Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ERC 23/1-F
Serial No.:
163251
Year of construction:
2007
Manufacturer:
+43.50.620.0
+43.50.620.3609
e-mail: service@engel.at
Version:
Printing date:
Language
www.engel.info
G/11/401/1/11
5.1.2007
Englisch
The contents of these documents remains our intellectual property and must not be copied or distributed electronically or mechanically, changed,
transmitted, translated into another language nor be used otherwise without our written consent in no manner of what kind ever. Furthermore, the contents
may neither be made known to third parties nor be used for non-approved purposes. These documents only serve the company-internal benefit and use.
Each violation will be prosecuted under criminal and civil law (12 and 13 UWG).
In the wake of the technical development we reserve the right to make changes without previous notice.
Copyright by ENGEL Austria Ges.m.b.H.
Version: G/11/401/1/11
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1
1.1
2
2.1
3
3.1
3.2
USE AS DIRECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
APPLIED STANDARDS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TEXT FORMATTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIVISION OF SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL AUTOMATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ERC 2X OVERVIEWW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ROTARY AXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1
2
3
4
4.1
4.2
4.3
5
5.1
ACCIDENT PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PICTOGRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SURVEY SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION OF THE SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY STOP BUTTONS FOR CELL SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY GATES INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROBOT SAFETY GUARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEHAVIOUR IN CASE OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USE AN ABC CLASS FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
18
22
23
23
24
26
29
29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1
1.1
1.2
2
2.1
2.1.1
2.1.2
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
3
3.1
3.2
3.3
3.4
4
5
6
6.1
6.2
6.3
6.4
6.5
6.6
7
7.1
7.2
8
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.2
9
10
10.1
10.2
11
11.1
11.2
11.3
11.4
31
31
33
34
35
35
37
41
41
42
42
42
43
43
43
45
46
47
50
51
55
55
56
56
56
57
57
57
58
60
60
60
61
62
62
63
64
64
65
66
67
68
69
70
71
72
73
73
4
11.5
12
Version: G/11/401/1/11
DELETE DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
PRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
QUICK SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
ROBOT GENERAL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
QUICK SETTING OF ROBOT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
ROBOT STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ROBOT PROGRAM SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
POWERING UP THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SERVO AXES REFERENCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
NORMAL POSITION (BRING ROBOT IN NORMAL POSITION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
MOUNT TAKEOVER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
READING OF A ROBOT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
EDITING A ROBOT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
STORING THE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
TEST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
EXCHANGE VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
PROGRAMMING SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
USING THE TEACH POINTER TO INSERT THE ROBOT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
INSERT ROBOT POSITION MANUALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
INSERT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
CREATE TEACH VARIANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
REMOVING VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
DELETE VARIABLES FROM USER-DEFINED SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
SEQUENCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
ROBOT MOVE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
ROBOT POSITION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
ROBOT SPECIAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ROBOT FUNCTION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
PERIPHERAL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
SEQUENCE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
STRUCTURE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
TEACH POINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
EXECUTE AS LONG AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
REPEAT UNTIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
IF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
PARALLEL OPEN BRANCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
PARALLEL CLOSED BRANCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
WAITING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
WAIT FOR TIME OR MARKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
WAIT UNTIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Version: G/11/401/1/11
4.7.10
COMMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.11
ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.12
JUMP TO SEQUENCE END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.13
ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.14
DELETE ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.15
SET POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.16
COPY ACTUAL POSITION TO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.17
INCREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.18
DECREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.19
CHECK WHETHER INTERMEDIATE LAYER POSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
CONDITION EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
DIALOG WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
184
184
185
186
186
186
186
186
186
186
187
187
GRID TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHOT GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETTING AND SIMULATION AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDIVIDUAL PART GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETTING AND SIMULATION AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TACH GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONFIGURE TEACH GRID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETTING AND SIMULATION AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
196
196
196
201
202
208
208
210
214
218
219
219
219
220
221
221
222
222
OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1
2
3
4
5
6
7
8
9
10
USER PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAKE-OFF STROKE CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOLD SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EJECTOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SOFTSERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITION COMPENSATION FOR TIEBAR-LESS MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRUE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMEDIATE DEPOSIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEIGH SCALE INTERMEDIATE DEPOSIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Version: G/11/401/1/11
GENERAL
You have decided on an ENGEL product which is produced and supplied under the most strict
quality controls.
The instruction manual must be considered as part of the robot and is destined for those
persons who are charged with activities on the plant. The instruction must be kept during the
life of the product and must be passed on to each following owner or user. Each obtained
addition must be integrated into the instruction manual.
The documentation for the robot comprises 3 manuals:
Operator manual (Operation)
Instruction manual (Start-up, maintenance, spare parts)
Technical manual (Elimination of faults)
The instruction manual is available in the following forms:
in paper form (without Technical manual). One electric schematic is in the control
cabinet.
as online help on the control unit (without spare parts and schematics)
on CD in PDF format
WARNING!
Do not use the robot without corresponding training.
Improper use of the cell can lead to personnel injury and equipment
damage.
Before the cell is put into operation read through the Safety section to
become familiar with the safety equipment.
Participation at an ENGEL training center is highly recommended.
The main aim of this manual is to provide a concise overview of the robot operation and to help
eliminate production malfunctions as quickly as possible.
An alarm list can be found in the index directory under *Symbols.
Version: G/11/401/1/11
USE AS DIRECTED
ENGEL products are constructed using the latest technological developments and the
accepted safety standards.
The robot for this cell is designed exclusively to handle injection molded parts, including takeoff from the mold and part placement into the mold.
Installation, operation, service and maintenance on ENGEL products is authorized only to
personnel trained at ENGEL.
ENGEL is not liable for any damage resulting from improper use and failure to follow the
information outlined in the standard manuals.
If any modifications are made to the machine by the customer, EC conformity is invalid and the
machine must not be put into operation!
1.1
98/37 EWG
Machine guidelines
73/23/EWG
93/68 EWG
89/336/EWG
92/31 EWG
93/68 EWG
EN 12100-1
Machine safety
EN 12100-2
Machine safety
EN 294
EN 201
EN 418
EN 60204-1
EN 61310-1
EN 61310-2
EN 775
Version: G/11/401/1/11
TEXT FORMATTINGS
DANGER!
Information provided with this symbol points out immediate dangers,
which can lead to death or serious physical injuries!
WARNING!
Information provided with this symbol warns of possible dangers, which
can lead to death or serious physical injuries!
CAUTION!
Information provided with this heading warns of possible dangers,
which can lead to equipment damage!
Note!
Information provided with this symbol offers application tips and useful information.
Example:
Information provided with this symbol offers practical examples.
Bullet sign (emphasis
Bullet (emphasis).
The operator does not have to adhere to fixed operational sequence or order.
Numbered sequence
1.
2.
3.
Reference to a text at the screen or control panel.
Alarms and Messages are listed throughout the manual in a table, which contains the alarm
class symbol, a description, cause and effect, and troubleshooting information.
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Sample for error message:
2.1
CAUTION!
The parameters in the illustrations are purely inccidental and should not
be used as a guide for machine set up.
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Standalone control
ENGEL robot and a non-ENGEL injection molding machine
ENGEL robot in connection with a peripheral unit
ENGEL robot without injection molding machine and peripheral unit
12
3.1
Version: G/11/401/1/11
ERC 2X OVERVIEWW
7
8
9
10
5
EUB
[1]
Support mount
For fastening the robot with screws on the stationary mold fixing platen of the injection
molding machine.
[2]
[3]
[4]
[5]
Support (Option)
[6]
[7]
Z-axis motor
[8]
X-axis motor
[9]
Y-axis motor
[10]
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3.2
ROTARY AXES
The manual axes serve to take off/deposit and/or to manipulate parts (Turning and swivelling).
Here it is distinguished between two types of axes:
Pneumatic axes
C Servomotor axes
180
0
above
90
below
B
right
max
middle
180
left
A
90
left
right
middle
max
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SAFETY
Due to the acceleration and force of the robot, always take great care when working in the
robots vicinity.
To protect personnel against potential dangers, robots come equipped with the appropriate
safety equipment.
DANGER!
Safety equipment must not be modified or removed! Before putting the
machine into operation check the safety equipment to ensure it is functioning properly.
[See Function of the safety devices on page 23.]
When a safety equipment defect is detected:
1.
2.
3.
4.
Resume machine operations only after the functionality of the safety equipment is
guaranteed.
DANGER!
Working and standing below moveable components, floating loads, or
both is strictly forbidden! This applies in all modes of operation, including when the robot is shut down.
Failure to adhere to this warning could result in fatal injuries.
During AUTOMATIC operations do not reach into or enter the robot work
area! When performing work on the Injection Molding Machine, the robot
or inside the guarding enclosure the robot must be moved to a safe
position.
CAUTION!
Caution must be used during machine set-up and operation, as incorrect settings can lead to equipment damage.
Settings must be compatible to the function of the machine, mold, material and peripheral units.
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WARNING!
After a robot collision, every screw in the guide rails, the guide carriage,
the end of arm tooling, and all swiveling axes and torques must be
checked by ENGEL customer service.
ENGEL is not liable in respect to operational errors.
Additional safety hints found throughout this manual must be observed.
WARNING!
Maintenance and repair work on the cell may only be carried out by
trained personnel, who possess comprehensive knowledge of the safety
precautions and operating elements!
The activities and maintenance intervals described in the instruction manual must be
observed.
To ensure personnel and equipment protection all maintenance on the safety devices must
conform to local enforced safety regulations.
Further work on the machine going beyond the described activities may only be carried out by
the ENGEL customer service.
ACCIDENT PREVENTION
Always wear protective clothing when working on the system (safety shoes, protective
gloves, face protector, etc). Observe local safety regulations for the injection molding
machine operations!
Always keep the equipment clean. This contributes considerably to serviceability and
thus to greatest possible safety for the operating personnel.
Do not remove any warning or information signs and markings from the machine or
additional devices!
Observe possible obstacles in the operator work area when stepping through the robot
teach sequence. Ensure the robot does not collide with the downstream equipment or
the Injection Molding Machine!
When working in the vicinity of hot components (barrels, injection molding equipment,
etc.) always wear protective gloves and mask!
Switch off motors during all work carried out in the movement areas of the machine!
Do not turn the control voltage or main voltage OFF during axis movement. This applies
when operating in all modes of operation.
Before turning the pneumatic system OFF, move the robot into the deposit area and
remove any parts from the end of arm tooling. In case pressure is lost, ensure the end
of arm tooling is rotated down to prevent an uncontrolled downward swivel.
Pay attention to that the control cabinets are always closed. No dust and no humidity
may penetrate.
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Protect all hoses against damage from, for example acids or mechanical abrasion.
Check all pipings for their work-safe state regularly. Switch off the plant immediately
when you detect a leakage, damage or break of a piping.
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PICTOGRAPHS
The following section illustrates and describes the safety hazard labels used to address a
potentially dangerous area or situation. Failure to adhere to this safety hazard labels could
result in fatal injuries..
Example:
Engel standard injection molding machine with robot.
EE
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21
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Read documentation!
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EE
12 11
10
[1]
Safety guarding
[2]
[3]
[4]
Moving/danger area of the robot (work envelope). This is the area the robot, including
the end of arm tooling and molded part can potentially cover.
[5]
[6]
Robot
[7]
[8]
[9]
[10]
[11]
[12]
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4.1
In case of an EMERGENCY STOP actuation the drive motors of the injection molding line and
of the robot are switched off immediately. Message::
EMERGENCY STOP
Reason
impact
The alarm lamp flashes, the current cycle and the motors are stopped
immediately.
All dangerous movements are blocked immediately.
All safety access doors are unlocked.
impact
The alarm lamp flashes, the current cycle and the motors are stopped
immediately.
All dangerous movements are blocked immediately.
All safety access doors are unlocked.
An EMERGENCY STOP acknowledgement is required.
2.
3.
4.
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Note!
The EMERGENCY STOP function is active in each mode of operation!
When the servomotors are turned OFF the X and Z-axes can be pushed by hand.
4.2
impact
removal
Depending on protection execution the opening of the rear safety gate on the clamping unit
causes an EMERGENCY STOP switch-off or has the same function as the safety gate on the
operator side.
impact
All injection unit movements are blocked and the cycle stops.
removal
The end of arm tooling must not consist of sharp-edged and pointed parts
No dangerous movements may be executed with the end of arm tooling (pinching or
shearing points))
The safety distance between the end of arm tooling and the safety device must be
greater than or equal to 120mm (4.72).
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Version: G/11/401/1/11
BR?
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4.3
Version: G/11/401/1/11
In automatic mode the operator actuates the key to demand access before opening the safety
guarding door (key flashes). As a result the machine interrupts the cycle after the part has
been taken from the injection mold. In the standard case, the robot stops all movements after
the take-off of the injection molded part (depending on the setting in the sequence editor). The
Access demand keyswitch on the door lights up, indicating that access is allowed and that the
door is unlocked.
On safety guardings without access demands, the protection door can always be opened. As
a result the robot stops all movements immediately.
Before opening the safety guarding door and entering the guarded area, remove the
acknowledgement key and take it with you.
WARNING!
The acknowledgement key must always be with the person who is inside
the safety guarding, in order to prevent any unintentional acknowledgement of the safety guarding and starting of the machine!
The safety guarding may only be acknowledged if all personnel and foreign objects are out of the danger area!
After opening the safety guarding door, all robot movements are blocked.
In set-up mode, up from the access authorization 5, by simultaneous pressing the consent key
and the respective pushbutton on the hand held control unit, the robot movements can be
executed with an open safety guarding door and/or open clamp unit safety gate.
DANGER!
Working below movable components, e.g. the Y-axis, is forbidden!
During robot movements, the work envelope of the robot must not be
entered or reached into!
After leaving the danger area, the operator can acknowledge the safety guarding door with the
key-operated switch, immediately after closing the door. The door is then locked again.
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In automatic mode the next cycle start occurs by actuating the start button on the control panel.
The robot cycle begins with the depositing of parts.
Note!
The safety guarding door is unlocked automatically and can be opened in case of an EMERGENCY STOP.
The protection door can only be acknowledged again when the EMERGENCY STOP condition
has been eliminated.
After switching on the control voltage there must also occur an acknowledgement. As long as
the protection door is not acknowledged, the following message appears:
removal
The acknowledgement must occur within 5 seconds, but not before 0.05 seconds after closing
the protection door.
The acknowledgement key must not be actuated too long (maximum of 10 seconds) either. If
these conditions are not fulfilled, the corresponding message is displayed:
impact
removal
impact
removal
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impact
removal
removal
Instead of the safety gate of the robot the rear safety gate of the injection molding machine is connected.
impact
removal
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5.1
Stay calm
2.
