Mitsubishi Electric MELFA CR800-D Series User Manual
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Mitsubishi Electric MELFA CR800-D Series User Manual

Mitsubishi Electric MELFA CR800-D Series User Manual

Industrial robot
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Mitsubishi Electric Industrial Robot
MELFA Smart Plus
CR800-D/R/Q series controller
User's Manual
2F-DQ510
2F-DQ511
2F-DQ520
2F-DQ521
BFP-A3559-E
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Summary of Contents for Mitsubishi Electric MELFA CR800-D Series

  • Page 1 Mitsubishi Electric Industrial Robot CR800-D/R/Q series controller MELFA Smart Plus User’s Manual 2F-DQ510 2F-DQ511 2F-DQ520 2F-DQ521 BFP-A3559-E...
  • Page 3 Safety Precautions Before using the robot, always carefully read the precautions below as well as the separate "Safety Manual" and take all necessary safety measures. A. These show precautions based on the Ordinance on Industrial Safety and Health (Articles 36, 104, 150, 151).
  • Page 4 B. This shows precaution points given in the separate "Safety Manual". For details, please read the text of the "Safety Manual". DANGER By using multiple control devices (GOT, PLC, push button switch) When automatic operation is performed, the interlock such as the operation right of each device is designed by the customer please.
  • Page 5 CAUTION Never make alterations on your own judgment or use maintenance parts other than those designated. Doing so can cause breakdown and malfunctions. WARNING When moving the robot arm from the outside, never stick a hand or finger into an opening. Depending on the posture, the hand or finger could get caught in the equipment.
  • Page 6 (VPNs), and antivirus solutions. Mitsubishi Electric shall have no responsibility or liability for any problems involving robot trouble and system trouble by unauthorized access, DoS attacks, computer viruses, and other cyberattacks.
  • Page 7 ■ User's Manual Revision History Printing Date Manual No. Revision Contents 2017-06-30 BFP-A3559 ・First edition 2018-02-01 BFP-A3559-A ・The CR800-Q controller was added. 2018-09-01 BFP-A3559-B ・2F-DQ520 and 2F-DQ521 were added. 2019-04-19 BFP-A3559-C ・The predictive maintenance function and the extended function of force sensor were added. 2020-10-30 BFP-A3559-D ・Amended the precautions regarding the prevention of...
  • Page 8 Although we strive to describe special handling as much as possible in this book, please interpret the items not described in this document as "can not". This manual is described on the premise that basic operations and functions of Mitsubishi Electric Industrial Robots are understood.

  • Page 9: Table Of Contents

    Contents Usage ....................................1-1 1.1 How to Use this Document ............................1-1 Confirmation before use............................... 2-2 2.1 Product confirmation ..............................2-2 MELFA Smart Plus card .............................. 3-3 3.1 List of function ................................3-3 3.1.1 Functions of A-type ..............................3-3 3.1.2 Functions of B-type ..............................3-5 3.2 Installing/removing and setting of the MELFA Smart Plus card ................
  • Page 10 6.3.2 System configuration ............................. 6-96 6.3.3 Specification ................................6-98 6.3.4 Operation procedure ............................6-100 6.3.5 Parameter setting ..............................6-101 6.3.6 Creation of robot program ........................... 6-105 6.3.7 Installation of a sample program ......................... 6-113 6.3.8 Calibration of Robot and Base Coordinate Systems (“A1” program) ............6-114 6.3.9 Resistration of User Mechanism Work Position (“B1”...

  • Page 11: Usage

    1 Usage 1.Usage This chapter explains the items to be checked and precautions before using the MELFA Smart Plus card/card pack. How to Use this Document This document explains the functions of the MELFA Smart Plus card as shown in Table 1-1.

  • Page 12: Confirmation Before Use

    2 Confirmation before use 2.Confirmation before use Product confirmation The standard configuration of the product you purchased is as follows. Please confirm. Table 2-1 Standard configuration of product Component name Model name Quantity Instruction manual (this CD-ROM) BF P-A3563 MELFA Smart Plus card pack A-type 2F-DQ510 One of the four...

  • Page 13: Melfa Smart Plus Card

    3 MELFA Smart Plus card 3.MELFA Smart Plus card MELFA Smart Plus card ....You can select and use one of the functions according to the MELFA Smart Plus card type. Refer to “3.1 List of function” for the details of functions. MELFA Smart Plus card pack ..
  • Page 14 3 MELFA Smart Plus card Parameter Function name Description “SMART+1” setting (*1) 3 Coordinated control for (1) Base coordinate cooperative control additional axes Allows synchronized operation where a robot is (Chapter 6) installed on an additional axis (linear axis) and its speed relative to the workpiece in specified.

  • Page 15: Functions Of B-Type

    3 MELFA Smart Plus card 3.1.2 Functions of B-type Table 3-3 List of functions of B-type Parameter Function name Description “SMART+1” setting (*1) 1 Extended function of During the adjustment for the model-less recognition of MELFA-3D Vision MELFA-3DVision, our AI and simulation technologies allow (Refer to the separate to automatically adjust sensor parameters without needing instruction manual:...

  • Page 16: Installing/Removing And Setting Of The Melfa Smart Plus Card

    3 MELFA Smart Plus card Installing/removing and setting of the MELFA Smart Plus card 3.2.1 Installing/removing of the MELFA Smart Plus card When installing or removing the MELFA Smart Plus card/card pack, it is required to keep Caution the card/card pack in parallel with the controller. Keep in parallel with the controller.
  • Page 17 3 MELFA Smart Plus card 3.2.1.1. Installing of the MELFA Smart Plus card Here is the procedure for installing the MELFA Smart Plus card/card pack. MELFA Smart Plus card MELFA Smart Plus card puck Figure 3-1 Installation of MELFA Smart Plus card/card pack Turn off the controller.
  • Page 18 3 MELFA Smart Plus card 3.2.1.2. Removing of the MELFA Smart Plus card Here is the procedure for removing the MELFA Smart Plus card/card pack. Removal lever Handle Figure 3-2 Removing of MELFA Smart Plus card/card pack Turn off the controller. Remove the MELFA Smart Plus card with the removal lever pushed up.

