the aim drive will be overwritten by the data set on the source disk. 6.8 Delete parts data set Procedure when deleting a data set (from user level 5): 1. From the selection window, choose the drive that contains the data set. 2. From the directory list, select the data set. 3. Press Parts data and Delete. The following data dialog box is displayed Really delete data set? with the name of the selected data set. 4. By confirming with the Execute key, the data set is deleted. Cancel Execute Help Overwrite? .Standard sequence Operation 75 6.9 Export injection protocol The export function gives you the ability to export the settings data and machine and robot sequences in various file formats. You can export to the following file formats: CSV for e.g. Excel TXT for e.g. Word HTML for e.g. Internet Explorer Exporting machine and robot sequences is only possible in HTML file format The sequences are additionally saved as PNG images. Example: Follow these steps to export the settings data for the machine. 1. Press the Parts data and Injection protocol keys. The following dialog box appears: 2. In the dialog box, select the screens you wish to export. To select all screens, press Select all. To remove the selection, press Delete. To export the machine and robot sequence, activate the matching screen switches. Delete OK Help Cancel Production Mold close Mold height Freely programmable in/outputs All Mold opening Sprue ejector Composeable page 0 of 34 selected Ejector Machine sequence Export Robot sequence Operation 76 Operator Manual - Robot | Version G/11/401/2/21 3. Select the screens for the protocol, and press OK to continue. The following dialog box appears. 4. Select the drive you wish to export to, as well as the file name and the file type. If you selected the machine or robot sequence, you can only select HTML as a file type. The sequences are additionally stored as PNG images with the file name and extension _imm_xxx or _erc_xxx . 5. Press Save to start exporting. The following dialog box appears. 6. A progress indicator appears for the Export process. The dialog is closed after success- fully completing the export. Save Help Cancel Choice: File name: File type: Save Export Cancel Operation 77 7 Cycle time analysis robot This overview shows the individual time components of the complete cycle time. You can use the special Cycle time - start and stop instructions in the Robot sequence to per- form three user-defined time measurements. The times are recorded on the Robot cycle time analysis screen. [1] Scroll window to the left [2] Set to full cycle time [3] Magnify and minimize [4] Scroll window to the right The current and last cycle are displayed separately in seconds, and on two-line bar graphics. The top bar shows the current cycle, and the lower line the last cycle. The active function is marked by a screen flag. The total cycle is represented in the area Total time and can be cut at the beginning and at the end with a time for the selected viewing. You can enable a start time display below the View menu key. In switched on state the control unit will then show the time from home position to the start of the movement in question. The message Start point is displayed above the bar diagram for easier identification. Cycle time list robot 1 Cycle time analysis robot Take-off Ejector advance Robot cycle last Ejector retract current Remaining time cy- User Time meter 1 + Info Panel Total time View 1 2 3 4 Operation 78 Operator Manual - Robot | Version G/11/401/2/21 8 operating modes Symbol Mode of opera- tion Function Manual Robot movements are possible in manual mode using the push buttons. In this case, the servoaxes move maximally at the corresponding manual moving speed and pneumatic movements at full speed. Setup Functions as per manual mode. You can only switch to setup mode while you are in manual mode. Teach Sequence set-up and group configuration possi- ble. You can only switch to Teach mode while you are in manual mode. Semi-automatic If the machine is in home position, the machine will perform a cycle when you press the start button. Semi-automatic Mode of operation Semi-automatic selected and program interruption switch actuated. No automatic operation possible. Functions as per manual mode. Fully automatic If the machine is in home position, the machine will perform cycles when you press the start but- ton until automatic mode is interrupted. Fully automatic Mode of operation Fully-automatic selected and program interruption switch actuated. No automatic operation possible. Functions as per manual mode. Edit If the imported parts data set does not match the machine, the control unit will switch to Edit operating mode and a message window will appear with notes on troubleshooting. Operation 79 9 Robot Operations CAUTION! Danger of damage to equipment! Incorrect settings can lead to problems with or damage to the equipment, so care must be taken during the setup and operation of the machine. Settings must be compatible to the function of the machine, mold, material and peripheral units. 9.1 Start up WARNING! Danger of crushing due to pneumatic movements! Compressed air build-up can cause uncontrolled movements of pneumatically operated components. Make sure the danger area is free of persons. Procedure: 1. Check that no people are inside the safety guarding of the machine. 2. Close the safety gates. 3. Switch on the main switch and the control voltage. 4. After start up of control unit switch on compressed air at the maintenance unit; operating pressure 0.6 MPa (6 bar) (87 psi). 5. For the functions of the safety equipment please refer to the chapter Safety. 6. Open - close protection door and acknowledge within 5 seconds using the key-operated switch. 7. Log in to the plant with a user authorization. 8. Select screen Alarms. 9. Check and, if necessary, eliminate the alarms. 10. Switch the robot motors on form the hand terminal or the injection molding machine con- trol panel. 11. If the safety gates are not closed, appears the message: Robot motors switched off Cause The robot motors are not yet switched on or have been switched off by the appearance of an alarm (see alarms on the screen). Effect Prevents switchover to automatic mode Operation 80 Operator Manual - Robot | Version G/11/401/2/21 Activate robot set-up mode Robot motor in the set-up mode only from level 5 Effect Robot motor cannot be switched on. Remedy When you select setup mode, the message Robot setup mode acti- vated appears. Robot motors can only be actuated with the safety gates open in setup mode at user level 5 or higher by holding down the consent key. Robot motors blocked - new start required! Effect Switching the robot motors on is not possible. Remedy Switch the control unit off and back on again. Switching the robot motors on in automatic mode is not pos- sible Cause Robot motors are switched off when an alarm occurs. Remedy Select manual mode and resolve the cause of the alarm. Operation 81 9.2 Putting out of operation The following shutdown procedure refers to the robot only. When shutting down the injection molding machine and the peripheral units, additionally con- sider the following. See corresponding operating manuals. WARNING! Danger of crushing due to moving components on the machine! When shutting down the plant, move all moving components (e.g. robot axes) to a safe position. For example, move the robot to the depositing area and remove the take-off/ insert parts from the end of arm tooling. Swivel the end of arm tooling down so that it cannot swivel down on its own if pressure is lost. Procedure if the machine is in automatic mode 1. Select semi-automatic mode. 2. Once the machine has completed the cycle, switch to manual mode. 3. Move the robot to the depositing position. 4. Deposit any parts on the end of arm tooling. 5. Move the robot to a safe position. 6. Switch off the robot motor. 7. Switch off control voltage. 8. Switch off main switch. 9. Switch off the compressed air on the maintenance unit. Procedure if the machine is in manual mode 1. Move the robot to the depositing position. 2. Deposit any parts on the end of arm tooling. 3. Move the robot to a safe position. 4. Switch off the robot motor. 5. Switch off control voltage. 6. Switch off main switch. 7. Switch off the compressed air on the maintenance unit. Operation 82 Operator Manual - Robot | Version G/11/401/2/21 Basic setting 83 Basic setting The standard pages are used for convenient robot operations, and for fast setting up of prede- fined sequence variants. 1 Quick Setup This page contains basic settings and functions of the robot, such as work area settings, tur- ning limits, swivelling limits, moving limits, group and individual configurations for vacuum/ compressed air. CAUTION! Danger of collision between robots, machine and peripheral units! You must perform the settings on the Quick Setup page immediately after mounting the mold. To do this, mount the end-of-arm tooling that matches the mold. Work area settings When commissioning the machine, or when you use a new mold, you must set the spatial data for the Machine, Take-off and Depositing areas. Machine area The machine area is the whole area theoretically accessible by the robot within the injection molding machine. The machine area defines the whole prohibited area for the plant and is set as a factory default. The robot cannot move in the prohibited area, except in the preset take-off/removal area when the mold is open. For the Max Z machine area, you must set a value that extends beyond the safety gate for half the length of the mold fixing platen, as the end-of-arm tooling is normally not big- ger than the mold fixing platen. This prevents collision between the safety gate and the takeover area in the depositing area. Take-off area Work area in machine area for part take-off. To access a mold without danger of colli- sion, a take-off area must be defined for each mold. This must be determined with a completely open mold. Never set values for the take-off area that cause danger of colli- sion for the mold! The take-off area is thus a mold-driven traversing area for the robot when the mold is open, and lies within the machine area. This area must be modified for each new mold you use. Quick Setup Machine area Take-off area Depositing area Z+ Min Max Min Max Min Max Work area settings Info Panel Work area setting okay Basic setting 84 Operator Manual - Robot | Version G/11/401/2/21 Depositing area Z+ Setting the work space depositing area Z+limits the maximum depositing area on the non-operator side to reflect the preset parameters. Limiting the depositing area helps to safeguard the whole depositing area with just a few work areas. Example: 3D view of the robot work areas with depositing on non-operator side [1] Work area depositing area Z+ [2] Machine area (=Blocking area clamping unit) [3] Take-off area Note! To avoid collisions with the robot, you must define the work areas and prohibited areas for the take-off/removal and depositing areas in the work area setup. 2 3 1 Basic setting 85 Turning, swivelling and moving limits (ENGEL sequences) These are Y positions where rotary axes movements are allowed to start or must be completed These limits only apply in automatic mode. CAUTION! Danger of collision between robots, machine and peripheral units! The turning, swiveling and moving limits apply to standard sequences defined by Engel. They do not apply to Engel teach sample sequences and depending on the way the sequence is setup, they may not apply for user-defined sequences. Y-position when moving out/in Z Maximum Y position at Vertical take-off when moving the Z-axis out from the machine area. The setting for the position of the Vertical closing safety increases the input area. Upper - lower swivelling limit depositing area Y positions in the depositing area within which the manual axes may move. Example: Robot with non-operator side depositing. Y-position when moving out/in Z Upper swivelling limit depositing area Lower swivelling limit depositing area Turning, swivelling and moving limits (ENGEL sequences) Depositing area Z+ Machine area Y-position when mov- ing out/in Z Upper swivelling limit depositing area Lower swivelling limit depositing area Basic setting 86 Operator Manual - Robot | Version G/11/401/2/21 Rotary axes moving out to deposit (ENGEL sequences) Position of rotary axes on move over machine area in depositing direction. Settings are only effective in automatic mode. CAUTION! Danger of collision between robots, machine and peripheral units! The rotary axes settings for moving into and out of the machine area apply to standard sequences defined by Engel. They do not apply to Engel teach sample sequences and depending on the way the sequence is setup, they may not apply for user-defined sequences. Rotary axes movements in machine area Selection whether and/or from when rotary axes movements are allowed in the machine area. No rotary axes movements in machine area Before moving out Z In parallel to Z moving-out Rotary axes positions moving out Z from machine area Defines the final position of the rotary axes for moving out Z. Rotary axes priority when moving out Defines the order of the rotary axes movement. When several axes are given the priority 1 the movements occur in parallel. Rotary axes movements to depositing from Corresponding to the selection Upper swivelling limit depositing area and/or Machine area max. , rotary axes may start their movement in parallel to the linear axes. The Y-axis waits until the manual axes have reached their final position on the lower swivelling limit depositing area and continues the movement only then. Rotary axes moving into take off (ENGEL sequences) Position of rotary axes on move over machine area in depositing direction. Settings are only effective in automatic mode. Rotary axes position for Z-movement into machine area Defines the final position of the rotary axes for Z moving in. Rotary axes priority when moving in Defines the order of the rotary axes movement. When several axes are given the priority 1 the movements occur in parallel. Rotary axes positions Rotary axes priority when moving out Rotary axes movements to depositing from Rotary axes moving out to deposit (ENGEL sequences) Rotary axes movements in machine area No rotary axes movements Upper swivelling limit deposit- Rotary axes moving into take off (ENGEL sequences) Rotary axes priority when moving in Rotary axes movements after depositing - up to Rotary axes position for Upper swivelling limit deposit- Basic setting 87 Rotary axes movements after depositing - up to When moving out from the deposit the rotary axes start moving, from the lower swivel- ling limit, in parallel to the linear axes. The rotaryl axes movement must be finished up to the adjustable selection Upper swi- velling limit depositing area, Machine area max. and/or Position before opening. Linear axis movement waits on the set position if rotary axes movement is not comple- ted. 1.1 Group configuration The group configuration serves to summarize individual vacuum/compressed air circuits in groups. Using the command Group vacuum/compressed air , several vacuum/compressed air circuits can be switched on/off with just one command. You can only configure the group in Teach mode. When you press the quick select key for the group in question, the group configuration dialog appears. Using the navigational arrows <<< and >>> you can move the complete content from Avail- able elements to Selected elements and vice-versa. You can select an individual vacuum/compressed air circuit, and move it using the navigational arrows < and > to insert it into Selected elements in the desired order. Example: Configure two vacuum/compressed air circuits for take-off. 1. To configure vacuum/compressed air circuits, you must first change to Teach mode. 2. Press the appropriate button on the Quick Setup screen for Take-off vacuum/com- pressed air circuits screen. Depositing vacuum/compressed air circuits Group configuration Take-off vacuum/compressed air circuits Cancel Execute Help Group configuration - Take-off vacuum/compressed air circuits Vacuum/compressed air 3 Vacuum/compressed air 2 Vacuum/compressed air 1 Available elements Selected elements Depositing vacuum/compressed air circuits Group configuration Take-off vacuum/compressed air circuits Basic setting 88 Operator Manual - Robot | Version G/11/401/2/21 3. Use the >>> button to move the vacuum/compressed air circuits to Selected elements. 4. Use Execute to store the current configuration. 5. This completes the vacuum/compressed air circuit configuration. Group configuration - Vacuum/compressed air circuits Vacuum/compressed air Vacuum/compressed air Available elements Selected elements Cancel Execute Help Group configuration - Vacuum/compressed air circuits Vacuum/compressed air Vacuum/compressed air Available elements Selected elements Cancel Execute Help Basic setting 89 1.2 Vacuum/compressed air circuits Vacuum/compressed air circuits are used to actuate pneumatic components, such as suction pads, grippers and barrels. A strip is available for each vacuum/compressed air circuit in Quick Setup. The following vac- uum/compressed air circuits are possible, depending on the version of the robot pneumatics: Vacuum/compressed air Block the vacuum circuit with a hand-actuated directional control valve if the vacuum/ compressed air circuit is used solely as a compressed air circuit. When a part is picked up by finger grippers with compressed air supply, and assuming parts monitoring is active, it is necessary to shut-off the vacuum circuit manually. The reason for this is that the vacuum monitor of vacuum/compressed air circuits is con- nected to the same input as the limit switch for parts monitoring on the finger gripper. In other words: If the vacuum circuit is not shut off, the vacuum monitor will continually sig- nal that it has built up a vacuum (=part picked up). Vacuum/Blowing/Compressed air Switchover between vacuum and compressed air is by means of an electrically actu- ated directional control valve. Vacuum Compressed air Dedicated instructions are available in the sequence for the vacuum/compressed air circuits. Vacuum/blow/compressed air with vacuum type setting Activated The program switch activates vacuum/compressed air circuit x. Vacuum circuit switched on ON Vacuum circuit shut OFF Activated Type Part monitoring Analog vacuum monitoring Vacuum Signal 10 and Vacuum/Blowing/Compressed air x Deactivated in the sequence Calibration OFF ON Blow function deactivated Blowing time Basic setting 90 Operator Manual - Robot | Version G/11/401/2/21 Deactivated in the sequence This flag indicates that the equipment is active. Type The settings Vacuum, Compressed air or Barrel are available in the selection field type for the vacuum/compressed air circuits. Depending on the type settings, the para- meters for the end positions, parts and vacuum monitoring are shown. Part monitoring Program switch activates monitoring. If the program switch is deactivated, monitoring for with monitoring instructions in the sequence does not occur. Signal 1 0 and Monitoring of part existing and part not existing. Signal 1 Monitoring of part existing. Blow function deactivated The blow function is only available with vacuum/blow/compressed air circuits. Please note that the blow function works for each Vacuum,, Compressed air or Barrel type. Blowing time The set time switches the vacuum/blow/compressed air circuit to blow after the circuit is switched off. This means that e. g. molded parts can be more easily removed from the end of arm tooling. Analog vacuum monitoring The control unit detects whether e. g. a part is in the end of arm tooling by monitoring the pressure in the vacuum circuit. OFF If the vacuum drops below the OFF value, then the control unit does not detect a part in the end of arm tooling. ON If the vacuum reaches the ON value, then the control unit detects a part in the end of arm tooling. Actual value display flag An active flag shows that a part is in the end of arm tooling. Calibration Switch offsuction pad ; actual value display should show 0 bar (0 psi). If this is not the case, calibrate the vacuum circuit with calibrate program switch =zero point determi- nation. Vacuum/compressed air circuit with compressed air type setting Final positions monitoring Program switch activates monitoring. Activated Type Final positions monitoring Part monitoring Compressed air Input- Signal 10 and Vacuum/compressed air x Deactivated in the sequence Basic setting 91 If the program switch is deactivated, monitoring for with monitoring instructions in the sequence does not occur. Input - and input + Monitoring of both final positions of a barrel. Input - Monitoring of - final position e.g. sprue cutter open. Part monitoring Program switch activates monitoring. If the program switch is deactivated, monitoring for with monitoring instructions in the sequence does not occur. The part monitoring setting depends on the selected type. Signal 1 0 and Monitoring of part existing and part not existing. Signal 1 Monitoring of part existing. Vacuum/compressed air circuit with barrel type setting Final positions monitoring Program switch activates monitoring. If the program switch is deactivated, monitoring for with monitoring instructions in the sequence does not occur. Input - and input + Monitoring of both final positions of a barrel. Input - Monitoring of - final position e.g. sprue cutter open. Activated Type Final positions monitoring barrel Input Vacuum/compressed air x Deactivated in the sequence Basic setting 92 Operator Manual - Robot | Version G/11/401/2/21 1.2.1 Vacuum economy mode Fr die Erzeugung von Druckluft bzw. Vakuum ist ein hoher Energieaufwand notwendig. Mit Hilfe der Vakuum Sparschaltung kann dieser Energieaufwand minimiert werden. Die Vakuum Sparschaltung ist nicht mit einer standard Pneumatikausfhrung mglich. Saving circuit Program switch enables or disables the economy mode. Deactivate the economy mode when using a vacuum/compressed air circuit solely as a compressed air circuit. Vacuum economy mode function: 1. Vacuum on =Part sucked onto end of arm tooling. 2. After the vacuum is fully formed, a valve switches the vacuum supply off and a non- return valve seals the vacuum in between the molded part and the non-return valve. 3. If the sealed-in vacuum falls below the value set in Analog vacuum monitoring ON on the screen page Quick Setup , the vacuum will be switched on again. But the Mimi- mum time for switching back on must first elapse. If the Minimum time for switching back on is not reached, excessive leakage is occur- ring in the vacuum circuit. This problem may be solved by deactivating the economy mode. 4. Points 2 and 3 repeat until the vacuum is switched off (=parts deposit). Switching diagram Activated Type Part monitoring Vacuum Signal 10 and Vacuum/compressed air x economy mode Deactivated in the sequence Analog vacuum monitoring Calibration OFF ON Saving circuit Mimimum time for switch- ing back on Vacuum Off Vacuum On P r e s s u r e Time Monitoring On - 0.6 bar Monitoring Off - 0.5 bar No pressure change (vacuum switch-off time) Basic setting 93 1.3 Depositing conveyor-belt The conveyor-belt transports the deposited molded parts out of the depositing area. Depositing conveyor-belt configurations: Depositing conveyor-belt with/without clearing switch and one moving direction. Depositing conveyor-belt with/without clearing switch and reversing operation. Depositing conveyor-belt with/without clearing switch, one moving direction, quality control parts and reject molding separation. Depositing conveyor-belt with/without clearing switch, reversing operation, quality con- trol parts and reject molding separation. Note! Instructions are available in the robot sequence for the depositing conveyor-belt. 1.3.1 Standard depositing conveyor-belt A standard depositing conveyor-belt can only transport molded parts in one direction. Depositing conveyor-belt - Cycle when all selected grids are full If all configured grids are full, the conveyor-belt runs for the preset time. Furthermore, you can continue to cycle the conveyor belt in manual or setup mode using the Con- veyor belt button on the hand terminal. If the conveyor belt has continued to cycle the set running time, the robot will restart depositing in the grid in the next cycle. When you press the Quick select key, the Group configuration dialog box appears so that you can configure the grids used (default setting: shot grid 1). This is only possible in Teach mode . If, e. g. the subsequence Part depositing in individual part grid 1 with conveyor belt is Depositing conveyor-belt - Running time Depositing conveyor-belt x Depositing conveyor-belt - Cycle when all selected grids are full Conveyor-belt Cancel Execute Help Shot grid 2 Shot grid 1 Available elements Selected elements Group configuration - depositing conveyor belt 1 - cycle when all selected grid po- Shot grid 3 Individual part grid 1 Individual part grid 2 Individual part grid 3 Teach grid 1 Teach grid 2 Basic setting 94 Operator Manual - Robot | Version G/11/401/2/21 inserted in the robot sequence, you must configure individual part grid 1 in the group configuration dialog. If the wrong grid is configured, the conveyor belt will not cycle, and the automatic cycle is interrupted. Depositing conveyor-belt - Running time Running time for the depositing conveyor-belt. The running time starts when the grid is full (last part deposited). After the conveyor-belt cycle the grid is reset. 1.3.2 Depositing conveyor-belt with reversing operation Reversing operation enables transport of molded parts in both directions. Depositing conveyor-belt with reversing operation Depositing conveyor belt - forwards running time Running time for depositing conveyor-belt in forwards direction. The flag indicates if the conveyor-belt is active. Depositing conveyor belt - backwards running time Running time for depositing conveyor-belt in backwards direction. The flag indicates if the conveyor-belt is active. 1.3.3 Depositing conveyor-belt quality control parts and reject molding sepa- ration Separate runtimes for the conveyor-belt can be set for the separation of quality control parts and reject moldings. Depositing conveyor-belt with reversing operation, quality control parts and reject molding separation Grid - full - depositing not possible Cause The robot was unable to deposit the parts in the grid because the conveyor belt has not been cycled. Effect Interrupting automatic cycle. Remedy Check the grids configured for the depositing conveyor belt. Depositing conveyor belt - forwards running time Depositing conveyor-belt x Depositing conveyor-belt - Cycle when all selected grids are full Depositing conveyor belt - backwards running time Depositing conveyor belt - forwards running time Depositing conveyor-belt x Depositing conveyor-belt - Cycle when all selected grids are full Depositing conveyor belt - backwards running time Depositing conveyor belt - runtime for reject molding Depositing conveyor belt - runtime for quality control part Basic setting 95 Depositing conveyor belt - runtime for reject molding Time the conveyor-belt continues to run backwards and forwards again after depositing a molded part. The conveyor-belt thereby returns to the starting position. The flag indi- cates if the conveyor-belt is active. When using a conveyor-belt with one moving direction, the conveyor-belt runs forwards for the set runtime. Depositing conveyor-belt - Runtime for quality control part Time the conveyor-belt continues to run backwards and forwards again after depositing a quality control part. The conveyor-belt thereby returns to the starting position. The flag indicates if the conveyor-belt is active. When using a conveyor-belt with one moving direction, the conveyor-belt runs forwards for the set runtime. 1.3.4 Clearing mechanism for clearing conveyor-belt The clearing mechanism is used to clear parts in an orderly manner, instead of dropping deposited parts off the clearing conveyor-belt into a box. The clearing mechanism comprises a switch and a light beam guard fitted at the end of the conveyor-belt. Pressing the switch in manual mode causes the conveyor-belt to move. When the light beam guard end position occupied is interrupted by a part, the conveyor-belt stops until the part has been cleared. If the switch is enabled, the conveyor-belt stops when the start button is pressed in automatic mode. The conveyor-belt is stepped based on the clearing conveyor-belt settings. When the light beam guard end position occupied is interrupted, the conveyor-belt stops until the part has been cleared. Additionally, the robot waits before depositing the next part until the conveyor-belt has completed a cycle. After switching from automatic to manual mode while the clearing switch is activated, you must turn the switch off and back on to allow the conveyor-belt to run. The robot setup includes configured inputs for the clearing mechanism. 2 General settings This page includes basic settings and functions of the robot. 2.1 Speed limitation If the program switch is enabled, all servoaxes move with the preset Override for automatic start speed after every restart. This function avoids the need for operators to set the override speed manually at the manual control unit. You can set the override speed at any time in automatic mode using the Increase override or Reduce override pushbuttons on the manual control unit. Clearing br14_043 Clearing switch Light beam guard final posi- tion occupied Basic setting 96 Operator Manual - Robot | Version G/11/401/2/21 2.2 Test mode When test mode is activated, you can step through the instructions in the sequence, e. g. to test the sequence step by step after changing the sequence. Test mode is activated by Modification of the robot sequence and subsequent quitting of teach mode. Press the Test mode key on the manual control device. Pressing the Test mode key again deactivates test mode. Test mode can be activated at any point in the sequence in automatic mode. Servoaxis move- ments that have started will be completed to position. If you then press the consent key, and keep it pressed, you can use the acknowledge step but- ton to start the next instruction. If the system is in manual mode when you enable test mode, you must first switch to automatic mode, and then press the start key. You can then step through the instructions in the sequence. To do so, you must press the Acknowledge step button on the manual control device along with the consent key. When you release the consent key, all servoaxis movements are stopped, and you need to press the consent key again to continue. All servoaxes move at the preset test mode speed at the maximum. Robot too small speed defined, set to Cause Set speed is too low for displayed movement. Effect Robot does not move. Remedy Increase speed for the displayed movement + Override speed at automatic start active Override at automatic start Speed limitation General settings Info Panel Test mode Step acknowledgement Basic setting 97 CAUTION! Danger of damage to equipment! A pneumatic axis or function that has already started will not stop when you re- lease the consent key. Test mode speed Maximum servoaxis speed in test mode. + Test mode active Test mode speed Test mode Basic setting 98 Operator Manual - Robot | Version G/11/401/2/21 2.3 Home position The home position is the position the robot occupies at the start of an automatic cycle. CAUTION! Danger of damage to equipment! Set the home position sequence and the home position parameters to avoid col- lisions between the robot, the machine and the peripheral units Speed to home position Speed of the servoaxes moving to the home position. Home position reached The flag indicates that all axes have reached home position. This can be achieved by moving to home position, but also by positioning the axes indi- vidually. The order in which the robot moves the axes to the home position is set in the home position sequence. Example: Home position sequence Speed to home position Home position reached Home position Home position + + Home position Robot sequence Home position from depositing area Home position - Standard sequence Info Panel Home position Extended view Home position from take- Basic setting 99 Move robot manually to home position Hold down the button Movement to home position on the hand control device or the control panel of the injection molding machine until the robot has reached the home position. If the robot is not at home position on starting an automatic cycle, the following message is dis- played: Move robot automatically to home position Enabling the following program switches on the Robot program switches screen page auto- matically moves the robot to home position in automatic mode when the start key is pressed. Movement to home position from machine area upon automatic start Movement to home position from depositing area upon automatic start Movement to home position enabled Cause On switching to automatic operating mode, the home position key was pressed, but the home position was not reached. Effect Switchover to automatic mode not possible. Remedy Execution of the home position run until the position is reached com- pletely. Robot not in Home position Effect Automatic operations with machine not possible. Remedy Move the robot to home position. Movement to Home position Basic setting 100 Operator Manual - Robot | Version G/11/401/2/21 2.4 Quick positioning The program is used for faster positioning of the robot at a predefined position. CAUTION! Danger of collision between robots, machine and peripheral units! If quick positioning is set, the robot moves directly to the quick position. It must therefore be ensured that no obstacles are located between the start and target positions. Quick position You can move to the preset position by pressing the Quick position key on the hand ter- minal while at the same time pressing the consent key. Speed to Quick position Speed of the servoaxes moving to the quick position. Position reached The active marker signals that the preset quick position has been reached. Quickpos still active Cause On switching to automatic operating mode, the quick position key was pressed, but the quick position was not reached. Effect Switchover to automatic mode not possible. Remedy Perform quick position move until the position is fully reached. Quick position Speed to Quick position Position reached Quick positioning + Quick position Basic setting 101 2.5 Quick setting of robot position For all position input fields (e.g.: home position, take-off position, ...) there is a quick set key on screen. The QuickSet/QuickPos dialog appears when you press the button. QuickPos Serves to specify the current positions for the selected robot axes as the Quick position on the General settings screen. QuickSet Used to for quick collection of position information for the selected robot axes at the cur- rent position. Example: Apply current values for the robot axes for Position before opening. 1. Select the take-off screen. 2. Press the quick set key for Position before opening. 3. Select QuickSet and All axes. All axes Cancel Execute Help QuickSet QuickPos Axes QuickSet/QuickPos Position before opening - Speed to position before opening All axes Cancel Execute Help QuickSet QuickPos Axes QuickSet/QuickPos Basic setting 102 Operator Manual - Robot | Version G/11/401/2/21 4. Press Execute to use the current robot axis values as the Position before opening. Example: In manual operations, the robot will stop at Position before opening and should be moved directly to the take-off position. The mold is completely open, and the basis is the simple robot sequence with 2 move-in positions. 1. Select the take-off screen. 2. Press the quick set key for Take-off position - XYZ. 3. Select QuickPos and All axes. 4. Press Execute to assign the take-off position to the quick position. 5. When you press the quick position key on the manual control device, while at the same time pressing the consent key, the robot travels from the Position prior to opening directly to the Position before opening . The robot does not move to the preset moving- in position. Position before opening - Position before opening =Home position Info Panel - robot actual values Speed to position before opening Take-off Take-off speed Time for part removal Waiting time before take-off Take-off position - X Y Z All axes Cancel Execute Help QuickSet QuickPos Axes QuickSet/QuickPos Basic setting 103 Example: Robot sequence diagram [1] Position before opening [2] Moving-in position 1 [3] Moving-in position 2 [4] Take-off position 2 4 3 1 Basic setting 104 Operator Manual - Robot | Version G/11/401/2/21 3 Robot program switches The program switch page includes the most important configuration possibilities for the robot and its sequences. Robot Robot main switch If the program switch is disabled, the control unit ignores all robot sequences. However the robot's position is monitored to ensure closing safety. Home position movement with parts By default, the robot switches all vacuum / compressed air circuits off when beginning movement to the home position. If the program switch is activated, the robot moves to the home position with parts on the end of arm tooling. For example, if the operator interrupts the Automatic cycle before the parts are deposi- ted, the robot deposits the parts during the next automatic cycle. When reject depositing is activated, the robot deposits parts on the reject deposit position and advances the rejects counter on the injection molding machine. One part is subtracted from the good piece counter of the injection molding machine as it was already produced prior to inter- ruption of the cycle. This function is not programmed in the Engel Teach sample sequence. Movement to home position from machine/depositing area upon automatic start When this program switch is activated, the robot automatically moves to home position in automatic mode when the start key is pressed, if the robot is in the machine or depo- siting area. The robot performs the movement to home position as defined in the home position sequence. After reaching home position, the robot processes the robot and user sequence. Before enabling the program switch, make sure that the the robot can move out of all possible situations in these areas without a collision. If needed, modify the home posi- tion sequence. Equipment type The configured safety package and the take-off sequence are displayed here. This field is factory set and is for information purposes only. Robot 1 program switch Robot main switch Home position movement with parts Equipment type ERC SIP1 or 2 Vertical Robot Info Panel Movement to home position from machine area upon automatic start Movement to home position from depositing area upon automatic start Basic setting 105 Take-off movement The following selection fields can be set depending on the plant's construction, the configured safety package and the permitted type of take-off. The selected setting affects the work areas and the standard robot variants (take-off, deposition,...). Allowed take-off movement The allowed take-off movement is preset at the factory. Take-off movement The selection box may contain the following take-off movements: Vertical The robot moves into and out of the mold from above =vertically (e.g.: injection molding machine with tiebars). The closing release for the mold is given when the Y-axis is up or when the position for Vertical closing safety is reached. Horizontal The robot moves into and out of the mold laterally =horizontally (e.g.: tiebarless injection molding machine). Closing release for the mold is given once the robot has left the take-off area (posi- tion for Horizontal closing safety reached or Z position >=home position). Vertically in/Horizontally out The robot will move from the top (vertically) into the mold, and to the side (horizon- tally) out of the mold (can save cycle time, depending on your application). The closing release occurs like at Take-off horizontal. Horizontally in/Vertically out The robot moves into the mold laterally (horizontally) and moves out vertically. The closing release occurs like at Take-off vertical. Depositing on the front side This flag indicates that the robot is designed for the front side depositing. Example: Injection molding machine with robot Vertically and horizontally Vertical Take-off movement Take-off movement Depositing on the front side Allowed take-off movement Vertical take-off Horizontal take off Basic setting 106 Operator Manual - Robot | Version G/11/401/2/21 Robot <-> machine Communication settings between robot and injection molding machine. Production without robot If the program switch is enabled, the robot will complete the current cycle and then wait at its home position. The injection molding machine will then go on producing without the robot, until the switch is disabled. The switch can also be actuated in automatic mode. Robot test run without machine active If the program switch is activated, the robot sequence is started without the injection molding machine sequence when the start key is pressed in semiautomatic or fully auto- matic mode. On the injection molding machine, the mold must be open, the ejector retracted, and any cores moved out. At the test run the mold remains open and the required signals of the cores, ejector etc. are simulated. Eject reject moldings When the program switch is activated, the ejector ejects the reject moldings (therefore also start-up cycles) in the discharge chute when production occurs with the robot. Ejector releases for mold opening Standard setting =enable retract . With this setting, the robot only enables the retrac- tion of the ejector when the mold opens. The following settings are available: enable retract enable advance enable retract to intermediate position enable advance to intermediate position enable block Block movements on the clamping unit at automatic start If the program switch is activated when you switch to semi-automatic or fully automatic mode, all mold, ejector, core movements, and air valve functions are locked. Individual releases must be programmed in the robot sequence. Early start By default, the robot waits until the mold is open before moving into the mold area. If the Early start program switch is activated, the robot moves into the mold area as soon as the early start position is reached. How far the robot moves into the mold area depends on the robot sequence setting. The robot e. g. moves to moving-in position 2 in the mold area with Take-off standard . Robot <-> machine Production without robot Robot test run without machine Block movements on the clamping unit at automatic start Early start Minimum mold position for early start and intermediate stop Early start position Mold open on early start position Take-off with mold intermediate stop Mold intermediate stop position Eject reject moldings Ejector releases for mold opening enable retract Basic setting 107 The robot waits at the moving-in position 2 until the condition Wait until mold open is met. The program switch and the early start position are queried by the Wait for part hando- ver release sequence. Minimum mold position for early start and intermediate stop This mold position limits the early start and intermediate stop position and therefore, is a safety limitation for the mold area. Early start position The robot enters the mold area from this mold position. Mold open on early start position The active flag signals when the early start position is reached. Take-off with mold intermediate stop When this field is selected the mold intermediate stopp is activated. This is possible after inserting the sequenz step Form open at robot start position in the machine sequence. Mold intermediate stop position At this position mold opening stops to allow molded part take-off by the robot. 3.1 Closing safety The settings for the closing safety are used to protect against collisions between the robot and the injection molding machine. The closing safety is divided into a vertical and a horizontal closing release. The Additional closing safety is also available for special applications. Settings closing release Flag indicates that the injection molding machine closing release exists. Vertical closing safety If the robot is at a position smaller than or equal to this set position, then the closing safety of the injection molding machine exists. Robot x test run without machine Cause Program switch Robot test run without machine is activated. Effect In automatic mode no machine movements occur. Remedy Deactivate program switch Robot test run without machine. closing release Vertical closing safety Horizontal closing safety Closing safety Confirmation of setting values Additional closing safety activated Additional closing safety Min Max Basic setting 108 Operator Manual - Robot | Version G/11/401/2/21 Horizontal closing safety If the robot is at a position greater than or equal to this set position, then the closing safety of the injection molding machine exists. Confirmation of setting values When a parts data set with new setting values for closing safety is loaded, the flag dis- appears and an alarm is displayed. Check the values for the closing safety and, if necessary, change the values so that ope- ration of the system is possible without danger. Confirm values with the program switch Confirmation of setting values. Additional closing safety activated Status flag (green =area active). Additional closing safety Robots cannot move into this prohibited area when the mold is closed. This prohibited area is used when, e. g. a mold has a barrel mounted on top which would collide with the robot when the mold is closed as the barrel is not in the machine area. Set the prohibited area Additional closing safety so that the prohibited area and the machine area overlap, otherwise the robot can move to the border between the prohib- ited area and the machine area. If the prohibited area Additional closing safety begins at Y=0.0 mm (Y=0.0 in), then the Z and X axes cannot move into this border range of the prohibited area when Y=0.0 mm (Y=0.0 in). If the same value is set for the minimum and maximum value of an axis, the prohibited area Additional closing safety is not active. Closing safety: " Vertical closing safety" setting was changed by importing parts data (x) Cause Parts data set with new setting value for vertical closing safety was imported. Effect Closing release for injection molding machine not present. Remedy Check or correct and confirm setting value for the Vertical closing safety on the robot program switch page. Closing safety: " Horizontal closing safety" setting was changed by importing parts data () Cause Parts data set with new setting value for horizontal closing safety was imported. Effect Closing release for injection molding machine not present. Remedy Check or correct and confirm setting value for horizontal closing safety on the robot program switch page. Basic setting 109 3.2 Depositing variants Program switch for enabling or disabling various depositing areas. 