3.
4.
5.
6.
7.
8.
Provide assistance and direction to anyone actively involved in fighting the fire
An ABC Class fire extinguisher is recommended due to its versatility and advantages
over other fire fighting equipment.
Be aware that the fire extinguisher powder can cause an obstruction to view and will
leave a heavy residue which then must be removed from the machine.
DANGER!
If you use an ABC Class fire extinguisher on an ENGEL molding
machine, keep back a minimum of one meter from the electrical panel
and/or the motor.
The use of water, D powder class or foam is forbidden.
Note!
If a fire has occurred on an ENGEL molding machine, it must not be put back into operation
until it has been inspected by an ENGEL Service Representative:
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Version: G/11/401/1/11
OPERATION
1
1.1
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Switch panel for the manual control of the individual machine movements.
Touch keys for the robot motor, referencing
and homing
Switch Motor
Switch cylinder heaters
Switch Mold heating
Emergency stop button
Control voltage switch
Key-operated safety keyswitch
Program interruption switch
start key
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1.2
Switch panel for the manual control of the individual machine movements.
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Version: G/11/401/1/11
Display
Override keys
Motor switch
Homel position
and Referencing
Acknowledge step
and test mode on/
off
Scroll keys
Function keys
NOTICE!
The hand control device is equipped with highly sensitive electronics.
Handling tips
Ensure no one can trip over the cable to avoid personnel injury and mechanical
damage.
Place the hand terminal into the designated fixture when it is not being used.
The function of the safety-relevant parts, such as the EMERGENCY STOP and the
Consent switches must be checked periodically to ensure they are functioning correctly.
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.
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2.1
Each function key has a green status LED which indicates the various states of the function in
question. Note that the LED only refers to the active function level.
LED status signals
2.1.1
Solid
Function is executed or key is actuated.
Slow flashing
Indicates that the key should be actuated.
Quick flashing
An alarm was generated during the execution of the function or axis movement.
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.
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Version: G/11/401/1/11
Consent keys:
The back of the hand terminal has two consent keys on the left and right-hand sides. The keys
are activated in three stages. To activate the keys ensure both are pressed into the midposition. When the keys are completely pressed in an emergency stop is triggered.
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2.1.2
Key symbol
Key explanation
Motor switch
Switch servomotors on and/or off.
Slow flashing of the LED signals that the motors are ready for switching on. A
quick flashing indicates existing errors which block the switching-on.
Error acknowledgement
Erasure of the displayed error messages. The display display changes to the error
page automatically.
The LED flashes when errors exist.
2nd function
The Second key switches over between the two function levels. The LED lights
when the functions of the second (lower) level can be selected. By pressing a key
(or the 2nd key) it is switched back in the first level automatically.
Increase override
Increases the current speeds of the servoaxes in the automatic mode by a factor
in percent.
The automatic speeds set on the screen pages are valid as maximum (100%).
38
Key symbol
Version: G/11/401/1/11
Key explanation
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 LED flashes when the normal position run is possible (Motor switch switched
on, axes referenced).
Step acknowledgement
Serves the stepwise passing of the instructions in the sequence. With switched-on
test mode the consent and step acknowledgement key must be pressed at the
same time in order to process the instructions.
Take over Teach instruction
Decrease override
Reduces the current speeds of the servoaxes in the automatic mode by a factor in
percent.
The automatic speeds set on the screen pages are valid as maximum (100%).
Suction/Gripper 1
Switching-on and/or -off of the vacuum/compressed air circuit in the manual and/
or set-up mode.
Scroll vertically
For information which cannot be represented on the display at once it is possible
to scroll vertically. The function is generally built up as ring. This means, from the
end it is jumped to the beginning of the page again. It is always scrolled page by
page and the contents is adapted to the available space.
The two orientation bars in the display show at a glance whether a scrolling is possible and which range is displayed at present.
Move X-axis in [+] direction
The movement can only be carried out 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.
Scroll horizontally
For information which cannot be represented once on the display it is possible to
scroll horizontally. The function is generally constructed as ring. This means, from
the end it is always jumped to the beginning of the page. It is always scrolled page
by page and the contents is adapted to the available space.
The two orientation bars in the display show at a glance whether a scrolling is possible and which range is displayed at present.
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Version: G/11/401/1/11
Key symbol
Key explanation
Move Y-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.
Conveyor-belt
Steps the conveyor-belt in the manual and/or set-up mode.
Quick position
The robot axes approach the set Quick position directly. The key must remain
pressed, otherwise the movements are stopped.
Move Z-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.
40
Key symbol
Version: G/11/401/1/11
Key explanation
Select Teach special instructions
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Version: G/11/401/1/11
2.2
2.2.1
Alarm messages
Waiting messages
Teach preview
Status page
Quick position
2
3
2.6
4
[1]
Display information
[2]
Alarm warning
The ! symbol appears when an alarm is generated.
[3]
[4]
[5]
Navigation
Changing the display page
+
By activating the above keys from the hand terminal, operators are able to move from the
current page to the next. When these keys are pressed from the last screen page the display
jumps back to the first page.
Scrolling
Scroll Vertically
Scroll Horizontally
For information that cannot be displayed simultaneously on the display, you can scroll the
display vertically or horizontally. The function is generally set up as a ring. Thus, jumping to the
start of the page when the end of the page is reached. Scrolling occurs page by page, whereby
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Version: G/11/401/1/11
the content is modified to reflect the available space.
The two orientation bars show whether or not scrolling is possible and gage the location of the
present display.
2.2.2
ALARM MESSAGES
The Alarm Screen displays all pending alarms. These alarms are displayed in a list format,
each line containing one alarm message. When no alarm exists, the message No error!
appears on the display.
No error!
1.6
With the exception of the alarm page an exclamation mark ! in the right, upper corner of the
display indicates an alarm at all other pages. By actuating the alarm acknowledgement key the
alarm page is opened automatically and it is tried to acknowledge the alarm.
2.2.3
WAITING MESSAGES
The Waiting Message Screen displays pending wait messages. The messages are displayed
in a list format, each line containing one wait message. When no wait message exists, the
message No waiting message! appears on the display.
Injection active
Wait for injection unit
unit finished
2.6
2.6
2.2.4
TEACH PREVIEW
After you have inserted the Teach pointer in the robot sequence, sequence teaching is
enabled. The action performed during teaching is shown on the display and can be transferred
to the sequence.
Robot movement
3.6
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Version: G/11/401/1/11
2.2.5
X
Y
Z
C1
551,2 mm
360,0 mm
850,5 mm
Above
4.6
These values are consistently updated and only the current position of the robot axes (in a
referenced state) are displayed).
2.2.6
STATUS PAGE
The following information is available via the Status Screen page:
Robot 1 active
Testmode active
Referenced
Mode of operaSpeed
2.2.7
Auto
100%
5.6
Testmode active
Switch test mode on or off [See Robot status on page 95.]
Mode of operation
Displays the current mode of operation.
Speed
Display of the preset override speed in %. Pressing the override buttons automatically
opens the status screen on the hand control device.
QUICK POSITION
The quick position page shows the axis position set values of the robot, which are approached
when executing this function.
NOTICE!
The set position is approached directly, therefore be aware of any potential collisions in the work envelope. The set work blocks and prohibited
areas remain valid during the procedure.
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Version: G/11/401/1/11
X
Y
Z
C1
330,0 mm
510,0 mm
100,5 mm
Above
6.6
Press the quick position button to go directly to the position displayed in manual or setup
operations.
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Version: G/11/401/1/11
Setting and displaying parameters for the injection molding machine and robot.
Robot operations.
EMERGENCY
STOP button
8.0 color touch
screen
Touch-sensitive
keys
Status LEDs
Function
Power
Motor
RC2
NOTICE!
The hand control device is equipped with highly sensitive electronics.
Handling tips
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Version: G/11/401/1/11
3.1
Ensure no one can trip over the cable to avoid personnel injury and mechanical
damage.
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.
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.
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
EMERGENCY STOP
button
Consent key
(on both sides)
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.
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Version: G/11/401/1/11
3.2
Switch position
Function
Switch contact
Not pressed
Zero position
Off (open)
Pressed
Consent
On (closed)
Panic
Pressed hard
Off (open)
Symbol
Key description
Function description
Motor switch
Error acknowledgement
Movement to Home
position
Referencing
Step acknowledgement
Serves the stepwise passing of the instructions in the sequence. With switched-on test
mode the consent and step acknowledgement key must be pressed at the same time
in order to process the instructions.
test mode
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Version: G/11/401/1/11
Symbol
Key description
Function description
Freely configurable
keys
Freely configurable
keys
Freely configurable
keys
Freely configurable
keys
Freely configurable
keys
Freely configurable
keys
C100 Dialog
Start action
Toggle robot
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Version: G/11/401/1/11
Symbol
B
C
Key description
Function description
Freely configurable
keys
Quick position
The robot axes approach the set Quick position directly. The key must remain pressed,
otherwise the movements are stopped.
Decrease override
Increase override
Increases the current speeds of the servoaxes in the automatic mode by a factor in
percent.
The automatic speeds set on the screen
pages are valid as maximum (100%).
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3.3
Version: G/11/401/1/11
Actual position
[-]
Robot
Peripheral unit
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
movement on screen. This does not perform an action. The movement occurs when you press
the Execute foil key.
Execute key on
manual mode device
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Version: G/11/401/1/11
3.4
Key symbol
Key explanation
Motor switch
Switch servomotors on and/or off.
Slow flashing of the LED signals that the motors are ready for switching on. A
quick flashing indicates existing errors which block the switching-on.
Error acknowledgement
Erasure of the displayed error messages. The display display changes to the error
page automatically.
The LED flashes when errors exist.
2nd function
The Second key switches over between the two function levels. The LED lights
when the functions of the second (lower) level can be selected. By pressing a key
(or the 2nd key) it is switched back in the first level automatically.
Increase override
Increases the current speeds of the servoaxes in the automatic mode by a factor
in percent.
The automatic speeds set on the screen pages are valid as maximum (100%).
52
Key symbol
Version: G/11/401/1/11
Key explanation
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 LED flashes when the normal position run is possible (Motor switch switched
on, axes referenced).
Step acknowledgement
Serves the stepwise passing of the instructions in the sequence. With switched-on
test mode the consent and step acknowledgement key must be pressed at the
same time in order to process the instructions.
Take over Teach instruction
Decrease override
Reduces the current speeds of the servoaxes in the automatic mode by a factor in
percent.
The automatic speeds set on the screen pages are valid as maximum (100%).
Suction/Gripper 1
Switching-on and/or -off of the vacuum/compressed air circuit in the manual and/
or set-up mode.
Scroll vertically
For information which cannot be represented on the display at once it is possible
to scroll vertically. The function is generally built up as ring. This means, from the
end it is jumped to the beginning of the page again. It is always scrolled page by
page and the contents is adapted to the available space.
The two orientation bars in the display show at a glance whether a scrolling is possible and which range is displayed at present.
Move X-axis in [+] direction
The movement can only be carried out 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.
Scroll horizontally
For information which cannot be represented once on the display it is possible to
scroll horizontally. The function is generally constructed as ring. This means, from
the end it is always jumped to the beginning of the page. It is always scrolled page
by page and the contents is adapted to the available space.
The two orientation bars in the display show at a glance whether a scrolling is possible and which range is displayed at present.
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Key symbol
Key explanation
Move Y-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.
Conveyor-belt
Steps the conveyor-belt in the manual and/or set-up mode.
Quick position
The robot axes approach the set Quick position directly. The key must remain
pressed, otherwise the movements are stopped.
Move Z-axis in [+] direction
The movement can only be carried out in the manual and/or set-up mode.
54
Key symbol
Version: G/11/401/1/11
Key explanation
Select Teach special instructions
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Version: G/11/401/1/11
USB INTERFACE
The function of the following USB devices is tested and guaranteed by Engel.
Device
Manufacturer
Type
Mouse
Microsoft
Keyboard
Tronix
floppy drive
Mitsumi
D353GUE
Memory stick
Buffalo
RUF-C256M/U2
Memory stick
SanDisk
Printer
----->
Note!
When using other manufacturers USB devices, possibe problems can arise.
2.
After the start-up of the control unit check the protection equipment
Check to ensure no personnel are inside the safety guarding enclosure
Open - close - acknowledge the safety guarding access door
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SCREEN STRUCTURE
The clearly constructed Touch Screen of the control system provides operators with a simple
and quick outlet to setup and program the robot.
6.1
TOP LINE
General settings
1
6.2
[1]
Machine number
[2]
Page title
[3]
User name
[4]
[5]
Date/time
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6.3
The positions of the servoaxes are displayed in millimetres [mm] and/or in degrees [gd].
For the pneumatic rotary axes and swivelling axes the actual status (e.g.: A [ - ], A [ + ]) is
displayed. During axis movement or if no final position is reached, the following onscreen
fields will appear [ - ] start, [ 0 ] start, [ + ] start.
The set override speed is displayed as a percentage and as a bar graph.
6.4
STATUS DISPLAY
The first line displays current messages, warnings and errors generated during operation. The
numeric figure, to the right of the message, indicates the total number of existing messages.
All messages can be viewed on the Error Message Screen page.
The second line displays the active operating states (symbol in color) or inactive states
(symbol in gray).
1
Program interruption key
2
6.5
[1]
[2]
[3]
[4]
Heating
[5]
[6]
[7]
Printer
[8]
Network access
PROGRAM KEYS
Setup
Teach or
Manual
SemiAutomatic
FullyAutomatic
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INPUT KEYBOARD
After inserting the authorization card, the corresponding parameters can be selected. The
following input dialogue appears once a parameter field is selected:
Set value
intermediate deposit
Cancel key
Increment key (increase value)
Decrement key (reduce value)
Copy key, copies the value from the previous entry to the
input field
Enter key
interruption
Press the enter key to store the value in the input field, assuming the value lies within the
possible minimum/maximum values.
Mold number
A virtual keyboard is displayed when parameters are selected that require alphanumeric input.
Special keys
Select all text
Select this key and use the arrow keys to drag the cursor across the required text
Copy the selected text
Insert the copied text
Insert the magnetic card with the required access authorization level.
2.
Select the corresponding screen page using the screen page selection keys.
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3.
4.
Type in the value with the numerical keyboard; the value appears in the input field.
5.
Press the cancel key to erase typing errors and re-enter the input.
6.
7.
Preview
Switch positon ON
When the enter key is pressed the controller takes over the switch position shown in the
preview.
Selection window (Example: Vacuum/compressed air)
For some settings, a drop-down menu containing different selections is available.