  • Page 19: Setting Of The Melfa Smart Plus Card (Only Melfa Smart Plus Card)

    3 MELFA Smart Plus card 3.2.2 Setting of the MELFA Smart Plus card (Only MELFA Smart Plus card) When using the MELFA Smart Plus card, you can use only one supported function. The setting method of the function to be used is shown below. If you use the MELFA Smart Plus card pack, this setting is not necessary.

  • Page 20: Robot Language Specification

    3 MELFA Smart Plus card Robot language specification This chapter explains the MELFA-BASIC VI robot program language relating to MELFA Smart Plus. Robot status variable list 3.3.1 Below is a list of state variables related to the MELFA Smart Plus. Table 3-5 Robot status variable list Variable name...
  • Page 21 3 MELFA Smart Plus card M_SmartPlus [Function] Refer to the available status of each function of MELFA Smart Plus. [Format] = M_SmartPlus() [Terminology] Specify numerical variable to assign. 0 : Disabled 1 : Enabled Specify the function ID. 1 : Calibration assistance function 2 : Robot mechanism temperature compensation function 3 : Coordinated control for additional axes...
  • Page 22 3 MELFA Smart Plus card C_SmartPlus [Function] Returns the function name of MELFA Smart Plus. [Format] = C_SmartPlus() [Terminology] Specify the character string variable to assign. Calibration assistance / Robot temperature compensation / Coordinated control for additional axes / Preventive Maintenance / Extended function of MELFA-3D Vision / Predictive Maintenance /...

  • Page 23: Error List

    3 MELFA Smart Plus card Error list The meaning of the error < > □００００＊ ・An error marked with a ＊ reset by turning the power OFF and ON. Take the measures given. ・The error type is indicated with a 4-digit number. ・Three types of error classes are inidcated.

  • Page 24: Calibration Assistance Function

    4 Calibration assistance function 4.Calibration assistance function This section explains the calibration assistance function using 2D vision sensor. In this section we use Cognex's vision for vision sensor, Describe the operation method when setting vision in the EasyBuilder view of Cognex In-Sight Explore. If you are using another vision sensor, please use the communication part of the sample program output by this function according to the specification of each manufacturer.
  • Page 25 4 Calibration assistance function (1) System components System components example is as follows a) D type robot Robot controller Teaching box Computer MELFA Smart Plus card Vision sensor Robot body Figure 4-2 D type System components example b) R type/Q type robot PLC（Robot CPU unit）...

  • Page 26: Automatic Calibration

    4 Calibration assistance function Automatic Calibration (1)Function Outline "Automatic calibration" is a function for matching the coordinate in the vision sensor with the coordinate in the robot. The function is possible to convert the image coordinate (work position, release position, etc.) measured by the vision sensor into robot coordinate.
  • Page 27 4 Calibration assistance function (3) Camera setting method Corresponding camera setting method by automatic calibration is as follows. Table 4-3 Corresponding camera setting method by automatic calibration Use the calculated Name Camera calibration data to change the coordinate Fixed method Applicable to the workpiece at the World coordinate (Top fixed)
  • Page 28 4 Calibration assistance function (4) Workflow Start work 1.Preparation and installation of equipment Refer to 4.2.(4-1) Prepare and install marks to make your vision perceive. 2.Set communication parameters Refer to 4.2.(4-2) Execute the visual sensor and robot communication settings. 3. Set robot data Refer to 4.2.(4-3) Set the calibration data and teach the initial point.
  • Page 29 4 Calibration assistance function (4-1)Preparation and installation of equipment In the automatic calibration, the robot recognizes the calibration plate while changing the posture and proceed with work.The calibration plate is a product for customers.Please prepare the plate according to the following contents. a) Fixed method (Top fixed) •There is a mark on the upper side Please fix the camera so...
  • Page 30 4 Calibration assistance function (4-2)Set communication parameters a) Vision side setting Start up the In-Sight Explorer, Set the IP address and subnet mask of the vision sensor. Select [System] - [Add Sensor/Device to Network] from the In-Sight Explorer menu. On the displayed "Add Sensor / Device to Network"...
  • Page 31 4 Calibration assistance function b) Robot side setting Start RT ToolBox 3 and set the parameters. ①Set IP address · Subnet mask. 1) Select - - - and display the Ethernet parameter screen. 2) Set the IP address and subnet mask of the robot from the IP address menu. ②Set IP address, port number, COM assignment of vision sensor.
  • Page 32 4 Calibration assistance function (4-3) Set robot data Set calibration data from the automatic calibration screen of RT ToolBox 3. ① Launch the automatic calibration screen Start RT ToolBox 3, select - , Display the automatic calibration screen. ...
  • Page 33 4 Calibration assistance function Vision Range [mm] Set the vision range of the vision sensor. (*3) Please set the viewing range (X, Y) based on the base coordinates. Resolution [pixel] Set the resolution of the vision sensor. Please check the specification of the vision sensor to be used.
  • Page 34 4 Calibration assistance function ③ The initial point of teaching 1) Start In-Sight Explorer, set the application step as [Set Up Image], select [Live Video], The camera image is displayed in the monitor. Figure 4-6 In-Sight Explorer Live video 2) Move the recognition mark by the robot's jog operation so that it is near the center of the camera field of view.
  • Page 35 4 Calibration assistance function 3) Teach the initial point on the automatic calibration screen of RT Toolbox 3. Teaching the initialized point Click the [Get the Robot Position] button, the initialized point is taught and the taught coordinate values are displayed.
  • Page 36 4 Calibration assistance function (4-4) create a vision job Set vision job from In-Sight Explorer. ①English symbolic tag setting Carry out work for using English symbolic tags. Select [System] - [Options] from the In-Sight Explorer menu. Check "Use English symbolic tags with EasyBuilder". Select [User Interface] from [Options], Check check...
  • Page 37 4 Calibration assistance function ②Create job Work imaging. From the application step, click [Set Up Image]. Click [Live Video] and take a picture of the target tool. Click [Live Video] again to stop live video. Specify the trigger. Change "Trigger" from"Camera"to "Manual".
  • Page 38 4 Calibration assistance function Register the work. (Model registration) Move the displayed "Model" frame and enclose the work. Click the [OK] button in "Directions". Register the work. (Adjustment) From "Edit Tool", click the "Settings" tab and change [Rotation Tolerance] to "180". （The work can be recognized up to ±...
  • Page 39 4 Calibration assistance function Set the communication format. (Preparation) From "Format Output String", click the [Add] button.  Open the "Select Output Data". Set the communication format. (Selection) Click the [+] mark in [Pattern_1], hold down the [Ctrl] key, and select in the following order.
  • Page 40 4 Calibration assistance function Save the vision program. From the application step, click Save Job. From "Save Job", click [Save]. The name of the job to be saved is "Calibration". file name different from “Calbration”, change the line of "CPRG $ =" in the robot program.
  • Page 41 4 Calibration assistance function (4-5) Operation execution Generate the robot calibration program and run it. ① Make sure there are no interfering objects within the range of motion of the robot. ② Bring the vision sensor online. ③ Push the [ENABLE] switch of T/B and disable T/B. Set the controller mode to "AUTOMATIC". ④...
  • Page 42 4 Calibration assistance function ⑦ Select override.The default setting is 5%. ※Please drop the robot speed as much as possible in order to avoid the influence of vibration etc. （Override 10% or less） ⑧ Press [Start] button to start operation. ⑨...
  • Page 43 4 Calibration assistance function To be able to recognize the target correctly, Adjust the recognition parameters etc. of the vision sensor. 9152 Error Within the default retry count, It was not possible to move the recognition target to the image center (within the default value). Cause Less number of retries, Or the termination condition may be strict.
  • Page 44 4 Calibration assistance function Table 4-5 Items to check during automatic calibration Solution Check item Whether the corresponding point is set Please correctly set corresponding points. correctly. For example, Whether the order of the argument of the instruction that sets the corresponding point is wrong.