3.3 Rotary axes Program switch for enabling or disabling pneumatic rotary axes. If the program switch is deactivated, no actuation or monitoring of the respective rotary axis takes place. The instructions in the robot sequence have no function for a deactivated rotary axis. Closing safety: Confirm changed settings Cause Parts data set with new setting value for horizontal and/or vertical closing safety was imported. Effect Closing release for injection molding machine not present. Remedy Check or correct and confirm setting values for closing safety on the robot program switch page. Closing safety lies above the permitted limit () Effect Check or correct and confirm setting value for the Vertical closing safety on the robot program switch page. Remedy Closing release for injection molding machine not present. Closing safety lies below the permitted limit (x) Effect Closing release for injection molding machine not present. Remedy Check or correct and confirm setting value for horizontal closing safety on the robot program switch page. Program switch Sprue depositing Sprue depositing - 1 position Program switch Quality Control depositing Quality Control deposit - 1 position Program switch reject depositing Reject deposit - 1 position Se- Se- Se- A-axis - activated Rotary axes C axis - activated Basic setting 110 Operator Manual - Robot | Version G/11/401/2/21 4 Status page The status page provides information about general robot and sequence states. General Displays all general signals and parameters. All motors switched on The flag signalizes that all servoaxes are supplied. Referencing all axes Flag signalizes that all servoaxes have been measured. Home position reached The flag signalizes that all servoaxes have reached the home position. Consent key pressed The flag indicates that the consent key on the manual control device has been pressed. Test mode active The flag indicates that test mode is active. Override speed Actual value for current override speed. This actual value is displayed top right on each screen as a percentage, and as a bar diagram. You can press the Increase override/reduce override buttons on the hand control device to increase/reduce the current servoaxis speeds by a percentage factor in auto- matic operating mode. The automatic speeds set on the screens represent the maxi- mum (100%). Cycles total Actual value counter for executed robot cycles. The counter can only be reset by pres- sing the Rbutton. Example: Override speed If the Speed to depositing position is set to 70%, and the override speed is 50%, the robot will move to the depositing position at 35% speed. + All motors switched on Home position reached Consent key pressed Test mode active General Override speed Status page Cycles total Info Panel Referencing all axes Reduce override button Increase override button Basic setting 111 closing release These flags show the states of the closing releases. Vacuum/compressed air The flags show the states of the digital outputs for the pneumatic valves with the appertaining monitoring inputs. The green checkmarks indicates that the hardware is okay. Swivelling cyl. CD1 The swivelling cylinder is the main cylinder of a pneumatic C-axis. The flags show the states of the digital outputs for the pneumatic valves with the appertaining monitoring inputs. The green checkmarks indicates that the hardware is okay. Output+ actuates the C axis for turning down. Input+ indicates that the C axis is down. Output- actuates the C axis for turning up. Input- indicates that the C axis is up. Robot override active! Effect Servoaxes move at the preset override speed. Remedy Set desired override speed. Closing release system General mold closing release Closing release sequence closing release + closing release Closing release alarms Vacuum/compressed air - input + Vacuum/compressed air - input - Vacuum/compressed air - output - Vacuum/compressed air - output + Vacuum/compressed air Vacuum/compressed air - input part monitoring Vacuum/compressed air - input vacuum monitoring + Vacuum/compressed air - analog vacuum monitoring C-axis - Swivelling cyl. CD1 - Input + C-axis - Swivelling cyl. CD1 - Input - C-axis - Swivelling cyl. CD1 - Output - C-axis - Swivelling cyl. CD1 - Output + Swivelling cyl. CD1 + Basic setting 112 Operator Manual - Robot | Version G/11/401/2/21 Locking cylinder CD2 Locking cylinder CD 2 is an optionally available clamping cartridge that locks the swiveling cyl- inder on reaching the final position, and thus holds the cylinder in position. The locking cylinder is used to ensure axis positioning in movements with heavy end-of-arm tooling. The flags show the states of the digital outputs for the pneumatic valves with the appertaining monitoring inputs. The green checkmarks indicates that the hardware is okay. Output+ actuates the locking cylinder for locking. Input+ indicates that the locking cylinder is locked. Output- actuates the locking cylinder for unlocking. Input- indicates that the locking cylinder is unlocked. C-axis - Locking cylinder CD2 - Input + C-axis - Locking cylinder CD2 - Input - C-axis - Locking cylinder CD2 - Output - C-axis - Locking cylinder CD2 - Output + Locking cylinder CD2 + Basic setting 113 5 Efficiency optimization Efficiency optimization reduces unnecessary mechanical stress during robot axis acceleration and braking. In automatic mode acceleration and braking of all servoaxes is gradually modified by measur- ing the time over multiple cycles, until the Set-value uncopied cycle time has been achieved. This does not affect the take-off speeds. The remaining time between reaching Wait for part handover release and Move-in release is measured. The robot is therefore always in the start position shortly before the next part is ready for take- off. Active Program switch enables or disables efficiency optimization. Override activated (optimization not possible) The override speed must be set to 100% for efficiency optimization. TestMode activated (optimization not possible) Test mode must be deactivated for efficiency optimization. Motor dynamic system active (optimization not possible) The motor dynamic system has determined an overload on an axis/drive (e.g. due to excess manipulation weight) and will reduce the speed. Efficiency optimization is thus no longer possible. Reset all profiles All optimized profiles for cycles are deleted. Efficiency optimization will restart automatic control. Set-value uncopied cycle time Speeds are reduced or increased until this time is reached, taking the Unoccupied cycle time window (+/-) into consideration. Optimization restarts below a value of 0.0 seconds. Thus, you must set a larger value. Unoccupied cycle time window (+/-) Tolerance for Set-value uncopied cycle time . If the remaining time is within the Set- value uncopied cycle time , speed optimization is not performed. A setting of 0.0 seconds causes the control unit to optimize speeds continuously. Minimum dynamism For example: Dynamics 50% means that at a set speed of 60% for a movement, effi- ciency optimization will reduce speed to a minimum of 30%. Minimum dynamism Efficiency optimization Unoccupied cycle time window (+/-) Set-value uncopied cycle time Reset all profiles Active + Override activated (optimization not possible) TestMode activated (optimization not possible) Efficiency optimization Info Panel Motor dynamic system active (optimization not possible) Standard cycle Active profile Basic setting 114 Operator Manual - Robot | Version G/11/401/2/21 Active profile Display of the current optimized cycle. Profile display Independently of the currently optimized cycle, the profile data of any desired cycle can be dis- played and set in the profile display strip. Profile selection The program switches, markers and actual values are displayed for the selected cycle. Standard cycle Cycle in which a good part is deposited. Rejects cycles Cycle in which a reject part is deposited. Quality control part cycle Cycle in which a quality control part is deposited. User cycle x Inserting the Set optimization profile instruction in the robot sequence allows you to optimize the individual subsequences in a sequence individually. Profile selected = Active profile When the program switch is activated, all program switches, flags and actual values of the current cycle are displayed in the Profile display tab (standard, reject, quality con- trol part or user cycle). Do not optimize parameters In manual mode, efficiency optimization can be activated or deactivated for the selected cycle in the Current Profile selection box. Valid measurement Optimization is running Optimization complete Optimization is complete if the remaining time is within the Set value remaining time tolerance. Last uncopied cycle time Remaining time achieved in last cycle. Reduction active This marker indicates that speeds have been reduced. Dynamics For example: Dynamics 50% means that, for a set speed of 60%, the robot is currently moving at 30%. Dynamics Standard cycle Profile display Reduction active Profile selection Do not optimize parameters Valid measurement Optimization is running Optimization complete Last uncopied cycle time Profile selected =Active profile + Basic setting 115 Sequence instructions for efficiency optimization The robot sequence provides special instructions for efficiency optimization. These instruc- tions can be used for additional sequence optimization. However, they do not need to be inserted into the sequence for basic efficiency optimization functionality. Inserting the Set optimization profile instruction in the sequence can be used to optimize indi- vidual subsequences (see example). The Reset optimization profile instruction has the same function as the Reset all profiles pro- gram switch on the efficiency optimization screen. If the instructions Full dynamism and Reduced dynamism are inserted in the sequence, effi- ciency optimization does not optimize all move instructions between the instructions. Example: Speed is not optimized for move instruction Shot grid 1 - Depositing position - grid . Insert the instructions Full dynamism and Reduced dynamism in the sequence. Efficiency optimization Set optimization profile Reset optimization profile Full dynamism Reduced dynamism Move in on shot grid 1 with conveyor-belt user Dynamic Optimization - Reduced dynamics Move in on shot grid 1 with conveyor-belt user Dynamic Optimization - Full dynamics Depositing conveyor-belt 1 - Wait depositing allowed Shot grid 1 - depositing position screened Position over depositing Shot grid 1 - depositing position screened Lower swivelling Wait until Special instructions rotary axes movement Basic setting 116 Operator Manual - Robot | Version G/11/401/2/21 Example: Dynamic Optimization - set optimization profile user cycle 1 The peripheral unit is set up so that free input 1 is always set when the robot deposits the sec- ond to last part in the shot grid. The robot thus replaces the full box with an empty one after depositing the last part in the shot grid. For Dynamic Optimization, part depositing with and without a box change is a standard cycle because a good part is always deposited. The time the robot needs for depositing differs, however. This means that the robot gets to the next part removal too late, after part depositing with box change. This results in Dynamic Optimization re-optimizing the speed for the stan- dard cycle. To allow Dynamic Optimization to optimize the two depositing processes separately, you must set the Set optimization profile instruction with setting user cycle x before the parts deposit- ing with box change sequence. All speeds for user cycle x are then optimized as of the Set optimization profile instruction. The speeds for the standard cycle are optimized as of removal standard. If the Set optimization profile instruction is inserted directly after take-off standard, optimiza- tion values for user cycle x are also used for reject and good part depositing. The Set optimization profile instruction allows you to define subsequences as standard, reject and quality control parts cycles. Robot sequence complete - user Part depositing with box change Take-off Standard Execute as long as Automatic mode of operation active Robot sequence complete - user Sprue depositing - 1 position If Free inputs free input 1 If Reject deposit Reject deposit 1 Position Dynamic optimi- User cycle Part depositing in shot Without conveyor-belt Basic setting 117 6 Home position, robot sequences and park position These screen pages are used to display parameters of user-defined home position, robot and park position sequences. The screens display the parameters for which the Display on screen program switches are activated. The screens are selected using the attached image selection buttons for the Robot 1 program switch screen. Example: Home position screen page Speed to home position Home position - user Home position + Info Panel Se- Basic setting 118 Operator Manual - Robot | Version G/11/401/2/21 7 Takeover head WARNING! Danger of crushing due to moving components on the machine! Before carrying out retooling work on the machine, move all moving compo- nents (e.g. robot axes) to a safe position. Observe the following items: Move the robot to the depositing area and remove the take-off/insert parts from the end of arm tooling. Swivel the end of arm tooling down so that it cannot swivel down on its own if pressure is lost. Before working on the pneumatics system, use the hand lever to shut off the supply to the maintenance unit, and ensure that the unit is pressureless! Discharge pressure accumulators! Observe the hints in the chapter Safety! Before setting the robot, mount an end of arm tooling that is suitable for the injection mold. Example: Gripper tools standard end-of-arm tooling Basic setting 119 Basic setting 120 Operator Manual - Robot | Version G/11/401/2/21 Work area setup 121 Work area setup The work area setup serves to define the work areas and prohibited areas for the robot. A work area is an area in which the robot is allowed to move A prohibited area is an area in which a robot is not permitted to move; it can be located within a work area. Undefined areas are always prohibited areas. CAUTION! Danger of collision between robots, machine and peripheral units! Work areas and prohibited areas must be set immediately after mold mounting. To do this, mount the end-of-arm tooling that matches the mold. [1] Selection tree List of all available areas. [2] Setting and visualization area Tab selection for settings, 3D display and overview. [3] Instruction menu keys Work area using the instruction: Print. Edit using the instruction: Delete messages. View using the commands: display options, selection dialog box on/off, message window on/off, maximize/minimize. Note! With several robots (e.g. tandem rise systems), the control unit also switches when toggling between the Info Panels the screen pages Grid editor and Work area setup for the applica- ble robot. + Work Areas and Prohibited Settings 3D view Overview Work area setup Robot In machine data 1 Info Panel In parts data 2 3 Work View Edit Work area setup 122 Operator Manual - Robot | Version G/11/401/2/21 CAUTION! Danger of damage to equipment! Movements with rotary axes are permitted without pressing the consent key in- side prohibited areas. The control unit will only monitor this if the control voltage is switched on. The robot sequences must be set to ensure that all move paths are outside the prohibited areas. 1 Settings robot When commissioning the machine, or when you use a new mold, you must set the spatial data for the areas in the Settings tab. This data is taken into consideration for calculating the work and prohibited areas in the robot node. These areas can also be set on the Quick Setup screen. Machine area The machine area is the whole area theoretically accessible by the robot within the injection molding machine. The machine area defines the whole prohibited area for the plant and is set as a factory default. The robot cannot move in the prohibited area, except in the preset take-off/removal area when the mold is open. For the Max Z machine area, you must set a value that extends beyond the safety gate for half the length of the mold fixing platen, as the end-of-arm tooling is normally not big- ger than the mold fixing platen. This prevents collision between the safety gate and the takeover area in the depositing area. Take-off area Work area in machine area for part take-off. To access a mold without danger of colli- sion, a take-off area must be defined for each mold. This must be determined with a completely open mold. Never set values for the take-off area that cause danger of colli- Work area setup In parts data Robot In machine data Settings 3D view Overview Min Max Min Min Max Min Max Machine area Take-off area Additional closing safety Work area depositing area Z+ + Info Panel Max Work Areas and Prohibit- Work area setup 123 sion for the mold! The take-off area is thus a mold-driven traversing area for the robot when the mold is open, and lies within the machine area. This area must be modified for each new mold you use. Additional closing safety Robots cannot move into this prohibited area when the mold is closed. This prohibited area is used when, e. g. a mold has a barrel mounted on top which would collide with the robot when the mold is closed as the barrel is not in the machine area. The prohibited area Additional closing safety must be set so that the prohibited area and the machine area overlap, otherwise the robot can move to the border between the prohibited area and the machine area. If the prohibited area Additional closing safety begins at Y=0.0 mm (Y=0.0 in), then the Z and X axes cannot move into this border range of the prohibited area when Y=0.0 mm (Y=0.0 in). If the same value is set for the minimum and maximum value of an axis, the prohibited area Additional closing safety is not active. Depositing area Z+ Setting the work space depositing area Z+limits the maximum depositing area on the non-operator side to reflect the preset parameters. Limiting the depositing area helps to safeguard the whole depositing area with just a few work areas. Example: 3D view of the robot work areas with depositing on non-operator side [1] Work area depositing area Z+(Operator rear side) [2] Machine area =prohibited area clamping unit. Blocks all work areas in the machine area with mold not open. [3] Take off area 1 2 3 Work area setup 124 Operator Manual - Robot | Version G/11/401/2/21 Example: 3D representation of work areas with two-sided depositing = butterfly opera- tions option [1] Work area depositing area Z+ [2] Machine area =prohibited area clamping unit [3] Take-off area [4] Work area depositing area Z- 1 2 3 4 Work area setup 125 2 Work Areas and Prohibited Areas The selection tree lists all available work and prohibited areas. When you select a work area or prohibited area, a tool tip appears with the start and end points of the area. Robot Predefined work and prohibited areas, which are calculated from the data for min./max. axis length, lower swiveling limit depositing area, switchover position of Y wait position switch (optional) and the settings for the machine, take-off and depositing areas, and the additional closing safety. Work area above depositing area Z- and Work area depositing area Z- are only visible with depositing on the operator side or butterfly deposit. In machine data User-defined work and prohibited areas which are stored in the machine data set. In parts data User-defined work and prohibited areas which are stored in the parts data set. User-defined work and prohibited areas can be switched on and off using the instructions Work areas/prohibited areas in the robot sequence. Set bordering prohibited areas so that the prohibited areas overlap, otherwise the robot could move to the borders between the prohibited areas. Work Areas and Prohibited Areas Prohibited area clamping unit Work area above clamping unit Work area setup Work area clamping unit Work area above depositing area Z + Work area depositing area Z + Work area between take-off area and depositing area Z+ Work area above machine Work area above depositing area Z - Work area depositing area Z - Robot In machine data In parts data + Info Panel Closing safety additional prohibited area Work area setup 126 Operator Manual - Robot | Version G/11/401/2/21 Work area above machine Moving area over the machine, with mold closed or without. Work area above clamping unit Moving area over the mold (with Y-waiting position switch). X Y Z Min. Axis position min. Axis position -0.3mm Axis position min. Max. Axis position max. Machine area min. Machine area max. X Y Z Min. Work area take-off area min. Machine area min. Work area take-off area min. Max. Work area take-off area max. Machine area min. With waiting position switch up to Y waiting position Work area take-off area max. Work area setup 127 Work area clamping unit Take-off area with mold open. Prohibited area clamping unit Robots cannot move into the prohibited areas when the mold is closed. X Y Z Min. Work area take-off area min. Work area take-off area min. Work area take-off area min. Max. Work area take-off area max. Work area take-off area max. Work area take-off area max. X Y Z Min. Prohibited area machine area min. - 0.045mm Y-Waiting position switch Work area take-off area max. Prohibited area machine area min. Prohibited area machine area min. -0.045mm Max. Prohibited area machine area max. +0.045mm Prohibited area machine area max. +0.045mm Prohibited area machine area max. +0.045mm Work area setup 128 Operator Manual - Robot | Version G/11/401/2/21 Closing safety additional prohibited area Robots cannot move into this prohibited area when the mold is closed. This prohibited area is used when, e. g. a mold has a barrel mounted on top which would collide with the robot when the mold is closed as the barrel is not in the machine area. Work area between take-off area and depositing area Z+ Moving area within the rear safety gate area. The work area is activated and/or deacti- vated in relation to the take-off type (horizontal/vertical). X Y Z Min. Axis position min. Axis position min. Axis position min. Max. Axis position max. Axis position max. Axis position max. X Y Z Min. Work area take-off area min. Prohibited area machine area min. Work area take-off area max. Max. Work area take-off area max. Work area take-off area max. Prohibited area machine area max. Work area setup 129 Work area above depositing area Z+ Maximum move area in depositing area non-operator side up to lower swiveling limit depositing area. Work area depositing area Z+ Maximum movable depositing area on non-operator side as of lower swiveling limit depositing area. X Y Z Min. Axis position min. Axis position min. - 0.3mm Prohibited area machine area max. Max. Axis position max. Lower swivelling limit depositing area Axis position max. X Y Z Min. Work area operator rear side min. Lower swivelling limit depositing area Work area operator rear side min. Max. Work area operator rear side max. Work area operator rear side max. Work area operator rear side max. Work area setup 130 Operator Manual - Robot | Version G/11/401/2/21 Work area above depositing area Z (visible with depositing on the operator side or butterfly deposit) Maximum move area in depositing area operator side up to lower swiveling limit depos- iting area. Work area above depositing area Z (only visible with depositing on the operator side or butterfly deposit) Maximum movable depositing area on operator side as of lower swiveling limit depos- iting area. X Y Z Min. Axis position min. Axis position min. -0,3mm Axis position min. Max. Axis position max. Lower swivelling limit depositing area Prohibited area machine area min. X Y Z Min. Work area operator side min. Lower swivelling limit depositing area Work area operator side min. Max. Work area operator side max. Work area operator side Ymax Work area operator side max. Work area setup 131 3 Area settings To change the settings for an area, you must select a single area node. Element attributes Basic settings for selected work or prohibited area. Example: Areas of an ERC Name Freely selectable name of the area. Type Fixing of the area type (Work area or prohibited area). Min/Max Area coordinates for the respective area. Activation switch Program switch for enabling or disabling area. When changing to manual mode Modifications are only possible in areas below the node in machine and parts data. For changing to manual mode the following behavior can be preset: Keep activation ,, Disable activation or Enable activation. Active Status flag (green =area active). Visible When this field is switched Off the work or prohibited area is not displayed on the 3D view window; however, the functionality of the area is maintained. Filled When this field is switched Off the work or prohibited area is displayed on the 3D view window, as an outlined red box and when switched On the area is filled in as a solid. Work Areas and Prohibit- Prohibited area Work area above Work area setup Work area clamping Work area above de- Work area deposit- Work area above Robot In machine data Settings 3D view Overview Element attributes Name Min Max Activation switch Description Filled Visible Active Type Work area above machine Work area Work area between + Info Panel In parts data Robot assigned Keep activation Robot When changing to manual Closing safety addi- Work area setup 132 Operator Manual - Robot | Version G/11/401/2/21 Description Field for short description of area. System name Clear designator for the control unit (cannot be changed). Robot assigned Assignment of the area to the corresponding robot. 4 3D view The 3D view window displays the arrangement of the work and prohibit areas. Different colors and line strengths are used to differentiate between the various areas and the status. The 3D display provides a number of viewing options. Example: Work area of a robot [1] Starting point coordinates (Zero point) The starting position is marked with a yellow crosshair. [2] Filled representation The side edges of the room are represented with black lines and the area of the room are filled out with the color of the area type. [3] Line representation Only the side edges of the area are represented with the corresponding color of the selected area. [4] Reset key This function resets the graphic to its fixed starting position. [5] Vertically rotation keys The graphics turns around the vertical axis. [6] Horizontal rotation keys The graphics turns around the horizontal axis. [7] Zoom In/Zoom Out These keys allow the graphic window area to be increased (+) or decreased (-). The focus is dependent on the preceding processing of the graphics. When the graphic has not been changed or has only been rotated using the Rotation keys, the zoom is focused in on the middle of the screen. When the graphic has been manually displaced, the zoom is focused in on the yellow crosshair/starting point. 1 2 Settings 3D view Overview 3 4 7 6 5 Work area setup 133 Work/Prohibited area color definitions Only one area can be selected at a time from the available onscreen selections. To identify the selected work area the edges of the graphic are bolded. Using color coding the state of the work area can be identified. Collision area When in the automatic mode a work area error appears, the robot movement stops with the following message: The 3D representation in the work area setup shows the collision position with a crosshair and a warning symbol. A dialog shows the data for the collision position. The start and end points are also indicated by crosshairs; the calculated travel path between the points is shown. Example: 3D representation of robot work areas Work area Active Inactive Selected Not selected Work area blue violet thick line and/or. edge thin line and/or. edge Prohibited area red pink thick line and/or. edge thin line and/or. edge Work area error: Cause The next robot movement would collide with a prohibited area. Effect The robot axes are stopped. Parameters <No.>Robot number. <Name>room name at which the collision has appeared. Pos1 starting position of the robot movement. Pos2 Final position of the robot movement. Collision point End point Start point Work area setup 134 Operator Manual - Robot | Version G/11/401/2/21 5 Overview The Overview tab shows a tabular list of all areas contained in the selected node. This window provides a quick overview of the most important work area data. Example: Work area of a robot [1] List of the areas that exist in the robot node [2] Start and end point of the listed areas [3] Status marking of the areas (green =active) Start point (X/Y/Z) End point (X/Y/Z) Work area above clamp- Name Work area above ma- Work area above depos- Work area above depos- Work area depositing Work area clamping unit Work area depositing Work ara rear safety Prohibited area clamp- 1 2 3 Work area setup Settings 3D view Overview + Work Areas and Prohibit- In machine data Robot In parts data Info Panel Work area setup 135 6 Alarms If a machine movement is cancelled by the robot in manual operations, a Robot interlock alert occurs. An additional wait point shows which movement is blocked. Closing safety - Robot within machine area Effect Required movement cannot be performed. Remedy Press the consent key and move the robot out of the prohibited area. Robot interlock Cause Robot release is not active. Effect The required machine movement cannot be performed. Remedy Move the robot on the correct release position. Ejector x not retracted Effect The requested movement cannot be carried out. Remedy Move ejector to ejector retracted position. Mold not open Effect The requested movement cannot be carried out. Remedy Mold opening Injection molding machine - Danger of collision with robot Cause The robot is within or on the edge of a prohibited area. Effect All linear axis movements are blocked for the robot. Remedy Press the consent key and move the robot out of the prohibited area. Work area setup 136 Operator Manual - Robot | Version G/11/401/2/21 Take-off invalid - robot was not in the take-off area Cause Take-off area set incorrectly. Effect Plant will stop after first cycle. Remedy Check take-off area and modify the take-off position. Z settings defective - Work area in machine area Effect No automatic operation possible. Remedy Set the Z values of the work area so that it is no longer inside the machine area. Take-off-depositing variants 137 Take-off-depositing variants Engel variants are preprogrammed sequences which can be included in the graphical sequence. The parametrization occurs on the screen pages provided for this purpose. The screens display the parameters for which the Display on screen program switches are activated. A matching screen is automatically generated after modifying and saving the robot sequence. 1 Engel - take-off variants At all Engel variants the function Early start is possible. If the robot has parts on the takeover head, it deposits at first the parts before the take-off (not at the Teach sample sequence!). The following take-off variants are preprogrammed: Take-off Standard This variant is preset at the delivery of the robot. It is an universal variant for many appli- cation cases. Several program switches enable a simple and comfortable cycle time optimization. Moving in via 2 separate intermediate positions Take over parts Moving out via 2 separate intermediate positions Take-off mold intermediate stop In this variant, take-off occurs on the mold intermediate stop position; the rest is the same as the default take-off. Take-off 6 positions This variant is the same as the take-off standard, but does it not include any switches for cycle time optimization. Take-off 3 positions This variant is designed for the simplest type of take-off. Only the position before open- ing and the take-off position need to be set. Moving in with Z >Y >X individual axis movements on take-off position Take over parts, ejector returns in parallel with X take-off stroke Moving out with X >Y >Z individual axis movements on position before opening (the same path as moving in). Take-off Teach sample sequence Moving in via an intermediate position, moving out via 2 intermediate positions. This take-off variant serves as model for a Teach sequence without screen switch. CAUTION: At the Teach sample sequence Quick Setup settings for rotary, swivelling and moving limits as well as settings for rotary axes are without effect when moving out from the machine area and moving into the machine area! Take-off-depositing variants 138 Operator Manual - Robot | Version G/11/401/2/21 1.1 Take-off Standard The standard take-off variant covers the main take-off requirements for molded parts. It con- tains two intermediate positions for moving in and out and a take-off position. Program swit- ches are provided for cycle time optimization. Moving-in with ejector advanced If enabled the ejector will advance parallel to the robot moving in. Switch on suction pad Switch on selection for sucker before or after the ejector is in front or when the robot moves in. Close sprue gripper before ejector advancing ejector Allows the closing of the sprue gripper still before the ejector is advanced. Move out as soon as part monitoring Allows the moving-out of the robot still before the expiry of the demolding time when the part monitoring gives the release. Move out without considering ejector position If the program switch is disabled, the ejector first retracts, and then the robot moves to move-out position 1. If enabled, the ejector moves back to moving-out position 1 parallel to the robot move- ment. Take-off vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup.
Position before opening = Home position If the program switch is activated, the position parameters for Home position are auto- matically set equal to the parameters for Position before opening . This causes the robot to wait at its home position for the mold to open before taking off a part. If the switch is disabled, the robot waits at the Position before opening . When auto- matic operations start, the robot moves from home position to Position before opening. Speed to position before opening Servoaxis speed for move to position before opening. The adjustable speed for the robot movement on the respective position is always valid Close sprue gripper before ejector advancing ejector Moving-in with ejector advanced Switch on suction pad Move out as soon as part monitoring OK Move out without considering ejector position after ejector advanced Take-off Standard Take-off Take-off vacuum/compressed air circuits Info Panel Se- Position before opening - Position before opening - XYZ =home position - XYZ Take-off position - ABC Speed to position before opening Take-off-depositing variants 139 for the axis which runs the longest way. The other axes move correspongingly slower in order that they reach the position at the same time. Position prior to opening - XYZ Robot waiting position before opening the mold. On this position the robot wait for the opening of the mold before the take-off of parts. Take-off position - ABC Position of the manual axes of the robot for take-off.
Moving in via 2 intermediate positions Speed for moving-in position 1 Speed of the servoaxes to moving-in position 1. Moving-in position 1 Robot position which is approached from completely open mold in order to move around obstacles (tiebars, mold guides). Speed for moving-in position 2 Speed of the servoaxes to moving-in position 2. Moving-in position 2 Robot position which is approached after the moving-in position 1 in order to move around obstacles (tiebars, mold guides). Subsequence: Moving-in standard The robot moves to the take-off position via two moving-in positions. Depending on the condi- tion fulfilled for the If structure commands, the commands Ejector enable advance and Take-off vacuum/compressed air circuits [ON] without monitoring are either started in the sequence or skipped. Speed for moving-in position 1 Moving-in position 1 Moving-in position 2 Speed for moving-in position 2 Take-off-depositing variants 140 Operator Manual - Robot | Version G/11/401/2/21 Example: Sequence diagram [1] Position before opening [2] Moving-in position 1 [3] Moving-in position 2 [4] Take-off position Switch on the suction pad {after ejector advanced}=at moving-in position 1 Moving-in standard Moving-in standard Moving-in with ejector advanced If enable advance Ejector If Moving-in position 1 Take-off vacuum/compressed air circuits Take-off position - XYZ Moving-in position 2 Mold open Wait until [ ON ] without monitoring Mold completely open 2 4 3 1 Take-off-depositing variants 141 Take-off Take-off speed Speed of the servoaxes to take-off position. Take-off position - X Y Z The robot removes the molded part from the mold at this position. Waiting time before take-off Waiting time before ejector advance and activation of the vacuum/compressed air cir- cuits. Time for part removal Wait time in take-off position for safe takeover of molded part. The ejector is then retracted and vacuum/compressed air monitoring is enabled. The robot then moves to moving-out position 1.
Moving out via 2 intermediate positions Speed for move-out position 1 Speed of the servoaxes to moving-out position 1. Moving-out position 1 The robot position accessed after the take-off position to avoid obstacles (tie-bars, tool guides). Speed for moving-out position 2 Speed of the servoaxes to moving-out position 2. Moving-out position 2 The robot position accessed after the take-off position 1 to avoid obstacles (tie-bars, tool guides). This position should be located outside the prohibited area of the machine. Speed in take off area Subsequence: Moving-out standard The robot moves via two moving-out positions to either the Position before opening or the Machine area - Max - Z position. The position the robot accesses depends on the condition fulfilled in the If structure command. The rotary axes movements follow the Quick Setup settings. Take-off speed Time for part removal Waiting time before take-off Take-off position - X Y Z Speed for move-out position 1 Speed for moving-out position 2 Moving-out position 1 Moving-out position 2 Speed in take off area Take-off-depositing variants 142 Operator Manual - Robot | Version G/11/401/2/21 Example: Sequence diagram [1] Position before opening [2] Moving-in position 1 [3] Moving-in position 2 [4] Take-off position [5] Moving-out position 1 [6] Moving-out position 2 Moving-in/out horizontally Moving-out standard Moving-out standard Rotary axes movement moving out from machine area Stop when safety gate requested Speed for move-out position 2 =100 If Moving-out position 1 Machine area - Max - Z Moving-out position 2 Position before Y-position when moving out/in Z Machine area Depositing area Mold completely open 2 4 3 1 5 6 Take-off-depositing variants 143 Part lost Cause Part monitoring is still inactive after the monitoring time expired. Effect Automatic cycle is stopped until the monitoring input is enabled. Remedy Check and set part monitoring or modify the automatic sequence. Take-off-depositing variants 144 Operator Manual - Robot | Version G/11/401/2/21 2 Engel depositing variants The following depositing variants are preprogrammed: Part depositing with/without grid and conveyor-belt Part deposit in individual part grid with conveyor-belt Part deposit in Teach grid 1/2 with conveyor-belt Part deposit Teach sample Reject deposit - 1 position Reject deposit - 3 positions Reject deposit Teach sample Control parts depositing 1 position Quality Control deposit - 3 positions Quality Control depositing - Teach sample Sprue depositing - 1 position Sprue depositing - 3 positions Sprue depositing Teach sample Take-off-depositing variants 145 2.1 Part deposit without grid and conveyor-belt This variant is preset when the robot is supplied and is used to deposit molded parts. Depositing blowing group Configuration of the vacuum/compressed air circuits is possible only in Teach mode. See chapter Quick Setup. Speed in depositing area Speed of servoaxes in depositing area. Speed to depositing position Speed of servoaxes from the position before opening to the depositing position. Depositing position The robot deposits the molded parts at this position. Waiting time before depositing Waiting time until depositing position reached. Depositing time Waiting time after depositing the molded part. Speed from depositing position Speed of the servoaxes from the depositing position to the home position. Part deposit without grid and conveyor-belt Speed in depositing area Speed to depositing position Depositing position Waiting time before depositing Depositing time Speed from depositing position Deposit Depositing blowing group Info Panel Se- Take-off-depositing variants 146 Operator Manual - Robot | Version G/11/401/2/21 2.2 Part depositing in shot grid with conveyor-belt This variant is preset at the delivery of the robot. The depositing variant enables a simple grid depositing of the parts on a conveyor-belt. Depositing vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Speed in depositing area Speed of the servoaxes in the depositing area (above the lower swivelling limit). Speed to depositing position Speed of servoaxes from the lower swivelling limit to the depositing position. Shot grid 1 Select this key to tell the control unit to open the Grid Editor. Waiting time before depositing Waiting time until depositing position reached. Depositing time Waiting time after depositing the molded part. Speed from depositing position Speed of servoaxes from the depositing position to the lower swivelling limit. Clearing conveyor-belt 1 - activated Program switch for enabling or disabling the conveyor belt. Clearing conveyor-belt 1 - running time : Running time for the depositing conveyor-belt. The running time starts when the grid is full (last part deposited). After the conveyor-belt cycle the grid is reset. Depositing conveyor-belt - Cycle when all selected grids are full If all configured grids are full, the conveyor-belt runs for the preset time. Furthermore, you can continue to cycle the conveyor belt in manual or setup mode using the Con- veyor belt button on the hand terminal. If the conveyor belt has continued to cycle the set running time, the robot will restart Part deposit in shot grid 1 with conveyor-belt Speed in depositing area Speed to depositing position Shot grid 1 Shot grid 1 Waiting time before depositing Depositing time Speed from depositing position Clearing conveyor-belt 1 - activated Clearing conveyor-belt 1 - running time Deposit Depositing vacuum/compressed air circuits Info Panel Se- Depositing conveyor-belt - Cycle when all selected grids are full Conveyor-belt Take-off-depositing variants 147 depositing in the grid in the next cycle. When you press the Quick select key, the Group configuration dialog box appears so that you can configure the grids used (default setting: shot grid 1). This is only possible in Teach mode . If, e. g. the subsequence Part depositing in individual part grid 1 with conveyor belt is inserted in the robot sequence, you must configure individual part grid 1 in the group configuration dialog. If the wrong grid is configured, the conveyor belt will not cycle, and the automatic cycle is interrupted. Cancel Execute Help Shot grid 2 Shot grid 1 Available elements Selected elements Group configuration - depositing conveyor belt 1 - cycle when all selected grid po- Shot grid 3 Individual part grid 1 Individual part grid 2 Individual part grid 3 Teach grid 1 Teach grid 2 Take-off-depositing variants 148 Operator Manual - Robot | Version G/11/401/2/21 Example: Shot grid 1 [1] Position over depositing. [2] Calculated depositing position in the shot grid. Depositing area Z+ Machine area Upper swivelling limit depositing area Lower swivelling limit depositing area Y positon when moving out/in Z Attributes Grid Grid editor Production Simulation Intermediate Parameters Shot grid 1 Teach grid Individual part grid Shot grid Shot grid 3 Shot grid 2 + 1 22 1 Info Panel Take-off-depositing variants 149 2.3 Part deposit in Teach grid 1 with conveyor-belt This variant allows the robot to deposit each part at a different position on the conveyor belt. To enable the robot to deposit each part at its own position, a sequence must be created for each part in the teach grid sequence. [See Teach grid sequence on page 174.] It should also be noted that a vacuum/compressed air circuit is available for each part. Teach grid 1 Select this key to tell the control unit to open the Grid Editor. Clearing conveyor-belt 1 - activated Program switch for enabling or disabling the conveyor belt. Clearing conveyor-belt 1 - running time : Running time for the depositing conveyor-belt. The running time starts when the grid is full (last part deposited). After the conveyor-belt cycle the grid is reset. Depositing conveyor-belt - Cycle when all selected grids are full If all configured grids are full, the conveyor-belt runs for the preset time. Furthermore, you can continue to cycle the conveyor belt in manual or setup mode using the Con- veyor belt button on the hand terminal. If the conveyor belt has continued to cycle the set running time, the robot will restart depositing in the grid in the next cycle. When the quick select key is pressed, the group configuration dialog box will appear for configuring the grids used (default setting: shot grid 1). This is only possible in Teach mode. Part deposit in Teach grid 1 with conveyor-belt Clearing conveyor-belt 1 - activated Clearing conveyor-belt 1 - running time Depositing conveyor-belt 1 - cycle when all selected grids are full Deposit Info Panel Se- Teach grid 1 Teach grid 1 Conveyor-belt Take-off-depositing variants 150 Operator Manual - Robot | Version G/11/401/2/21 2.4 Teach grid The instructions inserted in the teach grid sequence are displayed on this screen page. [See Teach grid sequence on page 174.] Teach grid 1 Select this key to tell the control unit to open the Grid Editor. In the grid editor select the teach grid sequence. Teach grid 1 Teach grid 1 Info Panel Se- Teach grid 1 Teach grid 1 Take-off-depositing variants 151 2.5 Reject deposit - 1 position This depositing variant enables, in case of a rejects recognition, the depositing of the parts on a separate rejects depositing position. A reject molding can be requested manually with the Reject request button on the hand con- trol device or the control panel of the injection molding machine. Program switch reject depositing Program switch enables or disables rejects depositing sequence. The appertaining flag displays that the rejects depositing sequence is processed. Eject reject moldings When the program switch is activated, the ejector ejects the reject moldings (therefore also start-up cycles) in the discharge chute when production occurs with the robot. Rejects signal The flag signals rejects depositing and is active until a good part is taken out. Rejects vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Speed in depositing area Speed of the servoaxes in the depositing area (above the lower swivelling limit). Speed to depositing position Speed of servoaxes from the lower swivelling limit to the depositing position. Reject depositing position Defines the depositing position for rejects depositing. Waiting time before depositing Waiting time until depositing position reached. Reject request Reject deposit - 1 position Program switch reject depositing Reject deposit Speed in depositing area Speed to depositing position Reject depositing position Waiting time before depositing Depositing time Speed from depositing position Rejects signal Rejects vacuum/compressed air circuits Info Panel Se- Eject reject moldings Take-off-depositing variants 152 Operator Manual - Robot | Version G/11/401/2/21 Depositing time Waiting time after depositing the reject molding. Speed from depositing position Speed of servoaxes from the depositing position to the lower swivelling limit. Take-off-depositing variants 153 2.6 Quality Control deposit - 1 position For automatic or manual requesting this depositing variant enables the deposit of quality con- trol parts at a separate quality control deposit position. A quality control part can be requested manually with the Quality control part request button on the hand control device or the control panel of the injection molding machine. Program switch Quality Control depositing Program switch enables or disables quality control part depositing sequence. The appertaining flag displays that the test part depositing sequence is processed. Quality control part demanded The flag signals that the injection molding machine is producing a quality control part. Quality Control vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Production cycles before Quality Control part depositing The entered number indicates after how many cycles the depositing of test parts is star- ted. Production cycles before Quality Control depositing - actual value The counter counts the cycles since the last quality control part was deposited. If the value matches the Production cycles before quality control part depositing count, a quality control part is deposited in the next cycle. Press the Rbutton to reset the coun- ter manually. Reset production cycle counter after manual request When the program switch is activated, the Production cycles before quality control parts counter is reset, after depositing a quality control part, when you press the qua- lity control part request button on the hand control device. Quality Control parts - set value Specifies the number of successive cycles to be deposited as quality control parts. Quality Control parts - actual value Actual value counter for quality control part depositing. The value is automatically reset when it reaches the Quality Control parts-set value . Press the Rbutton to reset the counter manually. Quality control part request Quality Control deposit - 1 position Program switch Quality Control depositing Production cycles before Quality Control part depositing Production cycles before Quality Control depositing - actual value Quality Control parts - set value Quality Control parts - actual value Reset production cycle counter after manual request Quality control deposit Quality control part demanded Quality Control vacuum/compressed air circuits Info Panel Se- Take-off-depositing variants 154 Operator Manual - Robot | Version G/11/401/2/21
Speed in depositing area Speed of the servoaxes in the depositing area (above the lower swivelling limit). Speed to depositing position Speed of servoaxes from the lower swivelling limit to the depositing position. Quality Control depositing position Defines the depositing position for the test part depositing. Waiting time before depositing Waiting time until depositing position reached. Depositing time Waiting time after depositing quality control part. Speed from depositing position Speed of servoaxes from the depositing position to the lower swivelling limit. Quality Control depositing Speed in depositing area Speed to depositing position Speed from depositing position Waiting time before depositing Depositing time Take-off-depositing variants 155 2.7 Sprue depositing - 1 position The sprue depositing function allows separate depositing of injection molded parts and sprue parts at separate positions. Program switch Sprue depositing Program switch enables or disables sprue depositing sequence. The appertaining flag displays that the sprue depositing sequence is processed. Sprue vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Speed in depositing area Speed of the servoaxes in the depositing area (above the lower swivelling limit). Speed to depositing position Speed of servoaxes from the lower swivelling limit to the depositing position. Sprue depositing position Defines the depositing position for the sprue depositing. Waiting time before depositing Waiting time until depositing position reached. Depositing time Waiting time after depositing the sprue part. Speed from depositing position Speed of servoaxes from the depositing position to the lower swivelling limit. Part not deposited Cause Part monitoring is still enabled although the function is switched off after the depositing time expires. Effect Automatic cycle is stopped until the monitoring input is disabled. Remedy Check and set part monitoring or modify the automatic sequence. Sprue depositing - 1 position Program switch Sprue depositing Speed from depositing position Depositing time Waiting time before depositing Sprue depositing position Speed to depositing position Speed in depositing area Sprue deposit Sprue vacuum/compressed air circuits Info Panel Se- Take-off-depositing variants 156 Operator Manual - Robot | Version G/11/401/2/21 3 Set up robot on injection mold WARNING! Danger to life and limb due to moving components! Never work or stand below moving components, e.g. the Y-axis. Never enter or reach into the robot work area while the robot is moving. The following approach refers only to the program Take-off 3 positions with vertical take-off: 1. On the plant, activate Set-up mode and at least access authorization level 5. 2. At the injection molding machine the mold must be open with not demolded injection molded part(s). Pay attention to the correct opening, ejector and core position(s). 3. Activate the required vacuum/compressed air circuits on the Quick Setup screen. 4. Place robot on the move-in position. Bring X- and Z-axis in position so that no collision with the injection mold arises when moving in the Y-axis. 5. Move-in with the Y-axis into the open injection mold. When for reasons of the exact posi- tioning movements with open safety gate of the injection molding machine must be run, then press the consent key on the hand control device in addition to the pushbutton. 6. Move the machine ejector to the Advanced ejector position . Ensure that plant parts do not collide. 7. Set the robot axes to Take-off position so that the part can be transferred. 8. Switch on sucker or gripper on the hand control device. 9. Set and/or take over position of the axes on screen page Take-off at Take-off position - XYZ . 10. Set required speeds for later automatic mode 11. Move Y-axis so that a collision-free moving-out from the mold with injection molded part(s) is possible. 12. Move Y-axis out from the mold on position 0 so that a collision-free closing of the injec- tion mold is possible. When necessary, also change the Z position. 13. Enter axis positions on the screen page Take-off under Position before opening . 14. Set times (takeover delay, takeover time, ejector delay). 15. Move the robot to the depositing position. 16. Select screen page Grid editor and Parameters. 17. Enter actual position in the Starting position. 18. Enter speed (V=10%). 19. Set swivelling limit. 20. Set parameters for C-axis (and/or A- and B-axis). 21. Set times (depositing delay time, depositing time, running time depositing conveyor- belt). Grid editor 157 Grid editor The Grid Editor is a tool for creating depositing or take-off grids. In these grids the robot can either deposit injection molded parts you produce, or pick-up insert/place parts. Shot, single part and teach grids are possible pre-programmed sequences in the robot sequence. CAUTION! Danger of damage to equipment due to improper settings! Set grids so as to avoid collisions between insert-place pick-up and molded parts depositing.