Vacuum
Vacuum
Compressed air
barrel
Standard
Contents
Free memory
Process is running, please wait...
Cancel
Help
Write
Interactive messages
Instruction keys
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7.1
Insert the User access card (writing facing out) into the designated card slot.
2.
Login is successful once the user name and number appear in the top-right corner of the
screen.
Logout
To log out remove the card from the slot.
7.2
PASSWORD LOGIN
(Default for EC200 and RC200 stand-alone; optional for CC200)
To login from the machine using a password:
1.
Password
Logout
Logout
2.
3.
4.
Login is successful once the user name and number appear in the top-right corner of the
screen.
Logout
For logout press the Logout key from the Setup screen page.
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German
Date/time
01.05.2005 15:42:15
Unit
ISO
Imperial
Absolute
Relative
User Login
9
User
Password
Logout
Logout
User
Display
System
Lock
Report
Screens
Settings
Through the Settings screen section the language, date, time and unit of measurement can be
changed.
Language
Several different languages are stored in the control unit. Select the required language
from the drop-down menu. Once selected, a status bar appears onscreen to display the
progress of the language switchover.
Date/time
Select this field to open the window displayed below. In this window the time and date
can be changed by pressing the -/+ keys.
Day: 25
Month 6
Year 2005
Hour: 11
Minute 0
Second: 5
Units
To change the units displayed onscreen select one of the options displayed here.
ISO
Displays units in Metric
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Imperial
Displays units in Imperial
Absolute
Displays absolute values
Relative
Displays relative values (percent))
Simple conversion examples
Category
Unit ISO
Unit Imperial
Conversion factors
Stroke
100 mm
3,94 in
Temperature absol.
100 C
212 F
Pressure
100 bar
1450.3 psi
Weight
100 g
3.53 oz
Weight
100 kg
220.5 lb
Force
100 kN
11.24 tf
Volume
100 cm
6.10 in
Volume
100 l
58.1 gal
Torque
100 Nm
73.756 lbf ft
User login
To login enter the correct user and password
8.1
USER ADMINISTRATION
Engel supplies the machine with predefined user access authorizations. It is possible to create
additional user access authorizations and to change existing ones.
For creating and changing user access authorizations an user access with administrator rights
is required.
8.1.1
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2.
Administra-
User
Local
Remote
Language
Unit
4
New
Delete
Cancel
Change
Save
Help
Ok
3.
4.
5
Name
User
Password confirmation!
Password
Confirmation
Confirmation
Local
Remote
Language
Language selection
Unit of measurement selection
Unit
Administrator
6
Cancel
8.1.2
Help
Ok
5.
In the new window that appears enter the settings for the new user. The chosen
password must be entered a second time in the confirmation field.
6.
7.
2.
3.
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Version: G/11/401/1/11
4.
Select the user access authorization to change. Once selected the user access
authorization is highlighted blue.
5.
6.
In this dialogue window the settings for the user access authorization can be changed.
The chosen password must be entered a second time in the confirmation field.
7.
2.
3.
4.
Select the user access authorization to delete. Once selected the user access
authorization is highlighted blue.
5.
6.
7.
8.1.4
Ok
2.
3.
4.
Select the user access authorization to save onto the card. Once selected the user
access is highlighted blue.
5.
Press [Save]. Select [OK] from the dialogue window that appears to confirm.
6.
Remove the access card from the slot and insert the new card to write the information
onto.
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8.2
USER LEVEL
User levels and applications
Level
Target group
Applications
Start-up personnel
Production personnel
Setup personnel
Reserved
Supervisor
Reserved
Reserved
Sequence programmer
10
Additional parameters for maintenance purposes and service tools for troubleshooting
11
from 12
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HELP SYSTEM
To access the online help system press the [?] key.
Help
Help
1
Cores are movable elements inside the mold, which generally move into the mold before
the injection process and move out afterwards.
Cores
Core movement is enabled when:
the safety gates on the clamping unit are closed,
2 safety switches are actuated,
3
4
Close
6
Back
Next
Contents
[1]
Menu strip with call-up of table of contents, index (alphabetically ordered headwords)
and navigation keys for previous or next page
[2]
Help window
[3]
Scroll keys (can also scroll through the screen text by dragging your finger along the
screen)
[4]
[5]
[6]
Table of contents
The help system is available for the specific screen pages, variables and alarms:
Spezific screen page help: To access, press the [?] key at the bottom right-hand corner
of the screen.
A general description of the functional unit or the program is provided.
Variable help: To access, press the [?] key in the particular input window..
Parameter functional descriptions and setting tips are provided.
Alarm help: To access, select the particular alarm message and press the [Help]key.
Cause of alarm and troubleshooting information is provided.
If no help entry is available for the selected page, variable, ..., you can use the table of contents
or index to search the whole machine documentation.
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10
The first generated alarm is displayed in a red message field, found in the bottom lefthand corner of the screen.
A separate Alarm screen page displays messages chronologically, according to the time
they were generated.
Waiting points are displayed on a separate page, which can be accessed via the class
7 tab, found on the top of the screen page.
Alarms
time
Description
Class
Robot motors switched off
X1 axis not referenced
Y axis not referenced
Z axis not referenced
Acknowledge
Settings
Help
To access alarm-specific help, touch the particular message and press the [Help] key.
Note!
An alarm list can be found in the index directory under *Symbols.
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The symbols beside the alarm texts specifies the alarm level/type:
Class
Reason
Effect
System fault
Cycle stop
Process malfunction
Cycle stop
Process malfunction
Cycle continues
Information
Waiting points
Specific effects can be assigned to certain process monitoring features (e.g. cycle stop, reject
sorting, light stack indicator activation or no effect).
WARNING!
Only trained service personnel are authorized to troubleshoot class 1-3
alarms.
10.1
At each cycle start, error messages from the previous cycle are deleted.
Certain alarms also require a manual acknowledgement. To do this either toggle the
Program Interruption switch OFF and ON, or select the message and press the
Acknowledgment key.
Alarms that are not cleared or acknowledged will still cause reactions and related messages.
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10.2
INTERACTIVE MESSAGES
In addition to the generated error messages, interactive symbols are also used in the program
to convey particular information. The following section describes the functionality of each
symbol:
Wait
Information
Warning
Error
Fatal error
At the end of the text, messages can still have another function or link:
The message is backed with a link. By touching the message the target is called
up and displayed.
This symbol is displayed if additional information exists in the online help. Touch
the symbol to access the online help.
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DATA DIALOGUE
The data dialogue serves to store and load data onto the machine and/or onto an external
storage device (i.e. Compact Flash, USB stick, network).
The screen page appears after switching on the control unit and/or after pressing the screen
page selection key.
Data dialogue
\harddisk 0
\harddisk 0
1
3
Training
2
STANDARD+CORE-
Name
STANDARD+CORE-
Author
STANDARD
Production date
STANDARD_Parallel
Change author
STANDARD_SEQUE
Change date
STANDARD+COREFIX
--Description
Machine number
Version
Parts data
[1]
Edit
Setup
View
[2]
Status information
Shows the status (symbol) and name of the active data file (Selection key for the display
of the attributes)).
[3]
[4]
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[5]
Message window shows dialogs for executed actions, error messages, information
etc. Can be faded out and in in the menu View.
[6]
11.1
STORAGE MEDIA
As input media serve Compact Flash cards or USB storage sticks.
Compact flash card
You can use each commercial Compact Flash card.
USB storage stick
Only use the folllowing USB storage sticks:
Memory stick
Buffalo
RUF-C256M/U2
Memory stick
SanDisk
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.
removal
Select a data carrier with more free space and try to save again.
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Version: G/11/401/1/11
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,
positions,... do not change.
Machine settings
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.
Example:
Procedure when loading an existing parts data set from a data carrier.
1.
2.
Select the data carrier. hard disk1\ is the memory card on the front panel, hard disk0\
is the control-internal memory. usbbulk\ is a connected USB memory stick.
3.
4.
Values corrected
impact
Message only
removal
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11.3
Example:
Procedure when storing an active parts data set on a data carrier.
1.
Select the active parts data set with the key at the top right of the screen.
2.
3.
Select the data carrier. hard disk1\ is the memory card on the front panel, hard
disk0\ is the control-internal memory.
4.
Free memory
C:\5632
kBytes
Required memory
C:\231
kBytes
Cancel
5.
6.
11.4
Help
Write
Change the set attributes, when necessary, and confirm with [Write].
The control unit stores the parts data set on the selected drive.
If a data set with the same name already exists on the data carrier, the dialog window
2.
Touch the required parts data set to select from the list.
3.
Name
Cancel
4.
C:\5632
Help
Copy
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5.
11.5
Press [Copy].
12
1.
From the selection window, choose the drive that contains the data set.
2.
3.
4.
PRINT
The control unit supports printing from various programs, and of screenshots. The control unit
supports PCL-3 capable printers by vendors that support this specification. To print on-site,
connect a printer to the USB port on the machines front panel.
When the machine is connected to a LAN network, printing to the networked printers is
possible.
The following printer types are tested for the CC200 control unit:
Local printers with USB connection
Manufacturer
Type
Hewlett Packard
HP 880C
Hewlett Packard
HP Deskjet 895C
Hewlett Packard
HP Deskjet 990Cxi
Hewlett Packard
HP Deskjet 995C
Hewlett Packard
Hewlett Packard
Hewlett Packard
HP Deskjet 6840
Manufacturer
Type
Hewlett Packard
HP Laserjet 4100dtn
Hewlett Packard
HP Laserjet 4000 PS
The control unit offers the following printing possibilities of screen pages (masks):
a hard copy of the current screen page with screen page selection keys
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A hard copy as PNG picture and graphic printouts of individual or several screen pages can be
stored in Postscript format as file.
A textual output in file format enables an export function in the data dialog.
Graphic or textual printout of screen pages on a local printer:
1.
Connect a printer with USB cable and switch the printer on.
2.
3.
Help
Setup
Ok
Press [Setup]
Settings for screen page output
Printer settings
Output on printer
Compress PS
Cancel
Help
OK
4.
5.
When switching over to Output on printer the printer dialog appears of the currently set
printer. Select the local printer and press [OK].
6.
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7.
Production
Programmable in/outputs
Freely composeable page
Shut-off nozzles
Minicam
Mold close
Set value graphics
Mold height
Mold open
Cancel
Help
Delete
Select all
8.
9.
2.
Press [Setup]
Settings for screen page output
Printer settings
Output on printer
Compress PS
Cancel
Help
OK
3.
4.
OK
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Version: G/11/401/1/11
5.
Cancel
Help
Save
6.
7.
Enter in the mask Settings for the screen page output a designation in the line
[File name].
With [OK] start the output process to file.
8.
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Version: G/11/401/1/11
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QUICK SETUP
This page contains basic settings and functions of the robot, such as work area settings,
turning limits, swivelling limits, moving limits, group and individual configurations for vacuum/
compressed air.
NOTICE!
These settings must be configured immediately after mounting a mold to
mitigate the danger of collision. To do this, mount the end of arm tooling
that matches the mold!
Work areas for machine, take-off and depositing area
Quick Setup
Actual position
Min
Max
Take-off area
Min
Max
Depositing area Z+
Min
Max
Machine area
The machine area is the whole theoretical moving area of the robot within the injection
molding machine. This defined room is switched with a safety condition depending on
the mold position. The machine area defines the whole blocking area of the plant and is
preset on the part of the factory.
Take-off area
Work area in machine area for part take-off. To access a mold without danger of
collision, 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
collision 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.
Depositing area Z+
A setting of the work area depositing area Z+ limits the maximum depositing area of the
operator rear side corresponding to the set parameters. The limitation of the depositing
area enables the safeguarding of the whole depositing area with only few work areas.
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Depositing on the operator rear side
[1]
[2]
[3]
Take-off area
Note!
To avoid collisions with the robot, you must define the work area and prohibited area for the
take-off and depositing areas. [See Work Areas and Prohibited Areas on page 113.]
impact
removal
impact
removal
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Version: G/11/401/1/11
Robot interlock
Reason
impact
removal
removal
removal
NOTICE!
The turning, swivelling and movement limits only apply to standard sequences defined by Engel.
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Example:
Turning, swivelling and moving limits
Depositing area Z+
Machine area
NOTICE!
The rotary axis settings for moving into and out of the machine area only
apply to standard sequences defined by Engel.
But the rotary axes settings are not valid for the Engel Teach sample sequences.
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Pneumatic axes
C Servomotor axes
180
0
above
90
below
B
right
max
middle
180
left
A
90
left
right
middle
max
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Version: G/11/401/1/11
Group configuration
Take-off vacuum/compressed air circuits
Depositing vacuum/compressed air circuits
Group configuration
Assignment of the vacuum/compressed air circuits in the corresponding groups.
If you need to take-off and deposit a sprue part, you must configure the vacuum/compressed
air circuits with which you will be taking-off and depositing the sprue part in the group
configuration.
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.
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Version: G/11/401/1/11
Available elements
Selected elements
Vacuum/compressed air 3
Vacuum/compressed air 1
Vacuum/compressed air 2
Cancel
Help
Execute
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 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/
compressed air circuits screen.
Group configuration
Take-off vacuum/compressed air circuits
Depositing vacuum/compressed air circuits
3.
Use the >>> button to move the vacuum/compressed air circuits to Selected elements.
Group configuration - Vacuum/compressed air circuits
Available elements
Selected elements
Vacuum/compressed air
Vacuum/compressed air
Cancel
Help
Execute
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Version: G/11/401/1/11
4.
Available elements
Selected elements
Vacuum/compressed air
Vacuum/compressed air
Cancel
5.
Help
Execute
Vacuum/compressed air x
Activated
Status marker
Type
Compressed air
Input
Part monitoring
Signal 0 and 1
Vacuum x
Activated
Status marker
Part monitoring
Signal 0 and 1
Vacuum/compressed air x
A strip is available for each vacuum/compressed air circuit.
Activated
Activates vacuum/compressed air circuit x.
Status marker
The flag displays that the equipment is active.
Type
Vacuum/compressed air circuits can be of the following types Vacuum, Compressed
air or Barrel.
Depending on the type setting, final position and part monitoring are configured
automatically.
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Part monitoring
Activating monitoring by enabling the program switch. The part monitoring setting
depends on the selected type.
Selectable settings:.
Signal 0 and 1
Monitors part available/not available.
Signal 1
Monitors part available.
Note!
In the Parameter tab of the robot setup you can specify settings for the vacuum/compressed
air circuits.