  • Page 45: Workpiece Coordinate Calibration

    4 Calibration assistance function Workpiece coordinate calibration (1) Function Outline Automatically obtain the positional relationship between robot coordinate and workpiece coordinate by program execution and store coordinate values in work coordinate parameters (WK1CORD to WK8CORD). For this function, it is a prerequisite to use the vision sensor as a hand eye. Only for hand eye system Figure 4-8 Image of work coordinate calibration (2) Standard Specifications...
  • Page 46 4 Calibration assistance function (3) Equipment preparation Prepare the following calibration sheet. Set the position of each marker in work coordinates in advance. Determine the X axis and Y axis of work coordinates with the center origin mark, the coordinate value of the cross mark is judged from the relative position.
  • Page 47 4 Calibration assistance function (4) Workflow Start work 1. Camera setting Refer to 4.3.(4-1) Attach the camera to the robot. 2. Implementation of hand eye calibration Refer to 4.2 Calibrate robot and vision sensor. 3. Setting of calibration sheet Refer to 4.3.(4-2) Place the calibration sheet on the side to set the work coordinates.
  • Page 48 4 Calibration assistance function (4-1) Setting of the vision sensor Please fix the vision sensor Tool coordinate parallel to the Z axis direction of the robot's tool coordinates. (4-2) Setting of calibration sheet The calibration sheet is fixed to the surface on which workpiece coordinates are to be defined. Please fix the calibration sheet to the surface on which workpiece coordinates are to be defined.
  • Page 49 4 Calibration assistance function (4-3) Teach base position of robot Move the robot so that the target tool is near the center of the camera field of view, teach the position of the robot. ① In-Sight Explorer application step as [Set Up Image] and select [Live Video], the camera image is displayed in the monitor.
  • Page 50 4 Calibration assistance function (4-4) Set condition data of robot Open sample program "WRKCALB.prg" with T/B or RT ToolBox 3, please change condition data as necessary. The condition data can be changed by setting the position variable / program change. The position variable and program description are as follows.
  • Page 51 4 Calibration assistance function Tolerance [mm] (Note 5) Parallel the vision MDH<=1.0 Then ' within the specified value (1 degree) sensor with the XY plane of work coordinates Tolerance [deg] (Note 4) (Note 1) Please set PGoal, PCamTL, MFlng referring to the figure below. Image coordinate Image coordinate PGoal =...
  • Page 52 4 Calibration assistance function (4-5) create a vision job Set vision job from In-Sight Explore. ①English symbolic tag setting Carry out work for using English symbolic tags. Select [System] - [Options] from the In-Sight Explorer menu. Check "Use English symbolic tags with EasyBuilder". Select [User Interface] from [Options], Check "Use English Symbolic Tags for EasyBuilder", Click the [OK] button.
  • Page 53 4 Calibration assistance function ②Create job Work imaging. From the application step, click [Set Up Image]. Click [Live Video] and take a picture of the target tool. Click [Live Video] again to stop live video. Specify the trigger. Change "Trigger" from"Camera"to "Manual".
  • Page 54 4 Calibration assistance function Register the origin mark.（Model register） Move the displayed "model" frame and enclose the work. Click the [OK] in "Directions". Note) Make sure the image coordinates of the model and work coordinates have the following relationship. When it is not the relationship below, calibration performed accurately.
  • Page 55 4 Calibration assistance function Register the cross mark.（Model register） Move the displayed "Model" frame and enclose the work. Click the [OK] in "Directions". Register the cross mark.（Adjustment） •From “Edit Tool”, Click the Settings tab, Adjust [Horizontal Offset] and [Vertical Offset], Align the output position with the Scale icon cross mark.
  • Page 56 4 Calibration assistance function Set the communication format. (Preparation) From "Format Output String", click the [Add] button.  Open the "Select Output data". Set the communication format. (Selection) Click the [+] mark in [Pattern_1] and [Pattern_2], hold down the [Ctrl] key, and select in the following order.
  • Page 57 4 Calibration assistance function Confirm communication format Confirm the value set in the format output string. The data to be sent to the robot controller is shown on the square frame on the right. It is also possible to change the number of digits in the decimal part of the data to be transmitted.
  • Page 58 4 Calibration assistance function Save the vision program. From the application step, click [Save Job]. From "Save Job", click [Save]. The name of the job to be saved is "WRKCALB". If the file name is different from “WRKCALB”, change the line of "CPRG $ =" in the robot program.
  • Page 59 4 Calibration assistance function (4-6) Operation execution Select the robot's calibration program and run it. ① Make sure there are no interfering objects. ② Online the vision sensor. ③ Push the [ENABLE] switch of T/B and disable T/B. Set the controller mode to "AUTOMATIC". ④...
  • Page 60 4 Calibration assistance function calibration again. Now, The XY component means the tool length from the flange to the center of the camera. b) When the object to be recognized is located within the field of view of the camera To be able to recognize the target correctly, Adjust the recognition parameters etc.
  • Page 61 4 Calibration assistance function variable MScore in the program. If the estimation error is large, check Table 4-5 on the confirmation items at the time of execution, Please re-execute the calibration. (4-7) Result When the calibration is completed normally, please make sure of the following as a precaution. 1) Make sure the workpiece coordinate data is set in the robot.
  • Page 62 4 Calibration assistance function (5) Sample program (WRKCALB.prg) '########################################################## 'Workpiece coordinate calibration program '########################################################## Dim POFS(2) Dim PW(4), PV(4), PVtmp(4) '### Initialization processing ### *Init P0 = P0 ' Teaching point PVSize = PVSize ' resolution (X, Y) PGoal = PGoal ' End condition (Posture of vision sensor in workpiece coordinates) PW(1) = PW(1) PW(2) = PW(2)
  • Page 63 4 Calibration assistance function MFLG = 1 GoSub *PrlVSWRK 'Parallelizing the vision sensor to the XY plane of work coordinates MScore = M_VSCErr(MCalNo) 'Accuracy evaluation of calibration data If MScore > 0.05 Then Error 9155 EndIf ' Calculate posture of workpiece coordinates PRob = P_Fbc PRob2Wrk = PRob * PT2V * Inv(PVSPose) Tool PTL...
  • Page 64 4 Calibration assistance function Return 'ecognition result of vision and Correspondence of workpiece coordinate *VSResSort ' X axis linear equation (ax+by+c=0) Ma = Cos(PVS.C) Mb = Sin(PVS.C) Mc = -Ma*PVS.X - Mb*PVS.Y ' Y axis linear equation (-bx+ay+d=0) Md = Mb*PVS.X - Ma*PVS.Y For M1=1 To 4 Step 1 Ptmp = PV(M1) If (Ma*Ptmp.X + Mb* Ptmp.Y + Mc) <...
  • Page 65 4 Calibration assistance function PC = PCS While MFIN<>1 Mov PC Type 0,0 Dly 0.5 GoSub *VSTRG PVSH = PVS GoSub *SCalcCenter ' Calculate the correction amount to the center position PC = PC*PH If MDH <= (MScale*2) Then ' Within the specified value (Plus or minus 1 pixel) MFIN = 1 'end flag Else...
  • Page 66 4 Calibration assistance function PRMov.A = PVSMov.B * MGain PRMov.B = PVSMov.A * MGain PRMov.C = PVSMov.C * MGain PRMov = PT2V * PRMov * Inv( PT2V ) PTrg = PTrg * PRMov If MDH <= 1.0 Then ' Within the specified value (1.0 degree) MFIN = 1 'end flag Else...