[1] Selection tree List of all available shot grids, individual part grids, and teach grids. [2] Setting and simulation area Tab selection for attributes, parameters, etc. [3] Instruction menu keys Grid using the commands: print, create, delete, and configure. Edit using the commands: move and delete messages. View using the commands: actual value display on/off, selection dialog on/off; mes- sage dialog on/off, and Maximize/Minimize. [4] Teach grid sequence [See Teach grid sequence on page 174.] + Grid Attributes Parame- Intermediate Production Simulation Shot grid 1 Shot grid 2 Shot grid 3 Individual part grid Teach grid Shot grid 1 Grid editor 2 Info Panel Name Description Shot grid 1 Element attributes Grid Edit View Teach grid se- 3 4 3 Grid editor 158 Operator Manual - Robot | Version G/11/401/2/21 Note! With several robots (e.g. tandem rise systems), the control unit also switches when toggling between the Info Panels the screen pages Grid editor and Work area setup for the applica- ble robot. 1 Shot grid With this grid type the robot deposits all parts from the shot at the same time. All Depositing vacuum/compressed air circuits switch off at the corresponding grid depositing position. The shot grid builds up a shot grid in a number of cycles (shots) depending on gaps, numbers and priorities. Example: The robot uses separate vacuum/compressed air circuits to pick up both parts from a mold with 2 cavities, and deposits the parts in the shot grid at the same time. In a grid layer the robot deposits four shots with two parts each. [1] Calculated depositing position for the fourth shot. 1.1 Shot grid - attributes Freely selectable name and short description for the selected element in the selection tree. 3 1 4 2 1 Z - X + + Grid Attributes Parame- Intermediate Production Simulation Shot grid 1 Shot grid 2 Shot grid 3 Individual part grid Teach grid Shot grid Grid editor Info Panel Name Description Shot grid 1 Element attributes Case 4-fold depositing Grid editor 159 1.2 Shot grid - parameters Starting position Depositing or pick-up point for first part on grid. Using the starting position and the Grid param- eters settings, the control unit calculates the depositing position for the individual shots. Grid parameters Parts layout on grid. Grid type Selecting Deposit grid or Pick-up grid. For a Deposit grid the sign for the Y distance is automatically set to minus . Distance Distance between shots on the grid for linear servoaxes (X,Y,Z). A positive value moves in the positive axis direction from the starting point, and a nega- tive value moves in the negative axis direction. The sign for the Y distance is set auto- matically by the grid type. Number Number of shots the robot deposits/picks up in each axis direction. Priority Specifies the axis order in which the shots are deposited/picked up on the grid. The axis with 1 has the highest priority. In assignment of priority 1,2,1 for the X, Y and Z axes the robot deposits the parts in the Y position diagonally. Set grid points The set value is calculated by reference to the grid number values. You can change the value manually to deposit/pick up a defined number of shots. The value must be smaller than the calculated value. After reaching the set value, the grid is reset. Current grid points Actual value for shots deposited/picked up on the grid. Reset grid Automatic operation not possible. Starting position Attri- Parame- Intermediate Production Simulation Grid type Distance Grid parameters Number Priority Set grid points Current grid points Deposit grid Reset grid R Grid editor 160 Operator Manual - Robot | Version G/11/401/2/21 Example: Starting position and grid spacing for part depositing. [1] Starting position (distance of parts * number of parts + shot grid starting position Z) within the machine area Effect No automatic operation possible Remedy Set the grid values so that no positions are inside the machine area. (distance of parts * number of parts + shot grid starting position Z) outside of axis limits Effect No automatic operation possible Remedy Set the grid values so that no positions are outside the axis limits. 3 1 4 2 1 Y
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D i s t a n c e Grid editor 161 1.3 Shot grid - intermediate layer Intermediate layers are carton, plastic plates or trays which are inserted between the Y grids (Y layers). The robot can deposit an intermediate layer as a bottom or Top layer. The parameters for picking up intermediate layers must be set on the Intermediate layers screen page. Used magazine Magazine sequence This selection is intended for multiple magazines of intermediate layers. In the standard case the robot can only pick up the intermediate layer from the magazine called Inter- mediate layers depositing . The intermediate layers program will not work if you select No sequence. Intermediate layer An intermediate layer serves to avoid wear, and to improve sorting of parts. Intermediate layer Program switch for enabling or disabling intermediate layers Bottom/top layers can still be deposited when the intermediate layer is disabled. Number of layers before intermediate layer The value indicates after how many part layers an intermediate layer is placed. Correction value per intermediate layer Distance between the Y-layers. Robot takes this value into account when calculating the Y-grid position and is only effective when the Intermediate layer program switch is acti- vated. Special layer An intermediate layer laid after the last, or below the first parts layer. Top layer Program switch for enabling or disabling covering layer. After the last parts layer, ano- ther intermediate layer is deposited as a Top layer. Bottom layer Program switch for enabling or disabling bottom layers. Before the first parts layer, an intermediate layer is deposited as a bottom layer. Used magazine Magazine sequence Intermediate layers de- Attri- Parame- Intermediate Production Simulation Intermediate layer Number of layers before intermediate layer Intermediate layer Correction value per intermediate layer Special layer Top layer Bottom layer Grid editor 162 Operator Manual - Robot | Version G/11/401/2/21 Starting position bottom layer X Y Z A B C - Starting position for bottom layer Example: Shot grid with bottom and covering layers and two intermediate layers. [1] Top layer [2] Intermediate layer [3] molded part [4] Bottom layer Starting position bottom layer 1 2 3 4 Starting position bottom layer Starting position for first grid layer C o r r e c t i o n
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d i s t a n c e Grid editor 163 1.4 Shot grid - Simulation/Production This is a graphical visualization of the set grid. The settings for the grid can be checked imme- diately using the simulation program. You can query the current grid status during production in the Production tab. [1] The intermediate layer (in this case without bottom and covering layers) is depicted as a white rectangle. [2] Representation of the shot grid with the shot number. The arrangement of the individual shots depends on the settings in the Grid parameters. The Y grid layers and intermediate layers appear in X and Z displaced, but lie exactly one on top of each other. [3] Limiting values of the depositing/take-off positions from the first and last shot in X, Z and Y direction. 2 1 3 Attri- Parame- Intermediate Production Simulation Grid editor 164 Operator Manual - Robot | Version G/11/401/2/21 2 Individual part grid The robot can use multiple vacuum/compressed air circuits to deposit individual shot parts at separate depositing positions. The number of depositing positions is derived from the number of vacuum/compressed air cir- cuits selected in the configuration. Example: A robot will use separate vacuum/compressed air circuits to pick up each part from a mold with 2 cavities. Each part is deposited on its own depositing position on the individual parts grid to ensure optimum use of space. In a grid layer the robot deposits four shots with two parts each. Advantage: No Teach grid required. The individual parts grid is simple to configure. [1] Calculated depositing position for vacuum/compressed air circuit 1 [2] Calculated depositing position for vacuum/compressed air circuit 2 Note! The following section describes those tabs for the individual parts grid that differ from the shot grid. 2.1 Individual part grid - Attributes Freely selectable name and short description for the selected element in the selection tree. 3 1 4 2 1 2 Z - X + + Grid Attributes Parame- Positions Intermediate Individual part Individual part grid Individual part grid Teach grid Shot grid Grid editor Info Panel Name Description Individual part grid 1 Element attributes Case 4-fold depositing Grid editor 165 2.2 Individual part grid - parameters Y-moving height In this plane, the robot moves along the X and Z axes from the previous to the next depositing position. That is: the robot moves its Y axis from the current depositing position to the set Y traveling height, then it moves along X and Z axes on the Y plane to a position above the next deposit- ing position. When the robot is above the depositing position, the Y axis moves to this position. Moving height The traveling height defines the position of the Y plane. The following parameters are available: Lower swivelling limit depositing area You can change this value on the Quick Setup screen page. Y-moving position absolute This is a Y axis position. This position can be modified if it is set as the Moving height. Y-moving position relative The stroke of the Y axis in the set direction (+/-). This position can be modified if it is set as the Moving height. Example: Y plane [1] Depositing position for vacuum/compressed air circuit 1 [2] Depositing position for vacuum/compressed air circuit 2 Y-moving height Attributes Parame- Intermediate Positions Moving height Y-moving position absolute Y-moving position relative Lower swivelling limit depositing area Lower swivelling limit depos- 2 1 Moving height Y-moving height Grid editor 166 Operator Manual - Robot | Version G/11/401/2/21 Grid parameters Parts layout on grid. Grid type Selecting Deposit grid or Pick-up grid. For a Deposit grid the sign for the Y distance is automatically set to minus . Action after interruption The robot performs the selected action after a cycle interruption during part depositing. Cycle grid The grid is deleted on the next cycle start. Continue grid When the next cycle starts, the robot deposits the parts still in the end of arm tooling in the grid. To allow this to happen, home position movement with parts must be activated and rejects depositing must be deactivated. Next shot The robot deposits the parts for the next cycle in the next shot. Note the setting for Home position movement with parts and rejects depositing. Repeat the shot After a cycle interruption, the operator must remove the parts of the last cycle from the grid and/or end of arm tooling. When the next cycle starts, the robot deposits the parts in the same shot as for the last cycle. Distance Distance between shots on the grid for linear servoaxes (X,Y,Z). A positive value moves in the positive axis direction from the starting point, and a nega- tive value moves in the negative axis direction. The sign for the Y distance is set auto- matically by the grid type. Number Number of shots the robot deposits/picks up in each axis direction. Priority Specifies the axis order in which the shots are deposited/picked up on the grid. The axis with 1 has the highest priority. In assignment of priority 1,2,1 for the X, Y and Z axes the robot deposits the parts in the Y position diagonally. Set grid points The set value is calculated by reference to the grid number values. You can change the value manually to deposit/pick up a defined number of shots. The value must be smaller than the calculated value. After reaching the set value, the grid is reset. Grid type Grid parameters Deposit grid Action after interruption Cycle grid Distance Number Priority Set grid points Current grid points Reset grid R Actual parts Grid editor 167 Current grid points Actual value for shots deposited/picked up on the grid. Actual parts Actual value of the deposited/taken-off parts in the grid. Reset grid Automatic operation not possible. 2.3 Individual part grid - positions Vacuum/compressed air x Starting depositing position for vacuum/compressed air circuit x. The robot moves to the depositing positions Vacuum/compressed air 1 and Vacuum/compressed air 2 in the order specified here. Using the starting position and the Grid parameters settings, the control unit calculates the depositing position for parts in the individual shots. Example: Starting positions for two vacuum/compressed air circuits and grid distances. [1] Depositing starting positions vacuum/compressed air circuit 1 [2] Depositing starting positions vacuum/compressed air circuit 2 Vacuum/compressed air 2 Vacuum/compressed air 1 Intermediate Positions Attri- Parame- X
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D i s t a n c e Grid editor 168 Operator Manual - Robot | Version G/11/401/2/21 Configure vacuum/compressed air circuit The depositing starting positions for the vacuum/compressed air circuits are displayed in the order of dialog box Group configuration - Vacuum /compressed air circuits . On the Grid Editor screen, the dialog is opened in Teach mode when you press the Grid and Configure buttons. Using the navigational arrows <<< and >>> you can move the complete content from Avail- able elements to Selected elements and vice-versa. You can select an individual vacuum/compressed air circuit, and move it using the navigational arrows < and > to insert it into Selected elements in the desired order. Note! You can also configure vacuum/compressed air circuits on the Quick Setup screen page in the group configuration for Individual part grids - Vacuum/compressed air circuits. (distance of parts * number of parts + individual part grid starting position Z) inside the machine area Effect No automatic operation possible Remedy Set the grid values so that no positions are inside the machine area. (distance of parts * number of parts + individual part grid starting position Z) outside of axis limits Effect No automatic operation possible Remedy Set the grid values so that no positions are outside the axis limits. Group configuration - Vacuum/compressed air circuits Vacuum/compressed air Vacuum/compressed air Available elements Selected elements Cancel Execute Help Grid editor 169 Example: Creating 2 depositing positions for the individual part grid 1. You need to configure vacuum/compressed air circuits 1 and 2 for this. 1. To configure vacuum/compressed air circuits, you must first change to Teach mode. 2. On the Grid Editor screen page select the required individual parts grid in the selection tree. 3. Press the menu buttons Grid and Configuration to display the Group configuration - Vacuum/compressed air circuit dialog box. Intermediate Positions Attributes Parame- Grid Individual part grid Individual part grid Shot grid Teach grid Grid editor + Individual part grid 1 Info Panel Group configuration - Vacuum/compressed air circuits Vacuum/compressed air Vacuum/compressed air Available elements Selected elements Cancel Execute Help Grid editor 170 Operator Manual - Robot | Version G/11/401/2/21 4. Select Vacuum/Compressed air circuit 1 and use the > key to move it to Selected Ele- ments .. 5. Select vacuum/compressed air circuit 2 and move it to the right using the > key. 6. Use Execute to store the current configuration. 7. The starting positions are now listed correspondingly in the Positions tab. Group configuration - Vacuum/compressed air circuits Vacuum/compressed air Vacuum/compressed air Available elements Selected elements Cancel Execute Help Group configuration - Vacuum/compressed air circuits Vacuum/compressed air Vacuum/compressed air Available elements Selected elements Cancel Execute Help Intermediate Positions Attributes Parameters Grid Individual part grid Individual part grid Shot grid Teach grid Grid editor + Individual part grid 1 Vacuum/compressed air 2 Vacuum/compressed air 1 Info Panel Grid editor 171 2.4 Individual part grid - intermediate layer Intermediate layers are carton, plastic plates or trays which are inserted between the Y grids (Y layers). The robot can deposit an intermediate layer as a bottom or Top layer. The parameters for picking up intermediate layers must be set on the Intermediate layers screen page. Description of the parameters [See Intermediate layer on page 161.] 2.5 Individual part grid - simulation/production This is a graphical visualization of the set grid. The settings for the grid can be checked imme- diately using the simulation program. You can query the current grid status during production in the Production tab. [1] Depositing position number for an individual shot (red number in white box). The exact positions are shown in the Positions tab. Correction value per intermediate layer Used magazine Magazine sequence Intermediate layers de- Attri- Parame- Intermediate Positions Intermediate layer Number of layers before intermediate Intermediate layer Special layer Top layer Bottom layer Starting position bottom layer 1 Parame- Intermediate Simula- Positions Grid editor 172 Operator Manual - Robot | Version G/11/401/2/21 3 Teach grid Teach grids are the most flexible grids of which two are for selection. In standard a Teach grid has the following structure An individual sequence must be created for each part in the teach grid sequence. This allows the robot to deposit each part at a different position. 3.1 Configure teach grid You can add several subgrids, shots and parts to the Teach grid as required. Before you can configure the Teach grid you must change to the Teach mode. You can select Create, Delete and Move in the command menu Grid and Edit . The command keys are only active if the command in question can be performed for the element selected in the selection tree (subgrid, shot or part). Instruction keys Create To create a sub-grid, shot or part. Delete To remove from a selected sub-grid, shot or part. Move Move the marked shot or part upwards or downwards in the selection tree. Note! Delete all subgrids, shots and parts you do not need for part depositing in the Teach grid from the selection tree. Teach grid 1 Shot 1 Subgrid 1 Part 1 Grid editor 173 Example: Adding a subgrid to Teach grid 1. 1. Before you can configure the Teach grid you must change to Teach mode. 2. On the Grid Editor screen page select the required individual Teach grid in the selec- tion tree. 3. Press the Grid and Create menu buttons to display the Create new subgrid dialog box. 4. Use the Execute menu button to insert subgrid 2 into Teach grid 1. 5. Save the configuration by quitting Teach mode. Grid editor + Name Description Teach grid 1 Element attributes Individual part grid Teach grid Shot grid Teach grid 1 Grid Attributes Parameters Intermediate Production Simulation Info Panel Teach grid 2 Create new subgrid Subgrid 2 Shot 1 Cancel Execute Help Part 1 Subgrid name Shot name Parts name Grid editor + Name Description Part 1 Element attributes Individual part grid Teach grid Shot grid Subgrid 1 Shot 1 Part 1 Teach grid 1 Grid Subgrid 2 Info Panel Grid editor 174 Operator Manual - Robot | Version G/11/401/2/21 3.2 Teach grid sequence An individual sequence must be created for each part in the teach grid sequence. This allows the robot to deposit each part at a different position. The Teach grid sequence starts in automatic mode when the Teach grid x instruction is reached in the robot sequence. Once the teach grid sequence has been worked through com- pletely, the machine will continue with the robot sequence. These two methods will take you to the teach grid sequence: Double click on the teach grid instruction in the robot sequence. Select the Teach grid sequence menu button in the grid editor. Depositing conveyor belt 1 - Part deposited Part deposit in Teach grid 1 with conveyor-belt Depositing conveyor-belt 1 - Wait depositing allowed Teach grid 1 Part deposit in Teach grid 1 with conveyor-belt Teach grid sequence Part 1 Part 1 Info Panel Se- Attributes Help Close Teach grid parts Teach grid Grid Teach grid 1 Subgrid 1 Shot 1 Part 2 Teach grid 2 structure instructions Sequence control Robot Injection molding ma- Sequences Peripheral unit Grid Teach pointer safety gate Instruc- Part 1 Grid editor 175 Instructions All robot and move instructions with the extended rasterized setting are available for the teach grid sequence. In the rasterized setting for a movement instruction the robot rasterizes the position for each shot as specified in the Grid Editor. Symbol Name Function Individual axis movement The selected axis moves to the set position. The robot rasterizes the position as specified in the Grid Editor. Linear axes movement All 3 linear axes (X, Y, Z) move in parallel to the set positions. The robot rasterizes the positions as specified in the Grid Editor. Robot movement All robot axes (X, Y, Z, A, B, C) move in paral- lel to the set positions. The robot rasterizes the positions as specified in the Grid Editor. Multi-position linear axes movement All linear axes (X, Y, Z) for which a position has been set move in parallel to these posi- tions. The robot rasterizes the positions as specified in the Grid Editor. Grid editor 176 Operator Manual - Robot | Version G/11/401/2/21 Example: In each cycle the robot deposits two parts at different positions. A sequence must be created for each part in the teach grid sequence. After the Position before opening or Machine area - Max - Z the robot moves to Linear axes position 2 . After completing the sequence for part 1, the sequence for part 2 starts. After depositing both parts, the robot continues with the instructions in the robot sequence. [1] Robot sequence [2] Teach grid sequence for part 1 [3] Teach grid sequence for part 2 Depositing conveyor belt 1 - Part deposited 1 2 3 Linear axes position 3 Depositing position 2 [OFF] with monitoring Vacuum/compressed air 2 Time=1 Depositing time Part 2 Upper swivelling limit depositing area Linear axes position 2 Depositing position 1 [OFF] with monitoring Vacuum/compressed air 1 Time=1 Depositing time Part 1 Lower swivelling limit depositing area If Moving-in/out horizontally Machine area - Max - Z Position before Take-off Standard Moving-out standard Part depositing on Teach grid 1 on the conveyor-belt Depositing conveyor-belt 1 Wait depositing allowed Teach grid 1 Part depositing on Teach grid 1 on the conveyor-belt X=0 Y=0 Z=800 V=5 X=100 Y=0 Z=1200 V=5 X=0 Y=400 Z=800 A=[ - ] B=[ - ] V=5 X=100 Y=400 Z=1200 A=[ - ] B=[ - ] V=5 Grid editor 177 Create teach grid sequence 1. Change to the Teach mode. 2. On the Grid Editor screen page select the required individual Teach grid in the selec- tion tree. 3. Selecting the Teach grid sequence menu button takes you from the Grid Editor screen to the teach grid sequence. 4. Select a part. It is not essential to close the dialog window to create a sequence. 5. In the teach grid sequence, you can create the sequence for a part or modify an existing sequence. The Grid Editor menu key lets you go back to the Grid Editor. Grid editor + Name Description Teach grid 1 Element attributes Individual part grid Teach grid Shot grid Teach grid 1 Grid Attributes Parameters Intermediate Production Simulation Info Panel Teach grid 2 Teach grid parts Teach grid Close Help Grid Teach grid 1 Teach grid 2 Subgrid 1 Shot 1 Part 1 Part 2 Shot 2 Teach grid sequence + Part 1 Robot Injection molding ma- Sequence control Sequences Peripheral unit Instructions: Part 1 Info Panel Se- Attributes Grid editor 178 Operator Manual - Robot | Version G/11/401/2/21 6. To change from the Teach grid sequence for Part 1 to Part 2 , click on the Part 1 selection box. 7. The Teach grid parts dialog box appears. 8. Select Part 2 to display the sequence for the part 2. 9. Save the sequence by quitting the Teach mode. 10. Now save the finished sequence in the parts data set. Teach grid sequence + Part 1 Robot Injection molding ma- Sequence control Sequences Peripheral unit Instructions: Part 1 Info Panel Se- Attributes Teach grid parts Teach grid Close Help Grid Teach grid 1 Teach grid 2 Subgrid 1 Shot 1 Part 1 Part 2 Shot 2 Teach grid sequence + Part 2 Robot Injection molding ma- Sequence control Sequences Peripheral unit Instructions: Part 2 Info Panel Se- Attri- Grid editor 179 Note! The sequence is saved in the parts data. Therefore rewrite the parts data after saving the sequence. 3.3 Teach grid - Attributes Freely selectable name and short description for the selected element in the selection tree. + Grid Attributes Parame- Intermediate Simulation Teach grid 1 Teach grid 2 Individual part grid Teach grid Shot grid Grid editor Info Panel Name Description Teach grid 1 Element attributes Case 4-fold depositing Production Grid editor 180 Operator Manual - Robot | Version G/11/401/2/21 3.4 Teach grid - parameter Grid parameters Parts layout on grid. Grid type Selecting Deposit grid or Pick-up grid. For a Deposit grid the sign for the Y distance is automatically set to minus . Action after interruption The robot performs the selected action after a cycle interruption during part depositing. Cycle grid The grid is deleted on the next cycle start. Continue grid When the next cycle starts, the robot deposits the parts still in the end of arm tooling in the grid. To allow this to happen, home position movement with parts must be activated and rejects depositing must be deactivated. Next shot The robot deposits the parts for the next cycle in the next shot. Note the setting for Home position movement with parts and rejects depositing. Repeat the shot After a cycle interruption, the operator must remove the parts of the last cycle from the grid and/or end of arm tooling. When the next cycle starts, the robot deposits the parts in the same shot as for the last cycle. Distance Distance between shots on the grid for linear servoaxes (X,Y,Z). A positive value moves in the positive axis direction from the starting point, and a nega- tive value moves in the negative axis direction. The sign for the Y distance is set auto- matically by the grid type. Number Number of shots the robot deposits/picks up in each axis direction. Priority Specifies the axis order in which the shots are deposited/picked up on the grid. The axis with 1 has the highest priority. Set/current grid points Number of sub-grids or shots that the robot deposits/picks in one Teach grid. Grid type Grid parameters Deposit grid Action after interruption Cycle grid Attributes Parame- Intermediate Production Simulation Distance Number Priority Set grid points Current grid points Reset grid R Grid editor 181 Reset grid Automatic operation not possible. 3.5 Teach grid - intermediate layer Intermediate layers are carton, plastic plates or trays which are inserted between the Y grids (Y layers). The robot can deposit an intermediate layer as a bottom or Top layer. The parameters for picking up intermediate layers must be set on the Intermediate layers screen page. Description of the parameters [See Intermediate layer on page 161.] Used magazine Magazine sequence Intermediate layers de- Attri- Parame- Intermediate Production Simulation Intermediate layer Number of layers before intermediate layer Intermediate layer Special layer Top layer Bottom layer Starting position bottom layer Correction value per intermediate layer Grid editor 182 Operator Manual - Robot | Version G/11/401/2/21 3.6 Teach grid - simulation/production There is no graphical simulation for a teach grid. The depositing order for sub-grids, shots and parts is displayed in tabular format. You can query the current grid status during production in the Production tab. Processing The subgrid, shot and part for the previous, current and next cycle are shown in the pro- grammed order. Depositing status The current / set number of total parts for all grids is shown. Below this you can see the current / set numbers juxtaposed for the programmed Teachgrids and Subgrids in X, Y and Z direction. Attri- Parame- Intermediate Production Simulation Subgrid 1 Subgrid 1 Subgrid 1 Processing Depositing status Shot 1 Shot 2 Shot 1 Part 1 Part 2 Part Shot Parts total Teach grid 1 Subgrid 1 Next Actual Last Act Set Act Set Act Set X Y Z Subgrid 1 Part 3 Set Act Grid editor 183 Example: A robot will use separate vacuum/compressed air circuits to pick up each part from a mold with 2 cavities. To save space, each part is deposited at a separate depositing position. A grid layer always contains four parts. The parts from shot 2 are displaced by the Z distance =300mm (11.81 in) with respect to the parts from the first shot. In the subgrid is a shot with 2 parts configured. [1] Part 1 [2] Part 2 + Grid Individual part grid Shot grid Grid editor Teach grid Subgrid 1 Teach grid 1 Attributes Parame- Intermediate Grid type Distance Grid parameters Number Priority Set grid points Deposit grid Part 1 Part 2 Shot 1 Info Panel 1 2 Teach grid 1 Subgrid 1 Shot 1 Shot 2 1 2 Z - X + X - distance Grid editor 184 Operator Manual - Robot | Version G/11/401/2/21 Example: A robot will use separate vacuum/compressed air circuits to pick up each part from a mold with 2 cavities. To save space, each part is deposited at a separate depositing position. A grid layer always contains four parts at different positions. Two subgrids with one shot and two parts each are configured for the Teach grid. The robot deposits the parts from the first cycle in subgrid 1, and the parts from the second cycle in subgrid 2. [1] Part 1 [2] Part 2 + Grid editor Teach grid Subgrid 1 Teach grid 1 Attributes Parame- Intermediate Grid type Distance Grid parameters Number Priority Set grid points Deposit grid Part 1 Part 2 Shot 1 Production Simulation Subgrid 2 Part 1 Part 2 Shot 1 Grid Individual part grid Shot grid Info Panel 1 2 Teach grid 1 Subgrid 2 Shot 1 Shot 1 2 1 Subgrid 1 Z - X + Robot sequence 185 Robot sequence The robot sequence is used for the graphic display, changing and creation of program sequences. The following views are possible in the robot sequence Simple view Circular display of all subsequences in a sequence. Extended view Complete display of all instructions in a sequences. Robot sequence Robot sequence Extended view Info Panel Part deposit without grid Take-off Standard Robot - Simple - sequence structure instructions Robot sequence Sequence control Robot Injection molding ma- Sequences Peripheral unit Grid Robot sequence Instruc- Robot - Simple - sequence List while Automatic mode of operation ac- If Sprue depositing - 1 position Reject deposit Take-off Standard If Reject deposit 1 Position Test part depositing active Quality control Position Part Shot Robot - Simple - sequence Info Panel Simple view Teach pointer safety gate Robot sequence 186 Operator Manual - Robot | Version G/11/401/2/21 1 Simple view The sequence is shown in circular form in the simple view. This view enables the exchange of a subsequence or complete sequence (=variant) from access level 5 and above in the Teach mode.. In addition, it is possible in this view to start the assistant for sequence set-up in the Teach mode of operation. [See Assistant for sequence set-up on page 199.] Example: Standard robot sequence [1] Sequence selection Toggling between machine sequence, robot sequence, etc. possible. [2] Switchover key Toggling between Extended view and Simple view possible. [3] Sequence window Graphic display of the selected sequence with short text. The window can be scrolled horizontally and vertically. [4] Assistant for sequence set-up Button with wand appears in the Teach mode of operation. 1 2 Robot sequence Robot sequence Quality Control deposit - 1 position Extended view + Info Panel Reject deposit - 1 position Part deposit in shot grid 1 with conveyor- Sprue depositing - 1 posi- Take-off Standard Robot - Simple - sequence 3 Editing mode active 4 Robot sequence 187 1.1 Symbols for robot sequence The symbol in the center of the circle shows the entire robot sequence. The symbols in the cir- cle show the individual subsequences of the entire sequence. The system will start in automatic mode with the first subsequence in the circle and work through all active subsequences in a clockwise direction. Disabled subsequences are crossed out in red and thus skipped. The system will process subsequences with an orange border under certain conditions, e.g. depending on the part manufactured (good part, quality control part or reject part)). The system processes the subsequences bordered in green consecutively. Jumping from the robot sequence to screen pages In each sequence/subsequence there is a button for jumping to the respective screen page. The screen pages in turn contain a button for returning to the robot sequence. Step pointer In automatic mode, active subsequences are marked in the sequence by a green step pointer. The step pointer can be activated/deactivated in the Extended view using the menu keys View and Step pointer. Sprue depositing - 1 position Sprue depositing - 1 position Quality Control deposit - 1 position Part deposit in shot grid 1 with con- veyor-belt Sprue depositing - 1 position Processing station Part deposit in shot grid 1 with con- veyor-belt Take-off Standard Moving-in with ejector advanced Take-off Standard Take-off Info Panel Se- Take-off Standard Robot sequence 188 Operator Manual - Robot | Version G/11/401/2/21 2 Extended view The complete sequence is shown in the extended view. This view enables the exchange of a subsequence or complete sequence (=variants) from access level 5 and above in the Teach mode. In addition, from access level 7 and above the sequences can be individually modified or newly created. From access level 9 and above the complete range of instructions is avai- lable for sequence processing.. Example: Robot sequence
[1] Selection window Instructions Structured listing of all instructions and sequence variants for sequence creation. [2] Sequence selection Toggling between machine sequence, robot sequence, etc. possible. [3] Switchover key Toggling between Extended view and Simple view. [4] Sequence window Graphic display of the selected sequence with short text. The window can be scrolled horizontally and vertically. [5] Instruction menu keys 2 1 structure instructions Robot sequence Sequence control Robot Injection molding ma- Sequences Peripheral unit Grid Robot sequence Instruc- Robot - Simple - sequence List while Automatic mode of operation ac- If Sprue depositing - 1 position Reject deposit Take-off Standard If Reject deposit 1 Position Test part depositing active Quality control Position Part Shot Robot - Simple - sequence + Info Panel Simple view Teach pointer safety gate 3 4 New Program Edit View Robot Set-up mode activated 5 Robot sequence 189 Find in list Use the menu keys View and Find in list to activate this function. This highlights the selected instruction in the sequence in the Instructions selection box. Fixed pointer Use the menu keys View and Place to activate this function. This causes the control unit to push the subsequence into the top left corner of the display panel when you open the subse- quence. 2.1 Symbols for robot sequence The graphic program sequence consists of serial and parallel steps as well as conditional branches and repeat loops. Each function step is represented as symbol with short text. The system processes activated subsequences step by step from the top down. Disabled sub- sequences are crossed out in red and thus skipped. For If structure instructions the system processes the instructions from the top down or to the right according to the requirement. Instruction Execute while automatic mode is active causes a restart of the robot sequence while automatic mode is active. Individual subsequences are indicated by an icon with a bold border, and can be opened by pressing the + symbol. These subsequences can be broken down into further subsequences and individual instruc- tions. When an instruction is selected it receives a red border and a long text is displayed. Sprue depositing - 1 position Take-off 3 posi- tions Take-off 3 posi- tions Take-off 3 posi- tions Moving-in 3 posi- tions Moving-in 3 positions Moving-in 3 positions Take-off position - Z Take-off position - Y Take-off position - Y Wait until Mold open Take-off position - Z Z=0 Individual axis movement Speed in take off area=100 Start Robot sequence 190 Operator Manual - Robot | Version G/11/401/2/21 When the instruction is double-clicked, a dialog window will open displaying parameters for setting. Pressing the Less menu key will hide the Display on screen page lines. In the Display on screen page selection box set the screen page on which the parameters are to be displayed. When the respective program switch is activated the control unit will display the parameters on the screen page. Jumping from the robot sequence to screen pages In each sequence/subsequence and instruction there is a button for jumping to the respective screen page. The screen pages in turn contain a button for returning to the robot sequence. Individual axis movement Type Position Display on screen page Take-off position - Z Cancel Help Execute Start Take-off position - Z Take-off 3 positions Speed in take off area Take-off 3 positions Display on screen page Speed in take off area Speed Less Key for changing the name of user-defined parameters Sprue depositing - 1 position Take-off Standard Robot - Simple - sequence Engel standard sequence (standard part take-off, sprue depositing, quality control part depositing, rejects and parts depositing) Moving-in with ejector advanced Take-off Standard Take-off Info Panel Se- Robot sequence 191 Step pointer In automatic mode, active instructions are marked in the sequence by a green step pointer. You can activate or deactivate the step pointer in the sequence using the menu keys View and Step pointer . You can select View and Go to pointer to view the instruction that has just been processed in the sequence. 2.2 Instruction types Every instruction type has its own background color. This makes it easy to identify an instruc- tion's function at first glance. Symbol Color Instruction type Function yellow Move instructions - To posi- tion The next instruction starts after reach- ing the position. green Move instructions - Start Move instruction starts and the pro- gram immediately jumps to the next instruction. If the next instruction is also a move instruction, the robot will not move precisely to this position, but use position smoothing based on parameters defined in the robot setup. yellow Switch function on/off and wait for final position The next instruction starts after reach- ing the final position / vacuum switch. green Switch function on/off The function starts and the next instruction starts immediately without waiting to reach the final position / vacuum switch. yellow Release to machine and wait for final position The next instruction starts after reach- ing the final position of the enabled machine movement. green Release to machine The robot enables the machine movement and the program immedi- ately jumps to the next instruction. tur- quoise General release or block in both directions The instruction takes effect immedi- ately, and the following instruction is executed immediately. orange structure instructions Structure commands typically contain conditions. The next instruction is executed after evaluating the condi- tions. Take-off Standard Robot sequence 192 Operator Manual - Robot | Version G/11/401/2/21 Example: A On position move instruction is followed by a Function. The vacuum/compressed air function will not start until the robot position has been reached. Example: A Start move instruction is followed by a Function. The vacuum/compressed air function starts parallel to the move instruction. They can be inserted sequentially or preferably in parallel within the sequence. 2.2.1 Overgrinding movements of linear axes In order to get a round, harmonic and mechanics-sparing movement, it is possible to overgrind the indidivdual movement sentences. Note! The following two examples are not relevant for a Speedy Robot because it is equipped only with a linear axis. Example: movement without overgrinding A On position move instruction, is followed by another On position move instruction. The move instruction at position 3 starts after reaching position 2. Position 3 Position 2 Position 1 Position 3 Position 2 Position 1 Robot sequence 193 Example: movement with overgrinding: A Goto position move instruction, is followed by a Start instruction, and then by another Goto position move instruction. After reaching position 1 the move instruction at position 2 starts, immediately followed by the move instruction at position 3. Position 2 is smoothed. The position smoothing process starts after 50 % of the stroke for the first move at the earliest. The calculated path must touch at least one point on the imaginary circular trajectory (smooth- ing radius). 2.2.2 Smoothing window The smoothing window function reduces jerky movements due to parallel traversing on the X- or Y-axis with the Z-axis when retracting from the machine area in the direction of the deposi- ting area while overgrinding a position. The same applies to movements in the opposite direc- tion.. The following conditions must be satisfied for retracting movements from the machine area to ensure the effectiveness of the smoothing window: Starting point of the first move instruction must lie in the machine area. First move instruction is a pure Z-movement and a Start move instruction. Destination of the first move instruction lies in the Window overgrinding area 1. Destination of the second move instruction lies in the depositing area. The following conditions must be satisfied for advance movements into the machine area to ensure the effectiveness of the smoothing window: Starting point of the first move instruction must lie in the depositing area. First move instruction is a Start move instruction. Destination of the first move instruction lies in the Window overgrinding area 1. Destination of the second move instruction lies in the machine area. Second move instruction is a pure Z-movement. Position 3 Position 2 Position 1 Position 3 Position 2 Position 1 The ball shows the overgrinding radius Robot sequence 194 Operator Manual - Robot | Version G/11/401/2/21 Example: Smoothing window [1] Path with smoothing window [2] Path without smoothing window [3] Window size limits the smoothing window [4] Depositing area [5] Smoothing range window Settings, see Robot setup - Robot node - Parameters tab. [6] Machine area Example: Optimum retracting movement from machine area [1] Starting point of first move instruction [2] Destination of first move instruction or starting point of second move instruction [3] Destination of the second move instruction [4] Window size limits the smoothing window [5] Optimum path +Z +
X +