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Depositing conveyor-belt x
Depositing conveyor-belt - Cycle when all selected grids are full
Depositing conveyor-belt - Running time
Depositing conveyor-belt x
Available elements
Selected elements
Shot grid 2
Shot grid 1
Shot grid 3
Individual part grid 1
Individual part grid 2
Individual part grid 3
Tach grid 1
Tach grid 2
Cancel
Help
Execute
If the robot sequence, e.g. the part sequence Part depositing in individual part grid 1
with conveyor belt is programmed, 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.
The robot was unable to deposit the parts in the grid because the
conveyor belt has not been cycled.
impact
removal
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1.1
test mode
Testmode active
Testmode speed
test mode
Testmode active
The control unit switches to test mode when you enter changes in the sequence editor,
or press the Test mode button on the hand control device. Press the button once more
to disable Test mode. [See test mode on page 146.]
Test mode button on
manual mode device
Testmode speed
Servo axis speed in test mode.
Home position
Home position
+
Speed to home position
Home position reached
Home position
The home position is the position the robot occupies at the start of an automatic cycle.
Home position
You can move to preset position by pressing the Home position button on the machine
control panel and/or hand control device.
Home position key on
manual mode device
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Version: G/11/401/1/11
impact
removal
Execution of the home position run until the position is reached completely.
Quick positioning
Quick position
+
Quick position speed
Position reached
Quick positioning
The program is used for faster positioning of the robot at a predefined position.
Quick position
You can move to the preset position by press the Quick positioning button on the hand
control device.
Quick position key on the
manual mode device
Position reached
The active marker signals that the preset quick position has been reached.
impact
removal
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Park position
Move to park position during production without robot
Park position
Park position
Park position for all axes adjustable on screen.
impact
removal
Perform park position move until the position has been fully reached.
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Version: G/11/401/1/11
QuickSet
All axes
Axes
Cancel
Help
Execute
QuickPos
Serves to specify the current position for the selected robot axis as the Quick position
on the General settingsscreen.
QuickSet
Used to for quick collection of position information for the selected robot axes at the
current position.
Example:
Apply current values for the robot axes for Position before opening .
1.
2.
Press
quick set
keyopening
for Position before opening.
Speedthe
to position
before
Position before opening
3.
QuickSet
All axes
Axes
Cancel
Help
Execute
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Version: G/11/401/1/11
4.
Press Execute to use the current robot axis values as the Position before opening.
Take-off
Actual position
Take-off Standard
Position before opening = Home position
Speed to position before opening
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.
2.
3.
QuickSet
All axes
Axes
Cancel
Help
Execute
4.
5.
When you press the quick position button on the hand control device, the robot travels
from the Position before opening directly to the take-off position. The robot does not
move to the preset moving-in position.
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Sequence sketch
[1]
[2]
Moving-in position 1
[3]
Moving-in position 2
[4]
Take-off position
NOTICE!
The positions are approached directly, pay attention to possible collisions.
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ROBOT STATUS
The status page provides information about general robot and sequence states.
Status page
Actual position
General
All motors switched on
All axes referenced
All axes in Home position
Hand terminal Consent key active
Testmode active
Override speed
Cycle counter
General
Testmode active
Indicates whether the test mode is activated.
Override speed
Actual value for current override speed.
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
automatic operating mode. The automatic speeds set on the screens represent the
maximum (100%).
Reduce override button on
hand control device
Cycle counter
Actual value counter for executed robot cycles. The counter can only be reset by
pressing 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.
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closing release
Electric mold closing release
Program mold closing release
closing release
These flags show the states of the closing releases.
Vacuum/compressed air
Vacuum/compressed air - output +
Vacuum/compressed air - output -
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
C-axis - Swivelling cyl. CD1 - Output +
C-axis - Swivelling cyl. CD1 - Output C-axis - Swivelling cyl. CD1 - Input +
C-axis - Swivelling cyl. CD1 - Input -
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Robot
Robot main switch
Home position movement with parts
ERC SIP3 Vertical
Equipment type
Robot
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.
Take-off movement
The following program switches can be set as a function of the constructional plant execution,
of the configured safety package and of the allowed take-off type. The chosen setting
influences the work areas and the robot standard variants (Take-off, depositing,...).
Take-off movement
Allowed take-off movement
Take-off movement
Vertical
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 above (Y-reference switch
or Y-waiting position switch actuated).
Horizontal
The robot moves into and out of the mold laterally = horizontally (e.g.: tiebarless
injection molding machine).
The closing release for the mold is given when the robot has left the take-off area (Zreference switch not actuated and/or Z-position >= home position).
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Vertical take-off
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Early start
Activates early start in the take-off sequence. The program switch and the early start
position are queried by the Wait for part acceptance releasesequence. To avoid
collisions, the sequence waits for Mold open , before accessing the take-off position
(the default is to wait until move-in position 2 has been reached). Moving-in positions 1
and 2 must be set to avoid collisions between the end of arm tooling and the mold.
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Depositing variants
Program switch for enabling or disabling various depositing areas.
Reject deposit - 1 position
Program switch reject depositing
Rotary axes
Program switch for enabling or disabling rotary axes.
Rotary axes
B-axis - Activated
C-axis activated
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2.
3.
Switch on the robot main switch form the Robot 1 program switch screen
4.
Switch on compressed air at the maintenance unit; operating pressure 6 bar (87 psi)
5.
Switch the robot motors on form the hand terminal or the injection molding machine
control panel.
The robot motors are not yet switched on or have been switched off
by the appearance of an alarm (see alarms on the screen).
impact
6.
removal
Switch on set-up. For confirmation appears the message: Robot setup mode activated.
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NOTICE!
Pay attention that there are no obstructions in the robots way during referencing.
The referencing sequence and the referencing order are set in the sequence editor.
The order of the individual axis referencing sequences determines the referencing order.
Standard referencing sequence:
Robot sequence
Referencing
Instructions:
Robot
Peripheral unit
Referencing
Sequence control
Grid
Sequences
structure instructions
Referencing process:
1.
2.
Use the referencing key on the hand control device or injection molding machine
operating panel to reference the robot axes. The robots linear axes will move slowly in
fixed order (Y>X>Z) to fixed referencing positions.
Referencing key on
manual mode device
3.
Hold the key down until referencing is complete and the robot stops.
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When an axis is not referenced, the following message appears:
Automatic mode is not possible and the alarm lamp flashes. The axis
can only be referenced or moved with the hand terminal touch keys.
The set work area data is not considered!
removal
NOTICE!
When the robot is not referenced it means no final positions are defined;
therefore, the respective axis moves until the EMERGENCY STOP!
The following message is displayed:
removal
Move out the axis from the EMERGENCY STOP position, carry out
referencing
There are less than two statistically valid values in the zero impulse
history.
impact
removal
Parameters
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impact
removal
Parameters
The current zero impulse angle lies in the range +/- 45. The zero
position of the axis can be displaced by a motor revolution.
impact
removal
Parameters
The digital input signal of the reference switch did not have the correct status on the switching position within the monitoring tolerance.
impact
removal
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3.2
NOTICE!
Danger of collision with peripheral unit, sprue cutter or support etc.
1.
Press the Homing key on the hand control device or on the injection molding machine
operating panel.
Home position key on
manual mode device
2.
3.3
Hold the key down until the robot has reached the home position.
DANGER!
Working or standing below moving components is prohibited! The robot
must be at an accessible position that does not endanger the user.
Before the parameter settings a takeover head suitable for the injection mold must be
mounted.
Example:
End of arm tooling with four spring-loaded suction pads and a sprue cutter.
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Settings
3D view
Overview
Robot
Work area above
Edit
View
[1]
[2]
[3]
[4]
Robot
Predefined work and prohibited areas from machine constants, take-off areas and
depositing areas.
In machine data
User-defined work and prohibited areas for storing in the machine data set.
In parts data
User-defined work and prohibited areas for storing in the parts data set.
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SETTINGS ROBOT
In order to change the robot settings, select the robot folder from the selection area, as shown
below.
Work area setup
Robot1
Work Areas and ProhibRobot
Work area above
Work area above
Work area clamping
Settings
3D view
Overview
Machine area
Min
Max
Take-off area
Prohibited area
Work area rear safety
Work area above deWork area depositWork area above deWork area deposit-
Min
Max
In machine data
Min
In parts data
[1]
[2]
Machine area = prohibited area clamping unit. Blocks all work areas in the machine area
with mold not open.
[3]
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Option: Dual-side deposit
1.2
[1]
[2]
[3]
Take-off area
[4]
Settings
3D view
Overview
Element attributes
Name
Type
Work area
Min
Prohibited area
Work area rear safe-
Max
Activation switch
Active
Visible
Filled
Description
System name
Element attributes
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
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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.
Description
Field for a short description of the room
System name
Clear designator for the control unit (cannot be changed)
Robot assigned
Assignment of the area to the corresponding robot
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 view window provides the following features
Work area setup
Robot1
Work Areas and Prohib-
Settings
3D view
Overview
Robot
Work area above
Work area above
[1]
[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]
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[6]
[7]
Work area
Active
Inactive
Selected
Not selected
Work area
blue
violet
Prohibited
area
red
pink
Collision area
When in the automatic mode a work area error appears, the robot movement stops with the
following message:
Robot synchronous axes work area error: <No.> <Name> [Pos1 > Pos2]
Reason
impact
Parameters
The 3D view window displays the collision point with a crosshair and a warning symbol. A
dialog shows the data of the collision position.
Collision point
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1.4
OVERVIEW
The Overview window displays a listing of all the areas within the selection.
This window provides a quick overview of the most important work area data.
Work area setup
Robot1
Settings
3D view
Name
Overview
In parts data
[1]
[2]
[3]
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Min.
Max.
Min.
Max.
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Min.
Max.
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Min.
Prohibited area
machine area min. 0.045mm (in)
Max.
Prohibited area
machine area max.
+0.045mm (in)
Moving area within the rear safety gate area. The work area is activated and/or deactivated in
relation to the take-off type (horizontal/vertical).
Min.
Max.
Maximum moving area in the operator rear-side deposit area, up to the lower swivelling limit
deposit area.
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Min.
Max.
Maximum movable deposit area on the operator rear-side, from the lower swivelling limit
deposit area.
Min.
Max.
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Maximum moving area in the operator side deposit area, to the lower swivelling limit deposit
area.
Min.
Max.
Maximum deposit area on the operator side, from the lower swivelling limit deposit area.
Min.
Max.
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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 corresponding screen page is generated automatically after the change and storage in the
sequence editor.
are preprogrammed:
Take-off Standard
This variant is preset at the delivery of the robot. It is an universal variant for many
application 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 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 for the most simple type of the take-off. Only the moving-in position
before opening and the take-off position must 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).
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TAKE-OFF STANDARD
The standard take-off variant covers a majority of most different take-off requirements for
injection molded parts. It is programmed with two intermediate positions for moving-in and -out
and a demolding position. For the cycle time optimization program switches are provided.
Take-off
Actual position
Take-off Standard
Cycle time
Last cycle time
2nd to last cycle time
Take-off time
Last take-off time
2nd to last take-off time
Moving-in with ejector advanced
Switch on suction pad
Take-off Standard
Take-off Standard
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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
automatic operations start, the robot moves from home position to Position before
opening.
Moving-in position 1
Robot position which is approached from completely open mold in order to move around
obstacles (tiebars, mold guides).
Moving-in position 2
Robot position which is approached after the moving-in position 1 in order to move
around obstacles (tiebars, mold guides).
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Sequence sketch
[1]
[2]
Moving-in position 1
[3]
Moving-in position 2
[4]
Take-off position
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Moving-in standard
If
Moving-in with ejector advanced
Ejector
enable advance
Moving-in position 1
If
Switch on the suction pad {after ejector advanced} = at moving-in position 1
Take-off vacuum/compressed air circuits
[ ON ] without monitoring
Moving-in position 2
Wait until
Mold open
Take-off position - XYZ
Moving-in standard
Take-off
Take-off speed
Take-off position - X Y Z
Waiting time before take-off
Time for part removal
Take-off speed
Speed of the servoaxes to take-off position.
Take-off position - X Y Z
At this position the molded part is taken over by the robot by means of vacuum/
compressed air.
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Moving out via 2 intermediate positions
Speed for move-out position 1
Moving-out position 1
Speed for move-out position 2
Moving-out position 2
Moving-out position 1
The robot position accessed after the take-off position to avoid obstacles (tie-bars, tool
guides).
Moving-out position 2
The robot position accessed after the take-off position 1 to avoid obstacles (tie-bars, tool
guides).
Sequence sketch
Depositing area
Machine area
6
1
3
5
Mold completely open
[1]
[2]
Moving-in position 1
[3]
Moving-in position 2
[4]
Take-off position
[5]
Moving-out position 1
[6]
Moving-out position 2
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Moving-out standard
Moving-out position 1
Moving-out position 2
Rotary axes movement moving out from machine area
Speed for move-out position 2 = 100
Stop when safety gate requested
If
Moving-in/out horizontally
Position before
Machine area - Max - Z
Moving-out standard
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2.1
Shot grid 1
Waiting time before depositing
Depositing time
Speed from depositing position
Depositing conveyor-belt - Activated
Depositing conveyor-belt - Running time
Shot grid 1
Select this key to tell the control unit to open the shot grid. [See Grid editor on
page 195.]
Depositing time
Waiting time after depositing the molded part.
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Example:
Shot grid 1
Depositing area Z+
Machine area
Y positon when
moving out/in Z
Grid editor
Robot
Grid
At-
Parame-
Intermediate
Shot grid
Shot grid 1
Shot grid 2
Shot grid 3
Individual part grid
Tach grid
[1]
[2]
Simulation Production
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2.2
REJECT DEPOSIT
This depositing variant enables, in case of a rejects recognition, the depositing of the parts on
a separate rejects depositing position.
Reject deposit
Actual position
Depositing time
Waiting time after depositing the reject molding.
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Depositing time
Waiting time after depositing quality control part.
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SPRUE DEPOSIT
The sprue depositing function allows separate depositing of injection molded parts and sprue
parts at separate positions.
Sprue deposit
Actual position
Depositing time
Waiting time after depositing the sprue part.
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2.5
INTERMEDIATE LAYERS
The intermediate layer program serves to separate individual grid layers using intermediate
layers (e.g. cartons). The parameters for picking up intermediate layers can be set in the
intermediate layer screen page. Settings for depositing intermediate layers can be set in the
Grid editor, intermediate layer tab. [See Tab - Intermediate layer on page 198.]
Intermediate layers
Actual position
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Sequence sketch: Pick up first intermediate deposit
[2]
[3]
[2]
[3]
Current pick-up position minus Search area before last saved position
[4]
[5]
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Pick up time
Speed intermediate layer lifting
Speed move out magazine
Pick up time
After activating the vacuum/compressed air circuits, the robot waits at the pick-up
position for the specified time.
Depositing time
Waiting time after depositing the sprue part.