  • Page 67: Inter-Robot Relational Calibration

    4 Calibration assistance function Inter-robot relational calibration (1) Function Outline "Inter-robot relational calibration" can determine the positional relationship between robots by defining the same workpiece coordinate with multiple robots. “Collision avoidance function”and“Cooperative operation function” is easy to set the required position relationship between robots. (CR800-R/Q only) Workpiece coordinate Robot 1 Robot 2...
  • Page 68 4 Calibration assistance function (3) Workflow Start work 1. Set the calibration sheet Refer to 4.4.(3-1) Within the motion range of each robot, Place the calibration sheet. 2. Perform work coordinate calibration（Robot1） Refer to 4.3 Perform calibration of RobotA and work coordinates. 3.
  • Page 69 4 Calibration assistance function (3-1) set the calibration sheet Within the motion range of each robot, Place the calibration sheet. Figure 4-12 Set the calibration sheet (3-2) Perform work coordinate calibration Using work coordinate data obtained in the previous object, Perform work coordinate calibration. The following describes how to set the relative calibration between robots in “Collision avoidance function"...
  • Page 70 4 Calibration assistance function Robot3 Work coordinate +Zb3 Rotation angle Zb3 Robot2 Base coordinate +Zb2 Rotation angle Zb2 Rotation angle +Yb3 Rotation angle Ab3 Rotation angle Bb2 +Xb3 +Yb2 +Zb1 Rotation angle Ab2 Rotation angle Zb1 +Xb2 Robot1 Base coordinate Rotation angle Bb1 +Yb1 Rotation angle Ab1...
  • Page 71 4 Calibration assistance function ② Cooperative operation function In order to use the cooperative operation functionit is necessary to perform Inter-robot relational calibration.By using this function, the object can be simplified. For cooperative operation function, refer to the instruction manual “Detailed explanations of functions and operations”.

  • Page 72: Robot Programming Language

    4 Calibration assistance function Robot Programming Language It describes commands, system functions, and state variables used in the automatic calibration function. 4.5.1 Language list (1) Command list Table 4-9 Commands used in the calibration support function Target function Command Explanation Page Tool length TlClrPt...