Y 4 5 6 3 2 1 1 2 3 4 5 Robot sequence 195 Example: Optimum advance movement into machine area [1] Starting point of first move instruction [2] Destination of first move instruction or starting point of second move instruction [3] Destination of the second move instruction [4] Window size limits the smoothing window [5] Optimum path Note! The robot moves from the starting point of the first move instruction to the target point of the second move instruction with the speed of the first move instruction. 2.3 Multiple selection Touching 2 instructions in a sequence selects these two instructions and any instructions between them. If you make a multiple selection, the selection is discarded the next time you select an instruction in the sequence. Touching an area outside the sequence discards all selections. 3 2 1 4 5 Robot sequence 196 Operator Manual - Robot | Version G/11/401/2/21 3 Sequences The entire sequence of an automated plant comprises a number of program sequences. Sequences can be separated to achieve a better overview for complex programs. The robot sequence, user sequence and machine sequence all start at the same time when the start but- ton is pressed. Sequence selection Robot sequence The robot sequence essentially contains a take-off and deposit sequence. Depending on the machine equipment, the robot sequence can, for example, also contain subse- quences for sprue, reject and quality control deposit. The following Engel-defined robot sequences are available: Robot - Simple - sequence Variant for standard applications with screen switch for sequence selection. The Robot - Simple - sequence contains as a default part take-off, sprue depositing, reject depositing, quality control part depositing and parts depositing in the grid on the peripheral unit. Robot - Complex sequence This also includes the program for intermediate layers, sprue separation and inter- mediate deposits. Robot Teach sample sequence Simple variant without screen switch for creating special Teach sequences (screen switches are without effect). Robot empty sequence Empty variant for creating an entire robot sequence. Home position Moves the robot from the deposit or take-off area to the start position with the pushbut- ton for movement to home position . Park position (optional) Moves the robot to a predefined parking position. Referencing The order in which the robot measures the axes in Automatic axis measurement must be set in the Referencing sequence. User sequence Sequence for peripheral unit or special applications not covered by the standard pro- gram. The user sequence starts parallel to the robot sequence. The sequence can be executed in manual mode via a pushbutton or input while the robot motors are switched on and robot is in the home position. Machine sequence Includes the injection molding machine sequence with closing, injection and opening sequence. Home position Referencing Park position Robot sequence Robot sequence User sequence Machine sequence Robot sequence 197 4 Create sequence The following conditions must be met for creating a sequence: Simple view Its possibly to create sequence with assistants help for the expiration production from user's authorization 5 in the mode of operation Teach. Exchanging a subsequence or complete sequence (=variants) from access level 5 and above in the Teach mode possible. Extended view Exchanging a subsequence or complete sequence (=variants) from access level 5 and above in the Teach mode possible. In addition, from access level 7 and above the sequences can be individually modified or newly created. From access level 9 and above the complete range of instructions is available for sequence processing. CAUTION! Danger of damage to equipment due to improper settings! As sequence changes are freely programmable, it is easier to make incorrect settings. How to switch into Teach mode of operation 1. Finish any automatic cycle that is running. 2. Press the Manual program key 3. Press the Teach program key Machine and robot movements occur at reduced pressure and speed in this mode. CAUTION! Danger of damage to equipment! In the mode of operation Teach the safety conditions of the sequence set last for machine and robot are effective. The new safety conditions only become effective after storing the changed se- quence. When you switch to Teach mode, the sequence background switches from gray to white. The following message appears: Editing mode active Effect Machine and robot movements occur with reduced pressures and/or speeds. Remedy Switch to manual mode. Robot sequence 198 Operator Manual - Robot | Version G/11/401/2/21 4.1 Save sequence You must save every sequence change you make. The control unit configures the screens and calculates the required safety conditions only after you save a sequence. CAUTION! Danger of damage to equipment due to improper settings! When running a machine adjust the freely programmable sequence to take ma- chine/robot interactions into consideration. When you save the sequence, the control unit will perform calculations to pre- vent some incorrect settings. Save sequence in the simple view: Quit Teach mode to save. The following dialog box appears. Cancel Cancels exiting Teach mode. The sequence is not saved. Undo Teach mode is exited. No sequence changes are saved. Execute Teach mode is exited, the changes to the sequences are saved. Save sequence in the extended view: Saving by pressing Program and Save menu keys. The control unit stays in Teach operating mode. Saving by exiting Teach mode. Note! The sequence is saved in the parts data. Therefore rewrite the parts data after saving the sequence. Execute Cancel Help Save robot sequence Do you want to save sequence changes? Undo Robot sequence 199 4.2 Assistant for sequence set-up The assistant for sequence set-up helps you in creating a new robot sequence. To start this assistant, change to the Teach mode of operation and select the button with the wand in the simple view. Key for starting the assistant for sequence set-up Robot sequence Robot sequence Quality Control deposit - 1 position Extended view + Info Panel Reject deposit - 1 position Part deposit in shot grid 1 with conveyor- Sprue depositing - 1 posi- Take-off Standard Robot - Simple - sequence Editing mode active Robot sequence 200 Operator Manual - Robot | Version G/11/401/2/21 Start page of assistant for sequence set-up Follow the instructions of the assistant and select the functions you need for your require- ments. The assistant then sets up a robot sequence using Engel defined subsequences based on the functions you have selected. Example: Page with function selection options in the assistant [1] A tool tip with a brief description is available for each function. [2] Function not selected [3] Function selected, cannot be de-selected Function is a permanent component of the robot sequence. [4] Function selected [5] Function not selectable The function Deposit intermediate layers would be available if the function Deposit parts in grid is selected. Assistant for sequence set-up Cancel Help Ready Continue Back Welcome to the sequence set-up assistant! This assistant helps you in creating a new robot sequence. You can adapt the robot sequence to your requirements by selecting pre-defined functions. The subsequent mask assistant leads you through the screen pages where settings can be made. To move on in the assistant, press Continue What should the new sequence be capable of?? Cancel Help Ready Continue Back Remove parts from the mold Insert-place parts in mold Pick & place pre-molded parts Deposit sprue Reject molding depositing Deposit quality control parts Deposit parts Deposit parts on conveyor belt Deposit parts in grid Deposit intermediate layers Reject molding depositing If rejects signal given, deposit parts at a separate posi- 2 3 4 1 5 Robot sequence 201 Last page of assistant for sequence set-up Mask assistant The mask assistant leads you through the screen pages where settings can be made for the created robot sequence. Back/Continue Menu buttons for scrolling through the screen pages where settings can be made for the created robot sequence. Finish Menu button for closing the mask assistant. The control unit automatically changes to the Simple view of the robot sequence. Assistant for sequence set-up Cancel Help Ready Continue Back Your requested functions for the robot sequence have now been selected! Clicking on Continue will save your sequence and launch the mask assistant. The assistant will lead you through the screen pages where settings can be made. Press Ready to accept your sequence and switch to the Simple view. You can now implement the necessary settings using the screen pages. Close sprue gripper before ejector advancing ejector Moving-in with ejector advanced Switch on suction pad Move out as soon as part monitoring OK Move out without considering ejector position after ejector advanced Take-off Standard Take-off Take-off vacuum/compressed air circuits Info Panel Se- Editing mode Help Finish Continue Back Mask assistant Speed for moving- Robot sequence 202 Operator Manual - Robot | Version G/11/401/2/21 4.3 Exchanging variants - Simple view The simple view enables the exchange of a subsequence or complete sequence (=variant) from access level 5 and above in the Teach mode. Classic operation must not be activated. [See Classic operation on page 222.] Engel defined sequences/subsequences, referred to as Variants are available for various applications. These sequences can be modified at any time in the Extended view to reflect your requirements. If you modify an Engel defined variant, the user-defined variant of every modified sequence/ subsequence is overwritten. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety conditions. Procedure 1. Change to Teach mode and Simple view. 2. Select the symbol of the sequence/subsequence you wish to change. 3. The following dialog box appears. 4. Select the desired variant and confirm by pressing Accept. 5. Quit the Teach mode. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety condi- tions. 6. Now save the finished sequence in the parts data set. Take-off Standard Name Description Take-off Standard Element attributes Moving in/out via 2 intermediate positions Take over parts Check function switches on Symbol Accept Cancel Help Exchanging variant Take-off 3 positions Take-off 6 positions Take-off mold inter- Take-off Standard Take-off with mold Take-off with ejector Take-off horizontal/vertical Engel-defined (10) Robot sequence 203 4.4 Exchanging variants - Extended view The extended view enables the exchange of individual subsequences or complete sequences (=variants) from access level 5 and above in the Teach mode.. Engel defined sequences/subsequences, referred to as Variants are available for various applications. From access level 7 and above these sequences can be modified to reflect your requirements. A modified Engel defined variant cannot be overwritten, but you can store it as a User defined variant. If you modify an Engel defined variant, the user-defined variant of every modified sequence/ subsequence is overwritten. You can only store one user defined sequence for each sequence/subsequence. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety conditions. Procedure 1. Change to Teach mode and Extended view. 2. Double-click on the symbol of the sequence/subsequence you wish to change. 3. The following dialog box appears. 4. Select the desired variant and confirm by pressing Accept. 5. To save your work, press Program and Save or leave sequence programming by quit- ting Teach mode. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety condi- tions. 6. Now save the finished sequence in the parts data set. Robot - Simple - sequence Automatic mode of operation active Execute as long as Sprue depositing - 1 position Take-off Standard Name Description Take-off Standard Element attributes Moving in/out via 2 intermediate positions Take over parts Check function switches on Symbol Accept Cancel Help Exchanging variant Take-off 3 positions Take-off 6 positions Take-off mold inter- Take-off Standard Take-off with mold Take-off with ejector Take-off horizontal/vertical Engel-defined (10) Robot sequence 204 Operator Manual - Robot | Version G/11/401/2/21 4.5 Using the Teach pointer to insert an instruction The teach pointer instruction is for fast programming of movements and actions. Set the Teach pointer at any position in the sequence where a desired sequence or movement is to be per- formed. Then perform the desired movement or action. Instruction: The control unit will show the movement or action performed in a turquoise box in the robot sequence and hand control device display. The Teach pointer can be used to program ejector and core movements as release signals for the sequence. Press the respective pushbutton for the machine movement. When the Take over Teach instruction button on the hand control device is pressed, the con- trol unit will insert the instruction in the sequence and the teach pointer will automatically jump ahead a step. Push buttons: If a robot movement is programmed with the Teach pointer, a complete robot position will always be inserted, even if only one axis is moved. The control unit assumes the current posi- tion for any axes which are not moved. You will need to manually optimize the smoothing between one robot movement and the next. Upon quitting the 'Teach' mode, the Teach pointer is automatically removed from the sequence. When a movement or action is performed without the Teach pointer being inserted in the sequence, the control unit displays the performed movement in the robot sequence. When the displayed movement or action is selected, it is inserted into the sequence by clicking at the desired position. Teach pointer + New Program Edit View Robot Set-up mode activated Robot movement Take over Teach instruction + New Program Edit View Robot Set-up mode activated Robot movement Robot sequence 205 Example: This is based on the Robot Teach sample sequence. Use the Teach pointer to insert the move-in points 2 and 3 after move-in point 1 and display the move-in points with speeds on the take-off screen. 1. Change to Teach mode and Extended view. 2. In the Instructions selection window highlight the Teach pointer and insert this into the sequence at the required position. 3. Move the robot axes to the next desired moving-in position. The control unit will show the movement or action performed in a turquoise box in the robot sequence and hand control device display. 4. Press the Take over Teach instruction pushbutton on the hand control device. This will cause the control unit to insert the instruction into the sequence and the teach pointer will automatically jump ahead a step. Take-off position - XYZ Robot sequence Robot sequence Robot Teach sample sequence Take-off Teach sample sequence Home position - XYZ Take-off position -ABC Wait until part take over allowed Moving-in position 1 Execute as long as Automatic mode of operation active Teach pointer + Take-off Teach sample sequence Info Panel Simple view structure instructions Sequence control Robot Injection molding ma- Sequences Peripheral unit Grid Instruc- Teach point- safety gate Take-off position - XYZ Robot sequence Robot sequence Take-off Teach sample sequence Take-off position -ABC Wait until part take over allowed Moving-in position 1 Teach pointer + Take-off Teach sample sequence Info Panel Simple view structure instructions Sequence control Robot Injection molding ma- Sequences Peripheral unit Grid Instruc- Teach point safety gate Robot position 2 Robot sequence 206 Operator Manual - Robot | Version G/11/401/2/21 5. Double-clicking the robot position x you just inserted opens a dialog window where you can enter settings for this position. 6. In the open dialog box, press the name change button for the position and change the name created by the system to Move-in position x. Press the name change button for speed and change the name created by the system to Speed for move-in position x . This will help you distinguish the speed for the move- in position more easily. 7. If you want to display the position and speed on the corresponding screen, additionally enable the selection boxes Display on screen. 8. Select Execute to accept the changes for the robot movement. The parameter lines with the position and speed are displayed on the Take-off screen when you store the sequence. 9. To insert a second position repeat steps 3 through 8. There is no need to remove the Teach pointer after programming because it is auto- matically removed from the sequence on saving. 10. To save your work, press Program and Save or leave sequence programming by quit- ting Teach mode. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety condi- tions. 11. After saving the sequence the position and speed parameter lines are displayed on the Take-off screen. You can use the screen editor to move these parameters to the correct position on the screen page to reflect the removal sequence. 12. Now save the finished sequence in the parts data set. Robot position 6 Speed 6 Type Position Display on screen page Cancel Help Execute Display on screen page Speed Take-off Teach sample... Take-off Teach sam- On position Speed 6 Robot movement Less Robot Moving-in position 2 Speed for moving-in position 2 Moving-in position 3 Speed for moving-in position 3 Robot sequence 207 4.6 Inserting an instruction or sequence manually You can insert any instruction or sequence available in the Instructions selection window into the sequence. Example: This is based on Robot - Simple - sequence and Take-off 6 positions. To reach the take-off point, insert an additional linear axis movement with the name moving-in position 3 after moving-in position 2. The movement type must be On position. The speed name should be Speed for moving-in position 3. 1. Change to Teach mode and Extended view. 2. Select the Linear axis movement move instruction in the selection tree and insert it into the sequence by clicking the corresponding insertion point below Move-in position 2. 3. The following dialog box appears. 4. Use the dialog box to enter settings for the linear axes movement. 5. Enter a meaningful name for the position and speed. The Display on screen switch adds the position at the bottom of the Take-off screen page. + Robot sequence Robot sequence Moving-in 6 positions Mold open Wait until Take-off position - XYZ Moving-in position 1 Moving-in position 2 Robot Instructions: Moving-in 6 positions Move commands Linear axes Rotary axes Robot movement Multi-position lin- Individual axis Info Panel Simple view Linear axes movement Linear axes position 3 Speed for moving-in posi- Speed for moving-in position 3 Type Position Display on screen page Display on screen page Speed Take-off 6 positions Take-off 6 positions On position Cancel Help Execute Less Linear Robot sequence 208 Operator Manual - Robot | Version G/11/401/2/21 6. Select Execute to insert the linear axis movement into the sequence. 7. To save your work, press Program and Save or leave sequence programming by quit- ting Teach mode. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety condi- tions. 8. After saving the sequence the position and speed parameter lines are displayed on the Take-off screen. You can use the screen editor to move these parameters to the correct position on the screen page to reflect the removal sequence. 9. Now save the finished sequence in the parts data set. Moving-in position 3 Robot sequence Instructions Moving-in position 2 Robot Speed for moving-in position 3 =50 On position Moving-in position 1 Linear axes Move commands Individual axis Rotary axes Robot movement Multi-position Relative move- Robot sequence Moving-in 6 positions Moving-in 6 positions Linear axes movement + Info Panel Moving-in 6 positions Simple view Moving-in position 3 Speed for moving-in position 3 Robot sequence 209 4.7 Inserting a parallel closed branch Parallel branches enable the machine to carry out parallel functions. You can program a par- allel closed branch using instructions and subsequences. Example: Performing a wait parallel to two instructions. 1. Change to Teach mode and Extended view. 2. First select the instructions for which you want to run a parallel wait. 3. Select the Parallel closed branch instruction in the Instruction selection window. 4. Click the selected instructions in the robot sequence. A parallel closed branch is inserted. 5. Select the Waiting time instruction in the Instructions selection window. 6. Touch at the desired point in the parallel closed branch in order to insert the instruction. 7. The following dialog box appears. 8. Use the dialog box to enter settings for the instruction. 9. Click Execute . The changed parameters will be accepted and the dialog box closed. Execute Waiting time Time Time module 1 Display on screen page Cancel Help Time module 1 Robot sequence Cancel Robot sequence 210 Operator Manual - Robot | Version G/11/401/2/21 10. This completes programming the Waiting time instruction parallel to the two instruc- tions. You must store the program to enable the sequence. 11. To save your work, press Program and Save or leave sequence programming by quit- ting Teach mode. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety condi- tions. 12. Now save the finished sequence in the parts data set. Robot sequence 211 4.8 Changing an instruction Changing the parameters of an instruction. Example: Changes the part removal time from 0.5 to 1s. 1. Change to Teach mode and Extended view. 2. In the robot sequence, double click the instruction you wish to modify. 3. The following dialog box appears. 4. You can change the parameters for the instruction in the dialog box. Change the time for part removal from 0.5 to 1s. 5. Click Execute . The changed parameters will be accepted and the dialog box closed. 6. To save your work, press Program and Save or leave sequence programming by quit- ting Teach mode. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety condi- tions. 7. Now save the finished sequence in the parts data set. Execute Waiting time Time Time for part removal Display on screen page Cancel Help Time for part removal Take-off 3 positions Less Robot sequence 212 Operator Manual - Robot | Version G/11/401/2/21 4.9 Copying instructions or a subsequence You can use the Copy or Cut functions in the robot sequence to write the selected area to the buffer. You can click a position in the sequence to insert the copied/cut area. If you do not click a sequence branch directly, you must press the Paste menu button before you insert a copied/cut area. This tells the control unit to store the copied/cut area in the buffer. You can then click on a position in the sequence to insert the area. The control unit does not automatically create separate parameters (positions, speeds, etc.) for the instructions and subsequences you copy; instead it uses the originals. When you change the position of a copy, this also changes the original data. However, if you create a new position for copied instructions, this does not automatically change. If this behavior is not what you need, you must use the Duplicate function for copying. This tells the control unit to create a copy of the original, but to create new parameters. Example: Copying a subsequence from the robot sequence to the user sequence. 1. Change to Teach mode and Extended view. 2. Highlight the required subsequence in the robot sequence and press the menu buttons Edit and Copy. 3. Switch to the user sequence. 4. Press the required position in the sequence to insert the instruction. 5. The subsequence is inserted into the sequence from the buffer. Home position Park position Robot sequence Robot sequence User sequence Machine sequence Teach variant Teach variant Robot sequence 213 4.10 Deleting an instruction or subsequence To deactivate a function, it may be necessary to remove one or multiple instructions from the sequence. Subsequences or complete sequences can also be removed. Example: Removing the sprue depositing subsequence. 1. Change to Teach mode and Extended view. 2. Select the sprue depositing subsequence in the robot sequence by touching it. The sequence is now outlined in red, and thus selected. 3. Press the menu keys Edit and Remove . The instruction is now erased from the machine sequence. A deletion can be undone with the menu buttons Edit and Undo. Robot sequence - user Execute as long as Automatic mode of operation active Sprue depositing - 1 position Take-off Standard Robot sequence 214 Operator Manual - Robot | Version G/11/401/2/21 4.11 Inserting an empty sequence The operator can insert an empty sequence with the menu buttons New and Sequence. Procedure 1. At least user level 9 is required for this purpose. 2. Change to Teach mode and Extended view. 3. Press the menu buttons New and Sequence. 4. The following dialog box appears. 5. Select Execute to insert an empty user sequence into the sequence. Sequence Teach variant + New Program Edit View Robot Set-up mode activated Cancel Help Execute The existing sequence will be replaced by an empty user sequence. The original sequence can be regenerated by exchanging variants. New user sequence Robot sequence Robot sequence + Info Panel Simple view Sequence control Robot Injection molding ma- Peripheral unit Instruc- safety gate Robot empty sequence - user (1) Robot empty sequence - user (1) Robot sequence 215 4.12 Create Teach variant You can use this function to create sequences/subsequences for peripheral units or special applications. Every new Teach variant is stored in the Sequences tree below User-defined sequence .. Procedure 1. At least user level 9 is required for this purpose. 2. Change to Teach mode and Extended view. 3. Press the menu buttons New and Teach variant. 4. The following dialog box appears. 5. Enter a name and if needed a short description for the variant. 6. Select the icon in the dialog box. 7. The following dialog box appears. 8. Select an icon for the new variant and confirm with Execute . The control unit cre- ates groups of teach variants based on the icons set. [See Example: Table and con- veyor-belt group on page 216.] Sequence Teach variant + New Program Edit View Robot Set-up mode activated Create Teach variant Name Description Cancel Help Execute Teach variant Symbol Symbols Display file name Symbols Robot sequence 216 Operator Manual - Robot | Version G/11/401/2/21 9. Use Execute to apply your settings. 10. A new User defined sequence branch in which you can access the sequence, can be created in the Instructions selection box in the Sequences branch. 11. Select the new sequence and insert the sequence at the required position in the sequence. Example: Table and conveyor-belt group Create variables Name Description Cancel Help Execute Reject molding lamp Symbol Table 1 Robot sequence Robot sequence + Info Panel Simple view Exchange variants Table 1 Conveyor-belt User-defined (2) Table 2 Robot sequence User Conveyor-belt 2 Robot - Simple - sequence Take-off Standard Element attributes Table 1 Table 2 Name Description Cancel Help Execute Symbol Execute as long as Automatic mode of operation active Robot sequence 217 4.13 Remove user-defined variant You can only remove user-defined variants that are not used in the sequence. You cannot remove Engel-defined variants. Procedure 1. Change to Teach mode and Extended view. 2. Press the menu buttons Program and Delete user sequence. 3. A dialog box with all unused user-defined variants will open. 4. Select the variants no longer needed and confirm with Execute. New Program Edit View Delete user sequence Delete variables Deactivate Print sequence Save Robot Set-up mode activated + Cancel Help Execute Robot - Empty sequence -user (1) Quality Control depositing -Empty subsequence user (1) Sprue depositing - Empty subsequence -user (1) Reject deposit - Empty subsequence -user (1) Deleting unused variants Robot sequence 218 Operator Manual - Robot | Version G/11/401/2/21 4.14 Removing user-defined variables During programming each new variable you create is stored below User-defined sequence . The pool may contain a number of variables which are not used by the current sequence. These variables can be removed from the variable pool using the Program and Remove vari- ables functions.. Before you remove the variables, you must save the current sequence. This tells the control unit which variables you need in the sequence. Procedure 1. Change to Teach mode and Extended view. 2. Press the menu buttons Program and Delete variables. 3. The following dialog box appears. 4. Upon pressing Execute all unused variables will be deleted. New Program Edit View Delete user sequence Delete variables Deactivate Print sequence Save Robot Set-up mode activated + Cancel Help Execute Do you want to delete unused variables? Delete variables Robot sequence 219 4.15 Print sequence In the robot sequence the complete sequence or individual subsequences can be printed out. Example: Printing out the robot sequence on a local printer. 1. Connect a printer to the USB interface of the plant. 2. Press the menu buttons Program and Print sequence. 3. The following dialog box appears. Selection To print out the highlighted section of a sequence. Manual sequence selection To print out the home position, robot and user sequence. Manual variant selection To print out all variants of sequences/subsequences. 4. Select the Setup menu button. New Program Edit View Delete user sequence Delete variables Deactivate Print sequence Save Robot Set-up mode activated + Print Selection Manual sequence selection Manual variant selection Cancel Help Setup Execute Robot sequence 220 Operator Manual - Robot | Version G/11/401/2/21 5. The following dialog box appears. 6. Switch on Output on printer . In addition, the selection possibility print to file is still available. 7. Upon switching to Output on printer the printer dialog of the currently selected printer will open. Select the local printer and press OK. 8. Select Manual sequence selection and confirm with Execute. 9. The following dialog box appears. Detail Tabular printout of each instruction in the selected sequence. Overview Graphic printout of the selected sequence. 10. Highlight the sequences you want to print out and shift them to the right. 11. Select either the Detail or Overview form of printout and confirm with Execute. Directory File name Print to file Type Printer settings Output on printer Cancel Help OK Settings for printing to file Settings for screen page output Print Selection Manual sequence selection Manual variant selection Cancel Help Setup Execute Execute Overview Manual sequence selection Help Cancel Home position User sequence Robot sequence Detail Robot sequence 221 4.16 Deactivating the equipment In the robot sequence programs from access level 5 and equipment from access level 12 can be activated/deactivated using a separate dialog box. Procedure 1. At least user level 12 is required for this purpose. 2. Press the Program and Deactivate menu buttons. 3. The following dialog box appears. 4. Switch the desired equipment or sequence on or off and confirm with Save. New Program Edit View Delete user sequence Delete variables Deactivate Print sequence Save Robot Set-up mode activated + Cancel Help Save Robot Activation A-axis C-axis Vacuum/compressed air 1 Vacuum/compressed air 2 Vacuum/compressed air 3 On On On On On On Equipment Robot sequence 222 Operator Manual - Robot | Version G/11/401/2/21 4.17 Classic operation Classic operation was used in systems with software versions <V2.10. This form of operation can be used by the operator in future by selecting the View and Classic operation menu but- tons in the Extended view. In this form of operation you can use the Variants and Sequence menu buttons in the Extended view to change between exchanging variants and sequence programming. Example: Robot sequence The Variant view enables the exchange of a subsequence or complete sequence with sequence preview. Variants can no longer be exchanged in the Sequence view. Further dif- ferences are described below. Robot sequence Sequence control Robot Injection molding ma- Sequences Peripheral unit Grid Robot sequence Instruc- Robot - Simple - sequence List while Automatic mode of operation ac- If Sprue depositing - 1 position Reject deposit Take-off Standard If Test part depositing active + Info Panel Simple view safety gate Variants Program Edit View Robot Set-up mode activated Robot sequence 223 4.17.1 Exchanging variants - classic operation The Variants view enables the exchange of a subsequence or complete sequence (=variant) from access level 5 and above in the Teach mode. Engel defined sequences/subsequences, referred to as Variants are available for various applications. These sequences can be modified at any time in the Sequence view to reflect your requirements. If you modify an Engel defined variant, the user-defined variant of every modified sequence/ subsequence is overwritten. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety conditions. Sequence Tab Note! In the Variants view you can only select sequences/subsequences, but not commands. Take-off Standard Se- Subse- Subsequence properties Engel-defined (7) Take-off 3 positions Take-off empty se- Take-off mold inter- Take-off 6 positions Robot - Simple - sequence Robot sequence Robot sequence Take-off can be switched Take-off with mold Take-off with ejector Take-off Standard Automatic mode of operation active Execute as long as 1 Position Reject deposit Reject deposit Position Quality Control depositing Quality control Shot part Take-off Standard Moving-in/out via 2 intermediate positions Take over parts Check function switches on screen for cycle time optimization Take-off Teach sam- + Info Panel Take-off and transfer Take-off and insertion Take-off with mold Simple view Robot sequence 224 Operator Manual - Robot | Version G/11/401/2/21 Subsequence Tab Each sequence comprises a number of subsequences. The subsequence variant selected in the selection box is displayed in this tab. This gives you the ability to view Engel or user- defined subsequences before they are transferred to the sequence. Subsequence properties tab Name, short description and icon for selected subsequence. These data can be modified only in the case of user-defined variants. Example: Replacing the Take-off standard with the Take-off 3 positions variant. This is based on the Robot sequence simple. 1. Change to the Teach mode. 2. In level 5 the Variant view is automatically enabled (light blue background). In level 7 or higher, you need to switch to the Variant view using the Variants menu key. Se- Subse- Subsequence properties Take-off Standard Take-off vacuum/compressed air circuits one or If Move to position before mold opening Move out without part take-off J ump to sequence end Se- Subse- Subsequence properties Name Description Take-off Standard Element attributes Moving in/out via 2 intermediate positions Take over parts Check function switches on screen for cycle time optimization Symbol Variants Program Edit View Robot Set-up mode activated + Robot sequence 225 3. Select Take-off standard in the sequence. The available Engel and User-defined sequences are displayed in the selection box. 4. Select the Take-off 3 positions variant in the selection box. You can view the sequence instructions in tab Subsequence. 5. Select Accept to insert the new variant in the sequence. 6. To save your work, press Program and Save or leave sequence programming by quit- ting Teach mode. When a sequence is saved or Teach mode is quit, the control unit saves all changes in the sequence, updates the screen pages and calculates the required safety condi- tions. 7. Now save the finished sequence in the parts data set. Take-off Standard Se- Subse- Subsequence properties Engel-defined (7) Take-off 3 positions Take-off empty se- Take-off mold inter- Take-off 6 positions Robot - Simple - sequence Robot sequence Robot sequence Take-off can be switched Take-off with mold Take-off with ejector Take-off Standard Automatic mode of operation active Execute as long as 1 Position Reject deposit Reject deposit Position Quality Control depositing Quality control Shot part Take-off Standard Moving-in/out via 2 intermediate positions Take over parts Check function switches on screen for cycle time optimization Take-off Teach sam- + Info Panel Take-off and insertion Take-off with mold Simple view Robot - Simple - sequence Take-off 3 positions Move in via Z,Y X take-off position Take over parts for 3/6 position take-off Move out the same path as move in + Take-off 3 positions Se- Subse- Subsequence properties Engel-defined (7) Take-off 3 positions Take-off empty se- Take-off mold inter- Take-off 6 positions Robot - Simple - sequence Robot sequence Take-off can be switched Take-off with mold T k ff ith j t Take-off Standard Automatic mode of operation active Execute as long as Info Panel Robot sequence Simple view Robot sequence 226 Operator Manual - Robot | Version G/11/401/2/21 4.17.2 Creating a Teach Variant - Classic operation You can use this function to create sequences/subsequences for peripheral units or special applications. Every new Teach variant is stored in the Sequences tree below User-defined sequence. Example: You want to create a special subsequence, insert the subsequence into the robot sequence and then program the sequence. 1. At least user level 9 is required for this purpose. 2. Change to the Teach mode. 3. Press the menu buttons Program and Create Teach variant. 4. In the dialog window Create variants , enter a name and if needed a short description for the variant. 5. Select the icon in the dialog box. Variants Program Edit View Create Teach variant Delete user sequence Delete variables Deactivate Print sequence Save + Robot Set-up mode activated Create variants Name Description Cancel Help Execute Reject molding lamp Symbol Robot sequence 227 6. The following dialog box appears. 7. Select an icon for the new variant and confirm with Execute. 8. Use Execute to apply your settings. 9. A new User defined sequence branch, where you can access the sequence, is created in the selection box in the Sequences branch. 10. Select the new sequence and insert the sequence at the required position in the sequence. Open this sequence and program the desired actions. 11. To save your work, press Program and Save or leave sequence programming by quit- ting Teach mode. When a sequence is saved or Teach mode is quit, the control unit saves all changes Symbols Display file name Create variables Name Description Cancel Help Execute Reject molding lamp Symbol + Robot sequence Robot sequence structure instructions Sequences Sequence control Robot Injection molding ma- Peripheral unit Grid Instruc- Execute as long as Automatic mode of operation ac- Simple robot sequence - User Take-off Standard Part deposit Shot grid Free output 1 Activate Wait until Rejects counter for machine Reject molding lamp Execute as long as Automatic mode of operation ac- Info Panel Simple view Robot sequence 228 Operator Manual - Robot | Version G/11/401/2/21 in the sequence, updates the screen pages and calculates the required safety condi- tions. 12. Now save the finished sequence in the parts data set. 4.17.3 Removing user-defined variants - Classic operation You can only remove user-defined variants that are not used in the sequence. You cannot remove Engel-defined variants. Example: Removing a user-defined variant from the User sequence. 1. At least user level 7 is required for this purpose. 2. Change to the Teach mode. 3. In the sequence selection dialog, change from Robot sequence to User sequence. 4. Use the Variant menu button to switch to the Variants view. The sequence is displayed on a light blue background. 5. Open the User-defined branch. 6. Select the sequence you wish to delete. 7. Press the menu buttons Program and Delete user sequence. 8. This removes the scale sequence from the variant pool User-defined sequences. Subsequence properties Robot sequence Se- Subse- Teach variant Weigh scale Robot sequence Engel-defined (1) User-defined (2) Teach variant Reject molding lamp Weigh + Robot sequence Info Panel Simple view Sequence Program Edit View Create Teach variant Delete user sequence Delete variables Deactivate Print sequence Save Robot Set-up mode activated Accept + Robot sequence 229 5 Sequence instructions In the selection window the necessary instruction groups are available for the following func- tions: Robot Robot move commands, position checks, special instructions, vacuum/compressed air, cylinder, outputs. Peripheral unit Depositing conveyor-belt, standard interface, reject request, cylinder, outputs. Injection molding machine Release signals for machine functions and the robot. Safety gates Instructions of the robot safety gate. Sequence control Stop sequence, stop when safety gate requested. Grid Shot grid, individual part grid and Teach grid. Sequences All sequences that are used in the standard sequences and individual instructions that are not listed under the other instruction groups. structure instructions Teach pointers, branchings, waiting instructions, assignments etc. Teach pointer 5.1 Robot This branch contains instructions for various robot functions. 5.1.1 Move commands Robot movements can occur with individual axes or parallel with several axes. There are 2 movement types: On position The next instruction starts after reaching the position. Symbol with a yellow background. Start Move instruction starts and the program immediately jumps to the next instruction. If the next instruction is also a move instruction, the robot will not move precisely to this posi- tion, but use position smoothing based on parameters defined in the robot setup. Symbol with a green background. CAUTION! Danger of damage to equipment due to improper settings! Changing a To position instruction to a Start instruction can trigger the subse- quent movements or actions too early in parallel. Parallel linear axis movements (X, Y, Z) always run so that they reach the set position at the same time. The adjustable speed is always valid for the axis which moves the widest way. The other axes move correspondingly slower. Robot sequence 230 Operator Manual - Robot | Version G/11/401/2/21 Symbol Name Function Individual axis movement The selected axis moves to the set position. Linear axes movement All 3 linear axes (X, Y, Z) move in parallel to the set positions. Rotary axes movement All rotary axes (A, B, C) move in parallel to the set positions. Robot movement All robot axes (X, Y, Z, A, B, C) move in paral- lel to the set positions. Multi-position linear axes position All linear axes (X, Y, Z) for which a position has been set move in parallel to these posi- tions. Relative movement The selected linear axis moves by the set value in plus or minus direction. Robot movement with check position All robot axes (X, Y, Z, A, B, C) move in paral- lel to the set check position. If the set release for the instruction is fulfilled, the robot moves on to the set positions. If the release is fulfilled before reaching the check position, the check position is smoothed. Stop movement The instruction interrupts a running Start movement instruction and starts the next instruction in the sequence. Overgrinding Starting at the Smooth instruction in the sequence, all Start move instructions with the radius set in this instruction are smoothed, as are allStart move instructions of the fol- lowing cycles in automatic mode. If this instruction is programmed several times in the sequence, the smoothing radius always remains in effect until the next Smooth instruction. Reference robot axis Insert the Reference robot axis instruction for each servoaxis in the Referencing sequence. The order in which the robot measures the servoaxes in Automatic axis measurement must be set in the Referencing sequence. Robot sequence 231 5.1.2 Position check Check this instruction to see whether the current robot position is in a range or on a position. Example: Check current position within range In the Movement to home position sequence, a query asks whether the linear axes are in a range. If the linear axes are in the set range, status flag 1 is set to True . The status flag is queried by the If structure command, and an X single axis movement, which is only executed in this case, is inserted. Symbol Name Function Check current position within range Checks whether the current linear axes position is in the defined range. The status flag is set if the lin- ear axes are in the range. Check current position to set position Checks whether the current linear axes position is on the defined position. The status flag is set if the current linear axes position is the same as the defined position. Check current position within range Linear axes position If Status marker 1 Movement from area 1 - X Robot sequence 232 Operator Manual - Robot | Version G/11/401/2/21 5.1.3 Special instructions This branch contains instructions for various special robot functions and three macro instruc- tions for rotary axes. 5.1.3.1 Switch off -axis Instructions: With the function Axis switch-off , you can switch off the power for the servoaxes. This permits moving of a servoaxis with the ejector on part handover, for example. Instruction Switch off axis - motor off switches off the power for the selected axis. This may happen only if the robot axes are at a standstill. A move instruction may not be programmed for an axis that does not have power. Instruction Switch off axis - motor on switches the power for the corresponding axis back on. Example: You need to transfer a molded part to a negative mold mounted on the end-of-arm tooling. The end-of-arm tooling is robust enough to allow it to be retracted by an ejector movement. In order to permit the axis to be moved with the ejector, the Switch off axis instructions must be programmed. Switch off -axis Motor off Motor on Switch off axis - motor on Time =0,3 Mold pause time Move out position 1 - X retract Ejector Take over parts standard user [ON] without monitoring Take-off vacuum/compressed air circuits X-axis Switch off axis - motor off advance Ejector X-axis Robot sequence 233 5.1.3.2 Mass identification The control unit usually automatically determines the robot's manipulation weight when the axes are moved. However, the instruction Wait until part take over allowed must be in the sequence, because the instruction Adjust dynamics is included in the instruction Wait until part take over allowed. If the instruction Wait until part take over allowed is not in the robot sequence, the instruction Adjust dynamics must be added to the sequence Instruction: The maximum acceleration of the robot axes is adjusted with the instruction Adjust dynamics . The basis for this adjustment is the highest manipulation weight that was determined since the last time this instruction was called. Low manipulation weight enables higher acceleration and higher manipulation weight enables lower acceleration of the robot. The maximum robot power can thus always be exploited. Dynamic adjustment is not implemented in robot sequences without the instruction Wait until part take over allowed and Adjust dynamics . The robot therefore only travels with the lower accelerations that are specified for the maximum allowable manipulation weight. 5.1.3.3 Brakes test The brake test serves detect decreasing brake performance due to wear or contamination of the Y holding brake. Instruction: CAUTION! Danger of damage to equipment! The brake test must only be performed at positions where slight movement of the axis will not cause a collision. In the standard case the brake test is performed during movement to the home position after expiration of the set test interval in the robot setup. For this purpose the Brake test after inspection interval instruction is programmed in the robot sequence Home position. Mass identification Adjust dynamics Brakes test Brake test after test interval Robot sequence 234 Operator Manual - Robot | Version G/11/401/2/21 Example: Robot sequence Home position with Brake test after inspection interval instruction. If the Brake test after inspection interval instruction is removed from the Home position robot sequence this must be programmed at another position in the sequence. In unmanned operations, where the system runs for weeks or months in automatic mode, a brake test will not be performed for an extended period of time. In this case, the instruction should also be added at a different position in the sequence. Robot motors must be switched on for brake test Effect Brake test not possible. Remedy Switch on robot motor. Manual mode required for brake test Cause Machine is not in manual mode. Effect Brake test not possible. Remedy Switch to manual mode. Home position Home position - Standard sequence Home position from take-off area Home position from depositing area Home position in home position If J ump to sequence end Brake test - Brake test after inspection interval Y axis brake test Robot sequence 235 5.1.3.4 Cycle time Instructions: The instructions Cycle time - start and Cycle time - stop allow for user-defined time mea- surements in the sequence which are displayed on the Cycle time analysis robot screen When the sequence reaches the Cycle time - start instruction, cycle time measurement starts; it stops at Cycle time - stop. To prevent a corruption of the result the exact starting/stopping points (status markers, pro- gram switches, ..) can be set with signal request for the two instructions. A corruption occurs when, for example, before the cycle time measurement instructions a move instruction is set which is trajectory smoothed, as the cycle measurement then starts or stops immediately. Example: Cycle time start dialog window Axis - Brake test failed Cause Braking force too weak. Effect Robot motor blocked. Remedy Switch control voltage off and back on to remove the blocking. Then carry out the movement to home position. Axis - Brake safety test required Cause Braking force too weak in last brake test. Effect Brake test required. Remedy Move to home position. Cycle time Start Stop Init new cycle Cancel Help More Execute Cycle time counter Start at Start at - state User Time meter 1 No selection positive edge of pulse Cycle time - start Robot sequence 236 Operator Manual - Robot | Version G/11/401/2/21 The instruction Cycle time - Init new cycle starts measuring the standard times on the screen Cycle time analysis robot . This instruction is only required for custom applications, as stan- dard time measurements for cycle time analysis are performed automatically. Example: To record the cycle time for the Parts depositing in teach grid 1 with conveyor-belt subse- quence, the Cycle time - start and stop instructions must be programmed. 