While the time is running the flag is active.
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Sequence sketch: Move from intermediate layer pick-up to depositing position
4
2
[2]
Current pick-up position minus Search area before last saved position
[3]
[4]
Example:
Pick up intermediate layer from a stack and then deposit after a Y layer on the depositing grid.
[1]
[2]
[3]
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On the injection molding machine switch on the set-up mode and at least access
authorization 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.
At the robot switch on vacuum / compressed air (screen page Quick Setup).
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
positioning 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.
7.
Set robot axes on takeover position so that the part can be taken over.
8.
9.
Set and/or take over position of the axes on screen page Take-off at Take-off position
- XYZ.
10.
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
injection 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.
15.
16.
17.
18.
Move all axes into the position where the part will be deposited.
19.
20.
21.
22.
23.
24.
Set times (depositing delay time, depositing time, running time depositing conveyorbelt).
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Robot sequence
Instruc-
Robot
Peripheral unit
Execute as long as
Automatic mode of operation ac-
Take-off 6 positions
Sequence control
Grid
If
Reject deposit
Reject deposit
1 Position
Sequences
structure instructions
If
Test part depositing
process malPosition
Variants
Program
Edit
View
[1]
Selection window
Structured listing of the equipment components, sequence variants and programming
instructions.
[2]
Sequence selection
Switchover to machine sequence, robot sequence, etc.
[3]
Status line
Displaying the current axis values.
[4]
Sequence window
Graphical display of the selected program sequence with short description. The window
can be scrolled horizontally and vertically.
[5]
[6]
Switchover key
Switching between variant exchange mode and sequence programming
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SEQUENCES
The whole sequence of an automated injection molding unit comprises a number of program
sequences. Sequences can be separated to achieve better readability for complex programs.
The robot sequence, teach sequence and machine sequence all start at the same time when
the start button is pressed.
Sequence selection
Robot sequence
Home position
Park position
Referencing
Robot sequence
Teach sequence
Machine sequence
Robot sequence
The following Engel-defined robot sequences are available:
Robot - Simple - sequence
Variant for standard applications with screen switch for sequence selection. In the
standard case it includes take-off, sprue depositing, reject depositing, test part
depositing and depositing of parts in the grid on the peripheral unit.
Robot - Complex sequence
This also includes the program for intermediate layers, sprue separation and
intermediate deposits.
Robot Teach sample sequence
Simple variant without screen switch for creating special Teach sequences (screen
switches are without effect).
Robot empty sequence
Creating a completely new robot sequence. The robot is provided with a convenient
programming tool (Teach pointer). The last action to be performed using the manual
controller is automatically transferred to the sequence. This can be robot movements
and functions (e.g. vacuum/compressed air, barrel functions).
Ejector and core releases are also automatically programmed if you perform the
corresponding movement on the injection molding machine, and then transfer it to
the manual control unit.
Home position
Moves the robot from the depositing or take-off area with a separate pushbutton
start position.
to
Referencing sequence
Serves to reference the robot axes after switching on the control unit with a separate
pushbutton
.
Teach sequence
Empty sequence for peripheral units or special applications not covered by the standard
program. The Teach sequence starts parallel to the robot sequence. This can occur in
manual mode or via a programmed pushbutton while the robot is in the home position.
Machine sequence
Includes the injection molding machine sequence with closing, injection and opening
sequence.
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Example:
Robot - Simple - sequence
If
Test part depositing active
process malfuncPosition
Part depositing in
Shot grid 1 with
The robot sequence mainly comprises a take-off sequence and conditional part depositing
sequences (rejects depositing, quality control part depositing, and part depositing). The
subsequences are processed step by step from the top down.
At the structure instruction If corresponding to the condition it is branched downwards or to
the right. The instruction Execute as long as automatic mode of operation active causes a
new start of the robot sequence as long as the automatic mode is active.
Disabled programs are crossed out in red in the sequence and are skipped.
Reject deposit - 1 position
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 commands.
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Example:
Take-off sequence with subsequence Move-in 3 positions.
1.
Take-off position - Y
Wait until
Mold open
Take-off position - Y
Moving-in 3 positions
Take-off
2.
The selected step is highlighted in red and a text window with the complete description
appears.
Take-off position - Z
Z=0
Individual axis movement
Speed in take off area=100
Start
3.
If you touch the Take-off position - Z command again, a dialog box appears where you
can read and set the individual parameters.
Individual axis movement
Type
Start
Take-off position - Z
Position
Name
Take-off position - Z
Display on screen page
Speed
Take-off 3 positions
Name
Take-off 3 positions
Help
Execute
Multiple selection
Touching 2 commands in a sequence selects these two commands and any commands
between them. If you make a multiple selection, the selection is discarded the next time you
select a command in the sequence. Touching an area outside the sequence discards all
selections.
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Display pointer
A green step pointer shows the sequences, subsequences and instructions that are currently
being processed in semi-automatic and fully-automatic operations.
You can activate or deactivate the step pointer in the Sequence Editor using the menu keys
View and Step counter.
Take-off Standard
Symbol
Color
Type
Function
yellow
yellow
yellow
The next instruction starts after reaching the condition of the final position
or the vacuum switch.
green
green
Release to machine
green
turquoise
orange
structure instructions
Example:
A Goto positionmove instruction, is followed by another Goto positionmove instruction.
Move instruction P3 starts when the robot has moved exactly to position P2 prior to this.
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P3
P1
P2
P3
P1
P2
A Goto position (P1)move instruction, is followed by a Start (P2)move instruction, and then
a move instruction Goto position (P3).
After reaching P1, the move to P2 and the move to P3 instructions immediately start. Position
P2 is approximated.
P3
P1
P2
P3
P1
P2
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Teach-In, edit sequence with restricted command set, inserting additional sequences
(as of user level 7).
Editing sequences with full command set (as of user level 9).
NOTICE!
Due to the freely programmable nature of the sequence editor, it is very
easy to make setting mistakes. Pay close attention to the settings
because incorrect settings can lead to equipment damage.
How to switch into Teach mode of operation
1.
2.
3.
During the switchover into the mode of operation Teach the background of the sequence editor
changes from gray to white. It appears the message:
Editiermodus aktiv
impact
removal
NOTICE!
Danger of collision!
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 sequence.
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2.
Help
Undo
Execute
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.
Note!
The sequence is saved in the parts data. Therefore rewrite the parts data after saving the
sequence.
3.2
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 programming.
Test mode is activated by
making changes in the Sequence Editor and then quitting Teach mode.
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NOTICE!
A pneumatic axis or function that has already started will not stop when
you release the consent key!
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EXCHANGE VARIANTS
Engel defined sequences/subsequences, referred to as Variants are available for various
applications. You can modify these sequences 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.
For applications such as sprue separation or intermediate deposit, a fully Engel defined Robot
sequence is available. These variants require corresponding hardware signals for monitoring.
The signals are optionally available as interface packages.
After inserting a variant of this type into the sequence, and then storing, the control unit will
display the corresponding setting parameters on the screen pages.
You can replace a variant and then store the sequence to display the modified sequence and
corresponding screen.
Note!
In the Variants view you can only select sequences/subsequences, but not commands.
Tab - Sequence
Robot sequence
Robot sequence
Subse-
Subsequence properties
Engel-defined (7)
Take-off empty seTake-off 3 positions
Take-off 6 positions
Take-off mold interTake-off Standard
Take-off with mold
Take-off with ejector
Take-off Teach samUser-defined (1)
Sequence
Program
Edit
View
Variants can only be replaced in the Variants view (light blue background) in Teach mode.
Press the Sequence menu key to change to the Sequenceview where you can only replace
programming sequences but no variants. [See Programming Sequences on page 152.]
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Tab - Subsequence
Se-
Subse-
Subsequence properties
Take-off Standard
If
Take-off vacuum/compressed air circuits one or
Move out without part take-off
Jump to sequence end
Subse-
Subsequence properties
Element attributes
Name
Take-off Standard
Description
Element attributes
Name and short description for selected part depositing (e.g. take-off standard). Which you
can only modify for 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.
2.
Program
Edit
View
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3.
Se-
Subse-
Subsequence properties
Engel-defined (7)
Take-off empty seTake-off 3 positions
Take-off 6 positions
Take-off mold interTake-off Standard
Take-off with mold
Take-off with ejector
Take-off Teach samUser-defined (1)
4.
5.
Subse-
Subsequence properties
Engel-defined (7)
Take-off empty seTake-off 3 positions
Take-off 6 positions
Take-off mold interTake-off Standard
Take-off with mold
Take-off with ejector
Take-off Teach samUser-defined (1)
6.
If
Quality Control depositing
process malpart dePosition
Shot grid
To save your work, press Program and Save or quit sequence programming by quitting
Teach mode.
You get the dialog Save robot sequence.
Save robot sequence
Do you want to save the sequence changes?
Cancel
Help
Undo
Execute
Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
You leave the mode of operation Teach. All sequence changes made by you are
rejected.
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Execute
Teach mode is exited, the changes to the sequences are saved.
7.
The control unit will apply your settings after you save the sequence.
The control unit configures the screen page and calculates the corresponding safety
conditions.
8.
Save the complete sequence in a new parts data set in the data dialog box. [See Write
a parts data set on page 73.]
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3.4
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PROGRAMMING SEQUENCES
This refers to changing Engel and/or user-defined variants or programming of new sequences.
Sequence programming is only possible in the Sequence view which has a white background
in Teach mode.
A modified Engel defined variant cannot be overwritten, but you can store it as a User defined
variant.
Note!
Only one user-defined variant exists for each sequence. In other words, you must store each
user-defined sequence in a part record of its own. The sequence data can be loaded separately from the settings.
There are 2 basic types of sequence programming
Note!
If you program a robot movement (linear and rotary axis) with the Teach pointer, a complete
robot position is always inserted, even if only one axis is moved. The control unit assumes the
current position for any axes which are not moved.
You may need to manually optimize the transition between one robot movement and the next,
as well as any parallel functions.
Various approaches to sequence programming
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subsequence.
When you create a new variant, you can select an icon to match the variant.
3.4.1
2.
3.
In the selection window, select the structure command Teach pointer and insert it into
the sequence below Moving-in position 1.
Robot sequence
Robot sequence
Sequences
structure instructions
Teach pointer
Execute as long as
Repeat until
If
Parallel open
Parallel closed
Waiting time
Wait for time or
Wait until
Comment
4.
5.
The accomplished action is shown in the turquoise field in the Sequence Editor and in
the C30 hand control device display.
6.
Press the
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7.
In the sequence, robot position 2 is created using the current axis positions and a new
speed.
The Teach pointer automatically moves to the next step.
Robot sequence
Robot sequence
Sequences
structure instructions
Execute as long as
Automatic mode of operation active
Home position - XYZ
Teach pointer
Execute as long as
Repeat until
If
Parallel open
Wait until part take over allowed
Parallel closed
Moving-in position 1
Waiting time
Robot position 2
Teach pointer
Comment
8.
Double click on the robot position x you just inserted to open a dialog where you can
enter settings for this position.
9.
In the dialog box, click on the Name button for the position and change the name
created by the system to Moving-in position x.
Click the Name speed button, and change the name created by the system to Speed
for moving-in position x. This will help you distinguish the speed for the moving-in
position easier.
Robot movement
Type
On position
Position
Robot position 6
Name
Speed 6
Speed 6
Display on screen page
Cancel
Execute
10.
If you want to display the position and speed on the corresponding screen, additionally
enable the selection boxes Display on screen.
11.
Select Execute to transfer the robot movement changes to the control unit.
The parameter lines with the position and speed are displayed on the Take-off screen
when you store the sequence.
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12.
13.
To save your work, press Program and Save or quit sequence programming by quitting
Teach mode.
You get the dialog Save robot sequence.
Save robot sequence
Do you want to save the sequence changes?
Cancel
Help
Undo
Execute
Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
You leave the mode of operation Teach. All sequence changes made by you are
rejected.
Execute
Teach mode is exited, the changes to the sequences are saved.
14.
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 take-off sequence.
[See Moving variables and strips on page 222.]
Moving-in position 2
Moving-in position speed 2
Moving-in position 3
Moving-in position speed 3
3.4.2
15.
In the Variant view, Subsequence properties tab, you can assign a unique name to userdefined sequences and create a short description.
16.
Save the complete sequence in a new parts data set in the data dialog box. [See Write
a parts data set on page 73.]
2.
3.
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4.
Select the move job Linear axes movement and insert it into the sequence by clicking
on the corresponding insert point below Moving-in position 2.
Robot sequence
Robot sequence
+
Instructions:
Moving-in 6 positions
Robot
Moving-in position 1
Move commands
Moving-in position 2
Individual axis
Wait until
Mold open
Take-off position - XYZ
Linear axes
Rotary axes
Robot movement
Moving-in 6 positions
Multi-position lin-
5.
Instructions
Robot
Move commands
Individual axis
Linear axes
Moving-in 6 positions
Moving-in position 1
Linear axes movement
Type
On position
Position
Name
Rotary axes
Robot move-
Multi-position
Speed
Relative move-
Stop movement
Take-off 6 positions
Name
Take-off 6 positions
Reference robot
Position check
Cancel
Help
Execute
6.
Use the dialog box to enter settings for the linear axes movement.
7.
Enter a meaningful text as Name for the inserted position and speed. The Display on
screen page switch adds the position at the bottom of the Take-off screen page.
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8.
Press Execute to insert the linear axis movement into the sequence.
Robot sequence
Robot sequence
Instructions
Moving-in 6 positions
Robot
Moving-in position 1
Move commands
Moving-in position 2
Individual axis
Moving-in position 3
Linear axes
Rotary axes
Robot moveMulti-position
Moving-in 6 positions
Relative move-
9.
St
To save your work, press Program and Save or quit sequence programming by quitting
Teach mode.
You get the dialog Save robot sequence.
Save robot sequence
Do you want to save the sequence changes?
Cancel
Help
Undo
Execute
Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
You leave the mode of operation Teach. All sequence changes made by you are
rejected.
Execute
Teach mode is exited, the changes to the sequences are saved.
10.
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 take-off sequence.
[See Moving variables and strips on page 222.]
Moving-in position 3
Moving-in position speed 3
11.
Save the complete sequence in a new parts data set in the data dialog box. [See Write
a parts data set on page 73.]
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INSERT SEQUENCE
In the Sequence view you can insert sequences/subsequences besides individual
commands.
Example:
You have removed the complete robot sequence and now want to insert the Robot complex
sequence.
1.
2.
You cannot switch to the Variants view because the robot sequence is empty.
Robot sequence
Robot sequence
InstrucRobot
Peripheral unit
Injection molding maSequence control
Grid
Sequences
structure instructions
3.