  • Page 73: Language Detailed Description

    4 Calibration assistance function 4.5.2 Language detailed description [Function] : Indicates the command word functions. [Format] : Indicates how to input the command word argument. The argument is shown in <>. [ ] indicates that the argument can be omitted. [] indicates that a space is required.
  • Page 74 4 Calibration assistance function TlClrPt (Tool Clear Point) [Function] In the tool length calibration, initialize the calculation auxiliary point set to the target tool number and the tool data (parameter MEXTL ). [Format] TlClrPt Specify the tool number to be registered. Setting range: 1 to 16 [Reference Program] Dim PTL(3)
  • Page 75 4 Calibration assistance function TlSetPt (Tool Set Point) [Function] In the tool length calibration, set the calculation auxiliary point. In order to calculate the tool length, at least three auxiliary points are required. [Format] TｌSetPt , , ...
  • Page 76 4 Calibration assistance function TlCal2D (Tool Calibration 2D) [Function] In the tool length calibration, calculate the tool length using the registered auxiliary point (3 points or more). The calculated tool data is set to the robot controller (parameter MEXTL ), and its accuracy is estimated.
  • Page 77 4 Calibration assistance function TlCal3D (Tool Calibration 3D) [Function] In the tool length calibration, calculate the tool length using the registered auxiliary point (3 points or more). The calculated tool data is set to the robot controller (parameter MEXTL ), and its accuracy is estimated.
  • Page 78 4 Calibration assistance function VSCalClr (Vision Calibration Clear) [Function] In the vision calibration, erase all corresponding points and calibration data set for the target calibration number. [Format] VSCalClr < Calibration number > Specify the target calibration number. Setting range: 1 to 8 [Reference Program] Dim P(4) CPRG$=”PatternMatching.job”...
  • Page 79 4 Calibration assistance function VSSetCP (Vision Set Calibration Point) [Function] In vision calibration, specify the combination (corresponding point) of the three-dimensional position (robot coordinates) of the calibration mark and the mark position (image coordinates) of the image. In order to perform the calibration, it is necessary to specify at least four corresponding points. [Format] VSSetCP ，
  • Page 80 4 Calibration assistance function VSRegCD (Vision Register Calibration Data) [Function] In the vision calibration, calibration data is calculated using the set corresponding point (4 points or more), the data is set to the robot controller (parameter VSCALB ), and the accuracy is estimated.
  • Page 81 4 Calibration assistance function (PVS calibration) ＰＶＳＣａｌ [Function] Using the calibration data (parameters VSCALB 1 to 8) set by the vision calibration function, convert the image coordinates of the vision sensor to the robot world coordinates. [Format] = PVSCal (,, ,...
  • Page 82 4 Calibration assistance function PVSDrct (PVS Direction) [Function] Estimate the camera posture from the vision calibration data. However, it is necessary to give the internal parameters of the vision sensor as an argument. [Format] = PVSDrct(, , ,...
  • Page 83 4 Calibration assistance function the internal parameters of the vision sensor. For the , only the value of the ABC component is substituted. 0 is assigned to the XYZ component. [Related instructions] VSRegCD [Related parameter] VSCALB1 to 8 Robot Programming Language 4-73...
  • Page 84 4 Calibration assistance function PCalObtP (P Calcurate Object Position) [Function] Calculate the position data of the point of interest (intersection) of the two position data. [Format] = PCalObtP(,< Position data B>,) Specify the first position data. ...
  • Page 85 4 Calibration assistance function [Reference Program] 'P1 : Position data A, P2 : Position data B MErr = PCalObtP(P1,P2,Pres) 'Calculate the intersection point of P1 and P2 If MErr <> 0 Then 'When the intersection point does not exist Error 9100 EndIf [Explanation] Calculate the intersection point of the straight line extended in + Z direction of the two position data and...
  • Page 86 4 Calibration assistance function M_TlErr [Function] Returns error of tool data calculated by tool length calibration (execution of TlCal2D / TlCal3D command). [Format] =M_TlErr（） Returns the execution result. Specify the target tool number. Setting range: 1 to 16 [Reference Program] Dim PTL(3) TlClrPt 1...
  • Page 87 4 Calibration assistance function M_VSCE ｒｒ [Function] In the vision calibration function, it returns the estimation error [mm] of the calibration data estimated by the VSRegCD command. [Format] = M_VSCErr() Specify numerical variable to assign. When estimation error can not be calculated, it becomes "-1".

  • Page 88: Robot Mechanism Temperature Compensation Function

    5 Robot mechanism temperature compensation function 5.Robot mechanism temperature compensation function This chapter explains the robot mechanism temperature compensation function. Specification Robot mechanism temperature compensation function is a function to measure the temperature of the robot arm and automatically correct errors due to thermal expansion of the arm. With this function, even if the temperature changes depending on the season and time zone, positional shift due to thermal expansion of the robot arm can be suppressed.

  • Page 89: Precautions

    5 Robot mechanism temperature compensation function Precautions Describe points to be aware of when using robot mechanism temperature compensation function. 5.2.1 Please enable this function from the beginning During automatic operation by the robot program, compensation is performed with the position data registered in the program as the reference position.

  • Page 90: Parameter Setting

    5 Robot mechanism temperature compensation function Parameter setting Parameters used in robot mechanism temperature compensation function are explained. (For the setting method of parameters, refer to "separate volume: instruction manual / detailed explanation of functions and operations".) Parameter Parameter No. of Factory setting etails explanation name...
  • Page 91 5 Robot mechanism temperature compensation function Parameter Parameter No. of Factory setting etails explanation name arrays Robot MTCSNGL1 Real In the vicinity of the singular point and in Vertical articulated mechanism value 4 the vicinity of the movement range, specify (6-axis) robot temperature the range in which the robot mechanism...

  • Page 92: Coordinated Control For Additional Axes

    6 Coordinated control for additional axes 6.Coordinated control for additional axes In this chapter, we explain coordinated control for additional axes. Table 6-1 Function list of coordinated control for additional axes Functions Contents Base coordinate Allows synchronized operation where a robot is installed on an additional axis cooperative control (linear drive axis) and its speed relative to the workpiece is specified.