5.1.3.5 Macro instructions The following three instructions for rotary axes are also designated as macro instructions and are used in Engel-defined sequences. CAUTION! Danger of damage to equipment due to improper settings! When removing manual axes macroinstructions settings on the Quick Setup screen page become ineffective. Instruction: The macro instruction takes rotary axes positions, their priorities and any parallel movements when moving Z out of the machine area into consideration. Parameter setting in Robot Quick Setup tab Rotary axes on moving out in depositing direction. conveyor-belt Part depositing in teach grid 1 with Teach grid 1 conveyor-belt Part depositing in teach grid 1 with Depositing conveyor belt 1 - Part deposited User Time meter 1 Cycle time - start User Time meter 1 Cycle time - stop Depositing conveyor-belt 1 - Wait depositing allowed Rotary axes movements moving out from machine area (Quick Setup) Robot sequence 237 Example: Instruction: The macro instruction takes the settings in the robot Quick Setup, the Rotary axes on moving out in depositing directiontab and parameter Rotary axes to deposit from into account. Example: Instruction: The macro instruction takes rotary axes positions, their priorities and any parallel movements when moving Z into the machine area into consideration. Parameter setting in the robot Quick Setup tab Rotary axes moving in take-off direction. Stop when safety gate requested Moving-out standard Moving-out position 1 Moving-out position 2 Speed for move-out position 2 =100 Rotary axes movement moving out from machine area Rotary axes movements before depositing (Quick Setup) Lower swivelling Moving-in shot grid 1 with conveyor-belt Position over depositing Wait until Shot grid 1 - depositing position screened Special instructions rotary axes movement Rotary axes movements after depositing (Quick Setup) Robot sequence 238 Operator Manual - Robot | Version G/11/401/2/21 Example: Moving-in/out vertically -> Special instructions rotary axes movement after depositing completed before Wait until Move from depositing area to machine area Move from depositing area to machine area Not in the depositing area - over upper swivelling limit If Wait until Upper swivelling limit depositing area If Special instructions rotary axes movement Wait until Manual position in the depositing area - Home position - XYZ Position before Robot sequence 239 5.1.4 Vacuum/compressed air Instruction to switch a vacuum/compressed air circuit on/off with or without monitor. Instruction: Dialog window and setting options for the instruction in the sequence: 1. Select required vacuum/compressed air circuit and confirm with Execute. 2. Implement settings and confirm with Execute. Activated The program switch activates vacuum/compressed air circuit x. Deactivated in the sequence This flag indicates that the equipment is active. Type The settings Vacuum, Compressed air or Barrel are available in the selection field type for the vacuum/compressed air circuits. Depending on the type settings, the parameters for the end positions, parts and vacuum monitoring are shown. Parts monitoring or Final positions monitoring [See Vacuum/compressed air circuits on page 89.] Blow function deactivated The blow function is only available with vacuum/blow/compressed air circuits. Please note that the blow function works for each Vacuum,, Compressed air or Barrel type. Blowing time The set time switches the vacuum/blow/compressed air circuit to blow after the circuit is Vacuum/compressed air Vacuum/compressed air Cancel Help Execute Choice: [ OFF ] with monitoring Action Vacuum/compressed air More Blowing time Vacuum/compressed air Vacuum/Blowing/Compressed Vacuum/compressed air Cancel Help Execute More Vacuum/Blowing/Compressed air 1 Activated Vacuum Type Signal 10 and Part monitoring Blow function deactivated Calibration [ OFF ] with monitoring Action Deactivated in the sequence Ana- OFF ON Robot sequence 240 Operator Manual - Robot | Version G/11/401/2/21 switched off. This means that e. g. molded parts can be more easily removed from the end of arm tooling. Analog vacuum monitoring The control unit detects whether e. g. a part is in the end of arm tooling by monitoring the pressure in the vacuum circuit. OFF If the vacuum drops below the OFF value, then the control unit does not detect a part in the end of arm tooling. ON If the vacuum reaches the ON value, then the control unit detects a part in the end of arm tooling. Actual value display flag An active flag shows that a part is in the end of arm tooling. Calibration Switch offsuction pad ; actual value display should show 0 bar (0 psi). If this is not the case, calibrate the vacuum circuit with calibrate program switch =zero point determi- nation. Action Set the desired movement for the vacuum/compressed air circuit. There are 2 instruc- tion types: With monitoring The next instruction starts after reaching the final position / vacuum switch. Symbols with a yellow background. Without monitoring The function starts and the next instruction starts immediately without waiting to reach the final position / vacuum switch. Symbols with a green background. Robot sequence 241 5.1.5 Vacuum/compressed air group Instruction to switch a vacuum/compressed air group on/off with or without monitor. Instruction: Dialog window and setting options for the instruction in the sequence: 1. Select required vacuum/compressed air group and confirm with Execute. 2. Implement settings and confirm with Execute. Take-off vacuum/compressed air circuits The group configuration serves to summarize individual vacuum/compressed air circuits in groups. Using the command Group vacuum/compressed air , several vacuum/com- pressed air circuits can be switched on/off with just one command. Action Set the desired movement for the vacuum/compressed air group. There are 2 instruc- tion types: With monitoring The next instruction starts after reaching the final position / vacuum switch. Symbols with a yellow background. Without monitoring The function starts and the next instruction starts immediately without waiting to reach the final position / vacuum switch. Symbols with a green background. Blowing time With the setting No selection , the blowing time set in the vacuum/compressed air cir- cuit robot setup is used. A user-defined blowing time can also be set using the selection field. The set time switches the vacuum/blow/compressed air circuit to blow after the circuit is switched off. This means that e. g. molded parts can be more easily removed from the end of arm tooling. The blow function is only available for groups with vacuum/blow/compressed air circuits. Vacuum/compressed air Vacuum/compressed air group Cancel Help Execute Choice: [ OFF ] with monitoring Action Vacuum/compressed air More No selection: Blowing time Vacuum/compressed air Vacuum/compressed air circuit Vacuum/compressed air Cancel Help Execute More [ OFF ] with monitoring Action No selection: Blowing time Take-off vacuum/compressed air circuits Robot sequence 242 Operator Manual - Robot | Version G/11/401/2/21 5.1.6 Vacuum/compressed air group off on part lost The instruction switches off the vacuum/compressed air circuits of the selected vacuum/com- pressed air group that have lost a part. Used in the Home position sequence. Instruction: Dialog window and setting options for the instruction in the sequence: 1. Select required vacuum/compressed air group and confirm with Execute. 2. Implement settings and confirm with Execute. Take-off vacuum/compressed air circuits The group configuration serves to summarize individual vacuum/compressed air circuits in groups. Using the command Group vacuum/compressed air off when part lost , sev- eral vacuum/compressed air circuits can be switched off with just one command if a part is lost. 5.1.7 barrel Activation of a robot barrel in the appropriate direction, +/ -, with or without monitoring. Instruction: 5/3-Directional valve (optional) The following must be noted when actuating a barrel using a 5/3 directional valve (special equipment): When the robot motor is switched off, e. g. when the safety gate is opened, the 5/3 directional valve depressurizes the barrel, allowing the barrel to leave its final position. Adjust the Home position sequence so that the barrel moves to a defined position dur- ing the movement to home position. Manual mode Opening the safety gate switches off the outputs that actuate the 5/3 directional valve. When the safety gate is closed again, the outputs are switched back on again, but only if a final position is active. Automatic mode Opening the safety gate switches off the outputs that actuate the 5/3 directional valve. When the safety gate is closed again, the outputs are switched back on again in the same state as before the safety gate was opened. Vacuum/compressed air group off on part lost Vacuum/compressed air group off on part lost Cancel Help Execute Choice: Vacuum/compressed air More Vacuum/compressed air group off on part lost Cancel Help Execute Choice: Vacuum/compressed air More Take-off vacuum/compressed air circuits barrel Robot sequence 243 If final position monitoring was active before the safety gate was opened, then the robot remains at the instruction Stop when safety gate requested until the respec- tive final position becomes active. If this does not occur, a corresponding alarm is output. Dialog window and setting options for the instruction in the sequence: 1. Select barrel and confirm with Execute. 2. Implement settings and confirm with Execute. Activated Program switch enables or disables barrel. Mode of operation Select operating mode end-position controlled and time-controlled . The default set- ting for ENGEL is end-position controlled and the time-controlled function is used for emergency operations in case of defective limit switch or cable break. If you select time- controlled the movement is complete for the control unit after the monitoring period has elapsed. End position monitoring +/- You can set various monitoring variants here to modify the axis functions in the best possible way. No monitoring The movement is not monitored for end position or monitoring time elapsed. Time-dependent After the monitoring time has elapsed, the movement is complete for the control unit. In case of a movement [ - ] to final position or [ +] to final position , the next instruction in the robot sequence starts after this time. Permanently The barrel must reach the final position within the monitoring time and is then contin- uously monitored. In case of a movement [ - ] to final position or [ +] to final posi- tion , the next instruction in the robot sequence starts after the final position is reached. barrel Cancel Help Execute Choice: [ - ] up to final position Action barrel More barrel Free barrels - Free barrel 1 barrel Cancel Help Execute Less Free barrels - Free barrel 1 Activated Free barrels - Free barrel 1 barrel No monitoring End position monitoring - No monitoring End position monitoring + Monitoring time [ - ] up to final position Action Robot sequence 244 Operator Manual - Robot | Version G/11/401/2/21 End position reached The axis must reach the final position once within the monitoring time In case of a movement [ - ] to final position or [ +] to final position , the next instruction in the robot sequence starts after the final position is reached. Permanently switch-on-delayed The barrel must reach the final position within the monitoring time. The Delay time for final position monitoring starts after reaching the final position. After the Delay time for final position monitoring has elapsed, the barrel is continuously monitored. This only applies for movements [ - ] to final position or [ +] to final position. End position reached switch-on delayed The barrel must reach the final position within the monitoring time. The Delay time for final position monitoring starts after reaching the final position. This only applies for movements [ - ] to final position or [ +] to final position. Monitoring time The end position must be reached within this time. Action Set the desired movement for the barrel. There are two types of instruction: With monitoring The next instruction starts after reaching the final position / vacuum switch. Symbols with a yellow background. Without monitoring The function starts and the next instruction starts immediately without waiting to reach the final position / vacuum switch. Symbols with a green background. 5.1.8 Cylinder group Activates a robot barrel group (all barrels) in the appropriate direction, +or -, with or without monitoring. Instruction: Dialog window and setting options for the instruction in the sequence: 1. Select required barrel group and confirm with Execute. 2. Implement settings and confirm with Execute. Cylinder group Cylinder group Cancel Help Execute Choice: [ - ] up to final position Action Cylinder group More Cylinder group All cylinders Cylinder group Cancel Help Execute More [ - ] up to final position Action All cylinders Robot sequence 245 All cylinders The group configuration serves to summarize individual cylinders in groups. This allows several cylinders to be moved with the instruction Cylinder group in a sequence with [ - ] to final position or [ +] to final position. Action Set the desired movement for the vacuum/compressed air group. There are 2 instruc- tion types: With monitoring The next instruction starts after reaching the final position / vacuum switch. Symbols with a yellow background. Without monitoring The function starts and the next instruction starts immediately without waiting to reach the final position / vacuum switch. Symbols with a green background. 5.1.9 outputs Outputs instruction for activating/deactivating robot outputs. Instruction: Dialog window and setting options for the instruction in the sequence: Output Select required output. Action Select output option Activate or Deactivate. Pulse duration If the output needs to be activated/deactivated for an adjustable pulse duration, then a time value also needs to be selected for this parameter. The following dialog box opens where you can enter or select a user-defined time value. outputs outputs Cancel Help Execute Vacuum / compressed air 1 - Deactivate Action Output Less Free output 1 Time value 1 Pulse duration Time value 1 Pulse duration Cancel Help Execute Choice: User Create Time value 1 No selection Robot sequence 246 Operator Manual - Robot | Version G/11/401/2/21 Time value The output is then activated/deactivated for a set pulse duration according to the Action parameter setting. Parameter is only displayed if a time value is set in the Pulse duration parameter. 5.1.10 Work areas/prohibited areas Enable/disable accessing of work area or prohibited area. Instruction: Dialog window and setting options for the instruction in the sequence: Work areas/prohibited areas Select robot work area or prohibited area to be enabled/disabled. Action Selection option [ ON ] or [ OFF ]. Work areas/prohibited Work areas/prohibited areas Cancel Help Execute Choice: Work areas/prohibited areas More [ OFF ] Action Robot sequence 247 5.2 Peripheral unit Instructions for controlling peripheral units. 5.2.1 Depositing conveyor-belt Instructions for controlling the depositing conveyor belt and the communication between the robot and the conveyor-belt. Instructions: Wait until depositing allowed and part deposited Collisions between end-of-arm-tooling and conveyor-belt should be prevented with the instruc- tion Wait until depositing allowed and Part deposited . The robot waits for the release from the conveyor-belt to deposit molded parts with the instruction Wait until depositing allowed . For Part depositing without grid with conveyor-belt , the Part deposited instruction means that the conveyor-belt is stepped after every cycle. For Part depositing with grid and conveyor- belt , this instruction means that the conveyor-belt is stepped after the grid is full. Stepping The instruction Cycle actuates the depositing conveyor-belt once for the depositing conveyor- belt running time. Action The instruction Action switches the conveyor-belt, depending on the setting, to [Off], [On] per- manent operation, [On] time-driven or [On] clear. The actions [On] permanent operation and [On] time-driven are possible in both conveyor- belt moving directions if the depositing conveyor-belt has reversing operation. Note! It must be noted that the grid must be reset after each step or actuation of the conveyor-belt. Depositing conveyor-belt Sequence instructions Wait until depositing allowed Part deposited Stepping Action Robot sequence 248 Operator Manual - Robot | Version G/11/401/2/21 5.2.2 Reject deposit Instruction: The Request instruction sets the Rejects signal status marker to TRUE . In the Engel- defined sequences, this status marker is queried with the structure instruction If before the subsequence Reject deposit. After the part is deposited on the rejects depositing, the instruction Reset rejects request resets the status marker Rejects signal. [See Reject deposit on page 273.] Example: The robot deposits a part on the scales. If the weight is not within tolerance limits, the instruc- tion Reject deposit request makes the robot pick up the part and deposit it on the rejects depositing. Instruction Part is reject increments the rejects counter and reduces the piece counter of the injection molding machine. [See Injection molding machine on page 253.] Reject deposit Request Time=0 Delay time weighing 1 Position Reject deposit Test part depositing active Quality control Shot grid 1 with Part depositing in Reject deposit If If Sprue depositing - 1 position Part pick-up Position Weighing part Weighing Weighing part Part is reject Reject deposit request Weigh scale: weight in tolerance range If Robot sequence 249 5.2.3 Quality control deposit Instruction: The Request instruction sets the Quality control part requested status marker to TRUE . In the Engel-defined sequences, this status marker is queried with the structure instruction If before the subsequence Quality Control part depositing. The robot deposits parts on the quality control part depositing until the set Quality Control parts - set value on the Quality control deposit screen page has been reached. [See Quality Control deposit - 1 position on page 153.] 5.2.4 barrel Activates a peripheral unit barrel in the appropriate direction, +/ -, with or without monitoring. Instruction: 5/3-Directional valve (optional) The following must be noted when actuating a barrel using a 5/3 directional valve (special equipment): When the robot motor is switched off, e. g. when the safety gate is opened, the 5/3 directional valve depressurizes the barrel, allowing the barrel to leave its final position. Adjust the Home position sequence so that the barrel moves to a defined position dur- ing the movement to home position. Manual mode Opening the safety gate switches off the outputs that actuate the 5/3 directional valve. When the safety gate is closed again, the outputs are switched back on again, but only if a final position is active. Automatic mode Opening the safety gate switches off the outputs that actuate the 5/3 directional valve. When the safety gate is closed again, the outputs are switched back on again in the same state as before the safety gate was opened. If final position monitoring was active before the safety gate was opened, then the robot remains at the instruction Stop when safety gate requested until the respec- tive final position becomes active. If this does not occur, a corresponding alarm is output. Dialog window and setting options for the instruction in the sequence: Quality control deposit Request barrel Robot sequence 250 Operator Manual - Robot | Version G/11/401/2/21 1. Select barrel and confirm with Execute. 2. Implement settings and confirm with Execute. Activated Program switch enables or disables barrel. Mode of operation Select operating mode end-position controlled and time-controlled . The default set- ting for ENGEL is end-position controlled and the time-controlled function is used for emergency operations in case of defective limit switch or cable break. If you select time- controlled the movement is complete for the control unit after the monitoring period has elapsed. End position monitoring +/- You can set various monitoring variants here to modify the axis functions in the best possible way. No monitoring The movement is not monitored for end position or monitoring time elapsed. Time-dependent After the monitoring time has elapsed, the movement is complete for the control unit. In case of a movement [ - ] to final position or [ +] to final position , the next instruction in the robot sequence starts after this time. Permanently The barrel must reach the final position within the monitoring time and is then contin- uously monitored. In case of a movement [ - ] to final position or [ +] to final posi- tion , the next instruction in the robot sequence starts after the final position is reached. End position reached The axis must reach the final position once within the monitoring time In case of a movement [ - ] to final position or [ +] to final position , the next instruction in the robot sequence starts after the final position is reached. Permanently switch-on-delayed The barrel must reach the final position within the monitoring time. The Delay time for final position monitoring starts after reaching the final position. After the Delay time for final position monitoring has elapsed, the barrel is continuously monitored. This only applies for movements [ - ] to final position or [ +] to final position. barrel Cancel Help Execute Choice: [ - ] up to final position Action barrel More barrel Free barrels - Free barrel 1 barrel Cancel Help Execute Less Free barrels - Free barrel 1 Activated Free barrels - Free barrel 1 barrel No monitoring End position monitoring - No monitoring End position monitoring + Monitoring time [ - ] up to final position Action Robot sequence 251 End position reached switch-on delayed The barrel must reach the final position within the monitoring time. The Delay time for final position monitoring starts after reaching the final position. This only applies for movements [ - ] to final position or [ +] to final position. Monitoring time The end position must be reached within this time. Action Set the desired movement for the barrel. There are two types of instruction: With monitoring The next instruction starts after reaching the final position / vacuum switch. Symbols with a yellow background. Without monitoring The function starts and the next instruction starts immediately without waiting to reach the final position / vacuum switch. Symbols with a green background. 5.2.5 outputs Outputs instruction for activating/deactivating peripheral unit outputs. Instruction: Dialog window and setting options for the instruction in the sequence: Output Select required output. Action Select output option Activate or Deactivate. Pulse duration If the output needs to be activated/deactivated for an adjustable pulse duration, then a outputs outputs Cancel Help Execute Free output 1 Deactivate Action Output Less Free output 1 Time value 1 Pulse duration Time value 1 Robot sequence 252 Operator Manual - Robot | Version G/11/401/2/21 time value also needs to be selected for this parameter. The following dialog box opens where you can enter or select a user-defined time value. Time value The output is then activated/deactivated for a set pulse duration according to the Action parameter setting. Parameter is only displayed if a time value is set in the Pulse duration parameter. Pulse duration Cancel Help Execute Choice: User Create Time value 1 No selection Robot sequence 253 5.3 Injection molding machine Instructions for the communication between robot and injection molding machine. The following instruction types are available: Release and wait After release, the cycle waits for the movement to be executed; then the next instruction is executed (symbols with yellow background). Release only After release, the cycle does not wait for the movement to be executed, but continues with the next command (icons with green background). Block/release Blocking or re-enabling a movement (symbols with blue background). CAUTION! Danger of damage to equipment due to improper settings! Modifying a yellow wait command to a green release command can trigger the subsequent movements or events too early in parallel. Note! If a movement is enabled in one direction, movements in the opposite direction will be blocked. 5.3.1 Mold Mold movement closing, opening or releasing/blocking in both directions. Clamping force build-up/reduction is not blocked. Instruction: Dialog window and setting options for the instruction in the sequence: Close; Open; Open to intermediate position After release, the cycle waits for the movement to be executed; then the next instruction Mold Mold Cancel Action More Close Close Open enable closing enable opening open to intermediate position enable opening to intermediate position Release closing at early start position enable block Robot sequence 254 Operator Manual - Robot | Version G/11/401/2/21 is executed (symbols with yellow background). If a movement is enabled in one direction, movements in the opposite direction will be blocked. enable closing, enable opening After release, the cycle does not wait for the movement to be executed, but continues with the next command (icons with green background). If a movement is enabled in one direction, movements in the opposite direction will be blocked. Enable opening to intermediate position; Release closing at early start position After release, the cycle does not wait for the movement to be executed, but continues with the next command (icons with green background). If a movement is enabled in one direction, movements in the opposite direction will not be blocked. Release; block Blocking or re-enabling movements in both directions (symbols with blue background) 5.3.2 Enable clamp force build-up/reduction This instruction releases the clamp force build-up/reduction. Instruction: 5.3.3 Block clamp force build-up-/reduction This instruction blocks the clamp force build-up/reduction. Instruction: In machines without tie-bars, clamp force build-up causes the C frame to expand, which in turn displaces depositing/pick-up positions. To allow for easy depositing/pick-up of parts, clamp force build-up/reduction must be blocked. [See Position compensation for tie-bar-less machines on page 275.]. Enable clamp force build-up/reduction Block clamp force build-up-/reduction Robot sequence 255 5.3.4 Ejector Ejector movement forward, back or release/lock in both directions. Instruction: Dialog window and setting options for the instruction in the sequence: advance, retract, advance to intermediate position, retract to intermediate posi- tion After release, the cycle waits for the movement to be executed; then the next instruction is executed (symbols with yellow background). If a movement is enabled in one direction, movements in the opposite direction will be blocked. enable advance; enable retract; advance to intermediate position; retract to inter- mediate position After release, the cycle does not wait for the movement to be executed, but continues with the next command (icons with green background). If a movement is enabled in one direction, movements in the opposite direction will be blocked. Release; block Blocking or re-enabling movements in both directions (symbols with blue background) Ejector Ejector Cancel Action More advance Close retract enable advance enable retract advance to intermediate position retract to intermediate position enable advance to intermediate position enable retract to intermediate position enable block Robot sequence 256 Operator Manual - Robot | Version G/11/401/2/21 5.3.5 Cores Core moving in, moving out or release/lock in both directions. Instruction: Dialog window and setting options for the instruction in the sequence: Action moving in and moving o;t After release, the cycle waits for the movement to be executed; then the next instruction is executed (symbols with yellow background). If a movement is enabled in one direction, movements in the opposite direction will be blocked. enable moving in, enable moving out After release, the cycle does not wait for the movement to be executed, but continues with the next command (icons with green background). If a movement is enabled in one direction, movements in the opposite direction will be blocked. Release; block Blocking or re-enabling movements in both directions (symbols with blue background) Signal The appropriate action will be transmitted to the injection molding machine for the set signal. Attention! The instruction specifies a maximum number of signals which may not be supported by the robot interface. Note the configuration and actual number of enable signals on the Robot interface screen page. Cores Core Cancel Action More Signal 1 move in Help Execute Signal Robot sequence 257 5.3.6 Air valves Instruction: Dialog window and setting options for the instruction in the sequence: Action enable, wait for blowing time After release, the cycle waits for the movement to be executed; then the next instruction is executed (symbols with yellow background). enable, do not wait for blowing time After release, the cycle does not wait for the movement to be executed, but continues with the next command (icons with green background). block Blocking of movements (symbols with blue background) Signal The appropriate action will be transmitted to the injection molding machine for the set signal. Attention! The instruction specifies a maximum number of signals which may not be supported by the robot interface. Note the configuration and actual number of enable signals on the Robot interface screen page. 5.3.7 Injection molding machine vacuum circuit Instruction is available, if the injection molding machine supports this option. Instruction: Dialog window and setting options for the instruction in the sequence: Action Air valves Core Cancel Action More Air valve 1 enable, wait for blowing Help Execute Signal Injection molding machine vacuum circuit Injection molding machine vacuum circuit Cancel Action More Vacuum circuit 1 switch on Help Execute Signal Robot sequence 258 Operator Manual - Robot | Version G/11/401/2/21 switch on, switch off After release, the cycle waits for the movement to be executed; then the next instruction is executed (symbols with yellow background). Release switch on, Release switch off After release, the cycle does not wait for the movement to be executed, but continues with the next command (icons with green background). Release; block Blocking or re-enabling movements (symbols with blue background) Signal The appropriate action will be transmitted to the injection molding machine for the set signal. Attention! The instruction specifies a maximum number of signals which may not be supported by the robot interface. Note the configuration and actual number of enable signals on the Robot interface screen page. 5.3.8 Wait until part take over allowed Instruction: Robot only moves into the mold when mold open or early start position (if set) has been reached. Attention: The instruction Wait until part take over allowed may only be used once in a cycle. Further functions are available for selection in the mold swiveling device option [See Mold swivelling device on page 313.] 5.3.9 Part is reject Instruction: If a molded part is classified as a good part by the injection molding machine, but is later dis- carded as a reject (e.g. automatic ultrasonic testing for bubbles), you can increment the rejects counter and decrease the shot counter for the injection molding machine with this instruction. [See Reject deposit on page 248.] x not moved in Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. Wait until part take over allowed Part is reject Robot sequence 259 x not moved out Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. x not open Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. x not closed Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. x not open on intermediate position Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. x not closed on intermediate position Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. Robot sequence 260 Operator Manual - Robot | Version G/11/401/2/21 x not in front Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. x not back Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. x not in front on intermediate position Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. x not back on intermediate position Cause The function is not at the position set in the sequence. Effect Automatic start is not possible. Remedy Set the position correctly in manual mode. Robot sequence 261 5.4 safety gate All instructions for the robot safety gates and robot light beam guards are listed below. 5.4.1 Robot safety gate Instructions: The Request opening instruction has the same function as the Access demand key on the protection door. See chapter Safety - Robot safety guarding. Example: The robot sequence stops due to the Robot safety gate 2 - request opening instruction at the next Stop when safety gate is requested instruction and enables the protection door to be opened. This saves the operator from having to make a manual request to open the protec- tion door when depositing a quality control part. Symbol Name Function Stop when safety gate requested Plant stops sequence with this instruction when the safety gate access request key or the light beam guard access request key is pressed. The plant also stops the sequence if the instruction Request open- ing for a safety guard or the instruction Request intervention for a light beam guard was inserted in the sequence. Robot safety gate request opening Stop when safety gate requested Mvoe out control depositing 1 position user Lower swivelling limit depositing area reached Wait until Robot safety gate 2 - Request opening Lower swivelling Mvoe out control depositing 1 position user Upper swivelling [ OFF ] with monitoring Quality Control vacuum/compressed air circuits Robot sequence 262 Operator Manual - Robot | Version G/11/401/2/21 5.4.2 Robot light beam guard The following instruction is only available if the plant is equipped with a light beam guard. Instructions: The Request intervention instruction has the same function as the Access demand key on the light beam guard control panel. See chapter Safety - Light beam guard. Example: The robot sequence stops due to the Robot light beam guard - Request intervention instruc- tion at the next Stop when safety gate is requested instruction and enables the light beam guard for interruption. This saves the operator from having to make a manual request to enable the light beam guard when depositing a quality control part. Robot light beam guard Request intervention Stop when safety gate requested Mvoe out control depositing 1 position user Lower swivelling limit depositing area reached Wait until Robot light beam guard - Request intervention Lower swivelling Mvoe out control depositing 1 position user Upper swivelling [ OFF ] with monitoring Quality Control vacuum/compressed air circuits Robot sequence 263 5.5 Sequence control Instructions for automatic sequence. 5.6 Grid These instructions are used for part depositing in a shot, individual part and Teach grid. 5.6.1 Shot grid Instructions: Instruction Increase increases the parameter of the shot grid by one shot. Instruction Delete deletes all shots from the shot grid =shot grid is empty. This instruction is not required in the Engel-defined Parts depositing in shot grid with conveyor-belt because the stepping of the conveyor-belt automatically deletes the shot grid. Example: Instruction Shot grid 1 - increase increases the parameters of the shot grid by one shot after a shot has been deposited. Symbol Name Function Stop sequence Stops automatic sequence. Wait for start button in semiautomatic In semi-automatic mode, the operator must actuate the Start button when the sequence reaches this instruction in the sequence to allow the cycle to con- tinue. Shot grid Increase Delete Shot grid 1 - Increase Shot grid part deposit 1 Time=0,5 Depositing time [ OFF ] without moni- Depositing vacuum/ Time=0,5 Waiting time before depositing Robot sequence 264 Operator Manual - Robot | Version G/11/401/2/21 Example: Structure instruction If queries the shot grid whether it is full. If the shot grid is full, instruction Shot grid 1 - delete deletes all the shots from the shot grid. Then the robot moves to the grid depositing position. 5.6.2 Individual part grid Instructions: Instruction Increase increases the parameter of the individual part grid by one shot. Instruction Delete deletes all shots from the individual part grid =individual part grid is empty. Instruction Switch off vacuum/compressed air switches off the vacuum/compressed air cir- cuits according to the order configured in the group configuration (individual parts grid x - vac- uum/compressed air circuits). The Determine next position instruction automatically calculates the next position in the indi- vidual part grid. With instruction Move at y-moving height , the y-axis moves at the traveling height set in the Grid Editor. Move into shot grid 1 Part deposit in shot grid 1 without conveyor-belt Special instructions rotary axes movement Wait until Shot grid 1 - depositing position screened Position over depositing Lower swivelling Shot grid 1 - delete Shot grid 1 grid full If Shot grid 1 - depositing position screened Individual part grid Increase Delete Switch off vacuum/compressed air Determine next position Movement to Y-moving height Robot sequence 265 Example: The robot deposits the parts from a shot at two different depositing positions. After the first part has been deposited the Individual part grid 1 - Determine next position instruction calculates the position for the second part of the shot. If the condition in structure instruction If is not fulfilled, the branch is processed in the 0 direction. Then the robot moves at the y-moving height; structure instruction Execute while directs it to the deposition position for the second part of the shot. After the part has been deposited, the deposition position for the next part is calculated. After all parts of the shot have been deposited, the condition in structure instruction If is ful- filled and the branch is processed in the 1 direction. The individual part grid is incremented by one shot. The robot moves at the y-moving height and jumps to the end of the sequence. Individual part grid part deposit 1 J ump to sequence end Individual part grid 1 - increase Speed from depositing position =100 Individual part grid 1 - move at y-moving height Individual part grid 1 - switch off vacuum/compressed air Speed from depositing position =100 Individual part grid 1 - move at y-moving height Position Individual part grid 1 - determine next Individual part grid 1 - all parts deposited If Time=0,5 Waiting time before depositing Time=0,5 Depositing time Individual part grid 1 - depositing position on grid Individual part grid part deposit 1 Individual part grid 1 - Depositing position grid - ABC Position over individual part depositing ( NOT individual part grid 1 All parts deposited Execute as long as Robot sequence 266 Operator Manual - Robot | Version G/11/401/2/21 5.6.3 Teach grid Instruction: Instruction Delete deletes the Teach grid. Individual part grid - Not all parts could be deposited Cause Although all parts have been deposited, a vacuum/compressed air circuit is active. Effect Cycle interruption Remedy Adjust robot sequence. Individual part grid - Not all parts could be picked up Cause Although all parts have been picked up, a vacuum/compressed air circuit is not active. Effect Cycle interruption Remedy Adjust robot sequence. Teach grid Delete Robot sequence 267 5.7 Sequences Pool of sequences/subsequences that are used in the standard sequences and individual instructions that are not listed under the other instruction groups. It must be ensured that only one variant of each sequence/subsequence is included in this pool. If another variant is desired, insert the existing variant in the sequence and select it in the Replace variant dialog box. [See Exchanging variants - Extended view on page 203.] Symbols with a thick border are sequences and subsequences, symbols with a thin border are instructions. Symbol Name Description Take-off can be switched over horizon- tally/vertically Complete sequence and subsequences for take-off. part depositing 1/2 Complete sequence and subsequences for part depositing. Pick-up part Complete sequence and subsequences for insert part pick-up. Home position Complete sequence and subsequences for moving to home position. intermediate deposit Complete sequence and subsequences for interme- diate deposit of parts. For example on a peripheral unit or for gripping before depositing. Intermediate layers depositing Complete sequence, subsequences and instruc- tions for intermediate layer pick up and separation of individual parts layers on grid. Robot sequence Referencing, home position, robot and user sequence Park position Complete sequence and subsequences for park position. Robot moves to its own park position, e. g. for changing end-of-arm tooling or production without robot. Robot sequence 268 Operator Manual - Robot | Version G/11/401/2/21 Quality Control part depositing Complete sequence and subsequences for quality control part depositing. Deposit quality control parts on a separate quality control depositing position Reject deposit Complete sequence and subsequences for park position. Deposit reject moldings on a separate reject depos- iting position. Sprue deposit Complete sequence and subsequences for sprue depositing. Deposit sprue at a separate sprue depositing posi- tion. Sprue separation Complete sequence and subsequences for sprue separation. Separate sprue from the injection-molded part, e. g. with a sprue separating tongs. Teach grid This instruction is located by default in the Part depositing in teach grid with conveyor-belt subse- quence. Double-clicking on the symbol will take you to the teach grid sequence. In the teach grid sequence a separate part depositing sequence can be created for each part. Symbol Name Description Robot sequence 269 5.7.1 Place holder Replace placeholder as necessary with proposed instruction for the required peripheral unit or use inputs/outputs to implement function. Instructions: Instructions: Replace placeholder with instruction 'Wait until part depositing allowed' for the required peripheral unit. Replace placeholder with instruction 'Part deposited' for the required peripheral unit. Replace placeholder with instruction 'Wait for part pick-up release' for the required peripheral unit. Replace placeholder with instruction 'Wait for part pick-up release' for the required peripheral unit. Cause Placeholder is present instead of an instruction in the sequence. Effect Cycle interruption Remedy Replace placeholder as necessary with proposed instruction for the required peripheral unit or use inputs/outputs to implement function. Part pick-up Placeholder Wait until part pick-up allowed Placeholder Part pick-up intermediate deposit Placeholder Wait until part depositing allowed Placeholder Part deposited Placeholder Wait until part pick-up allowed Placeholder Part pick-up Robot sequence 270 Operator Manual - Robot | Version G/11/401/2/21 5.7.2 Intermediate layers depositing Instructions: Instructions for programming an intermediate layer deposit. Instruction Magazine empty signals to the control unit that the intermediate layers magazine is empty. Instruction Activate new search triggers a search move for the stacking height in order to pick up an intermediate layer. This instruction is not programmed in the Engel-defined sequence Standard intermediate layers. Example: After the intermediate layer has been deposited, instruction Intermediate layer deposited informs the Grid Editor that the intermediate layer has been deposited. Intermediate layers depositing Intermediate layer deposited Magazine empty Check whether intermediate layer possible Activate new search Deposit intermediate layer Time=0,5 Depositing time Deposit intermediate layer Intermediate layer deposited Time=0,5 Waiting time before depositing [ OFF ] without monitoring Intermediate layers vacuum/compressed air circuits Robot sequence 271 Example: Instruction Check whether intermediate layer is possible checks whether parts are located on the end of arm tooling. Retrieve intermediate layers Intermediate layers standard Check whether intermediate layer possible Grid calculation NOT active Wait until Request of layers -> Execute as long as Robot sequence 272 Operator Manual - Robot | Version G/11/401/2/21 5.7.3 Quality Control part depositing Instruction: The instruction increments the control parts counter on the Control parts screen. Example: The control parts counter is incremented after depositing the molded part on the quality con- trol part depositing. Quality Control part depositing Increase Quality control deposit counter Increase Quality control deposit counter Quality Control deposit - 1 position Time=0,5 Depositing time [ OFF ] without moni- Vacuum control part Time=0,5 Waiting time before depositing Deposit test part Moving-in Quality Control depositing - 1 position Robot sequence 273 5.7.4 Reject deposit Instruction: Reset the status marker Rejects signal . Must always be pre-programmed if the instruction Reject deposit request is pre-programmed in the sequence. Example: After the part is deposited on the rejects depositing, the instruction Reset rejects request resets the status marker Rejects signal. Reject deposit Reset rejects request Reset rejects request Reject deposit - 1 position Time=0,5 Depositing time [ OFF ] without moni- Vacuum reject Time=0,5 Waiting time before depositing Deposit rejects standard Moving-in 1 position Robot sequence 274 Operator Manual - Robot | Version G/11/401/2/21 5.7.5 Parts deposit check The instruction Parts deposit check is part of the Start with the part on the end of arm tooling subsequence in all Engel take-off variants. If this instruction is processed twice consecutively, the robot will stop the sequence.. Instruction: Example: Before the robot moves into the mold to take-off the molded part, a check is made whether parts are present on the end of arm tooling. If parts are on the end of arm tooling, the robot deposits these first. After the parts are deposited, the robot checks again whether parts are on the end of arm tooling. If there are still parts on the end of arm tooling, the instruction Parts deposit check is carried out a second time. The robot stops the sequence if the instruction Parts deposit check is carried out a second time consecutively. One reason could be that different vacuum/compressed air circuits are configured in the Take- off group than in the Deposit group in the group configuration. This means that the robot only deposits the Deposit groups parts and the Take-off group parts remain on the end of arm tool- ing. Parts deposit check Parts deposit check Take-off Standard Part is reject One or multiple take-off vacuum/compressed air circuits If Move to position before mold opening Start with the part on the end of arm tooling Rejects request - request Start with the part on the end of arm tooling Rejects depositing program switch rejects depositing If J ump to sequence end Move out without take-off of parts Robot sequence 275 5.7.6 Position compensation for tie-bar-less machines With tiebar-less injection molding machines the depositing and pick-up positions are displaced on clamp force build-up by C frame expansion. This can cause issues with the robot on depos- iting or picking up parts. The variant Pick up parts with clamp force position compensation is available for picking up parts in the robot sequence. Variant: Pick up parts with clamp force position compensation At mold standstill the robot will lock the mold and Clamping force build-up/reduction. Subse- quently the condition Clamping force built up is queried and depending on Clamping force built up/reduced it moves to its own pick-up position. Check group configuration and vacuum/compressed air circuits Cause Robot could not start to take-off molded parts from the mold as parts are still present on the end of arm tooling. Effect Interrupting automatic cycle. Wait until Mold standstill Take-up position - If Mold clamp force built up Move in with clamp force position compensation Take-up position - XYZ Position via parts take-up Move in with clamp force position compensation Lower swivelling Wait until Special instructions for rotary axis movement from Take-up position - ABC Mold block Block clamp force build-up-/reduction Placeholder Wait until part pick-up allowed Replace placeholder for instruction Wait until part pick-up allowed for Robot sequence 276 Operator Manual - Robot | Version G/11/401/2/21 The Delay time for pick-up starts when the robot reaches the pick-up position. After the delay has elapsed, the part is picked up. After the pick-up time has elapsed, the robot moves to the lower swiveling limit. After this, the mold, and clamp force build-up/reduction are released. Wait until Lower swivelling limit depositing area reached Mold enable Enable clamp force build-up/reduction Lower swivelling limit Move out with clamp force position compensation Move out with clamp force position compensation Upper swivelling If Robot sequence first cycle Placeholder Wait until part pick-up allowed Replace placeholder for instruction Part picked up for the Insert-placing vacuum/compressed air circuits [ ON ] with monitoring Part pick-up Part pick-up Pick up time Time=0 Delay time reception Time=0 Insert-place vac- [ ON ] without moni- Robot sequence 277 5.8 structure instructions Structure instructions can be programmed in the robot sequence from access level 7. An extended range of structure instructions is available from access level 9. Conditions can be programmed in some structure instructions. To display the condition with the existing state, e.g. (TRUE) as long text next to the instruction, click on the respective instruction in the sequence. Example: Structure instruction Wait until. The sequence waits until the condition Wait until open mold is {TRUE}. 