In the selection box below Sequences, select Robot complex sequence from robot
sequence and add it to the sequence.
Robot sequence
Robot sequence
Referencing
Home position Home position
Robot - Empty
Robot - Simple Robot empty seRobot - Complex
Robot Teach
4.
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3.4.4
Example:
You want to create a special subsequence, insert the subsequence into the robot sequence
and then program the sequence.
The basis for this is the Simple robot sequence which is located in the Sequence view (white
background).
1.
2.
3.
Click onj the menu gbuttons Program and Create Teach variant.
Automatic mode of operation active
Sequence control
Grid
Sequences
Take-off Standard
Create Teach variant
Delete user sequence
structure instructions
Delete variables
Deactivate
Print sequence
Save
Variants
Program
Edit
View
4.
In the dialog window Create variants , enter a name and if needed a short description
for the variant.
5.
Description
Symbol
Cancel
Help
Execute
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6.
Symbols
Predefined ODS
Cancel
Help
Execute
7.
8.
Description
Symbol
Cancel
Help
Execute
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9.
A new User defined sequence branch, where you can access the sequence, is created
in the selection box in the Sequences branch.
Robot sequence
Robot sequence
Intermediate layers
Robot sequence
Robot - Simple - sequence
Park position
intermediate de-
Execute as long as
Automatic mode of operation ac-
Take-off Standard
Reject deposit
Sprue deposit
If
Reject deposit
Reject deposit
1 Position
Tach grid 1
Tach grid 2
If
Quality control part depositing
process malPart deShot grid
Position
10.
Select the new sequence and insert the sequence at the required position in the
sequence.
Open this sequence and program the required actions.
Robot sequence
Robot sequence
Instruc-
Robot
Peripheral unit
Injection molding maSequence control
Grid
Sequences
structure instructions
Take-off
Standard
Part deposit
Shot grid
11.
12.
All commands for which Display on screen has been enabled, are automatically
displayed on the Robot parameters screen after saving. This is assigned as a
subscreen to the program switch screen.
Robot 1 program switch
Actual position
+
Robot main switch
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REMOVING VARIANTS
You can only remove user-defined variants that are not used in the sequence. You cannot
remove Engel-defined variants.
You can remove user-defined variants in the Teach sequence in the Variants view (light blue
background).
Example:
Removing a user-defined variant from the Teach sequence.
1.
2.
In the sequence selection dialog, change from Robot sequence to Teach sequence.
3.
Use the Variantmenu button to switch to the Variants view. The sequence is displayed
on a light blue background.
4.
5.
6.
weigh scale
Robot sequence
Se-
Subse-
Subsequence properties
Engel
Teach variant
User-defined (2)
Teach variant
Variants
7.
Program
Edit
View
Accept
This removes the scale sequence from the variant pool User-defined sequences.
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3.4.6
2.
Robot sequence
Robot sequence simple - user
Instruc-
Execute as long as
Automatic mode of operation ac-
Robot
Peripheral unit
Injection molding ma-
Take-off
Standard
Sequence control
Grid
Sequences
structure instructions
Delete variables
Deactivate
Print sequence
Save
Variants
Program
Edit
View
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SEQUENCE INSTRUCTIONS
In the selection window the necessary instruction groups are available for the following
functions:
4.1
4.1.1
Robot
Robot move commands, position checks, special instructions, vacuum/compressed air,
cylinder, outputs.
Peripheral unit
Depositing conveyor-belt, standard interface, reject request, cylinder, outputs.
Sequence control
Stop sequence, stop when safety gate requested.
Grid
Shot grid, individual part grid.
Sequences
All sequences and subsequences which are used in the standard sequences.
structure instructions
Teach pointers, branchings, waiting instructions, assignments etc.
ROBOT
ROBOT MOVE INSTRUCTIONS
Robot movements can occur with individual axes or parallel with several axes. There are 2
movement types:
On position
The position is approached exactly and afterwards the next instruction is executed
(Symbol with yellow background)
Start
The movement starts and the next command is performed(icon with green background).
Servoaxes smoove the movements from one position to the next.
NOTICE!
Danger of collision!
By changing a position instruction to a start instruction the following
movements or actions can be released 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.
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Symbol
4.1.2
Name
Function
Robot movement
All 3 linear axes (X,Y,Z) move parallel on different positions which are selected in the condition editor (e.g. Y-on upper swivelling limit
depositing area, X and Z-on depositing position).
As an example this instruction is used for
moving only 2 axes.
Relative movement
Stop movement
Symbol
Name
Function
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Example:
Check current position within range
In the movement to home position sequence, a range is queried and a marker is set to true if
the linear axes are within the range. The branch is queried by the If structure command and
an X single axis movement, which is only executed in this case, is inserted.
Check current position within range
Range 1
If
Range 1
Movement from area 1 - X
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4.1.3
NOTICE!
Danger of collision!
When removing manual axes macroinstructions settings on the Quick
Setup screen page become ineffective.
Symbol
Name
Function
Start
Stop
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Example:
Switch off axis
You need to transfer an injection part to a negative mold mounted on the end of arm tooling.
The Softservo program is not available. The end of arm tooling is robust enough to allow it to
be retracted by an ejector movement.
Take over parts standard user
Take-off vacuum/compressed air circuits
[ON] without monitoring
Switch off axis - Start
X - axis
Ejector
advance
Switch off axis - Stop
X - axis
Mold pause time
Time = 0,3
Ejector
retract
Example:
Rotary axes movements moving out from machine area (Quick Setup)
Moving-out standard
Moving-out position 1
Moving-out position 2
Rotary axes movement moving out from machine area
Speed for move-out position 2 = 100
Stop when safety gate requested
If
Moving-in/out horizontally
Position before
Moving-out standard
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Example:
Rotary axes movements before depositing (Quick Setup)
Moving-in shot grid 1 with conveyor-belt
Position over depositing
Lower swivelling
Wait until
Special instructions rotary axes movement
Shot grid 1 - depositing position screened
Example:
Rotary axes movements after depositing (Quick Setup)
Move from depositing area to machine area
If
Not in the depositing area - over upper swivelling limit
Upper swivelling limit depositing area
Wait until
Special instructions rotary axes movement
Wait until
in the depositing area -
If
Moving-in/out vertically ->
Position before
Home position - XYZ
Manual position
Wait until
Special instructions rotary axes movement after depositing completed before
Move from depositing area to machine area
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4.1.4
Version: G/11/401/1/11
Symbol
Name
Function
Vacuum/compressed air
Vacuum/compressed air
group
barrel
Cylinder group
outputs
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4.2
PERIPHERAL UNIT
Additional functions are activated/deactivated, switched on/off or interrogated.
Symbol
Name
Function
Depositing conveyor-belt
The conveyor belt program itself is not visible. These commands prevent a collision
between the end of arm tooling and the conveyor-belt. In Engel depositing sequences
with conveyor-belt, the commands Wait until
depositing allowed and Part deposited are
programmed.
For special applications the instructions
Stepping and Action are available.
Stepping actuates the depositing conveyorbelt once for the depositing conveyor-belt
running time.
Action switches the conveyor-belt to permanent operation, time-controlled, clearing
or off.
Sequence instructions
Wait until depositing
allowed
Part deposited
Stepping
Action
Standard interface
Depositing instructions
Wait until depositing
allowed
Part deposited
Pick-up commands
Wait until pick-up allowed
Part picked up
Reject request
Request
Option, used in partial sequence Intermediate layer. In the robot setup for this purpose
2 in/outputs each are configured.
Parts are deposited e.g. in an imprinting
machine ( Wait depositing allowed).
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 printing machine receives
a signal indicating that the Part has been
picked up.
barrel
outputs
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4.3
Version: G/11/401/1/11
Only release
After release, the cycle does not wait for the movement to be executed, but continues
with the next command (icons with green background).
NOTICE!
Danger of collision!
Modifying a yellow wait command to a green release command can trigger the subsequent movements or events too early in parallel.
Symbol
Name
Function description
Mold
Ejector
Cores
Air valves
Part is reject
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impact
removal
impact
removal
impact
removal
impact
removal
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impact
removal
impact
removal
impact
removal
impact
removal
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impact
removal
impact
removal
176
4.4
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SEQUENCE CONTROL
Instructions for automatic sequence
Symbol
4.5
Name
Function
Stop sequence
GRID
These functions must be used for the depositing of parts. They refer to shot grid and individual
part grid.
Symbol
Name
Function
Shot grid
At the shot grid (standard depositing) the following instructions can be used:
Increase
Delete
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4.6
SEQUENCES
A pool of all sequences/subsequences for insertion into the robot sequence.
You can replace complete sequences/subsequences in the Variants view. [See Exchange
variants on page 148.]
You can insert or delete complete sequences/subsequences in the Sequence view. [See Insert
sequence on page 158.]
Additional sequences
Symbol
Name
Function
Intermediate layer
Park position
intermediate deposit
Sprue separation
Tach grid
178
4.7
Version: G/11/401/1/11
STRUCTURE INSTRUCTIONS
Special instructions for programming the robot sequence.
Symbol
Name
Function description
Teach pointer
Execute as long as
Repeat until
If
Waiting time
Wait until
Comment
Assignment
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Symbol
Name
Function description
Alarm
Delete alarm
Set position
Increase
Decrease
180
4.7.1
Version: G/11/401/1/11
TEACH POINTER
Used for quick programming of a Teach sequence for special applications. Set the Teach
pointer at a position in the sequence where you need to perform a special sequence or a
specific movement. [See Programming Sequences on page 152.]
4.7.2
EXECUTE AS LONG AS
The instructions in the Execute as long as loop are repeated while the programmed condition
is fulfilled. If the condition is not fulfilled when the program flow reaches the Execute as long
as condition, the instruction that follows the sequence starts immediately.
Example:
In an automatic sequence, you wish to repeat the additional peripheral unit subsequence until
Input 1 of User Package 1 is no longer active.
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4.7.3
REPEAT UNTIL
The instructions in the Repeat until loop are repeated until the programmed condition is
fulfilled. 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.
Example:
In an automatic sequence, you wish to start the additional peripheral unit subsequence at
least once, and then repeat the subsequence until Input 1 of User Package 1 is active.
Additional peripheral
Repeat until
User package 1 Input 1 {FALSE}
Part deposit in shot grid 1 with conveyor-belt
4.7.4
IF
In the sequence one or several conditions are interrogated. These must be selected by the
operator before.
If the condition is {TRUE} the main branch is continued to be processed.
If the condition is {WRONG} the alternative branch is processed.
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Example:
If parts are located at the end of arm tooling after the movement to home position (e.g.: program switch Movement to home position with parts) is activated, the cycle continues at the
end of the sequence.
Take-off Standard
If
Take-off vacuum/compressed air circuits Monitoring of parts active {TRUE}
Move out without part take-off
Jump to sequence end
4.7.5
Example:
After depositing the part on the conveyor-belt, the Y axis must have reached the lower swivelling limit. The peripheral unit must be stepped without waiting in the sequence.
Wait until
Lower swivelling limit depositing area reached
Upper swivelY=0
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4.7.6
4.7.7
WAITING TIME
These times can be used as often as required in the sequence as delays or waiting times. You
can create a time block in a dialog box and display the block on the screen. It is also possible
to use existing robot times.
Example:
After the depositing of parts on the conveyor-belt it must be waited for 0.5 seconds in order to
reduce the vacuum.
Shot grid part deposit 1
Waiting time before depositing
Time=
Depositing vacuum
[OFF] without moni-
Depositing
Time=0,5
4.7.8
Note!
If the time = 0, the command is processed and the sequence continues.
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4.7.9
Version: G/11/401/1/11
WAIT UNTIL
In the sequence it is waited until one or several conditions are fulfilled. It can be waited for
counters, markers, actual positions, set positions, values, etc. The conditions must be
programmed by the operator.
Example:
It shall be checked whether parts are still on the takeover head after depositing. The Y-axis
must have reached the lower swivelling limit.
Move out from depositing with conveyor-belt
Lower swivelling
Y=0
Upper swivelling
Y=0
Wait until
Lower swivelling limit depositing area
reached {FALSE}
[OFF] with monitoring
Depositing conveyor-belt - Part deposited
4.7.10
COMMENT
To make programmed robot sequences more intelligible, operators can add Comments ,
which have no effect on the sequence.
4.7.11
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.
Example:
See condition editor
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4.7.12
Example:
The automatic cycle is started and if e.g. at the movement to home position still molded parts
are on the takeover head, these shall be deposited on the conveyor-belt.
Take-off Standard
If
Take-off vacuum/compressed air circuits one or several with monitoring
Move out without take-off of parts
Jump to sequence end
If
Test part depositing
Reject deposit
1 Position
Quality Control
Position
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4.7.13
Version: G/11/401/1/11
ALARM
When this command is reached in a robot sequence, the selected alarm action becomes
active. The alarm screen displays the alarm text you created previously. Alarm actions can be
set from Immediate system stop to Info.
Example:
For an additional peripheral unit for insert parts, you need to query a signal to determine if
insert parts exist. If the peripheral unit is almost empty, you want to issue an alert for information purposes only. The message text is: Caution! Insert parts for machine xxx running null!
If
User package 1 Input 1 = true
Information
Caution! Insert parts for machine xxx running null!
4.7.14
DELETE ALARM
This command deletes any alarm messages you programmed previously.
4.7.15
SET POSITION
Existing or user-defined positions are used for robot positions programmed in the sequence.
4.7.16
4.7.17
INCREASE
Incrementing a counter or a position by a specific value.
You can use existing counters and positions or create new ones.
This instruction lets you add a stroke to a position, or increment a counter.
4.7.18
DECREASE
Decrementing a counter or a position by a specific value. The functionality is the same as for
Increase.
4.7.19
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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 the If structure command into a sequence, or you double click on an If condition,
the condition editor is launched.
Two variable types are distinguished by the condition editor
5.1
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.
DIALOG WINDOW
Depending on which user level you log in, the Condition Editor dialog box has a variety of
functions.
Type
TRUE
FALSE
CLR
Number
Cancel
Help
DEL.
Execute
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As of user level 9
Operators can program AND/OR operations.
The dialog box is extended to reflect this ability.
Condition editor - If
Type
Robot
Name
TRUE
XOR
NOT
OR
AND
FALSE
Text
MOD
Number
Cancel
Help
CLR
Execute
DEL.
[1]
[2]
[3]
Instruction menu
The created condition can be inserted into the sequence by pressing Execute.
[4]
[5]
[6]
[7]
Name
Renaming of marked user variables.
[8]
Element
Selection tree of all available elements of the selected type.
For each type the user can createuser-defined variables. Those should be named
intuitively to make the sequence clear and easier to read.