  • Page 93: Calibration Of Base Coordinates

    6 Coordinated control for additional axes Calibration of base coordinates 6.1.1 Overview In this chapter, we explain how to match the base coordinates of robot and additional axis / user mechanisms. This setting is necessary when you use base coordinate cooperative control or additional axis tracking. 6.1.2 Specification You can match the base coordinates of robot and additional axis / user mechanisms by setting the offset from the robot's world coordinate system origin to the base coordinate origin of the additional axis / user...

  • Page 94: Operation Procedure

    6 Coordinated control for additional axes 6.1.3 Operation procedure Operation start 1. Setting of additional axis / user mechanisms （Advance preparation） Set additional axis / user mechanisms that you use. 2. Setting of base coordinate offset of additional axis / user mechanisms Refer to 6.1.4 Set the parameter of base coordinate offset of additional axis/user mechanisms.

  • Page 95: Base Coordinate Cooperative Control

    6 Coordinated control for additional axes Base coordinate cooperative control 6.2.1 Overview You can move robot base coordinate by using additional axis(traveling axis). If you move traveling axis on which robot rides, robot moves. In that case, if the origin of the base coordinate system of robot is on the traveling axis, the base coordinates will also draw a similar trajectry with the movement of the traveling axis.
  • Page 96 6 Coordinated control for additional axes Figure 6-3 Move image of robot alone When the target position is set outside the movement range of the robot, robot can move to a position where the robot alone can not move by enlarging movement range to move the robot and the additional axis simultaneously.
  • Page 97 6 Coordinated control for additional axes In additon, for a work of complicated shape with large size which was difficult with conventional interpolation operation, it is possible to operate by executing a spline interpolation command in coordination control of base coordinate.

  • Page 98: System Configration

    6 Coordinated control for additional axes 6.2.2 System configration 6.2.2.1. Customer preparation equipment The following table shows the equipment that customers need to prepare, which is necessary for the base coordinate coordinated control system. Table 6-3 The list of customer preparation equipment. Equipment name Format Quantity...

  • Page 99: Specification

    6 Coordinated control for additional axes 6.2.3 Specification (1) Basic specification Basic function is below. Table 6-4 Basic specification of base coordinate corporative control. Item Specification Usable robot Vertical Multiple-joint roobts, Horizontal multiple-joint robots Usable robot language MELFA-BASIC VI State variable ...
  • Page 100 6 Coordinated control for additional axes (2) Restrictions Restriction of this function is below. Table 6-5 Restrictions of base coordinate cooperative control Restrictions Contents Interpolation processing It is possible to use Mov, Mvs, Mvr, Mvr2, Mvr3, Mva command, Spline interpolation. Peculiar point transit interpolation.

  • Page 101: Operation Procedure

    6 Coordinated control for additional axes 6.2.4 Operation procedure Operation start 1.Setting of additional axis Set additional axis (traveling axis) that you use. (1) Set additional axis (2) Execute origin setting of additional axis. 2.Setting of base coordinate offset of additional axis Refer to 6.1 Set base coordinate offset data of additional axis.

  • Page 102: Parameter Setting

    6 Coordinated control for additional axes 6.2.5 Parameter setting The parameter list which is used is below. Table 6-6 The list of parameter of base coordinate cooperative control Parameter Element Factory Parameter Explanation of contents name number setting Base coordinate BSSYNC Integer Enable or disable base coordinate cooperative...

  • Page 103: Creatinn Of Robot Program

    6 Coordinated control for additional axes 6.2.6 Creatinn of robot program In this chapter, robot program language MELFA-BASIC VI which is used in this function is explained. 6.2.6.1. The list of robot status variable. The list of robot status variable related to this function is below. Table 6-7 The list of robot status variable Number Attribute...
  • Page 104 6 Coordinated control for additional axes M_BsCoopMd 【Function】 When the coordinated control for base coordinate is effective, specify and refer to the direction to which additional axis moves at spilne interpolation operation. 【Format】 M_BｓCoopMd = = M_BsCoopMd 【Terminology】...

  • Page 105: Additional Axis Tracking

    6 Coordinated control for additional axes Additional axis tracking 6.3.1 Specification With this function, the robot can execute another interpolation operation following the work attached to the user mechanisms. Figure 6 6 shows an example of how the robot follows the workpiece and traces the outline of the workpiece. Figure 6-7 Move image of additional axis tracking.

  • Page 106: System Configuration

    6 Coordinated control for additional axes 6.3.2 System configuration 6.3.2.1. Customer preparation equipment The following table shows the equipment that customers need to prepare, which is necessary for the additional axis tracking system. Table 6-8 The list of customer preparation equipment Equipment name Format Quantity...
  • Page 107 6 Coordinated control for additional axes 6.3.2.2. Example of system configuration Example of additional axis tracking system is below. Travel axis User mechanism Servo motor Figure 6-8 Example of additional axis tracking system configuration * For details of connection method, refer to Chapter 5 of "Additional axis function instruction manual (BFP-A3504)".

  • Page 108: Specification

    6 Coordinated control for additional axes 6.3.3 Specification (1) Basic specification Basic function is below. Table 6-9 Basic specification of additional axis tracking Item Specification Usable robot Vertical Multiple-joint roobts, Horizontal multiple-joint robots Usable robot language MELFA-BASIC VI Status variable ...
  • Page 109 6 Coordinated control for additional axes (2) Restrictions Restriction of this function is below. Table 6-10 Restrictions of additional axis tracking Restrictions Contents Interporation processing Mov, Mvs, Mvr, Mvr2, Mvr3, Mvc command is available. Mva command, Ex-Tcontrol interpolation, Spline/Ex-T spline interpolation is unavailable.
  • Page 110 6 Coordinated control for additional axes 6.3.4 Operation procedure Operation start 1.Setting of user mechanisms Set the user mechanisms that you use. (1) Set the mecha number and axis number that you use. (2) Perform advanced setting of user mechanisms that you use. 2.Setting parameter Refer to 6.3.5 Parameter setting related to additional axis tracking is explained.