5.8.1 Execute as long as The instructions in the Execute as long as loop are repeated until the programmed condition is no longer fulfilled. The next instruction in the sequence then starts. If the condition is not ful- filled when the sequence reaches the Execute as long as instruction, this is skipped and the next instruction after the loop starts immediately. Instruction: When the instruction is inserted, a condition editor opens where you can program the required conditions. [See Condition editor on page 293.] Example: In the automatic sequence, the additional peripheral unit subsequence should be repeated until the Free input 1 is no longer active. Wait until Mold open {FALSE} Wait until Mold open {TRUE} Condition Actual state Condition Actual state Execute as long as Simple robot sequence - User Execute as long as Execute as long as Automatic mode of operation active Free input 1 {FALSE} Additional peripheral Take-off Standard Robot sequence 278 Operator Manual - Robot | Version G/11/401/2/21 5.8.2 Repeat until The instructions in the Repeat until loop are repeated until the programmed condition is ful- filled. The next instruction in the sequence then starts. The instructions in the Repeat until loop are executed at least once, whether or not the condition is fulfilled. Instruction: When the instruction is inserted, a condition editor opens where you can program the required conditions. [See Condition editor on page 293.] Example: In the automatic sequence, the additional peripheral unit subsequence should be started at least once and then repeated until the Free input 1 is active. Repeat until Simple robot sequence - User Simple robot sequence - User Repeat until Execute as long as Automatic mode of operation active Free input 1 {FALSE} Additional peripheral Take-off Standard Part deposit in shot grid 1 with conveyor-belt Robot sequence 279 5.8.3 If The If instruction can be used to query one or more conditions. Depending on whether the condition is fulfilled or not, the robot processes the branches. If the condition is {TRUE}, main branch I is processed. If the condition is {FALSE}, branch 0 is processed. Instruction: When the instruction is inserted, a condition editor opens where you can program the required conditions. [See Condition editor on page 293.] Example: If parts are located at the end of arm tooling after the movement to home position (e. g. pro- gram switch Movement to home position with parts) is activated, the cycle continues at the end of the sequence. If Take-off Standard If Take-off vacuum/compressed air circuits Monitoring of parts active {TRUE} Move out without part take-off J ump to sequence end Robot sequence 280 Operator Manual - Robot | Version G/11/401/2/21 5.8.4 Parallel open branch You can use the parallel open branch to execute instructions in parallel. In case of parallel open branch, the sequence does not wait for the end of the parallel sequence. In contrast to the Parallel closed branch , the movements in the Parallel open branch do not need to be completed in order to start the next step in the robot sequence. This instruction is cycle-overlapping. Instruction: Example: After the lower swiveling limit in the depositing area has been reached, the peripheral unit is stepped parallel to the sequence. The sequence does not wait for the end in the parallel open branch. 5.8.5 Parallel closed branch You can use the parallel closed branch to execute instructions in parallel. To allow the next step in the robot sequence to start, all movements in the Parallel closed branch must be completed. Instruction: Parallel open branch Move out from depositing with conveyor-belt Wait until Lower swivelling limit depositing area reached Upper swivelling Y=0 Peripheral unit cycle Peripheral unit cycle Free output 1 Free output 1 Set Reset Clock time Time=5 Parallel closed branch Robot sequence 281 5.8.6 Waiting time When the set time has elapsed, the robot continues the sequence. You can insert this instruc- tion as often as required in the sequence as a delay or waiting time. Instruction: Dialog window and setting options for the instruction in the sequence: Time Select a user-defined time module or existing robot time. Time module When the set time has elapsed, the robot continues the sequence. Waiting time Waiting time Cancel Help Execute Time module 1 Time More Time module 1 Time Cancel Help Execute Choice: Peripheral unit Time module 1 Take-off can be switched over horizontally/verti- Part deposit 1 Part deposit 2 Pick-up part Intermediate layers depositing Quality Control part depositing Reject deposit Sprue deposit User Robot sequence 282 Operator Manual - Robot | Version G/11/401/2/21 Example: After part deposition on the conveyor-belt, the robot waits 0.5 seconds to release the vacuum. 5.8.7 Wait for time or marker When the set time has elapsed or the defined marker is set, the robot continues the sequence. You can insert this instruction as often as required in the sequence. Instruction: Dialog window and setting options for the instruction in the sequence: Time Select a user-defined time module or existing robot time. Time module When the set time has elapsed, the robot continues the sequence. Marker Select a user-defined status marker or existing robot marker. Status marker When the defined marker has been set, the robot continues the sequence. Shot grid part deposit 1 Shot grid part deposit 1 Waiting time before depositing Time= Shot grid 1 - Increase Depositing vacuum [OFF] without moni- Depositing Time=0,5 Wait for time or marker Wait for time or marker Cancel Help Execute Time module 1 Time More Time module 1 Status marker 1 Marker Status marker 1 Robot sequence 283 5.8.8 Wait time or input When the set time has elapsed or the defined input is set, the robot continues the sequence. You can insert this instruction as often as required in the sequence. Instruction: Dialog window and setting options for the instruction in the sequence: Time Select a user-defined time module or existing robot time. Time module When the set time has elapsed, the robot continues the sequence. Input Select input. Free input When the defined input has been set, the robot continues the sequence. Wait time or input Wait time or input Cancel Help Execute Time module 1 Time More Time module 1 Free input Input Free input Robot sequence 284 Operator Manual - Robot | Version G/11/401/2/21 5.8.9 Wait until The robot continues the sequence when all conditions in the Wait until instruction have been met. Instruction: When the instruction is inserted, a condition editor opens where you can program the required conditions. [See Condition editor on page 293.] Example: After deposition, a check is made whether parts are still on the end-of-arm tooling. The y-axis must have reached the lower swiveling limit. 5.8.10 Comment To make robot sequences more intelligible, operators can add a Comment. Instruction: Dialog window and setting options for the instruction in the sequence: Comment Enter the required comment. Wait until Move out from depositing with conveyor-belt Wait until Lower swivelling limit depositing area reached {FALSE} Depositing conveyor-belt - Part deposited Move out from depositing with conveyor-belt [OFF] with monitoring Lower swivelling Y=0 Upper swivelling Y=0 Comment Comment Cancel Help Execute Comment More Robot sequence 285 5.8.11 Assignment With this instruction it is possible to assign a value to markers, values, program switches, set positions manual axes, set positions servoaxes and counters. This value must be interrogated in the sequence again with certain structure instructions such as If and Wait until. Instruction: Example: Add structure command Assignment to robot sequence. For the assignment command, cre- ate a variable with a Part 1 deposited marker, and set the TRUE condition. 1. In the Instructions selection window, select the Assignment structure instruction and insert this into the sequence at the desired position. 2. The Assignment dialog box will appear. 3. Press Selection. Assignment variable value Assignment Choice: No condition Cancel Help Execute More variable value Assignment Choice: No condition Cancel Help Execute More Robot sequence 286 Operator Manual - Robot | Version G/11/401/2/21 4. The following dialog box appears. 5. Select the Selection icon and then the Create menu button. 6. The following dialog box appears. 7. Change the basic type to Marker and the name to Part1 deposited. 8. Press Execute to transfer the variable to the Assignment dialog box. 9. Press the text box to open the Conditions Editor. Cancel Execute Help variable Choice: Marker Counter Values Create Cancel Execute Help Create variables value 1 Values Name Type variable value Assignment Part 1 deposited No condition Cancel Help Execute More Robot sequence 287 10. Insert a true condition, and apply by pressing Execute. 11. Use the Execute menu button to insert the assignment into the sequence. Display on screen page Condition Editor - Assignment Type Element MOD DEL. XOR CLR NOT OR AND TRUE FALSE Number Selection of type Linkage (optional) Selection of vari- Text TRUE Cancel Execute Help Less Assignment Part1 deposited {TRUE} TRUE Robot sequence 288 Operator Manual - Robot | Version G/11/401/2/21 5.8.12 J ump to sequence end With this instruction, the execution flow immediately jumps to the end of the sequence/subse- quence in which the instruction is programmed. It is also possible to use this command with other sequences. Instruction: Example: If there are still molded parts on the end of arm tooling when an automatic cycle is started, these are deposited onto the conveyor-belt before molded parts are removed from the mold. Jump to sequence end Take-off Standard Moving-in standard Move to position before mold opening Wait until part take over allowed Take over parts standard J ump to sequence end Move out without take-off of parts If Take-off vacuum/compressed air circuits one or several with monitoring Moving-out standard Take-off Standard Sprue depositing - 1 position If If Reject deposit Test part depositing Reject deposit 1 Position Quality Control Position Depositing of parts in shot grid Conveyor-belt Robot sequence 289 5.8.13 Alarm Instruction is used to set an alarm. You can assign an alarm class and separate alarm text to the alarm. The alarm class can trigger an Immediate machine stop up to a Wait point. Instruction: Dialog window and setting options for the instruction: Type Alarm selection is from class 3 to 7. Alarms with alarm class 3 to 5 must be acknowledged or deleted using the program interruption key or with the Acknowledge menu key on the Alarms screen page. Alarms in alarm classes 6 and 7 can also be deleted with the Delete alarm instruction. Name The alarm name set here will be displayed on the alarm screen page when this instruc- tion is reached in the robot sequence. Example: If there is an additional peripheral unit for insert parts, a signal is needed to query whether insert parts exist. If the peripheral unit is almost empty, an alarm message should for issued information purposes only. The message text should be: Caution! Insert parts for plant xxx running low! Alarm Alarm Cancel Help Execute System fault Type More Name 1 Alarm 1 Information Caution! Insert parts for machine xxx running null! If Free input 1 =True Robot sequence 290 Operator Manual - Robot | Version G/11/401/2/21 5.8.14 Delete alarm This instruction deletes any alarm class 6 messages you programmed previously 7. Instruction: Dialog window and setting options for the instruction in the sequence: Type Only the alarms previously set in the sequence with the Alarms instruction can be selected. 5.8.15 Set position Copy a position to another position. Instruction: Dialog window and setting options for the instruction in the sequence: Instruction Depending on the setting, the control unit copies a single axis, linear axis, rotary axis or robot position. from/to The position selected at of is copied by the control unit for the position selected at on. Delete alarm Alarm Cancel Help Execute Missing selection Type More Set position Set individual axis position (of/on) Cancel Help Execute Set individual axis position Instruction More Robot position 1 - X of Robot position 2 - X on Robot position 1 - X Robot position 2 - X Robot sequence 291 5.8.16 Copy actual position to Copy an actual position to an individual axis, linear axis, rotary axis or robot position. Instruction: Dialog window and setting options for the instruction in the sequence: Instruction You can select whether to copy the actual position to an individual axis, linear axis, rotary axis or robot position here. The following parameters change according to the selection. on Select position to which you want to copy the actual position. Position 5.8.17 Increase Increments a counter or a position by a specific value). Instruction: Dialog window and setting options for the instruction in the sequence: Instruction Depending on the selection, the control unit increases a counter or a position. of Select the counter/position that the control unit should increase. Copy actual position to Copy actual position to individual axes positions Cancel Help Execute Copy actual position to indi- Instruction More Part deposit 1 - Depositing po- on Depositing position -Z Increase Increase counter (of/by) Cancel Help Execute Decrease counter (by) Instruction More Quality control part depositing of Counter 1 by Counter 1 Quality control parts set value - shot actual value Robot sequence 292 Operator Manual - Robot | Version G/11/401/2/21 by Select the counter/stroke that the control unit should use for increasing. 5.8.18 Decrease Decrements a counter or a position by a specific value). Instruction: Dialog window and setting options for the instruction in the sequence: Instruction Depending on the selection, the control unit decreases a counter or a position. of Select the counter/position that the control unit should decrease. by Select the counter/stroke that the control unit should use for decreasing. Decrease Decrease counter (by) Cancel Help Execute Decrease counter (by) Instruction More Quality control part depositing of Counter 1 by Counter 1 Quality control parts set value - shot actual value Robot sequence 293 6 Condition editor The condition editor serves to create logic condition expressions. For a structure command such as If, Wait until etc., you need at least one condition, which is programmed in the condition editor. If you insert e. g. the If structure command into a sequence, or if you double click on an If condition, the condition editor is launched. Two variable types are distinguished by the condition editor Boolean variables These are markers, program switches, or digital inputs and outputs. In case of Boolean variable types, only the states true and false are distinguished. Non-Boolean variables These are counters, current or set positions and values and they expect a number as their parameter. 6.1 Dialog window Depending on access level, a variety of functions is available in the Condition editor dialog box. User accesss authorization 7 Operators can only program a single condition. Display on screen page Condition editor - If Cancel Execute Help Type Element Choice: Error on analog input/output DEL. CLR TRUE FALSE Number Selection of type Linkage (optional) Selection of vari- Text Robot sequence 294 Operator Manual - Robot | Version G/11/401/2/21 As of user level 9 Extended dialog box The operator may, e.g. program AND/OR links. [1] Display window for the programmed conditions [2] Arrow left / right To jump from one programmed condition to the next in the display window, first of all highlight a condition. [3] Type Selection of variable type, e.g. Program switches, digital inputs/outputs, etc. [4] Assignment functions Buttons are only active if the corresponding function for the selected condition is possi- ble. [5] Element Selection of all available elements of the selected type. For each type the user can create user-defined variables. Those should be named intuitively to make the sequence clear and easier to read. [6] Name changing Renaming a user-defined variable Standard variables cannot be renamed. [7] Display on screen page In the Display on screen page selection box set the screen page on which the variable is to be displayed. When the respective program switch is activated the control unit will display the variable on the screen page. [8] Structuring and processing functions for the condition [9] Menu keys The created condition can be inserted into the sequence by pressing Execute. Press the Less or More menu keys to hide/display additional functions. Display on screen page Condition editor - If Cancel Execute Help Type Element Choice: Error on analog input/output 1 2 2 5 3 8 4 9 6 7 MOD DEL. XOR CLR NOT OR AND TRUE FALSE Number Selection of type Linkage (optional) Selection of vari- Text Less Robot sequence 295 The following variable types are available as structure instructions Type Program switch These are a derivative of markers that are used in the standard program. However, ones that are saved in the node User-defined sequence can also be created. Status flag sequence Robot sequence markers are available; ones that are saved in the node User-defined sequence can also be created. General markers Ten machine markers are available as elements. How- ever, ones that are saved in the node User-defined sequence can also be created. The machine markers 1 and 2 can be described in the machine sequence and they can be interrogated in the robot sequences. Status marker For each robot position, function, in/output and machine state it is described via the status markers whether a state is True or False. However, ones that are saved in the node User-defined sequence can also be created. With the structure instruction If a status is interrogated and the program sequence is branched correspondingly. Digital in and outputs The status of inputs/outputs can be queried in structure instructions such as If,, Wait until, ,Execute as long as and Repeat until. Error on the digital input and/ or output The hardware modules for the inputs/outputs supply a hardware check signal which can be queried to determine if the status is valid. Possible use in safety-critical sequences. Rotary axes set positions The setting parameters of rotary axes can be queried accordingly in structure instructions such as If. Actual positions rotary axes The actual values of rotary axes positions can be queried accordingly in structure instructions such as If. Counter Counters created by the user can be queried/assigned in structure instructions such as Increment, If,, Wait until, Allocation. Values Values, created by the user can be queried/assigned in structure instructions such as, Increment, If, Wait until Assignment . Servoaxes actual positions The actual values of servo axes positions can be queried accordingly in structure instructions such as If. Servoaxes set positions The setting parameters of servo axes can be queried accordingly in structure instructions such as If. Robot sequence 296 Operator Manual - Robot | Version G/11/401/2/21 Use of brackets for operations with non-Boolean variables If you link a non-Boolean variable and another condition with an AND/OR operation, the non- Boolean variable must be enclosed in brackets. If you do not use brackets at the start of the expression, the keys for the AND, OR, etc. oper- ations will not be active (black key label). Assignment functions TRUE Allocates the Boolean value TRUE (1) to the expression. FALSE Allocates the Boolean value FALSE (0) to the expression. Text Opens the input dialog and supports string input). Number Opens the input dialog and enables the input of numbers. Structuring and process- ing functions XOR Logic XOR for Boolean data types. NOT Logic NOT for Boolean data types. OR Logic OR for Boolean data types. AND Logic AND for Boolean data types. ( ) Brackets for structuring expressions. / Division * Multiplication - Subraction + Addition < Smaller > larger <= Less than or equal to >= Greater than or equal to = Equal <> not equal MOD Modulo (supplies a whole-number remainder of a division) e.g. 5 mod 2 =1 , (5/2 =2 remainder = 1). CLR Deletes the entire condition. <- Deletes the element inserted last. DEL Deletes a highlighted element. Robot sequence 297 Display on screen page Condition editor - If Type Element MOD DEL. XOR CLR NOT OR AND TRUE FALSE Number Selection of type Linkage (optional) Selection of vari- Text (Rejects counter >10) AND rejects depositing rejects request active Cancel Execute Help Less Robot sequence 298 Operator Manual - Robot | Version G/11/401/2/21 Example: Add structure command Assignment to robot sequence. For the assignment command, cre- ate a variable with a Part 1 deposited marker, and set the TRUE condition. 1. In the Instructions selection window, select the Assignment structure instruction and insert this into the sequence at the desired position. 2. The Assignment dialog box will appear. 3. Press Selection. 4. The following dialog box appears. 5. Select the Selection icon and then the Create menu button. variable value Assignment Choice: No condition Cancel Help Execute More variable value Assignment Choice: No condition Cancel Help Execute More Cancel Execute Help variable Choice: Marker Counter Values Create Robot sequence 299 6. The following dialog box appears. 7. Change the basic type to Marker and the name to Part1 deposited. 8. Press Execute to transfer the variable to the Assignment dialog box. 9. Press the text box to open the Conditions Editor. 10. Insert a true condition, and apply by pressing Execute. 11. Use the Execute menu button to insert the assignment into the sequence. Cancel Execute Help Create variables value 1 Values Name Type variable value Assignment Part 1 deposited No condition Cancel Help Execute More Display on screen page Condition Editor - Assignment Type Element MOD DEL. XOR CLR NOT OR AND TRUE FALSE Number Selection of type Linkage (optional) Selection of vari- Text TRUE Cancel Execute Help Less Assignment Part1 deposited {TRUE} TRUE Robot sequence 300 Operator Manual - Robot | Version G/11/401/2/21 6.2 Status marker - Vacuum/compressed air Status marker active =1, when Suction pad/Gripper =Active. This means the suction pad/gripper is currently moving. The status marker is only briefly 1 at the start of the movement if the setting is [ON] with- out monitoring. Status marker timeout =1, when Monitoring time of suction pad/gripper expired and inputs not correctly switched on, e.g. in Suction pad [Off] with monitoring . This status marker is reset as soon as a new instruction is called, e.g. Suction pad [Off] without monitoring. Status marker OFF with monitoring =1, when Type =Compressed air and Input - =1 and program switch parts monitoring =1. Type =Cylinder and Input - =1 and program switch parts monitoring =1. Program switch parts monitoring =0 and Input - =1. Program switch parts monitoring =0 and Type No cylinder and Output - =1. Status marker ON with monitoring =1, when Type =Vacuum and Input vacuum monitoring =1 or when Analog vacuum monitoring has reached the set level and program switch parts monitoring active =1. Type =Compressed air and Input parts monitoring =1 and program switch parts moni- toring active=1 and parts monitoring =Signal 0 and 1 set or Output + =active. Type =Cylinder or parts monitoring not active and Signal 0 and 1 is set for parts mon- itoring and Input + =active. Program switch parts monitoring active =0 and Type No cylinder and Output + =1. Status marker OFF without monitoring =1, when Output - =1. Status marker ON without monitoring =1, when Output + =1. Status marker Everything OFF =1, when Output +and - 0. Status marker Deactivated in the sequence =1, when Suction pad/blowing/gripper deactivated in the sequence. Robot deactivated in the sequence. Program switch for the suction pad/blowing/gripper deactivated. Robot sequence 301 6.3 Status marker - Vacuum/compressed air group Status marker Everything active =1, when All vacuum/compressed air circuits in this group active (description, see status marker - Vacuum/compressed air). Status marker All in Timeout =1, when All vacuum/compressed air circuits in this group in Timeout (description, see status marker - Vacuum/compressed air). Status marker [OFF] with monitoring =1, when All vacuum/compressed air circuits in this group [OFF with monitoring] (description, see status marker - Vacuum/compressed air). Status marker [ON] with monitoring =1, when All vacuum/compressed air circuits in this group [ON with monitoring] (description, see status marker - Vacuum/compressed air). Status marker [OFF] =1, when All vacuum/compressed air circuits in this group [OFF] (without monitoring, description, see status marker - Vacuum/compressed air). Status marker [ON] =1, when All vacuum/compressed air circuits in this group [ON] (without monitoring, description, see status marker - Vacuum/compressed air). Status marker Everything [OFF] =1, when All vacuum/compressed air circuits in this group set to Everything [OFF] (description, see status marker - Vacuum/compressed air). Status markerOne or more active =1, when At least one or more vacuum/compressed air circuits in this group active (description, see status marker - Vacuum/compressed air). Status marker One or more in Timeout =1, when At least one or more vacuum/compressed air circuits in this group in Timeout (descrip- tion, see status marker - Vacuum/compressed air). Status marker One or more [OFF] with monitoring =1, when At least one or more vacuum/compressed air circuits in this group [OFF] with monito- ring (description, see status marker - Vacuum/compressed air). Status marker One or more [ON] with monitoring =1, when At least one or more vacuum/compressed air circuits in this group [ON] with monitoring (description, see status marker - Vacuum/compressed air). Status marker One or more [OFF] =1, when At least one or more vacuum/compressed air circuits in this group [OFF] without moni- toring (description, see status marker - Vacuum/compressed air). Status marker One or more [ON] =1, when At least one or more vacuum/compressed air circuits in this group [ON] without monito- ring (description, see status marker - Vacuum/compressed air). Status marker One or more in Everything [OFF] =1, when At least one or more vacuum/compressed air circuits in this group Everything [OFF] (description, see status marker - Vacuum/compressed air). Robot sequence 302 Operator Manual - Robot | Version G/11/401/2/21 Screen page editor 303 Screen page editor The screen page editor enables screen pages to be created and edited. You can also change standard screen pages. However you can only add screen lines and vari- ables or erase added screen lines and variables. How to start the screen page editor 1. Change to the screen page which you want to edit. 2. Press the screen page selection key Screen page editor. 3. The following dialog window appears. Create new screen Opens the mask editor to create a new screen page. The control unit stores the screen page in the parts data set when the page is Quit. Create new screen page in machine data set Is only available for screen pages of the injection molding machine. With Finish the control unit saves the screen page in the machine data set. Delete this screen To delete the displayed page. You can only delete user-defined screen pages. Edit this screen page Opens the screen page editor for editing the screen page to which you have changed. Only the addition of lines and variables is possible on standard screen pages. 4. Select the required action and press Execute . If you have selected Create new screen page, Create new screen page in machine data set or Edit this screen page , the mask editor will start. What do you want to do? Create new screen Delete this screen Edit this screen page Cancel Help Execute Create new screen page in machine data set Screen page editor 304 Operator Manual - Robot | Version G/11/401/2/21
[1] Structured view of the current screen page [2] Properties Shows the parameters of the selected element in the Structure view. [3] View Preview window of the selected screen page. [4] Menu keys New with instructions for adding strips, variables and comments. Edit with instructions for editing a screen page. Finish closes the screen configuration. View with the commands: Selection window on/off, Message window on/off and Maximize/Minimize. Example page Example page Name Quick call-up key Screen authorization Symbol Properties Speed Position Time Comment Strips 2 Position Screen page Strips 1 1 2 3 Properties View Info Panel 4 New Edit Finish View Screen page editor 305 1 Components of screen pages The structure of a screen page is built up as follows: A Screen page consists of one or several strips. In the strips you can insert variables . There are several variants of variables. For example: Actual value, set value, markers, switches, etc. 2 Strips There are three types of stripes. Depending on the stripe type you have different processing possibilities. Standard stripes (only injection molding machine) You cannot add or remove any variables to these stripes. You cannot erase or displace these stripes either. You can insert user stripes on a mask only after the last standard stripes. User-defined stripe When you add a stripe, this is always a user stripe. You can add and remove variables to these stripes. You can also displace and erase this stripe. Conditional stripe (only robot) When you program a sequence in the robot sequence, after the storage the correspond- ing variables appear in conditonal stripes on the respective screen pages. You can add and remove variables to this stripe. You can also displace and erase this stripe. 3 Edit screen pages You can adapt the screen page Freely composeable page to your requirements. How to edit a screen page 1. Change to the screen page which you want to edit. In this case to the Freely compose- able page. 2. Press the key Screen page editor. 3. In the dialog window choose Edit this screen page and press Execute. Comment Strips 2 Screen page Strips 1 Properties View Strips 1 Strips 2 Speed Time Comment Info Panel Speed Position Time Position Example page Screen page editor 306 Operator Manual - Robot | Version G/11/401/2/21 4. The screen page editor starts. In the screen page editor you change the settings for this screen page. Name Designation of the screen page. This name is displayed in the top line. Quick call-up key Assign a position to the quick call-up key of the new page. You can choose between machine and robot quick access. You can assign the quick call-up key only to a posi- tion which is marked with unoccupied. Screen authorization Set the user level from which the new screen page can be edited. Symbol Select a symbol for the quick call-up key of the screen page. 4 Paste of existing strips You can insert strips from existing screen pages into another screen page. Inserting an existing strip: 1. Press the menu key New and Strips from screen. 2. A dialog window appears with a selection of the screen pages. Robot composeable page Example page Name Quick call-up key Screen authorization Symbol Properties Speed Position Time Comment Strips 2 Position Robot compose- User Properties View Info Panel Robot screens Quick Setup General settings Test mode Quick positioning Home position Park position Status page Torque monitoring Select screen Machine screens Robot screens Cancel Help Execute Screen page editor 307 3. Select the required strip. In this case the Home position strip on the General settings screen. 4. Press. Execute Now you have inserted the strip into your screen page. 5 Paste new strips Besides the existing strips you can also insert new user-defined strips into the screen page. Inserting a new strip: 1. Press the menu key New and Strips. 2. A new strip has been inserted into the screen page. 3. Name the strip according to your requirements at Name. Now you have inserted a new strip into the screen page. 6 Paste variables from a list You can insert variables from a defined list into your screen page. How to insert variables from other screen pages into your screen page. 1. Choose the strip into which you want to insert the variable. 2. Press the New and Variable from list buttons. Robot composeable page Info Panel 3 Properties View Screen page Strips 1 Name Actual value right Strips 1 2 Properties Screen page editor 308 Operator Manual - Robot | Version G/11/401/2/21 3. A dialog window appears in which you can select the requested variable. 4. Choose the requested variable. 5. Press Execute. Now you have inserted a variable from a list into your mask. 7 Paste variables from other screen pages You can insert variables into your screen page which are in use on other screen pages. How to insert variables from other screen pages into your screen page. 1. Choose the strip into which you want to insert the variable. 2. Press the menu key New and Variable from screen. Choose variable from list Machine data ENGEL standard Show variables text Cancel Help Execute Machine list Robot list Machine data PROJ ECT-ERC13 Screen page editor 309 3. A dialog window appears in which you can select the requested variable. 4. Choose the requested variable. 5. Press Execute. Now you have inserted a variable from an existing screen page into your screen page. 8 Search variable The function Search variable gives you the ability to search for a variable in the variable list, and to insert the variable into the mask. Variable off Select whether to search for a machine or robot variable. Search for Status page Torque monitoring Robot 1 program switch Take-off movement Program switch reject depositing Robot Reject deposit - 1 position Robot <->machine Select screen Machine screens Robot screens Cancel Help Execute Quality Control deposit - 1 position Search variable Search result Search criteri- Variable off Search for Machine Robot Restrict to Robot System name Long text Type All Delete parameters Help Search Screen page editor 310 Operator Manual - Robot | Version G/11/401/2/21 To search for a variable, you need to enter known parameters for the variable. The more parameters you know and enter, the more exact the search results will be. Restrict to Select a variable group to restrict the search to this group. System name Name of variable software-side e.g. Robot.sv_iRobotCycleCounter. Long text Clear text for variable e.g. Teach Grid. Type Limit search to the following data types: All Values Positions Actual value Counter Markers and switches Delete parameters This menu key deletes your entries. After entering the parameters, press Search to start searching The view reverts to the Search Results tab. Depending on the search parameters you set, a number of elements may be found. Select the required variable and press Execute to insert the variable into the mask. Search variable Search result Search criterion Robot Help Execute 2 Elements found Search finished Teach grid 1 - Teach grid Teach grid 2 - Teach grid Screen page editor 311 9 Paste a comment Comments give you the possibility to insert a freely defineable text line into the screen page. Inserting a comment: 1. Choose the stripe into which you want to insert the comment. 2. Press the menu key New and Comment. 3. You have inserted the comment in the line. 4. Enter the requested text into the line Comment. 10 Moving variables and strips You can sort individual variables and strips on a screen page by using the Screen Editor. Do this to move a variable: 1. Select the variable you want to move. 2. Press the menu keys Edit and Move. 3. A dialog box appears where you can move the selected variable. 4. After moving the variable to the required position, press Close . You have now moved the variable to the required position on the screen. You can move a strip in the same way. Move to bottom Close Down Up to top Screen page editor 312 Operator Manual - Robot | Version G/11/401/2/21 Options 313 Options 1 Mold swivelling device On multi-color machines, the mold swivelling device enables the premolded part to be trans- ported into the finished injection cavity. It is either mounted on the moving platen as rotary table or integrated into the mold as an index plate. Insert the following instructions in the robot sequence to prevent any collisions between robot and mold swiveling device during part take-off: Instruction: Dialog window and setting options for the instruction in the sequence: mold turning The following settings are possible: Wait for mold swiveling Robot first moves into the mold when mold open or early start position (if set) has been reached and the mold swiveling device has finished turning. Ignore mold swiveling Robot moves into the mold when mold open or early start position (if set) has been reached. The mold swiveling device is ignored. This means the robot still moves into the mold while the mold swiveling device is turning. Rotary table Index plate Wait until part take over allowed Wait until part take-over allowed Cancel Help Execute Wait for mold swiveling mold turning More Options 314 Operator Manual - Robot | Version G/11/401/2/21 Instruction: Dialog window and setting options for the instruction in the sequence: Action The following settings are possible: swivel After release, the cycle waits for the movement to be executed; then the next instruc- tion is executed (symbols with yellow background). Release swiveling After release, the cycle does not wait for the movement to be executed, but contin- ues with the next command (icons with green background). Release/block For blocking or releasing a movement (symbols with blue background). Wait for swiveled finished The status marker Mold device - Mold swiveling finished (=TRUE) is waited for when the mold swiveling device is set to Wait for mold swiveling finished . If the instruction Mold swiveling device release swiveling was previously entered into the sequence, then the status marker must first signal FALSE. Example: Part removal from the mold swiveling device. [1] The following conditions must be fulfilled with this instruction so that the robot can move into the mold: Mold open or early start position (if set) reached. Mold swiveling device swiveling finished. Mold swivelling device Mold swivelling device Cancel Help Execute swivel Action More Moving in standard - user Wait for mold swiveling Wait until part take over allowed Take over part standard Move out standard user Moving in standard - user 1 Options 315 [1] Instruction blocks the movement of the robot to the take-off position until the swiveling of the mold swiveling device is finished. [2] Instruction blocks the mold swiveling device. [3] Instruction releases the mold swiveling device after the robot has moved out of the mold. Moving-in position 2 Mold open Wait until Mold swivelling device Take-off position - XYZ Y-position on Z-move out/in enable Mold swivelling device Moving in standard -user Take over parts standard Move out standard user Moving-out position 2 Moving-out position 1 Wait for swiveled finished Mold swivelling device block 1 2 3 Options 316 Operator Manual - Robot | Version G/11/401/2/21 2 Rotary table for insert injection molding machines The rotary table is used to transport the molded parts from take-off/insert-placing station to the injection station. Example: Insert H with rotary table [1] Take-off/insert-placing station [2] Injection station Insert the following instruction into the robot sequence to prevent any collisions between robot and the rotary table on part take-off or insertion: Instruction: Dialog window and setting options for the instruction in the sequence: Action The following settings are possible: in position The sequence is not continued until the rotary table has rotated after mold opening. Release/block Release/block the rotary table movement (symbols with blue background). 2 1 Rotary table Rotary table Cancel Help Execute in position Action More Options 317 3 Take-off with closed mold (option) Shorter cycle times can be achieved with a take-off with closed mold. However, take-off with closed mold is only possible with purpose-built injection molds. Example: Mold with three stations. The station with the finished molded parts is outside the mold. This makes take-off with a closed mold possible. [1] Pre-molding (Station 1) [2] Finished part (Station 2) [3] Take-off position (Station 3) Program switch for activating take-off with closed mold The work area between the take-off area and depositing area Z+is enabled for the robot to enter when the program switch is activated, the mold closed and the clamp force built up. Note! The robot, home position and referencing sequence must be modified for the take-off with closed mold or use the sequences set up by ENGEL for this application. Injection molding machine rotary table - Danger of collision with robot Injection molding machine rotary table - signal " In end position" missing Effect Alarm lamp flashes, the current cycle and motors are stopped imme- diately. Remedy Switch to manual mode, acknowledge the alarm, switch on the robot motor, move the robot out of the take-off area using the consent key. 3 2 1 Mold intermediate stop position Take-off with closed mold Options 318 Operator Manual - Robot | Version G/11/401/2/21 Early start not possible, by take-off with closed mold. Effect Automatic operation not possible. Remedy Switch off early start. Take-off with mold intermediate stop not possible, by take-off with closed mold. Effect Automatic operation not possible. Remedy Switch off take-off with mold intermediate stop. Options 319 4 Sprue separation The sprue separation subsequence is programmed for this option in Robot - Complex sequenz in the robot sequence. This subsequence contains 2 moving-in and moving-out positions and a separate sprue sep- aration position. WARNING! SectionDanger from cutting knives and grippers! Body parts can be injured or cut off. When working on the machine, use suitable protective clothing (safety shoes, protective gloves, face protection, ...). When working on the cutting knives and grippers, ensure that the system is pressureless and the plant is switched off. Program switch Sprue separation The program switch acivates and/or deactivates the program Sprue separation. Sprue cutters Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Speed to moving-in position 1 Speed of the servoaxes to moving-in position 1. Moving-in position 1 Robot position accessed first in Depositing area Z+ to avoid obstacles for sprue cutter. Speed to moving-in position 2 Speed of the servoaxes to moving-in position 2 Moving-in position 2 Robot position accessed after moving-in position 1 to avoid obstacles for sprue cutter.