Standard system variables cannot be renamed.
[9]
Type
Selection tree for variable types (e.g. markers, counters, digital inputs and outputs, etc.).
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Type
Test signal of digital inputs
and outputs
Marker
Program switch
Status marker
Counter
Values
In structure instructions such as Ifactual values of servoaxes positions can be interrogated correspondingly.
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Assignment functions
TRUE
FALSE
Text
Number
NOT
OR
AND
()
Division
Multiplication
Subraction
Addition
<
smaller
>
larger
<=
>=
equal
<>
not equal
MOD
CLR
<-
DEL
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Condition editor - If
(Rejects counter
> 10)
AND rejects depositing rejects request active
Type
TRUE
XOR
NOT
OR
MOD
CLR
AND
FALSE
Robot
Name
Text
Number
Cancel
Help
DEL.
Execute
Example:
Add structure command Assignment to robot sequence. For the assignment command, create a variable with a Part 1 deposited marker, and set the TRUE condition.
1.
In the selection window, select the Assignment structure command and insert it into the
sequence at the required position.
Assignment
2.
3.
Click Selection.
Assignment
Selection:
variable
value
Name
No condition
Cancel
Help
Execute
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4.
Create
Cancel
Help
Execute
5.
Select the Selection icon and then the Create menu button.
6.
value 1
Type
Values
Cancel
Help
Execute
7.
Change the basic type to Marker and the name to Part1 deposited.
8.
9.
Part 1 deposited
variable
Display on screen page
Robot sequence
value
Cancel
Help
Execute
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10.
TRUE
Type
Digital in and outputs
TRUE
XOR
NOT
OR
AND
Element
FALSE
Robot
Name
Display on screen page
Text
Number
MOD
Cancel
11.
Help
DEL.
Execute
variable
Display on screen page
value
Robot sequence
TRUE
Cancel
12.
Name
Help
Execute
Use the Execute menu button to insert the assignment into the sequence.
Assignment
Part1 deposited {TRUE}
TRUE
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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, or pick-up insert parts.
Grid editor
Robot
Grid
At-
Shot grid
Parame-
Intermediate
Simulation Production
Starting position
Shot grid 1
Shot grid 2
Shot grid 3
Individual part grid
Grid parameters
Grid type
Deposit grid
Distance
Tach grid
Number
Tach grid 1
Priority
Subgrid 1
Shot set
Shot 1
Actual shot
Grid
Edit
Parts sequence
[1]
Status line
Displaying the current axis values.
[2]
Selection tree
Listing of the available grids.
[3]
[4]
View
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GRID TYPES
3 shot grids, 2 individual part grids and 2 Teach grids are available
1.1
SHOT GRID
The robot deposits all parts for a shot simultaneously, that is, all deposit vacuum/compressed
air circuits are switched off on the corresponding grid depositing positions.
Corresponding to number, distance and priority the shot grid arises from several cycles
(shots).
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.
Z-
X+
2
1
[1]
1.1.1
Grid
At-
Parame-
Intermediate
Simulation Production
Shot grid
Shot grid 1
Shot grid 2
Shot grid 3
Element attributes
Name
Shot grid 1
Description
Element attributes
Freely selectable name and short description for the selected element (e.g. Shot grid 1) in the
selection tree.
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Tab parameters
At-
Parame-
Intermediate
Simulation Production
Starting position
Grid parameters
Grid type
Deposit grid
Distance
Number
Priority
Shot set
Actual shot
Starting position
Depositing or pick-up point for first part on grid. Using the starting position and the Grid
parameterssettings, the control unit calculates the depositing position for the individual shots.
Grid parameters
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
negative value moves in the negative axis direction. The sign for the Y distance is set
automatically 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.
Shot set
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.
Actual shot
Actual value for shots deposited/picked up on the grid.
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Example:
-d
is
ta
nc
e
Y - distance
Z
ta
is
-D
e
nc
4
2
[1]
Starting position
Parame-
Intermediate
Simulation Production
Used magazine
Magazine sequence
Intermediate layer
Intermediate layer
Number of layers before intermediate
Special layer
Top layer
Bottom 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. [See Intermediate layers on page 133.]
Used magazine
Magazine sequence
In the standard case only Intermediate layers depositing is available. Selection is
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provided for options.
The intermediate layers program will not work if you select No sequence.
Intermediate layer
Intermediate layer
Program switch for enabling or disabling intermediate layers. Bottom/covering layers
can still be deposited.
Special layer
Top layer
Program switch for enabling or disabling covering layer. After the last parts layer,
another 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.
Example:
Thickness of
intermediate
Y - distance
Shot grid with bottom and covering layers and two intermediate layers.
2
3
4
[1]
Top layer
[2]
Intermediate layer
[3]
molded part
[4]
Bottom layer
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Tab - Simulation/Production
This is a visualization of the set grid. The settings for the grid can be checked immediately
using the simulation program. You can query the current grid status during production in the
Production tab.
At-
Parame-
Intermediate
Simulation Production
2
3
[1]
[2]
Intermediate layers (in this case as bottom and intermediate layers without covering
layer) are depicted as white rectangles.
[3]
Limiting values of the depositing/take-off positions from the first and last shot in X, Z and
Y direction.
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1.2
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.
Z-
X+
2
2
1
[1]
[2]
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Version: G/11/401/1/11
Positions
Intermediate
Sim
Y-moving height
Moving
Grid parameters
Grid type
Deposit grid
Distance
Number
Priority
Shot set
Actual shot
Actual parts
Y-moving height
Moving height
At the selected moving height, 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 at the set Y
movling height, then it moves along X and Z axes on the Y plane to a position above the
next depositing position. When the robot is above the depositing position, the Y axis
moves to this position.
The following parameters are available:
Lower swivelling limit depositing area
Y-moving position absolute
Y-moving position relative
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Example:
Sketch of Y moving height
Y move height
[1]
[2]
Tab - positions
At-
Parame-
Positions
Intermediate
Sim
Vacuum/compressed air
mm
mm
mm
mm
mm
Vacuum/compressed air
mm
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 parameterssettings, the control unit calculates the
depositing position for parts in the individual shots.
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Example:
-d
is
ta
nc
e
Y - distance
Starting positions for two vacuum/compressed air circuits and grid distances.
Z
e
nc
ta
is
-D
[1]
[2]
Available elements
Selected elements
Vacuum/compressed air
Vacuum/compressed air
Cancel
Help
Execute
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 vacuum/compressed air circuit, and move it using the navigational
arrows < and > to insert it into Selected elements in the desired order.
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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. [See
Group configuration on page 84.]
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.
Grid editor
Robot
Grid
At-
Parame-
Positions
Intermediate
Sim
Shot grid
Vacuum/compressed air
mm
mm
mm
3.
Vacuum/compressed air
Press the menu buttons Grid and Configurationto display the Group configuration Vacuum/compressed air circuitdialog box.
Group configuration - Vacuum/compressed air circuits
Available elements
Selected elements
Vacuum/compressed air
Vacuum/compressed air
Cancel
Help
Execute
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4.
Select Vacuum/Compressed air circuit 1 and use the > key to move it to Selected
Elements.
Group configuration - Vacuum/compressed air circuits
Available elements
Selected elements
Vacuum/compressed air
Vacuum/compressed air
Cancel
Help
Execute
5.
Select vacuum/compressed air circuit 2 and move it to the right using the > key.
6.
Available elements
Selected elements
Vacuum/compressed air
Vacuum/compressed air
Cancel
7.
Help
Execute
Grid
At-
Parame-
Positions
Intermediate
Sim
Shot grid
Individual part grid
Individual part grid 1
Vacuum/compressed air
mm
mm
mm
mm
mm
Vacuum/compressed air
mm
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Tab - Simulation/Production
This is a visualization of the set grid. The settings for the grid can be checked immediately
using the simulation program. You can query the current grid status during production in the
Production tab.
Parame-
Positions
Intermediate
Simulation Pr
[1]
Depositing position number for an individual shot (red number in white box). The exact
positions are shown in the Positions tab.
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TACH GRID
Teach grids are the most flexible grids; two are available. A Part sequence is programmed to
reflect the requirements for each part (the smallest element on the Teach grid). This allows the
robot to deposit each part at a different position.
In standard a Teach grid has the following structure
Tach grid 1
Subgrid 1
Shot 1
Part 1
1.3.1
Teach grid x
Consists of a subgrid, of a shot and of a part.
Operators can extend the structure by creating subgrids, shots, or parts.
The depositing order can be modified directly in the structure tree using Edit, Move in
the instruction menu.
Subgrid x
Several subgrids can be created in the Teach grid x.
Shot x
Several shots can be created in the Subgrid x.
Part x
Several parts can be created in the Shot x.
The depositing sequence for a part can be programmed individually in Part sequence
Create
Creates a new subgrid, shot or part.
Delete
Removes a selected subgrid, shot or part.
Move
Change of the Teach grid structure, of subgrid, shot or part. Push marked element in the
selection tree upwards and/or downwards
Note!
Delete all subgrids, shots and parts you do not need for part depositing in the Teach grid from
the selection tree.
Example:
Adding a subgrid to Teach grid 1.
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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
selection tree.
Grid editor
Robot
Element attributes
Grid
Shot grid
Name
Part 1
Tach grid
Tach grid 1
Subgrid 1
Subgrid 2
3.
Press the Grid and Createmenu buttons to display the Create new subgriddialog box.
Create new subgrid
Subgrid name
Subgrid 2
Shot name
Shot 1
Parts name
Part 1
Cancel
4.
Help
Execute
Use the Execute menu button to insert subgrid 2 into Teach grid 1.
Grid editor
Robot
Element attributes
Grid
Shot grid
Name
Part 1
Description
Tach grid 1
Subgrid 1
Subgrid 2
Shot 1
Part 1
5.
Tach grid 2
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PARTS SEQUENCE
In the Teach grid sequence you can program an individual part sequence for each part in a
shot.
The first instruction in the part sequence starts when the sequence reaches the Teach grid x
instruction in the robot sequence.
You must use the Robot movement with grid move instruction for the depositing position in
the part sequence. This tells the robot to rasterize this position only when depositing injection
molding parts as specified in the Grid Editor. Do not use this instruction for any other
movement, unless you want to rasterize these positions too.
Symbol
Name
Function
Example:
In each cycle the robot deposits two parts at different positions. To do this, two parts
sequences have been programmed 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 part sequence for part 1, the part sequence for part 2 starts.
After depositing both parts, the robot continues with the instructions in the robot sequence.
1
If
Moving-in/out horizontally
Position before
Machine area - Max - Z
Part 1
Linear axes position 2
Depositing position 1
Vacuum/compressed air 1
[OFF] with monitoring
Depositing time
Time=1
Lower swivelling limit depositing area
Moving-out standard
Take-off Standard
Part depositing on Teach grid 1 on the conveyor-belt
Depositing conveyor-belt 1 Wait depositing allowed
Tach grid 1
3
Part2
[1]
Robot sequence
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[2]
[3]
Note!
Double click the Teach grid x instruction in the robot sequence to open the Grid Editor
screen.
Programming the Part Sequence
1.
Switch to Teach mode and select a Part in the selection tree on the Grid Editor screen
page.
2.
Selecting the Parts sequencemenu button takes you from the Grid Editor screen to the
Teach grid sequence.
3.
Help
Close
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4.
In the Teach grid sequence, you can program the sequence for a part, or modify an
existing sequence. The Grid Editor menu key lets you go back to the Grid Editor.
Teach grid sePart 1
Instructions:
Part 1
Robot
Peripheral unit
Injection molding maSequence control
Sequences
structure instructions
Grid editor
5.
Program
View
To change from the Teach grid sequence for Part 1 to Part 2 , click on the Part
1selection box.
Teach grid sePart 1
Edit
Instructions:
Robot
Peripheral unit
Injection molding ma-
Part 1
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6.
Help
7.
Close
Select Part 2 and confirm by pressing Closein the Teach grid parts dialog box to display
the sequence for the part 2.
Teach grid sePart 2
Instructions:
Part 2
Robot
Peripheral unit
Injection molding maSequence control
Sequences
structure instructions
8.
Help
Undo
Execute
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.
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Note!
The sequence is saved in the parts data. Therefore rewrite the parts data after saving the
sequence.
1.3.3
At-
Shot grid
Individual part grid
Tach grid
Tach grid 1
Subgrid 1
Shot 1
Part 1
Tach grid 2
Simulation Production
Intermediate
Parame-
Processing
Shot
Subgrid 1
Part
Last Subgrid 1
Shot 1
Part 1
Actual Subgrid 1
Shot 1
Part 2
Next Subgrid 1
Shot 1
Part 1
Act
Set
X
Act
Y
Set
Act
Set
Act
Set
Tach grid 1
Subgrid 1
There is no graphical simulation for a teach grid. The depositing order for subgrids, 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
programmed 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.
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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.
Grid editor
Robot
Grid
At-
Parame-
Shot grid
Intermediate
Grid parameters
Grid type
Tach grid
Deposit grid
Distance
Tach grid 1
Number
Subgrid 1
Priority
Shot 1
Shot set
Part 1
Part 2
Z-
Tach grid 1
Subgrid 1
X+
Shot 2
Shot 1
2
1
Z - Distance
[1]
Part 1
[2]
Part 2
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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.
Grid editor
Robot
Tach grid
At-
Tach grid 1
Subgrid 1
Shot 1
Part 1
Part 2
Subgrid 2
Shot 1
Parame-
Intermediate
Simulation Production
Grid parameters
Grid type
Deposit grid
Distance
Number
Priority
Shot set
Part 1
Part 2
The robot deposits the parts from the first cycle in subgrid 1, and the parts from the second
cycle in subgrid 2.
Z-
Tach grid 1
Subgrid 2
X+
Subgrid 1
Shot 1
1
Shot 1
2
1
[1]
Part 1
[2]
Part 2
[3]
Part 3
[4]
Part 4
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2.
3.
Help
Execute
Choose the requested action and press Execute. When you have chosen Create new
screen or Edit this screen page , the screen page editor starts.
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Example page
Screen page
2
Properties
Strips 1
View
Properties
Speed
Example page
Name
Position
Key
Position
Time
Version
Strips 2
Symbol
Comment
Screen
Edit
Finish
View
[1]
[2]
Properties
Shows the parameters of the element selected in the structure view.
[3]
View
Preview window for the chosen screen page.
[4]
Properties
View
Strips 1
Strips 1
Actual value
Set value
Speed
flag
flag
Strips 2
Comment
Time
Strips 2
Comment
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STRIPS
There are three types of stripes. Depending on the stripe type you have different processing
possibilities.
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.
Change to the screen page which you want to edit. In this case to the Freely
composeable page.
2.
3.