  • Page 111: Parameter Setting

    6 Coordinated control for additional axes 6.3.5 Parameter setting The parameter which is used is below. Table 6-11 The list of parameter of additional axis tracking Parameter Element Factory Parameter Content explanation name number setting Workpiece WKnSYNC Integer 2 Set the mechanism number and axis number 0, 1...
  • Page 112 6 Coordinated control for additional axes Parameter Element Factory Parameter Content explanation name number setting Setting axis No. AXJNO Integer 16 Designate what number of the axis of the robot 0, 0, 0, 0, (*2) arm is used for the additional axis. 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ,0, 0...
  • Page 113 6 Coordinated control for additional axes Parameter Element Factory Parameter Content explanation name number setting Rated speed (*2) AXMREV Integer 16 Rated speed (Unit: r/min.) of motor 2000, 2000, 2000, 2000, Rated speed (Unit: mm/s.) of linear motor 2000, 2000, 2000, 2000, 2000, 2000, 2000, 2000,...
  • Page 114 6 Coordinated control for additional axes Parameter Element Factory Parameter Content explanation name number setting Joint movement MEJAR Real Set the overrun limit value for the joint Setting range (*2) numbe 16 coordinate system. value Sets the movement range for each axis. for each Expanding of the movement range is not mechanism...

  • Page 115: Creation Of Robot Program

    6 Coordinated control for additional axes 6.3.6 Creation of robot program In this chapter, robot program language MELFA-BASIC VI which is used in this function is explained. 6.3.6.1. The list of robot status variable The list of status variable related to this function is below. Table 6-12 The list of robot status variable Variable name Number...
  • Page 116 6 Coordinated control for additional axes M_AxTrkWkNo 【Function】 Specify and refer to the Workpiece number used by additional axs tracking. 【Format】 M_AxTrkWkNo= < Workpiece number > = M_AxTrkWkNo 【Terminology】 Specify the target work number. Setting range：0～8 ...
  • Page 117 6 Coordinated control for additional axes P_WkCalib 【Function】 Specify and refer to the position relationship of workpiece reference point and mounting target axis coordinate. 【Format】 P_WkCalib [()] = < Position variable 1> = P_WkCalib [()] 【Terminology】...
  • Page 118 6 Coordinated control for additional axes P_TrkPAcl / P_TrkPDcl 【Function】 Change the tracking acceleration/deceleration coefficient of the parameter “TRPACL/TRPDCL”. 【Format】 P_TrkPAcl() = = P_TrkPAcl() P_TrkPDcl() = = P_TrkPDcl() 【Terminology】...
  • Page 119 6 Coordinated control for additional axes P_TrkBase 【Function】 Specify and refer to the origin of the workpiece to be followed by additional axis tracking. The robot moves to the relative position correspond to this reference point by the movement instruction during the additional axis tracking 【Format】...
  • Page 120 6 Coordinated control for additional axes P_TrkTarget 【Function】 Refer to the workpiece current position to be followed by additional axis tracking. 【Format】 = P_TrkTarget 【Terminology】 Specifies the position variable to assign. 【Reference program】 PWrkNow = P_TrkTarget ' Specify the workpiece current position to be followed by additional axis tracking.
  • Page 121 6 Coordinated control for additional axes 6.3.6.3. The list of command The list of command related to this function is shown below. Table 6-13 The list of command Command Function name Enable or disable additional axis tracking function. 6.3.6.4. Detail explanation of robot(system) status variable Detail of status variable of this function is below.
  • Page 122 6 Coordinated control for additional axes 【Function】 After Trk ON is executed, the robot goes into the tracking mode and operates while following the conveyer operation until Trk OFF is executed. 【Format】 Trk On [, [, [][,[][,[]]]]] Trk Off 【Terminology】...

  • Page 123: Installation Of A Sample Program

    6 Coordinated control for additional axes 6.3.7 Installation of a sample program This chapter explains the structure of the sample robot programs. Poogram structures are shown in “Table 6-14 The list of sample programs”. Table 6-14 The list of sample programs Prgram name Description Explanation...

  • Page 124: Calibration Of Robot And Base Coordinate Systems ("A1" Program)

    6 Coordinated control for additional axes 6.3.8 Calibration of Robot and Base Coordinate Systems (“A1” program) This chapter explains the tasks carried out by using “A1” program. Calibration of robot and base coordinate systems refers to determining the origin position of user mechanisms in the robot coordinate system.
  • Page 125 6 Coordinated control for additional axes (a) Display the following command. A1 5 '# COPYRIGHT : MIT 6 '############################## 7 '(1)Input a mechanism number to 8 MMechNo = 2 EDIT DELETE INSERT TEACH (b) Press the [F1] (EDIT) key and specify the mechanism number in the variable “MMechNo”. Example) When “3”...
  • Page 126 6 Coordinated control for additional axes (8) Press the [F1] (FWD) key and execute step feed. “(3) Move the robot to ... “is displayed. A1 8 MMechNo = 3 9 '(2)Input a parameter name "BSWO 10 CPrmName$ = "BSWOFST1" 11 '(3)Move the robot to the origin EDIT DELETE...
  • Page 127 6 Coordinated control for additional axes (10) Press the [F1] (FWD) key and execute step feed. “(5) Move the robot to ... “is displayed. A1 12 PBOfstO = P_Fbc(1) 13 '(4)Move the robot to the X axis 14 PBOfstX = P_Fbc(1) 15 '(5)Move the robot to the +Y dire EDIT DELETE...
  • Page 128 6 Coordinated control for additional axes Perform step operation until “End”. * The origin position of the user mechanism in the robot coordinate system is calculated based on this operation. 6.3.8.2. Confirmation after operation Check the parameter “BSWOFSTn”. * This value indicates the offset from base coordinate origin of the robot to base coordinate origin of the user mechanism.