Sprue separation Sprue separation Program switch Sprue separation Speed to moving-in position 1 Moving-in position 1 Moving-in position 2 Speed to moving-in position 2 Sprue cutters Info Panel Se- Options 320 Operator Manual - Robot | Version G/11/401/2/21 Speed to sprue separation position Speed of the servoaxes to sprue separation position. Sprue separateion position After reaching this position, the subsequence for Separate sprue starts in the robot sequence. Delay time After reaching the sprue separation position, the sprue cutter waits for this time before closing. Sprue separation time After this time has expired, the sprue cutter opens.
Speed to moving-out position 1 Speed of the servoaxes to moving-out position 1. Moving-out position 1 Robot position which is approached after the sprue separation position in order to drive round obstacles. Speed to moving-out position 2 Speed of the servoaxes to moving-out position 2. Moving-out position 2 Robot position which is approached after the moving-out position 1 in order to drive round obstacles. Sprue separateion position Speed to sprue separation position Delay time Sprue separation time Moving-out position 1 Moving-out position 2 Speed to moving-out position 1 Speed to moving-out position 2 Options 321 Example: The robot travels via two move-in positions to the sprue separation position where the cutter separates the sprue from the molded part. After separating the sprue, the robot travels towards the depositing position via two moving-out positions. [1] Move-in position 1 for sprue separation [2] Move-in position 2 for sprue separation [3] Sprue separateion position [4] Move-out position 1 for sprue separation [5] Move-out position 2 for sprue separation [6] Position over depositing [7] Depositing of parts on conveyor-belt Depositing area Z+ Machine area Upper swivelling limit depositing area Lower swivelling limit depositing area 4 1 3 5 2 6 7 1 3 2 5 7 4 6 Options 322 Operator Manual - Robot | Version G/11/401/2/21 Subsequence: Sprue separation - user Sprue separation - User Sprue cutters Moving-out position 2 Moving-out 2 position Sprue separation - User Moving-out position 1 Moving-out 2 position Separate sprue Sprue cutter Sprue cutters Sprue separation time Separate sprue Delay time Time =0,5 Time =0,5 [ +] up to final position [ - ] up to final position Moving-in 2 positions - User Moving-in 2 positions - User [ - ] up to final position Moving-in position 1 Moving-in position 2 Sprue separateion position Options 323 5 intermediate deposit Intermediate depositing is often used when molded parts have to be rehandled prior to depo- siting on a conveyor-belt or in cartons. Optional hardware with 2 inputs and outputs is required for this. These inputs and outputs are configured in the robot setup and serve as an interface between the robot and the peripheral units. Sequence instructions for the interface intermediate deposit The following instructions are available in the robot sequence's peripheral unit node for the Intermediate depositing interface. The intermediate deposit subsequence is programmed for this option in Robot - Complex sequenz in the robot sequence. The following screen is compiled from the instructions in this subsequence. Program switch - Intermediate deposit Program switch enables or disables the intermediate deposit program. Interface intermediate deposit Sequence instructions Wait until depositing allowed Robot waits until input Part deposit allowed is active. Part deposited Instruction sets the output Part deposited . Output remains active until the input Part deposited allowed becomes inactive. The output remains active as long as the Minimum pulse time signal part deposited time set in the Robot setup. Pick-up commands Wait until pick-up allowed Robot waits until input Tack-up part allowed is active. Part picked up Instruction sets the output Part picked up . Output remains active until the input Take-up part allowed becomes inactive. The output remains active as long as the Minimum pulse time signal part picked up time set in the Robot setup. intermediate deposit intermediate deposit Program switch - Intermediate deposit Speed in depositing area Depositing position Depositing vacuum/compressed air circuits Speed to depositing position Info Panel Se- Options 324 Operator Manual - Robot | Version G/11/401/2/21 Depositing vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Speed in depositing area Speed of the servoaxes in the depositing area (above the lower swivelling limit). Speed to depositing position Speed of servoaxes from the lower swivelling limit to the depositing position. Depositing position Position accessed first by the robot in Depositing area Z+.
Delay time depositing Waiting time until depositing position reached. Depositing time Waiting time after depositing the molded part. Speed from depositing position Speed of the servoaxes from the depositing position to the waiting position. Waiting position Waiting position for robot until molded part pick-up is released.
Speed to the reception position Speed of the servoaxes from the waiting position to the pick-up position. Pick-up position Position to which the robot travels to pick-up molded parts again. Delay time reception Waiting time after reaching pick-up position. Pick up time Waiting time after picking up molded part. Speed after pick-up position Speed of servoaxes from the depositing position to the lower swiveling limit. Depositing time Waiting position Delay time depositing Speed from depositing position Delay time reception Speed after pick-up position Pick up time Speed to the reception position Pick-up position Options 325 Example: Parts are deposited in a printing machine (wait for depositing release). Robot moves on waiting position (Part deposited). When printing is finished (Wait until pick-up allowed), the robot moves to the pick-up position and picks up the parts. Following this, the imprinting machine receives a signal indicating that the Part has been picked up. Example: The molded part is deposited in a rotating unit (wait for depositing release). After depositing the part, the robot travels to its waiting position (part deposited). After the peripheral unit has rotated the molded part through 90 (wait for pick-up release), the robot moves to the pick-up position and picks up the molded part which was rotated by the peripheral unit. Following this, the rotating unit receives a signal indicating that the Part has been picked up. [1] Depositing position [2] Waiting position [3] Pick-up position 1 3 2 Options 326 Operator Manual - Robot | Version G/11/401/2/21 6 Pick-up part This option serves to pick up insert-place parts from a defined position. The Robot sequence with pick-up and insert/place is programmed in the robot sequence for this option. Program switch pick-up insert parts If the program switch is set, parts are picked up. Depositing vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Speed in the reception area Servo axis speed in pick-up area. Take-up position - ABC Position of rotary axes on picking up parts. Speed to the reception position Speed of the servoaxes to pick-up position. Take-up position - XYZ Position at which the parts are picked up. Delay time reception Delay for robot oscillation. Pick up time Waiting time at pick-up position for part pick-up. Speed after pick-up position Speed of servoaxes from the depositing position to the lower swiveling limit. Pick-up part Pick-up part + Pick up time Speed after pick-up position Program switch pick-up insert parts Speed in the reception area Take-up position - ABC Speed to the reception position Take-up position - XYZ Delay time reception Depositing vacuum/compressed air circuits Info Panel Se- Options 327 7 Weigh scale intermediate deposit This option allows you to use scales to check the weight of the molded parts during production. The robot automatically deposits any reject parts at the reject position. This ensures that the good part depositing area will only contain parts whose injection weight is within weight tole- rance. This avoids the need for the operator to manually inspect the molded parts. A serial interface for communications between the robot and scales is configured in the robot setup for this option. Sequence instructions for scales The following instructions are available for the scales in the robot sequence's peripheral unit node. The Robot sequence with intermediate depositing on scales is programmed in the robot sequence for this option. The following screen is compiled from the instructions in this sequence. Program switch - Intermediate deposit on weigh scale Program switch enables or disables the intermediate deposit on weigh scales program. Speed in depositing area Speed of the servoaxes in the depositing area (above the lower swivelling limit). Speed to depositing position Speed of servoaxes from the lower swivelling limit to the depositing position. Weigh scale Sequence instructions Wait until depositing allowed Part deposited Pick-up commands Wait until pick-up allowed Part picked up Weighing Reset scale Weigh scale intermediate deposit Program switch - Intermediate deposit on weigh scale Speed in depositing area Depositing position Delay time depositing Speed to depositing position Weigh scale intermediate deposit + Info Panel Se- Options 328 Operator Manual - Robot | Version G/11/401/2/21 Delay time depositing Waiting time until depositing position reached Depositing position Position accessed first by the robot in Depositing area Z+.
Depositing time Waiting time after depositing the molded part. Speed from depositing position Speed of the servoaxes from the depositing position to the waiting position. Waiting position Waiting position for robot until molded part pick-up is released. Delay time weighing Wait time that delays weighing after depositing the molded part.
Speed to the reception position Speed of the servoaxes from the waiting position to the pick-up position. Delay time reception Waiting time after reaching pick-up position. Pick-up position Position to which the robot travels to pick-up molded parts again. Pick up time Waiting time after picking up molded part. Speed after pick-up position Speed of servoaxes from the depositing position to the lower swiveling limit. Weigh scale You can insert settings for the scales at this point. Waiting position Speed from depositing position Delay time weighing Depositing time + Delay time reception Speed after pick-up position Pick up time Pick-up position Speed to the reception position + Options 329 Weigh scale activated Program switch enables or disables the Scale program. Automatic taring If the program switch is enabled, the scales are tared after weighing the part. An If structure command is used to query the program switch in the Robot sequence with intermediate depositing on scales. Scales empty Weighing error Zero tolerance Zero tolerance indicates by what extent the weight of the empty scales is allowed to deviate. Weight fluctuations of the weighing scales can be caused by vibrations, for example. Keep zero tolerance as low as possible. Reason: If the empty scales show a weight of 5 grams, and zero tolerance is set to 7 grams, the 5 grams are not deducted but added to the weight of the molded part. This falsifies the results by 5 grams. This means that a molded part with a weight of 1 kg will be shown as 1.005 kg on the scales. Test assessment You can set weight limits for the scales here. Weight set value Set value for molded part. Weight actual value Weight of current sample. Weight within tolerance This flag indicates that the results are within the tolerance window. Negative / positive tolerance The tolerance specifies the amount by which the weight of the molded part is allowed to deviate. If the weight deviation is too large the molded part is separated out as a reject molding. Automatic taring Weighing error Zero tolerance Weigh scale activated Weigh scale Scales empty + Weight actual value Weight within tolerance Weight set value Negative tolerance Positive tolerance + Test assessment Options 330 Operator Manual - Robot | Version G/11/401/2/21 Example: The molded part is deposited on scales (wait for depositing release). After depositing, the robot travels to wait position (part deposited) and sends a signal to the scales to start measurement (weighing). After the scales have ascertained the weight (wait for pick-up release), the robot moves to the pick-up position and picks up the weighed part. Following this, the scales receive a signal indicating that the Part has been picked up. The robot moves the molded part to the depositing or rejects position, depending on the weighing results. If the automatic tare program switch is enabled, the scales are tared after reaching the lower swiveling limit. [1] Depositing position [2] Waiting position [3] Pick-up position 1 3 2 Options 331 8 Intermediate layers standard The intermediate layer program serves to separate individual grid layers with intermediate lay- ers (e.g. cartons). The parameters for picking-up intermediate layers can be set in the interme- diate layer screen. Settings for depositing intermediate layers can be set in the Grid editor , intermediate layer tab. The intermediate layers subsequence is programmed for this option in Robot - Complex sequenz in the robot sequence. Program switch Intermediate layers Program switch for enabling or disabling intermediate layer sequence. The corresponding flag shows that the intermediate layer sequence is being processed. New search necessary The flag is lit when it is uncertain if the stored position is correct when a malfunction or system restart has occurred. You need to redetermine the pick-up position in this case. Intermediate layers vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Delay time vacuum monitoring If a vacuum circuit is used as a touch limit switch, the vacuum limit is briefly reached due to inertia of the air (line length) when the vacuum circuit is switched on. In this case the axis would already stop while moving into the magazine, although no intermediate layer exists. This can be prevented with the delay time. Speed in the intermediate layers area Speed of servoaxes from lower swiveling limit to Search start position. Search start position Starting at this position the robot travels at Speed intermediate layer search until the Intermediate layers standard Program switch Intermediate layers Search area before last saved position Speed intermediate layer search Search start position New search necessary Magazine moving-in speed Speed in the intermediate layers area Intermediate layers Maximum search position + Intermediate layers vacuum/compressed air circuits Info Panel Se- Last stored intermediate layers position Touch limit switch Delay time vacuum monitoring Options 332 Operator Manual - Robot | Version G/11/401/2/21 stack height has been determined. After determining the stack height, the robot travels away from this position at Magazine moving-in speed in the subsequent cycles. Magazine moving-in speed Speed of servoaxes from Search start position to pick-up position of the last intermedi- ate layer picked up, minus Search area prior to last stored position. Speed intermediate layer search The robot travels away from Search start position at the speed set here to determine the initial pick-up position. In ongoing production, the robot will then move at this speed from the pick-up position of the last intermediate layer minus Search area before last saved position. Search area before last saved position The value is subtracted from the last known pick-up position. Starting at this calculated position, the search move to the next intermediate layer starts. Touch limit switch Serves to determine the pick-up point of an intermediate layer. Maximum search position This parameter delimits the search movement of the axis applying the set value. If this value is overstepped, the robot stops and issues an error message indicating that the magazine is empty. Sequence sketch: Pick up first intermediate deposit [1] Lower swivelling limit [2] Search start position [3] Pick-up position of first intermediate layer determined 3 Maximum search position Speed in the intermediate layers area Speed intermediate layer search 1 2 Options 333 Sequence sketch: Pick up another intermediate deposit [1] Lower swivelling limit [2] Search start position [3] Current pick-up position minus Search area before last saved position [4] Pick-up position of first intermediate layer determined [5] Search area before last saved position Pick up time After activating the vacuum/compressed air circuits, the robot waits at the pick-up posi- tion for the specified time. Speed intermediate layer lifting Slow speed for picking up the intermediate layer up to the calculated position (current pick-up position minus Search area before last saved position). Speed move out magazine After reaching the calculated position (current pick-up position minus Search area before last saved position ), the robot travels at this speed to the lower swiveling limit depositing area. Speed to depositing position Speed of servoaxes from the lower swivelling limit to the depositing position. Waiting time before depositing Waiting time until depositing position reached. While the time is running the flag is active. 1 2 Maximum search position Speed in the intermediate layers area Magazine moving-in speed 4 5 Speed intermediate layer search 3 + Speed to depositing position Speed move out magazine Waiting time before depositing Depositing time Speed from depositing position Speed intermediate layer lifting Pick up time Options 334 Operator Manual - Robot | Version G/11/401/2/21 Depositing time Waiting time after depositing the sprue part. While the time is running the flag is active. Speed from depositing position Speed of servoaxes from the depositing position to the lower swivelling limit. Sequence sketch: Move from intermediate layer pick-up to depositing position [1] Pick-up position of first intermediate layer determined [2] Current pick-up position minus Search area before last saved position [3] Lower swivelling limit [4] Search area before last saved position 1 Maximum search position Speed move out magazine Speed intermediate layer lifting Speed to depositing position 3 4 2 Options 335 Example: Pick up intermediate layer from a stack and then deposit after a Y layer on the depositing grid. [1] Reception of the intermediate layer. [2] Move from intermediate deposit to depositing grid. [3] Depositing the intermediate layer on the depositing grid. 1 2 3 Options 336 Operator Manual - Robot | Version G/11/401/2/21 9 Park position The option serves to automatically position the robot at a predefined position e.g. for changing the end-of-arm tooling or for production without robot. Move to park position during production without robot For Production without robot in automatic operations, if this switch is enabled, the robot will move to park position after injecting. Park position Park position for all axes adjustable on screen. Speed to park position Speed of the servo axes moving to the parking position. Park position reached This flag signals when the park position is reached. Move robot to park position Hold down the button Park position on the hand control device or the control panel of the injection molding machine until the robot has reached the park position. Park position sequence still active Cause On switching to automatic operating mode, the park position key was pressed, but the park position was not reached. Effect Switchover to automatic mode not possible. Remedy Perform park position move until the position has been fully reached. Park position Speed to park position Park position reached Park position Move to park position during production without robot + Park position Options 337 10 Take-off stroke correction Take-off stroke correction is used to correct the take-off position of the take-off axis (X or Z axis) in case of a deviation of the mold opening position. With hydraulic injection molding machines, deviations can occur due to high opening speed in connection with a heavy mold half on the moving mold fixing platen. The correction is designed to ensure support for taking off or insert/placing of parts from or in the mold. Take-off stroke correction determines the difference between the actual mold position and tar- get mold position after the opening movement has been completed whenever a part is taken off. Following this, the difference is added to, or subtracted from, the set take-off position in X direction, thus representing the new take-off position for this cycle. Sequence instructions for take-off stroke correction To allow the control unit to perform take-off stroke correction, you need to program the take- off stroke correction - start and take-off stroke correction - stop instructions in the robot sequence. Take-off position = actual position of mold Take-off position +take-off stroke correction Take-off position - take-off stroke correction Set mold position Actual mold position Take-off stroke correction Start Stop Options 338 Operator Manual - Robot | Version G/11/401/2/21 CAUTION! Danger of damage to equipment! After setting the take-off position, you must calculate the take-off stroke offset. Failure to do so can cause a collision between the robot and the mold. Calculating take-off stroke offset Activate the switch to calculate the Take-off stroke offset when the mold is open in manual mode. Take-off stroke calculation error An active flag indicates that the take-off stroke difference is greater than the maximum take-off stroke difference. Take-off stroke offset Calculated difference between current mold position and set mold position for open mold by activating the Calculate take-off stroke difference in manual mold. Effective take-off stroke difference Actual difference between current mold position and target mold position for open mold in automatic mode. There are more take-off stroke correction parameters in the robot setup. Example: Take-off stroke correction with and without calculation of the take-off stroke offset Take-off stroke correction without offset calculation at a mold position of 403 mm. X take-off position +3 mm take-off stroke correction --->Robot moves to mold position of 405 mm. The X axis is corrected by 3 mm in +direction, although the actual deviation is only 1 mm. The reason for this is that the take-off position was set to a mold position of 402 mm. This means that the robot moves 2 mm further than the mold, and a collision occurs between the robot and the mold. Take-off stroke correction with offset calculation at a mold position of 403 mm. X take-off position - 2 mm take-off stroke offset +3mm take-off stroke correction --->Robot Take-off stroke correction Take-off stroke calculation error Take-off stroke offset Calculating take-off stroke offset Effective take-off stroke difference Opening stroke 400 mm Actual mold position 402 mm on setting take-off position for robot Options 339 moves to mold position of 403 mm. The X axis is corrected by 1 mm (=effective take-off difference) in +direction, as the deviation between the actual and set mold positions has been stored as the take-off stroke offset after setting the take-off position. Example: In the Moving-in standard subsequence, the special robot instruction Take-off stroke correc- tion - start is inserted before the take-off position. The X axis is corrected to reflect the current mold stroke position. After the Take-off position the robot special instruction Take-off stroke correction stop is inserted. Take-off stroke correction - start Take-off position - XYZ Take-off stroke correction - stop Moving-in standard Options 340 Operator Manual - Robot | Version G/11/401/2/21 11 Run empty Emptying is important for controlled production shutdown on Combimelt machines. Each cycle, one unit shuts down in the same order as for production start-up. The robot can use a program to block emptying of the injection molding machine. The injection molding machine waits for the robot to release emptying. Specify when the robot sends the Emptying to machine release in the robot sequence. Strips are displayed when Combimelt machines are used. Example: The robot releases emptying of the injection molding machine when the grid is full. Emptying release by robot sequence program If the program switch is disabled, the injection molding machine starts emptying without waiting for the release signal from the robot. If the program switch is enabled, the injection molding machine starts to empty when the robot issues the release signal. Request machine emptying Release machine emptying Release signal for emptying from robot to machine. Current run-out cycle Actual value display. Number of run-out cycles Pre-set run-out cycles for injection molding machine. If Release emptying manually {TRUE} AND shutdown cycles activated {FALSE} AND shot grid 1 grid full {FALSE} Assignment Injection molding machine - release emptying manually {ON} TRUE Run empty Request machine emptying Release machine emptying Current run-out cycle Number of run-out cycles Emptying release by robot sequence program Options 341 12 Mold synchronization Mold synchronization allows a reduction of the take-over time. If the Early start program switch is activated, the robot moves into the mold from the early start position. The end of arm tooling approaches the mold up to a calculated safety distance, and synchronously follows mold opening. After the mold completes the opening stroke, the robot moves to the take-off position. CAUTION! Danger of damage to equipment due to improper settings! When operating the machine, use settings that precisely match the require- ments for safe operations of the machine, molds, and peripheral units. Sequence instructions for mold synchronization To allow the control unit to perform mold synchronization, you need to program the Mold syn- chronization start and Mold synchronization stop instructions in the robot sequence. The Take-off with mold synchronization sequence is programmed in the robot sequence for this option. There are more mold synchronization parameters in the robot setup. Example: ENGEL sequence variant Special instruction mold synchronization - Start is inserted before Move-in position 2 . The X-axis now moves synchronously with the Mold opening movement up to Move-in position 2 . After Mold open , mold synchronization stops again. Mold synchronization Start Stop Mold open Mold synchronization - Stop Take-off position - XYZ Moving-in position 2 Moving in with mold synchronization Mold synchronization - Start Moving-in position 2 Wait until Moving in with mold synchronization Take-off position - ABC Options 342 Operator Manual - Robot | Version G/11/401/2/21 13 Ejector synchronization In ejector synchronization, the end of arm tooling moves synchronously with the ejector move- ment. If the axis cannot follow the ejector speed, the ejector stops. CAUTION! Danger of damage to equipment due to improper settings! When operating the machine, use settings that precisely match the require- ments for safe operations of the machine, molds, and peripheral units. Sequence instructions for ejector synchronization To allow the control unit to perform ejector synchronization, you need to program the Ejector synchronization start and Ejector synchronization stop instructions in the robot sequence. The Take-off with ejector synchronization sequence is programmed for this option in the robot sequence. There are more parameters for optimization of ejector synchronization in the robot setup. Example: ENGEL sequence variant Special instruction Ejector synchronization start is inserted before the release instruction Advance ejector . The x-axis thus moves synchronously with the Advance ejector move- ment. After Advanced ejector , mold synchronization stops. Ejector synchronization Start Stop Take-off position Ejector advanced position Options 343 Ejector stroke greater than axis stroke Effect No automatic operation possible. Remedy Adapting the ejector stroke to the axis stroke. Ejector Time for part removal Ejector synchronization - stop Take-off vacuum Take over parts with ejector synchronization Ejector synchronization - start advance [ON] without moni- Time=0,2 Take over parts with ejector synchronization Ejector retract Position before opening - X Take-off vacuum/compressed air circuits [ ON ] with monitoring Waiting time before take-off Time=0,5 Options 344 Operator Manual - Robot | Version G/11/401/2/21 14 Mold and ejector synchronization This program supports removal of the produced part with the robot already during the mold opening movement. Under ideal circumstances this allows the injection molding machine to start mold closing after mold opening without any delay. CAUTION! Danger of damage to equipment due to improper settings! When operating the machine, use settings that precisely match the require- ments for safe operations of the machine, molds, and peripheral units. Conditions for mold and ejector synchronization: Early start possible. Part removal during mold opening must be possible (ejector parallel to mold opening or part removal without ejector possible). The following is recommended for mold and ejector synchronization: Large mold opening stroke. Constant opening speed. Fast robot. Sequence instructions for mold and ejector synchronization To allow the control unit to perform mold and ejector synchronization, you must program the instructions Mold ejector synchronization - start and Mold ejector synchronization - stop in the robot sequence. The Take-off with mold and ejector synchronization sequence is programmed for this option in the robot sequence. There are more mold and ejector synchronization optimization parameters in the robot setup. Mold- ejector synchronization Start Stop Options 345 Mold and ejector synchronization sequence: Machine Mold opening start Mold closing Mold opening end Retract ejector start Ejector advanced Advance ejector start Early start position reached Robot Wait until early start position reached Mold and ejector synchronization Robot attempts to reach take-off position Robot has reached take-off position Suction pad ON Ejector forward release Wait until ejector forward Ejector return release Synchronization ended (robot standing still) Move out from machine Part deposit Options 346 Operator Manual - Robot | Version G/11/401/2/21 Example: ENGEL sequence variant The x-axis now moves synchronously with the Mold opening and Advance ejector move- ment. After part takeover, mold and ejector synchronization is cancelled, and move out starts. Ejector Time for part removal Take-off vacuum Accept part with mold and ejector synchronization Mold and ejector synchronization - start Moving-in position 2 advance [ON] without moni- Time=0,5 Mold and ejector synchronization - stop Accept part with mold and ejector synchronization Take-off vacuum/compressed air circuits [ ON ] with monitoring Ejector Position before retract Waiting time before take-off Time=0,5 Moving-in position 2 Take-off position - XYZ Move in with mold and ejector synchronization Move in with mold and ejector synchronization Take-off position - ABC Options 347 15 Softservo The Softservo option is used for take-off, inserting and picking up parts using an adjustable torque. Softservo applications: Moving the X axis or in case of longitudinal layout the Z axis (depositing area at the face side of the clamping unit) with the ejector or core pull. The robot supports injection mold- ing machine movements with the set torque. Can be employed instead of the ejector synchronization. Insert-placing of parts with set torque. Sequence instructions for Softservo To allow the control unit to activate the Softservo function in automatic mode, you must pro- gram the Softservo Start and Softservo Stop instructions in the robot sequence. You can set the required torque in the Softservo - Start instruction. The set torque acts on all move instructions of the take-off axis that are included between the instructions Softservo - Start and Softservo - Stop. If there are no move instructions between the Softservo - Start and Softservo - Stop instruc- tions, the take-off axis attempts to hold the position with the torque set in the Softservo - Start instruction. Softservo in manual mode To set the torque, you can enable the Softservo function in manual mode using the Softservo key on the manual control device. When the Softservo is activated, the take-off axis moves with the torque set in the parameter Torque in manual mode in the Robot Setup. Name - Softservo active Cause A movement in automatic mode uses Softservo, or Softservo was switched on using the pushbutton on the hand terminal. Effect Softservo active. Softservo Start Stop Softservo Options 348 Operator Manual - Robot | Version G/11/401/2/21 Example: While advancing, the ejector presses the molded part onto the end of arm tooling and shifts the X axis. The robot supports the ejector movement with Move instructions - Start to the Position with ejector advanced - X with the torque set in the Softservo - Start instruction. When the ejector is advanced, the Softservo is deactivated again. Sequence sketch Take over part - user Moving-in 3 positions Ejector advance Softservo - stop retract Position before Ejector Take over part - user Softservo - start Part removal =0,5 Take-off vacuum/compressed air circuits [ ON ] with monitoring Position for advanced ejector - X Individual axis movement Take-off vacuum/compressed air circuits [ ON ] without monitoring Take-off position - X Take-off position Position for advanced ejector - X Options 349 16 Compensation of loads The load compensation option calculates the torque required to hold the vertical stroke. The control unit takes this torque into consideration when calculating move instructions for accele- ration and braking. This is necessary to prevent robot oscillation in case of heavy parts. In contrast to gravity compensation, which is only used for movements to home position, load compensation occurs in every cycle in automatic mode. CAUTION! Danger of damage to equipment due to improper settings! Load balancing must only be performed at positions where slight lowering of the axis will not cause a collision. Sequence instructions for load compensation To allow the control unit to perform load compensation, you need to program the Load com- pensation - start instruction in the robot sequence. When calculating load compensation, the robot must be at a known position; that is, you are not permitted to smooth a previous move instruction. Load compensation cannot be performed at pick-up or part-removal position as slight dropping of the axis could cause a collision. Softservo not activated as access to axis by Switch off -axis is blocked. Please check the robot sequence or deactivate at first Switch off -axis.. Cause Softservo instructions are programmed in the robot sequence between the Switch off axis - start and Switch off axis - stop instruc- tions. Effect Cycle stops and robot motor switches off. Remedy Correct robot sequence. Compensation of loads Start Options 350 Operator Manual - Robot | Version G/11/401/2/21 Example: Load compensation after picking up a insert-place part After picking up the insert-place part the robot moves to the upper swiveling limit where load compensation occurs. As of this position the robot will take the measured torque into consid- eration for further move instructions. Load compensation must only be performed at positions where slight lowering of the axis will not cause a collision. Additionally, you cannot position smooth the previous move instruction. Move-in Wait until Lower swivelling Lower swivelling limit depositing area reached Part pick-up moving-out moving-out Pick-up part Load compensation - start Upper swivelling Insert-placing vacuum/ compressed air circuits [ ON ] with monitoring Depositing conveyor belt 1 - Part deposited Options 351 Example: Load compensation after picking up a molded part At moving-out position 2 a compensation of loads is performed with the instruction Load compensation - start . The robot will then take the measured torque from the position prior to opening into consideration for further move instructions. Load compensation must only be performed at positions where slight lowering of the axis will not cause a collision. Additionally, you cannot position smooth the previous move instruction. Speed for move-out position 2 =100 Rotary axes movement moving out from machine area Moving-out standard Stop when safety gate requested Position before opening - Z Moving-out position 2 Moving-out standard Load compensation - start Moving-out position 1 Options 352 Operator Manual - Robot | Version G/11/401/2/21 17 Moving area safeguarding The moving area safeguarding serves as additional collision protection and is effected by means of an inductive limit switch and cams in the unrestricted moving area. Main applications: Areas of user intervention (taking in of cartons, foils etc). To avoid collisions with a peripheral unit or another robot in overlapping action radii or move areas. Permanent prohibited areas are visible in the work area setup. Example: Prohibited areas for moving area safeguarding The robot sequences must be programmed to ensure that all move paths are outside the pro- hibited areas. If the robot enters a prohibited area, the following message appears: CAUTION! Danger of damage to equipment! Movements with rotary axes are permitted without pressing the consent key inside pro- hibited areas. The control unit will only monitor this if the control voltage is switched on. Prohibited area left - move-out only possible with consent key Cause The robot is inside a moving area safeguarding prohibited area. Effect All linear axis movements are blocked for the robot. Remedy Press the consent key and move the robot out of the prohibited area in set-up mode. + Work Areas and Prohibit- Settings 3D view Overview Work area setup Prohibited area Work area above Work area clamping Work area above ma- Robot Moving area safe- Prohibited area Mov- Prohibited area Mov- Prohibited area Mov- Prohibited area Info Panel Options 353 18 Crane protection The crane safeguard is a collision protection system between the robot and the crane. CAUTION! Danger of damage to equipment! The control unit will only monitor this if the control voltage is switched on. Two conditions must be fulfilled to ensure that the crane receives a release signal for the robot area: 1. Inductive limit switch standing at cam (Input robot in release position 1 active). 2. Robot motors switched off. Crane protection The flags indicate the states of the digital inputs / outputs for crane protection. Crane in the robot area Effect Robot motor cannot be switched on. Remedy Move crane out of robot area until Input crane outside of robot area is active. Name - Crane release not possible (missing configuration) Cause Inputs/outputs for crane safeguard not configured. Effect No movements possible. Remedy Configure missing inputs/outputs. Sensor defective Cause Signal from Input robot in park position 1 has not reacted or has reacted incorrectly. Effect The crane will not be released for swiveling into the robot area. Remedy Check park position switch. Crane protection - output release crane Crane protection - Input robot in release position 1 Crane protection - input crane is outside robot area Crane protection + Options 354 Operator Manual - Robot | Version G/11/401/2/21 19 Warning signal light The warning signal lamps allow for visible and audible signaling of various machine states. Warning signal lamp types: LED signal lamp mounted on the front side of the Z axis. This signal lamp can display 8 different colors. A warning signal lamp which can comprise multicolored signal lamps and multiple audi- ble alarms (signal horns). Example: Warning signal lamp [1] LED signal lamp [2] 3-color warning signal light The special instructions Activate and Deactivate warning signal light are available in the robot sequence. You can use these instructions to activate and deactivate individual signal lights and audible alarms in the sequence. If these instructions are programmed, then set the parameter Active for signal from to Sequence for the warning signal light. Symbol Name Function Activate Instruction activates the signal light or audible alarm. LED signal 1 to LED signal 5 are available for the LED signal lamp. These signals can be assigned various signal colors and behaviors in the Robot Setup. Deactivate Instruction deactivates the signal light or audible alarm. 1 2 Options 355 Mapping an alarm to a warning signal light Warning signal lights and audible alarms can react to specific alarms. To allow this to happen you must map the required alarms to the warning signal lights in the robot setup. Approach for mapping alarms: 1. Switch to Teach mode. 2. Select the subitem alarm selection for a warning signal light. 3. After pressing the Setup and Change menu keys, the dialog box for the group configu- ration appears. 4. Using the navigational arrows <<< and >>> you can move the complete content from Available elements to Selected elements and vice-versa. You can select an individual alarm, and move it using the navigational arrows < and > insert it into Selected elements in the desired order. You can move a maximum of 20 alarms to Selected elements. + Robot setup Description Name Element attributes System name Basic module Alarm selection Orange signal lamp Green signal lamp Alarm selec- Yellow warning sig- Blue signal lamp Red signal lamp Acoustic alarm Info Panel Cancel Execute Help Group configuration - alarm selection Available elements Selected elements Options 356 Operator Manual - Robot | Version G/11/401/2/21 5. Press Execute to instruct the control unit to add the selected alarms to the Parameters tab. 6. After mapping the alarms, set the parameter Active for signal from to Selected alarms for the warning signal light in the robot setup. When an audible alarm is triggered, the Audible alarm active dialog box appears. You can press Execute to switch off the audible alarm. Note! There are additional warning signal light setting parameters in the robot setup. + Robot setup Alarm selection - group elements Attri- Parame- Orange signal lamp Green signal lamp Alarm selec- Yellow warning sig- Blue signal lamp Red signal lamp Acoustic alarm Info Panel Audible alarm active Switch off the audible alarm? interruption Help Execute Options 357 20 Torque monitoring Torque monitoring serves to monitor the force for activities with a servoaxis (e.g. inserting/pla- cing parts into a mold). Sequence instructions Program the instructions Torque monitoring - Start and Torque monitoring - Stop in the robot sequence so that the control unit monitors the torque. The control unit monitors the torque of all movements between both instructions for the set axis. Set the minimum required and maximum allowed torque in the instruction Torque moni- toring - Start for this purpose. In addition, it is also possible to limit monitoring to a specific movement range. This can pre- vent the torque monitoring from being triggered e.g. when accelerating or braking the ser- voaxis. If the force output is not within the set tolerance window, then three actions are available. Set status marker Set status marker and stop all move commands Set status marker and stop motor The instruction Torque monitoring - Stop in the sequence resets the status marker. Example: Monitoring x axis torque for the take-off movement. 