In the dialog window choose Edit this screen page and press Execute.
4.
The screen page editor starts. In the screen page editor you change the settings for this
screen page
Example page
Example page
Properties
View
Properties
Name
Example 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
position 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.
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Robot screens
Robot screens
Quick Setup
General settings
test mode
Home position
Quick positioning
Park position
Status page
Torque monitoring
Cancel
Help
Execute
3.
Select the required strip. In this case the Home position strip on the General
settingsscreen.
4.
Press Execute.
Now you have inserted the strip into your screen page.
2.
3.
Properties
View
Name
Strips 1
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Now you have inserted a new strip into the screen page.
Choose the strip into which you want to insert the variable.
2.
3.
A dialog window appears in which you can select the requested variable.
Select screen
Machine screens
Robot screens
Status page
Torque monitoring
Robot 1 program switch
Robot
Take-off movement
Robot <-> machine
Reject deposit - 1 position
Program switch reject depositing
Quality Control deposit - 1 position
Cancel
Help
4.
5.
Press Execute.
Execute
Now you have inserted a variable from an existing screen page into your screen page.
Choose the strip into which you want to insert the variable.
2.
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3.
A dialog window appears in which you can select the requested variable.
Choose variable from list
System list
%firmware
%KEOPS
%resource 1
%resource 2
AnalogCoordination
Analog
AnaolgResource1
AutoprotectInj1
AutoSequence1
Display text
Cancel
Help
4.
5.
Press Execute.
Execute
Now you have inserted a variable from a list into your mask.
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.
3.
4.
2.
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3.
A dialog box appears where you can move the selected variable.
Move
to top
Up
Down
to bottom
Close
4.
You have now moved the variable to the required position on the screen.
You can move a strip in the same way.
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OPTIONS
1
USER PACKAGE
Consists of 2 cylinders with 4 digital inputs and outputs and 4 freely programmable digital
inputs and outputs. Activation of a cylinder function from the node Robot and/or Peripheral unit
in the corresponding direction + / -, with and/or without monitoring.
barrel
STANDARD INTERFACE
The peripheral unit Standard interface is used in the intermediate layerpart sequence. 2
inputs/outputs each are configured for this purpose in the robot setup.
Parts are deposited e.g. in an imprinting machine (Wait depositing allowed).
Robot moves on waiting position (Part deposited).
When imprinting finished (wait Pick-up allowed), the robot moves on the take-up position and
takes up the parts again.
Following this, the imprinting machine receives a signal indicating that the Part has been
picked up.
Symbol
Name
Standard interface
Depositing instructions
Wait until depositing
allowed
Part deposited
Pick-up commands
Wait until pick-up allowed
Part picked up
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Example:
In the Moving-in standard subsequence, the special robot instruction Take-off stroke correction - 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
MOLD SYNCHRONIZATION
The early start program switch must be enabled.
From the early start position the robot moves into the mold. The takeover head approaches the
mold up to a safety distance and follows the mold opening synchronously. When the mold has
reached the opening stroke, the demolding position is approached by the robot. ENGEL
sequence variant is available.
Example:
Moving in with mold synchronization
Mold synchronization - Start
Take-off safety position
Take-off safety position
Wait until
Mold open
Mold synchronization - Stop
Take-off position - XYZ
EJECTOR SYNCHRONIZATION
The takeover head moves synchronously with the ejector movement. When the X-axis can no
longer follow the ejector speed, the ejector is stopped.
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Example:
Special instruction Ejector synchronizations - Start is inserted before the release instruction
Ejector advance . The x-axis will now move back synchronously with the Ejector advance
movement. Ejector synchronization is stopped at the Ejector advanced.
Take over parts with ejector synchronization
Ejector synchronizations - Start
Take-off position
Ejector
advance
Take-off vacuum
[ON] without moni-
SOFTSERVO
Serves to demold, insert and take up parts with an adjustable torque.
Example:
The ejector presses the molded part on the takeover head at the advance and pushes the Xaxis back. When the ejector is advanced, softservo is deactivated again.
Take over parts
Softservo - start
Torque demolding = -0,8
Move out position 1 - X
Ejector
advance
Softservo - stop
Ejector
retract
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Example:
Picking up insertion parts with built-up clamping force and relative positions.
After Position over moving-out position the mold and the clamping force build-up/reduction
are both locked.
The condition in the If command causes the robot to move to the Pick up insertion part Pick-up position - Y if clamping force is not built up.
If clamping force is built up, the robot moves in X and Z direction by a relative position. The
Insert part pick-up - pick-up position - Y is copied to Memory position - Y , and increased
by the value set in the Increment position (from/by) parameter.
The robot then moves to the calculated Memory position - Y.
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Lower swivelling
Y=400
Wait until
Lower swivelling limit depositing area reached
Manual position 1
C=[ - ]
Mold
enable
Upper swivelling
Y=0
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 clamping force build-up/reduction are released.
Example:
Picking up insertion parts with built-up clamping force and absolute positions.
After Position over moving-out position the mold and the clamping force build-up/reduction
are both locked.
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The condition in the If command causes the robot to move to the Pick up insertion part Pick-up position - Y if clamping force is not built up.
If clamping force is built up, the robot first moves to the X and Z pick-up positions and then to
the Y pick-up position.
Note!
You can program the sequence for pick-up parts, release mold and clamping force build-up/
reduction like in the first example.
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SPRUE SEPARATION
With the insertion of a sprue separation sequence to the robot sequence a separate sprue
separation position can be set for the molded part with 2 moving-in and -out positions.
Sprue separation
Actual position
Sprue separation
Program switch Sprue separation
Speed to moving-in position 1
Moving-in position 1
Sprue separation
Moving-in position 1
Robot position accessed first in Depositing area Z+ to avoid obstacles for sprue cutter.
Moving-in position 2
Robot position accessed after moving-in position 1 to avoid obstacles for sprue cutter.
Delay time
Sprue separation time
Delay time
After reaching the sprue separation position, the sprue cutter waits for this time before
closing.
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Moving-out position 1
Robot position which is approached after the sprue separation position in order to drive
round obstacles.
Moving-out position 2
Robot position which is approached after the moving-out position 1 in order to drive
round obstacles.
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.
Depositing area Z+
Machine area
1
3
6
5
4
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[1]
[2]
[3]
[4]
[5]
[6]
[7]
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INTERMEDIATE DEPOSIT
Intermediate depositing is often used when molded parts have to be rehandled before
depositing on a conveyor-belt or in cartons. Optional hardware, comprising digital I/Os as
interfaces for the individual signals is required.
intermediate deposit
Actual position
intermediate deposit
Program switch - Intermediate deposit
Speed in depositing area
Speed to depositing position
Depositing position
intermediate deposit
Depositing position
Position accessed first by the robot in Depositing area Z+.
Depositing time
Waiting time after depositing the molded part.
Waiting position
Waiting position for robot until molded part pick-up is released.
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Pick-up position
Robot position to which the robot moves to pick-up molded parts again.
Pick up time
Waiting time after picking up a molded part.
Example:
The molded part is deposited on the rotary station. After depositing the part, the robot moves
to its waiting position. While the robot is waiting at the waiting position, the peripheral unit
rotates the molded part through 90. After the peripheral unit has rotated the part, the Pick-up
part released signal is sent to the robot. The robot then moves to the pick-up position to pickup the molded part that has been rotated by the peripheral unit.
3
1
[1]
Depositing position
[2]
Waiting position
[3]
Pick-up position
236
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Version: G/11/401/1/11
Depositing time
Speed from depositing position
Waiting position
Depositing position
Position accessed first by the robot in Depositing area Z+.
Depositing time
Waiting time after depositing the molded part.
Waiting position
Waiting position for robot until molded part pick-up is released.
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Pick-up position
Pick up time
Speed after pick-up position
Pick-up position
Position to which the robot moves to pick-up molded parts.
Pick up time
Waiting time after picking up a molded part.
weigh scale
Weight actual value
Weight within tolerance
weigh scale
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Quick Setup
Actual position
weigh scale
Weigh scale activated
Weight actual value
Weight within tolerance
Weightset value
Negative tolerance
Positive tolerance
Zero tolerance
weigh scale
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 the 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.
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Example:
The robot deposits a molded part on the scales. After depositing, the robot travels to waiting
position and sends a signal to the scales to start weighing. After the weight has been measured, molded part pick-up is released. The robot travels to pick-up position and moves the
molded part either to the depositing position or to the reject position depending on the results.
3
1
[1]
Depositing position
[2]
Waiting position
[3]
Pick-up position
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SPECIAL DESCRIPTION
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Symbols
* Part not deposited 132
*Activate robot set-up mode 101
*Axis - positive/negative axis emergency stop 103
*Axis not referenced 103
*Axis reference switch defective 104
*Axis zero impulse statistics omitted 103
*Axis zero impulse statistics too small 104
*Axis zero impulse statistics warning 104
*Clamping unit safety gate 2 not entirely open 28
*Clamping unit safety gate open 24
*Closing safety - Robot within machine area 80
*Core not moved in 173
*Core not moved out 173
*Ejector not advanced at intermediate position 175
*Ejector not in front 174
*Ejector not retracted 81, 174
*Ejector not retracted at intermediate position 175
*EMERGENCY STOP 23
*Flash card is full 71
*Maximum number of parts exceeded 88
*Mold not closed 173
*Mold not closed at intermediate position 174
*Mold not open 81, 173
*Mold not open at intermediate position 174
*Movement to home position enabled 90
*Nozzle safety gate open 10, 24
*Park position sequence still active 91
*Part lost 125
*Quickpos still active 90
*Robot interlock 81
*Robot motor in setup operations requires level 5 101
*Robot motors switched off 101
*Robot safety gate emergency stop unlocking active! emergency stop acknowledgement required! 23
*Robot safety gate acknowledgement key actuated too fast 28
*Robot safety gate acknowledgement key actuated too long 27
*Robot safety gate acknowledgement key not actuated too long
27
*Robot safety gate not connected 28
*Robot safety gate open 27
*Robot safety gate open-close-acknowledge 27
*Robot synchronous axes work area error 111
*Robot test run without machine active 99
*Take-off invalid - robot was not in the take-off area 80
*Value corrected 72
Numerics
3D view 110
A
Accident prevention 16
Actual axis value display 57
Alarm messages 67
Automatic sequence 140
Axis actual values 43
B
barrel 225
Behaviour in case of fire 29
C
Changing user access authorizations 63
Condition editor 187
Consent keys 36, 46
Control panel machine 31
Control system CC200 31
Control system EC 200 33
Copy parts data set 73
D
Data dialogue 70
Delete data set 74
Delete variables 163
Deleting user access authorization 64
Demolding stroke 12
Depositing area 79
Depositing conveyor-belt 88
Depositing variants 126
Division of the instruction manual 7
Dual-side deposit 108
E
Editing mode active 145
Ejector synchronization 226
EMERGENCY STOP 23
EMERGENCY STOP buttons 23
Engel - take-off variants 119
Exchange variants 148
F
Foil keys on the KETOP C100E 47
Function keys of the KETOP C100E 51
Function keys of the KETOP C30E 37
Function of the safety devices 23
G
General 7
General automation information 11
Grid editor 195
Grid types 196
Group configuration 84
H
Hand control device - Display and navigation 41
Hand control device KETOP C100E 45
Hand terminal - Alarm messages 42
Hand terminal - Display 41
Hand terminal - Status page 43
Hand terminal - Waiting messages 42
Hand terminal function keys 35
Hand terminal robot KETOP C30E 34
Handling tips30 34
Help system 66
Home position 140
I
Individual part grid 201
Input keyboard 58
Insert command manually 155
Insert sequence 158
Instruction manual 7
Instruction manual structure 7
Instructions for Use of Ketop C100E 45
Interactive messages 69
intermediate deposit 234
Intermediate layers 133
M
Machine area 79
Manual buttons on KETOP C30E 35
Mask editor - components of masks 218
Mask editor - Paste a comment 222
Mask editor - Paste new strips 220
244
Mask editor - Paste of existing strips 219
Mask editor - Paste variables from a list 221
Mask editor - Paste variables from existing screen pages 221
Mask editor - stripes 219
Mold synchronization 226
Mount takeover head 105
Moving-in intermediate position 121
Moving-out intermediate position 124
N
Normal position (Bring robot in normal position) 105
P
Park position 91
Part deposit 127
Parts sequence 210
Pictographs 18
Place of work-operating personnel 22
Plant 112
Plant areas 113
Pneumatic axes 13
Position compensation for tiebar-less machines 228
Powering up the robot 101
Print 74
Printing textually and graphically 75
Program keys 57
Program sequence 152
Prohibited area 107
Q
Quality Control part depositing 130
Quick position 43
Quick setting of robot position 92
Quick Setup 79
QuickSet QuickPos 92
R
Read data set 72
Read sequence 141
Reject deposit 129
Removing variants 162
Robot function instructions 170
Robot general settings 89
Robot move instructions 164
Robot overview 12
Robot position checks 165
Robot program switches 97
Robot Safety guarding 26
Robot sequence 140
Robot special instructions 167
Robot status 95
Rotary axes overview 13
S
Safety 15
Safety controls 35, 46
Safety distance for tiebarless machine range 24
Safety equipment 22
Safety gates injection molding machine 24
Safety guarding that can be entered 22
Safety hints 15
Save robot sequence 146
Saving user access authorization 64
Screen keys on the KETOP C100E 50
Screen page editor 217
Screen page editor - Edit screen page 219
Screen structure 56
Sequence 140
Sequence editor 139
Version: G/11/401/1/11
Sequence instructions 164
Sequence instructions - grid 176
Sequence instructions - injection molding machine 172
Sequence instructions - peripheral unit 171
Sequence instructions - robot 164
Sequence instructions - sequence control 176
Sequences 177
Servo axes referencing 102
Servomotor axes 13
Set sequence 145
Set up robot on tool 137
Setup 61
Shot grid 196
Softservo 227
Sprue deposit 132
Sprue separation 231
Standard interface 225
Standards 8
Status display 57
Storage media 71
structure instructions 178
Switching on the system 55
Swivelling limit 81
T
Tach grid 208
Take-off area 79
Take-off Standard 120
Take-off stroke correction 225
Teach preview on manual control unit 42
test mode 146
Text formattings 9
U
USB interface 55
Use as directed 8
User access authorization - login with card 60
User access authorization - password login 60
User accesss authorization 60
User administration 62
User sequence 140
Using the Teach pointer to insert a command 153
V
Vertical stroke 12
W
weigh scale 236
Work area 107
Work area settings 109
Work area setup 107
Work area setup settings 108
Write a parts data set 73
X
X-axis 12
Y
Y-axis 12
Z
Z-axis 12
be the first.