  • Page 129: Resistration Of User Mechanism Work Position ("B1" Program)

    6 Coordinated control for additional axes 6.3.9 Resistration of User Mechanism Work Position (“B1” program) This chapter explains the tasks carried out by using “B1” program. “B1” program performs specified tasks and registers the work position to be used by the additional axis tracking.
  • Page 130 6 Coordinated control for additional axes (a) Display the following command. B1 5 '# COPYRIGHT : MIT 6 '############################## 7 ' (1)Input a work number to th 8 MWrkNo = 1 EDIT DELETE INSERT TEACH (b) Press the [F1] (EDIT) key and specify the workpiece number in the variable “MWrkNo”. Example) When “2”...
  • Page 131 6 Coordinated control for additional axes B1 11 ' (3)Input an operating speed of 12 MSpd = 300 13 ' (4)Move user mechanisms to the 14 P_102(MWrkNo) = P_Fbc(MMechNo) EDIT DELETE INSERT TEACH Move the user mechanism to the work start position. Start position (10) Press the [F1] (FWD) key and execute step feed.
  • Page 132 6 Coordinated control for additional axes B1 17 ' (6) Perform step operation until 18 P_109(MWrkNo).X = MMechNo 19 P_109(MWrkNo).Y = MSpd 20 End EDIT DELETE INSERT TEACH 6.3.9.2. Confirmation after operation Check the value of “P_102()”, “P_103()”, “P_109()” using T/B. Enter the work number in the array element.

  • Page 133: Work Base Position Registration ("C1" Program)

    6 Coordinated control for additional axes 6.3.10 Work Base Position Registration (“C1” program) This chapter explains the tasks carried out by using “C1” program. “C1” Program performs specified tasks and register the work base coordinate. The procedures of operations specified by “C1” program and items to be confirmed after the operations are explained below.
  • Page 134 TEACH DELETE INSERT TEACH (c) Press the [F1] (FWD) key and the change is determined. C1 5 '# COPYRIGHT : MITSUBISHI ELECTRIC 6'################################ 7 '(1)Input a workpiece number to the 8 MWrkNo = 2 'Set a wo EDIT DELETE...
  • Page 135 6 Coordinated control for additional axes (8) Press the [F1] (FWD) key and execute step feed. “(3)Move the robot to the work … “is displayed. Execute work according to the comment in the robot program. C1 11 Next M1 12 ' (2) Mov the robot to the origin 13 PUMOrg = P_Fbc(1) 14 ' (3)Move the robot to the work...
  • Page 136 6 Coordinated control for additional axes 6.3.10.2. Confirmation after operation Confirm the values of “P_100()” and “P_101()” using T/B. Enter work numbers in array elements.  “P_100()”: Work base coordinate  “P_101()”: Offset amount of axis to which work coordinate is attached Check that each of the values above has been entered correctly.

  • Page 137: Teaching And Setting Of Adjustment Variables ("1" Program)

    6 Coordinated control for additional axes 6.3.11 Teaching and Setting of Adjustment Variables (“1” program) This chapter explains operations required to run “1” program. In addition, this chapter explains a method to check the operation in the condition that it was designated, and to coordinate again.
  • Page 138 6 Coordinated control for additional axes 6.3.11.2. Setting of adjustment variables in the program The following section explains how to set adjustment variables, which are required at transportation, and details about their setting. Please refer to separate manual “Detailed Explanations of Functions and Operations” for how to set adjustment variables.
  • Page 139 6 Coordinated control for additional axes 6.3.11.3. Automatic Operation This chapter explains how to prepare the robot before starting the system. Confirm that there isn't an intervention thing in the robot movement area. Set the T/B [ENABLE] switch to "DISABLE" Set the controller mode to "AUTOMATIC".
  • Page 140 6 Coordinated control for additional axes Automatic operation will start when the [START] button is pressed. *Prepare for the unexpected operation of the robot, please can press anytime emergency stop switch of T/B. Confirm to be a work that is moved to waiting point position after following the workpiece. If you check the operation, press the [STOP] button and stop the robot.
  • Page 141 6 Coordinated control for additional axes 6.3.11.4. Adjustment of operating conditions In automatic operation, if you want to adjust the vertical movement and adsorption time of the robot arm that was described in "6.3.11.2 Setting of adjustment variables in the program" should be changed in the following procedure.
  • Page 142 6 Coordinated control for additional axes (3) Double-click the variable you want to change, and change the appropriate value for displayed in the "Edit Position data". For example, change to "-50" from "-30" the value of the Z-coordinate of the PUp1 : (4) Click [OK] button, and confirm that was able to change the value of the variable that is specified in the "Variable Monitor".

  • Page 143: Troubleshooting

    6 Coordinated control for additional axes Troubleshooting In this chapter, we explain cause and measure when an error occurred. Error number related to coordinated control for additional axes is below. ■■■■ □□ ◆ ◇◇ ■■■■：Function number ：Additional axis tracking 0□ ：Base coordinate corporate control 1□...
  • Page 144 6 Coordinated control for additional axes Error number Error cause and measures Error message Cannot be used (base coop). Cause A synchronous addition axis control is effective. Masures Invalidate a synchronous addition axis control. Error message Jrc cannot be executed. Cause The base coop is executing.

  • Page 145: Appendix

    7 Appendix 7.Appendix Display of option card information You can display the option card information in RT ToolBox3 option. When you click “Online”->”Board”->"Slotn (n = 1 to 2): MELFA Smart Plus" of the tree on the workspace in online state, you can read MELFA Smart Plus card information in the property window.
  • Page 146 7 Appendix Table 7-1 Card information of MELFA Smart Plus card/card pack Display item Display example Meaning Software version Remarks of controller Card name MELFA Smart Plus Card name Ver. A1 or later MELFA Smart Plus A-type Ver. A3 or later MELFA Smart Plus B-type Ver.
  • Page 148 Feb. 2021 MEE Printed in Japan on recycled paper. Specifications are subject to change without notice.

This manual is also suitable for:

Melfa cr800-r seriesMelfa cr800-q seriesMelfa smart plus 2f-dq510Melfa smart plus 2f-dq511Melfa smart plus 2f-dq520Melfa smart plus 2f-dq521

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