1. Add the torque monitoring - start instruction at the position in the robot sequence as of which you wish to monitor the torque for a movement. Torque monitoring Start Stop + Robot sequence Robot sequence Softservo Start Stop Info Panel Torque moni- Move-out - standard Moving-out position 2 Moving-out position 1 Options 358 Operator Manual - Robot | Version G/11/401/2/21 2. Implement the following settings in the dialog window. Selected axis Select axis to be monitored. Minimum required torque / maximum allowed torque Select torque from automatically generated torque pool. Torque x Set value for the Minimum required torque and the Maximum allowed torque. Monitoring from position / monitoring up to position Select strokes from the automatically generated stroke pool. Positions limit the torque monitoring of an axis to an area. Stroke x Set stroke for the Monitoring from position and Monitoring up to position. Torque when an error is recognized If the set torque is exceeded/undershot, this triggers the action set here. Set error marker The control unit sets the marker when an error appears in torque monitoring The instruction Torque monitoring - Stop resets the marker. Status flag torque monitoring 3. Use Execute to accept the settings. Choice Torque 1 Torque 2 Status marker torque monitor- Torque monitoring - Start Selected axis Minimally required torque Torque 1 Maximally allowed torque Name Name Name Help Execute Cancel Torque 2 Set error marker Name More Stroke 1 Stroke 2 Status flag torque monitoring 1 Set status marker Torque when an error is recog- Stroke 2 Name Monitoring up to position Stroke 1 Name Monitoring from position Options 359 4. Add the torque monitoring - stop instruction at the position in the robot sequence as of which you wish to stop monitoring the torque for a movement. This is typically after the movement you wish to monitor. 5. Select axis. The torque monitoring stops for the selected axis. 6. Use Execute to accept the settings. + Robot sequence Robot sequence Softservo Start Stop Info Panel Torque moni- Move-out - standard Moving-out position 2 Moving-out position 1 Mold and ejec- Choice Torque monitoring - Stop Selected axis Help Execute Cancel More Options 360 Operator Manual - Robot | Version G/11/401/2/21 21 Takeoverheadcoding The end-of-arm tooling head coding serves to identify the end-of-arm tooling head and respec- tive parts data set A plug on the end-of-arm tooling head transmits the actual value of the end- of-arm tooling head coding to the control unit, which compares the actual value with the set value. Takeover head coding activated Green flag indicates an active end-of-arm tooling head coding. Takeover head code - actual value Code of connected end-of-arm tooling head. Takeover head code - set value Control unit compares the set value with the actual value transmitted by the end-of-arm tooling head. The set value is stored in the parts data set. When value 0 is set, end-of-arm tooling head coding is deactivated. If the actual value does not match the set value, the following alarm will be issued: Robot: Incorrect end of arm tooling Cause Actual value does not match the set value. Effect No automatic operation possible. Remedy Fit the correct end-of-arm tooling head or import the parts data set. If the parts data set belongs to the mounted end-of-arm tooling head, correct the set value and re-write the parts data set. Takeover head code - set value Takeover head coding activated Takeover head code - actual value + Robot end of arm tooling coding Options 361 22 High speed head changing system This option supports automatic coupling and uncoupling of the holding plate on the end of arm tooling quick-change system. This supports quick changing of the robot's end of arm tooling. To couple and uncouple the end of arm tooling, there is a swivel switch on the y-axis. Buttons for coupling and uncoupling can be configured on the hand terminal. If you have a standard end-of-arm tooling quick-change system, the holding plate at the end of arm tooling is fixed in place with screws. WARNING! Danger of crushing by moving components on the end of arm tooling and by the coupling! Compressed air is built up during the coupling process; this can lead to uncontrolled movements of pneumatically actuated components at the end of arm tooling. Move the robot axes to a position where you can safely change the end of arm tooling. Do not reach into areas with the end of arm tooling coupling and/or moving parts. Procedure for changing the end of arm tooling: 1. Move the robot to a position where you can safely change the end of arm tooling (e.g. Y axes to depositing position, C axes swiveled up). 2. Switch off robot motors. 3. Uncouple the end-of-arm tooling from the robot by activating the Uncouple switch. 4. Remove the end of arm tooling from the robot. 5. Position the new end-of-arm tooling. 6. Couple the end-of-arm tooling with the robot by activating the Couple switch. 7. Check the settings for all sequences and positions. If needed, modify sequence and positions to match the new end of arm tooling. CAUTION! Danger of collision between robots, machine and peripheral units! Sequences, work areas and prohibited areas must be set immediately after changing the end of arm tooling. Options 362 Operator Manual - Robot | Version G/11/401/2/21 23 Air conditioning unit An air conditioning unit ensures a constant operating temperature in the switching cabinet. Air conditioning units are mainly used at locations with a high ambient temperature where cool- ing with normal fans is insufficient. Since the switch cabinet does not take in external air via air vents, the switch cabinet can be classified as dust-free. The air conditioning unit is fitted in the switch cabinet door. Robot air conditioning unit OKAY This flag is set if the air conditioning unit is cooling properly. Automatic interruption in case of error If an air conditioning unit malfunction occurs while the program switch is enabled, the control unit interrupts automatic mode. The current cycle is always completed. Cycle stop delay Delays Automatic interruption in case of error by the set number of cycles. Air conditioning unit x defective Cause Air conditioning unit is not cooling properly. Effect The alarm lamp flashes. Motor stop after the set cycle stop delay. Cycle stop delay Automatic interruption in case of error Robot air conditioning unit OKAY Air conditioning unit Options 363 24 Tray server ENGEL Tray Servers (ETS) are units for the automatic provision of special plastic trays used for automated parts storage on an injection molding machine. Tray servers are specifically used when injection molded parts must be temporarily stored in correct position for further processing stages and need to be protected for transport. The parts storage in specially designed plastic trays meets this requirement. Example: ETS5 [1] Unstacking unit [2] Stacking unit [3] Filling position [4] Waiting position Screen page Depositing Interface Program switch activates the tray server. Filling of cartons Only available with ETS 4. ETS 5 can only transport flat trays. Grid for tray position 0 (cycled when all grids full) and Grid for tray position 180 (cycled when all grids full) The robot places the parts in the configured grids according to the orientation of the sup- plied trays (0 or 180). The orientation of the trays serves for better stacking. If all configured grids are full for each Grid for tray position 0or 180 (cycled when all grids full) , the tray server will cycle. You can additionally step the tray server in manual or set-up mode by pressing the Tray cycle key on the manual control device. 4 3 1 2 Deposit Info Panel Tray server settings Interface Filling of cartons Tray is prepared Prepared tray is rotated by 180 Grid for tray position 0 (cycled when all grids full) Grid for tray position 180 (cycled when all grids full) Options 364 Operator Manual - Robot | Version G/11/401/2/21 The following conditions must be met to activate a tray server cycle by pressing the Tray cycle pushbutton (output Tray cycle becomes active): Robot in manual or setup mode Robot above depositing area Ready for operation input active Depositing vacuum/compressed air circuits Configuration of the vacuum/compressed air circuits is only possible in Teach mode. See chapter Quick Setup. Speed in depositing area Speed of the servoaxes in the depositing area (above the lower swivelling limit). Speed to depositing position Speed of servoaxes from the lower swivelling limit to the depositing position. Shot grid 2/3 Select this key to tell the control unit to open the Grid Editor. Waiting time before depositing Waiting time until depositing position reached. Depositing time Waiting time after depositing the molded part. Speed from depositing position Speed of servoaxes from the depositing position to the lower swivelling limit. Tray cycle Depositing of parts in shot grid 2/3 with tray server Speed in depositing area Speed to depositing position Shot grid 2 Waiting time before depositing Depositing time Speed from depositing position Depositing vacuum/compressed air circuits Se- Shot grid 3 Shot grid 2 Shot grid 3 Options 365 Sequence instructions Instructions for communication between tray server and robot. Wait until depositing allowed and part deposited Collisions between end-of-arm-tooling and tray server should be prevented with the instruc- tions Wait until depositing allowed and Part deposited . The robot waits for the release from the tray server to deposit molded parts with the instruction Wait until depositing allowed. Stepping The Cycle instruction triggers a tray cycle of the tray server. The tray server then conveys the filled tray out and transports an empty tray into the filling position. Note! It must be noted that the grid must be reset after each cycle or actuation of the tray server. Tray server not ready for operation Effect No automatic mode or tray cycle blocked Remedy Check tray server Tray server Wait until depositing allowed Part deposited Stepping Sequence instructions Options 366 Operator Manual - Robot | Version G/11/401/2/21 Special programs 367 Special programs Special programs 368 Operator Manual - Robot | Version G/11/401/2/21 Index 369 Index Symbols *(distance of parts * number of parts +individual part grid starting position Z) inside the machine area . . . . . . . . . . . . . . . . . 168 *(distance of parts * number of parts +individual part grid starting position Z) outside of axis limits . . . . . . . . . . . . . . . . . . . . 168 *(distance of parts * number of parts +shot grid starting position Z) outside of axis limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 *(distance of parts * number of parts +shot grid starting position Z) within the machine area . . . . . . . . . . . . . . . . . . . . . . . . 160 *Acknowledgement contactor x defective . . . . . . . . . . . . . 32 *Activate robot set-up mode . . . . . . . . . . . . . . . . . . . . . . . . 80 *Air conditioning unit x defective . . . . . . . . . . . . . . . . . . . 362 *Axis - Brake safety test required . . . . . . . . . . . . . . . . . . . 235 *Axis - Brake test failed . . . . . . . . . . . . . . . . . . . . . . . . . . 235 *Check group configuration and vacuum/compressed air circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 *Clamp unit safety gate x interrupts cycle . . . . . . . . . . . . . 27 *Clamping unit safety gate 2 not entirely open . . . . . . . . . . 33 *Clamping unit safety gate disconnected but not completely open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 *Clamping unit safety gate open . . . . . . . . . . . . . . . . . . . . 27 *Closing safety - Robot within machine area . . . . . . . . . . 135 *Closing safety lies above the permitted limit () . . . . . . . . 109 *Closing safety lies below the permitted limit (x) . . . . . . . 109 *Closing safety: "Horizontal closing safety" setting was changed by importing parts data () . . . . . . . . . . . . . . . . . . . . . . . . . 108 *Closing safety: "Vertical closing safety" setting was changed by importing parts data (x) . . . . . . . . . . . . . . . . . . . . . . . . . . 108 *Closing safety: Confirm changed settings . . . . . . . . . . . 109 *Crane in the robot area . . . . . . . . . . . . . . . . . . . . . . . . . . 353 *Early start not possible, by take-off with closed mold. . . 318 *Editing mode active . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 *Ejector stroke greater than axis stroke . . . . . . . . . . . . . . 343 *Ejector x not retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 *EMERGENCY STOP pressed . . . . . . . . . . . . . . . . . . . . . 26 *Flash card is full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 *Grid - full - depositing not possible . . . . . . . . . . . . . . . . . . 94 *Individual part grid - Not all parts could be deposited . . . 266 *Individual part grid - Not all parts could be picked up . . . 266 *Injection molding machine - Danger of collision with robot 135 *Injection molding machine rotary table - Danger of collision with robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 *Injection molding machine rotary table - signal "In end position" missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 *Manual mode required for brake test . . . . . . . . . . . . . . . 234 *Mold not open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 *Movement to home position enabled . . . . . . . . . . . . . . . . 99 *Name - Crane release not possible (missing configuration) 353 *Name - Softservo active . . . . . . . . . . . . . . . . . . . . . . . . . 347 *Nozzle safety gate open . . . . . . . . . . . . . . . . . . . . . . . . . . 28 *Park position sequence still active . . . . . . . . . . . . . . . . . 336 *Part lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 *Part not deposited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 *Prohibited area left - move-out only possible with consent key 352 *Quickpos still active . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 *Replace placeholder with instruction 'Part deposited' for the re- quired peripheral unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 *Replace placeholder with instruction 'Wait for part pick-up re- lease' for the required peripheral unit. . . . . . . . . . . . . . . . 269 *Replace placeholder with instruction 'Wait until part depositing allowed' for the required peripheral unit. . . . . . . . . . . . . . 269 *Robot consent key pressed on automatic manual switchover 41 *Robot consent key pressed on starting up the control unit 41 *Robot interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 *Robot motor in the set-up mode only from level 5 . . . . . . .80 *Robot motors blocked - new start required! . . . . . . . . . . . .80 *Robot motors must be switched on for brake test . . . . . .234 *Robot motors switched off . . . . . . . . . . . . . . . . . . . . . . . . .79 *Robot not in Home position . . . . . . . . . . . . . . . . . . . . . . . .99 *Robot override active! . . . . . . . . . . . . . . . . . . . . . . . . . . .111 *Robot safety gate not connected . . . . . . . . . . . . . . . . . . . .33 *Robot safety gate open . . . . . . . . . . . . . . . . . . . . . . . . . . .31 *Robot safety gate opening-closing-acknowledging . . . . . .31 *Robot safety gate x unlocked by EMERGENCY STOP . . .26 *Robot safety gate x: acknowledgement key pressed too early 31 *Robot safety gate: Acknowledgement key actuated too fast 32 *Robot safety gate: Acknowledgement key actuated too long 32 *Robot safety gate: Acknowledgement key too long not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 *Robot too small speed defined, set to . . . . . . . . . . . . . . . .96 *Robot x test run without machine . . . . . . . . . . . . . . . . . . .107 *Robot: Incorrect end of arm tooling . . . . . . . . . . . . . . . . .360 *Safety gate 2 not connected and open . . . . . . . . . . . . . . . .33 *Sensor defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353 *Softservo not activated as access to axis by Switch off -axis is blocked. Please check the robot sequence or deactivate at first Switch off -axis.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349 *Switching the robot motors on in automatic mode is not possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 *Take-off invalid - robot was not in the take-off area . . . . .136 *Take-off with mold intermediate stop not possible, by take-off with closed mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318 *Tray server not ready for operation . . . . . . . . . . . . . . . . .365 *Unable to load parts data set. Please check the sequence. () 70 *User sequence Cannot be started - EMERGENCY STOP 26 *User sequence cannot be started - Robot motors switched off 196 *Values corrected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 *Work area error: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 *x not back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 *x not back on intermediate position . . . . . . . . . . . . . . . . .260 *x not closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 *x not closed on intermediate position . . . . . . . . . . . . . . . .259 *x not in front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 *x not in front on intermediate position . . . . . . . . . . . . . . .260 *x not moved in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258 *x not moved out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 *x not open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 *x not open on intermediate position . . . . . . . . . . . . . . . . .259 *Z settings defective - Work area in machine area . . . . . .136 Numerics 3D view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 A ABC-axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Access demand protection door . . . . . . . . . . . . . . . . . . . . .29 Additional closing safety . . . . . . . . . . . . . . . . . . . . . . . . . .122 Additional equipements . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362 Air valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256, 257 Area settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Assistant for sequence set-up . . . . . . . . . . . . . . . . . . . . . .199 B barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242, 249 Behavior in case of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Bottom layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 Brakes test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233 Index 370 Operator Manual - Robot | Version G/11/401/2/21 C Changing an instruction . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Changing users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Classic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Clearing circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Closing safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Closing safety additional prohibited area . . . . . . . . . . . . . 128 Compensation of loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Components of the control unit . . . . . . . . . . . . . . . . . . . . . . 36 Condition editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Configurable foil keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Configuring the keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Consent key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Conveyor-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93, 247 Copy parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Crane protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 Create sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Create Teach variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Creating a user authorization card . . . . . . . . . . . . . . . . . . . 65 Creating, changing or deleting users . . . . . . . . . . . . . . . . . 63 Cross transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cycle time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Cycle time analysis robot . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Cylinder group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 D Danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Data dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Deactivating the equipment . . . . . . . . . . . . . . . . . . . . . . . 221 Delete instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Delete parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Delete subsequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Delete user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Delete user sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Delete variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Demolding stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Depositing area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Depositing conveyor-belt . . . . . . . . . . . . . . . . . . . . . .93, 247 Depositing conveyor-belt with quality control parts and reject mol- ding separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Depositing conveyor-belt with reversing operation . . . . . . . 94 Depositing variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Dialog window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Dual-side deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Duplicating instructions or subsequences . . . . . . . . . . . . 212 E Early start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Economy mode vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Efficiency optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Ejector synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . 342 EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . . . . . . 26 Enable clamp force build-up/reduction . . . . . . . . . . .254, 258 End of arm tooling replaceable system . . . . . . . . . . . . . . 361 Exchanging variants - Extended view . . . . . . . . . . . . . . . . 203 Exchanging variants - Simple view . . . . . . . . . . . . . . . . . . 202 Export injection protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Extended view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 F Foil keys on the KETOP C100E . . . . . . . . . . . . . . . . . . . . . 42 Free pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 G General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Grid editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Group configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 H High speed head changing system . . . . . . . . . . . . . . . . . 361 Home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98, 196 Home position (Bring robot in home position) . . . . . . . . . . 99 Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 I Importing/exporting user data . . . . . . . . . . . . . . . . . . . . . . 66 Individual axis movement - Teach grid sequence . . . . . . 175 Individual part grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Info Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Injection molding machine safety gates . . . . . . . . . . . . . . . 27 Input field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Input keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Insert command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Insert sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Inserting instructions or subsequences . . . . . . . . . . . . . . 212 Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Instruction manual structure . . . . . . . . . . . . . . . . . . . . . . . . 11 Instruction types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Instructions for Use of Ketop C100E . . . . . . . . . . . . . . . . . 38 intermediate deposit . . . . . . . . . . . . . . . . . . . . . . . . . 269, 323 Intermediate layer . . . . . . . . . . . . . . . . . . . . . . . . . . 161, 171 Intermediate layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Intermediate layers depositing . . . . . . . . . . . . . . . . . . . . . 270 K KETOP C100E pushbuttons . . . . . . . . . . . . . . . . . . . . . . . 42 L Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Linear axes movement - Teach grid sequence . . . . . . . . 175 Log-in by entering password . . . . . . . . . . . . . . . . . . . . . . . 62 M Machine area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 122 Machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Machine sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Macro instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Mandatory Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Manual movement to home position . . . . . . . . . . . . . . . . . 99 Mask assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Mask editor - components of masks . . . . . . . . . . . . . . . . 305 Mask editor - Paste a comment . . . . . . . . . . . . . . . . . . . . 311 Mask editor - Paste new strips . . . . . . . . . . . . . . . . . . . . . 307 Mask editor - Paste of existing strips . . . . . . . . . . . . . . . . 306 Mask editor - Paste variables from a list . . . . . . . . . . . . . 307 Mask editor - Paste variables from existing screen pages 308 Mask editor - Search variable . . . . . . . . . . . . . . . . . . . . . 309 Mask editor - stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Mass identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Mold and ejector synchronization . . . . . . . . . . . . . . . . . . . 344 Mold swivelling device . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Mold synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Move commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Moving-in intermediate position . . . . . . . . . . . . . . . . . . . . 139 Moving-out intermediate position . . . . . . . . . . . . . . . . . . . 141 Multi-position linear axes movement - Teach grid sequence 175 O operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Optimized deposit path . . . . . . . . . . . . . . . . . . . . . . . . . . 193 outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245, 251 overgrinding radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Override speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Overview axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Overview rotary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 P Park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196, 336 Index 371 Part deposit in Teach grid 1 with conveyor-belt . . . . . . . . 149 Part deposit without grid and conveyor-belt . . . . . . . . . . . 145 Part pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 Parts data set - Copy all . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Parts deposit check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Pick-up part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Place holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Pneumatic axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Position check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 Position compensation for tie-bar-less machines . . . . . . . 275 Print sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Printing textually and graphically . . . . . . . . . . . . . . . . . . . 219 Production without robot . . . . . . . . . . . . . . . . . . . . . . . . . 106 Program switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Prohibited area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Prohibited area clamping unit . . . . . . . . . . . . . . . . . . . . . . 127 Prohibitory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Protection door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Putting out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Q Quality control deposit . . . . . . . . . . . . . . . . . . . . . . . 153, 249 Quality Control part depositing . . . . . . . . . . . . . . . . . . . . . 272 Quality control parts and reject molding separation . . . . . . 94 Quick positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Quick setting of robot position . . . . . . . . . . . . . . . . . . . . . 101 Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 QuickSet QuickPos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 R Read parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Read sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Referencing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Reject deposit . . . . . . . . . . . . . . . . . . . . . . . . 151, 248, 273 Rescue actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Reversing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Robot machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Robot Editor - Inserting a Sequence . . . . . . . . . . . . . . . . 207 Robot light beam guard . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Robot movement - Teach grid sequence . . . . . . . . . . . . . 175 Robot Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Robot overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Robot program switches . . . . . . . . . . . . . . . . . . . . . . . . . 104 Robot safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Robot safety guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Robot sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185, 196 Robot sequence - Changing an instruction . . . . . . . . . . . 211 Robot sequence - Copying an instruction or subsequence 212 Robot sequence - coupling . . . . . . . . . . . . . . . . . . . . . . . 189 Robot sequence - Creating a Teach Variant . . . . . . . . . . 215 Robot sequence - Deactivate equipment . . . . . . . . . . . . . 221 Robot sequence - Delete instruction or subsequence . . . 213 Robot sequence - Duplicate instruction or subsequence . 212 Robot sequence - Exchanging variants . . . . . . . . . . 202, 203 Robot sequence - Extended view . . . . . . . . . . . . . . . . . . 188 Robot sequence - Insert instruction . . . . . . . . . . . . . . . . . 207 Robot sequence - Inserting a parallel closed branch . . . . 209 Robot sequence - Inserting an empty sequence . . . . . . . 214 Robot sequence - Instructions . . . . . . . . . . . . . . . . . . . . . 229 Robot sequence - multiple selections . . . . . . . . . . . . . . . 195 Robot sequence - position . . . . . . . . . . . . . . . . . . . . . . . . 189 Robot sequence - Print sequence . . . . . . . . . . . . . . . . . . 219 Robot sequence - Remove variant . . . . . . . . . . . . . . . . . . 217 Robot sequence - Removing Variants . . . . . . . . . . . . . . . 218 Robot sequence - simple view . . . . . . . . . . . . . . . . . . . . . 186 Robot sequence - step pointer . . . . . . . . . . . . . . . . . 187, 191 Robot sequence symbols - Extended view . . . . . . . . . . . 189 Robot sequence symbols - Simple view . . . . . . . . . . . . . .187 Rotary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 109 Rotary table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316 Rotation limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Run empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340 S Safety distance for tiebarless machine range . . . . . . . . . . .28 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25 Safety gate acknowledgement key . . . . . . . . . . . . . . . . . . .29 Safety guarding that can be entered . . . . . . . . . . . . . . . . . .25 Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Safety keys KETOP C100E . . . . . . . . . . . . . . . . . . . . . . . . .40 Safety package 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Save sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 Screen keys on the KETOP C100E . . . . . . . . . . . . . . . . . . .45 Screen page editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303 Screen page editor - Edit screen page . . . . . . . . . . . . . . .305 Screen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Selection field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Sequence instruction - Air valves . . . . . . . . . . . . . . . . . . .257 Sequence instruction - Alarm . . . . . . . . . . . . . . . . . . . . . . .289 Sequence instruction - Assignment . . . . . . . . . . . . . . . . . .285 Sequence instruction - Barrel . . . . . . . . . . . . . . . . . 242, 249 Sequence instruction - Barrel group . . . . . . . . . . . . . . . . .244 Sequence instruction - Block clamp force build-up/reduction . 254 Sequence instruction - Check current position to set position . 231 Sequence instruction - Check current position within range 231 Sequence instruction - Comment . . . . . . . . . . . . . . . . . . .284 Sequence instruction - Copy actual position to . . . . . . . . .291 Sequence instruction - Cores . . . . . . . . . . . . . . . . . . . . . .256 Sequence instruction - Cycle time . . . . . . . . . . . . . . . . . . .235 Sequence instruction - Decrease . . . . . . . . . . . . . . . . . . . .292 Sequence instruction - Delete alarm . . . . . . . . . . . . . . . . .290 Sequence instruction - Depositing conveyor-belt . . . . . . .247 Sequence instruction - Ejector . . . . . . . . . . . . . . . . . . . . . .255 Sequence instruction - Ejector synchronization . . . . . . . . .342 Sequence instruction - Enable clamp force build-up/reduction 254 Sequence instruction - Execute while . . . . . . . . . . . . . . . .277 Sequence instruction - Grid . . . . . . . . . . . . . . . . . . . . . . . .263 Sequence instruction - If . . . . . . . . . . . . . . . . . . . . . . . . . .279 Sequence instruction - Increase . . . . . . . . . . . . . . . . . . . .291 Sequence instruction - Increase Quality control deposit counter 272 Sequence instruction - Individual axes movement . . . . . .230 Sequence instruction - Individual part grid . . . . . . . . . . . . .264 Sequence instruction - Injection molding machine . . . . . .253 Sequence instruction - Injection molding machine vacuum cir- cuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 Sequence instruction - Interface intermediate deposit . . . .323 Sequence instruction - Intermediate layers depositing . . .270 Sequence instruction - J ump to sequence end . . . . . . . . .288 Sequence instruction - Linear axes movement . . . . . . . . .230 Sequence instruction - Load compensation . . . . . . . . . . . .349 Sequence instruction - Mass identification . . . . . . . . . . . .233 Sequence instruction - Mold . . . . . . . . . . . . . . . . . . . . . . .253 Sequence instruction - Mold and ejector synchronization .344 Sequence instruction - Mold synchronization . . . . . . . . . .341 Sequence instruction - Move instructions . . . . . . . . . . . . .229 Sequence instruction - Multi-position linear axes movement 230 Sequence instruction - Parallel closed branch . . . . . . . . . .280 Sequence instruction - Parallel open branch . . . . . . . . . . .280 Sequence instruction - Part is reject . . . . . . . . . . . . . . . . .258 Sequence instruction - Part pick-up . . . . . . . . . . . . . . . . . .269 Sequence instruction - Parts deposit check . . . . . . . . . . . .274 Sequence instruction - Peripheral unit . . . . . . . . . . . . . . . .247 Sequence instruction - Peripheral unit outputs . . . . . . . . .251 Index 372 Operator Manual - Robot | Version G/11/401/2/21 Sequence instruction - Position check . . . . . . . . . . . . . . . 231 Sequence instruction - Position smoothing . . . . . . . . . . . 230 Sequence instruction - Quality control deposit . . . . . . . . . 249 Sequence instruction - Quality Control part depositing . . 272 Sequence instruction - Rejects depositing . . . . . . . .248, 273 Sequence instruction - Relative movement . . . . . . . . . . . 230 Sequence instruction - Repeat until . . . . . . . . . . . . . . . . . 278 Sequence instruction - Request intervention . . . . . . . . . . 262 Sequence instruction - Request opening . . . . . . . . . . . . . 261 Sequence instruction - Reset rejects request . . . . . . . . . . 273 Sequence instruction - Robot axis referencing . . . . . . . . . 230 Sequence instruction - Robot movement . . . . . . . . . . . . . 230 Sequence instruction - Robot movement with check position 230 Sequence instruction - Robot outputs . . . . . . . . . . . . . . . 245 Sequence instruction - Rotary axes movement . . . . . . . . 230 Sequence instruction - Rotary axes movement after depositing (Quick Setup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Sequence instruction - Rotary axes movement before depositing (Quick Setup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Sequence instruction - Rotary axes movement when moving-out from machine area (Quick Setup) . . . . . . . . . . . . . . . . . . . 236 Sequence instruction - Safety gate . . . . . . . . . . . . . . . . . . 261 Sequence instruction - Sequence control . . . . . . . . . . . . . 263 Sequence instruction - Sequences . . . . . . . . . . . . . . . . . . 267 Sequence instruction - Set position . . . . . . . . . . . . . . . . . 290 Sequence instruction - Shot grid . . . . . . . . . . . . . . . . . . . 263 Sequence instruction - Softservo . . . . . . . . . . . . . . . . . . . 347 Sequence instruction - Stop movement . . . . . . . . . . . . . . 230 Sequence instruction - Stop sequence . . . . . . . . . . . . . . . 263 Sequence instruction - Stop when safety gate requested 261 Sequence instruction - Structure instructions . . . . . . . . . . 277 Sequence instruction - Switch off axis . . . . . . . . . . . . . . . 232 Sequence instruction - Take-off stroke correction . . . . . . 337 Sequence instruction - Teach grid . . . . . . . . . . . . . . . . . . 266 Sequence instruction - Torque monitoring . . . . . . . . . . . . 357 Sequence instruction - Tray server . . . . . . . . . . . . . . . . . . 365 Sequence instruction - Vacuum/compressed air . . . . . . . 239 Sequence instruction - Vacuum/compressed air group . . 241 Sequence instruction - Vacuum/compressed air group off when part lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Sequence instruction - Wait for start button in semiautomatic 263 Sequence instruction - Wait until . . . . . . . . . . . . . . . . . . . 284 Sequence instruction - Wait until part take over allowed . 258 Sequence instruction - Waiting time . . . . . . . . . . . . . . . . . 281 Sequence instruction - Waiting time or input . . . . . . . . . . 283 Sequence instruction - Waiting time or marker . . . . . . . . . 282 Sequence instruction - Warning signal light . . . . . . . . . . . 354 Sequence instruction - Weigh scale . . . . . . . . . . . . . . . . . 327 Sequence instruction - Work areas/prohibited areas . . . . 246 Sequence instructions - Intermediate deposit . . . . . . . . . 269 Servomotor axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Shot grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Simple view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Smoothing window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Softservo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 Speed limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Sprue deposit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Sprue separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Status marker - Vacuum/compressed air . . . . . . . . . . . . . 300 Status marker - Vacuum/compressed air group . . . . . . . . 301 Status page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Storage media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 structure instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Swivelling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Swivelling limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 T Take-off area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 122 Take-off movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Take-off position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Take-off stroke correction . . . . . . . . . . . . . . . . . . . . . . . . 337 Take-off with closed mold . . . . . . . . . . . . . . . . . . . . . . . . 317 Takeover head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Takeoverheadcoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Teach grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Teach grid - screen page . . . . . . . . . . . . . . . . . . . . . . . . . 150 Teach grid sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Teach pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Text formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Tool-tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Top layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Torque monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Travel limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Tray server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 U Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 USB storage media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 User administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 User level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 User login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 User sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 User settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 V Vacuum economy mode . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Vacuum/compressed air . . . . . . . . . . . . . . . . . . . . . . . . . 239 Vacuum/compressed air circuits . . . . . . . . . . . . . . . . . . . . 89 Vacuum/compressed air group . . . . . . . . . . . . . . . . . . . . 241 Vacuum/compressed air group off on part lost . . . . . . . . 242 Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Vertical stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 W Wait until part take over allowed . . . . . . . . . . . . . . . 257, 258 Warning signal light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Weigh scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Work area above clamping unit . . . . . . . . . . . . . . . . . . . . 126 Work area above depositing area Z- . . . . . . . . . . . . . . . . 130 Work area above machine . . . . . . . . . . . . . . . . . . . . . . . . 126 Work area between take-off area and depositing area Z+ 128 Work area clamping unit . . . . . . . . . . . . . . . . . . . . . . . . . 127 Work area depositing area . . . . . . . . . . . . . . . . . . . . . . . . 122 Work area depositing area Z- . . . . . . . . . . . . . . . . . . . . . . 130 Work area depositing area Z+ . . . . . . . . . . . . . . . . . . . . . 129 Work area setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Work area setup - Settings . . . . . . . . . . . . . . . . . . . . . . . . 122 Work areas and prohibited areas of the plant . . . . . . . . . 125 Write a parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Writing parts data sets separately . . . . . . . . . . . . . . . . . . . 72 X X-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Y Y-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Z Z-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ENGEL AUSTRIA GmbH. 4311 Schwertberg tel: +43.(0)50.620.0 fax: +43.(0)50.620.3609 e-mail: [email protected] www.engelglobal.com