ROBOTIC EQUIPMENT
TMC300Ext Instruction Manual
Valid from serial number 5110265A200000391 2020-12-17
TMC300Ext Instruction Manual
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Copyright and disclaimer
All rights reserved. No parts of this manual may be reproduced in any form without the express written
permission of ROEQ ApS. ROEQ makes no warranties, express or implied, in respect
of this document or its contents. In addition, the contents of the document are subject to change without
prior notice. Every precaution has been taken in the preparation of this manual. Nevertheless, ROEQ
assumes no responsibility for errors or omissions or any damages resulting from the use of the
information contained.
Copyright © 2019 by ROEQ ApS
Contact the manufacturer:
ROEQ ApS
Kobbervænget 5
DK-5492 Vissenbjerg
www.ROEQ.dk
info@ROEQ.dk
CVR: 38656872
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Table of contents
1 Introduction ................................................................................................................................. 5
1.1 Intended readership ..................................................................................................................... 5
1.2 Where to find information ........................................................................................................... 5
1.3 Revision history ............................................................................................................................ 5
2 Safety ............................................................................................................................................ 6
2.1 Overview ...................................................................................................................................... 6
2.2 Safety concept .............................................................................................................................. 6
2.3 General safety instructions .......................................................................................................... 7
2.3.1 Warning notes .............................................................................................................................. 7
2.3.2 Caution notes ............................................................................................................................... 8
2.3.3 Notices .......................................................................................................................................... 9
2.4 Safety circuit ............................................................................................................................... 10
2.5 Safety system specifications ...................................................................................................... 10
2.6 Intended use .............................................................................................................................. 10
2.7 Foreseeable misuse .................................................................................................................... 11
2.8 Risk assessment .......................................................................................................................... 11
2.9 Residual risks .............................................................................................................................. 11
2.9.1 Crush hazards ............................................................................................................................. 11
2.9.2 Low speed collision hazards ....................................................................................................... 11
2.10 Directive conformity................................................................................................................... 12
3 Commissioning ........................................................................................................................... 13
3.1 E-Stop and Reset ........................................................................................................................ 13
3.2 Safety zones ............................................................................................................................... 13
3.3 Alleviating crushing hazards ....................................................................................................... 13
3.4 Use .............................................................................................................................................. 14
3.5 TMC300Ext mounting ................................................................................................................. 15
3.6 SICK setup (Applies for ROEQ Cart300 solutions) ...................................................................... 17
3.6.1 Connecting to the Sick Safe laser scanner system ..................................................................... 17
3.6.2 Setting up COM settings (Sick scanners) .................................................................................... 17
3.6.3 Backup of existing laser scanner configuration (front/rear scanners) Recommended ............. 19
3.6.4 Uploading laser scanner configuration to Sick Safe laser scanners ........................................... 22
3.7 ROEQ cart and docking station mounting .................................................................................. 27
3.8 Setting parameters in the MiR robot ......................................................................................... 29
3.8.1 Setting the distance to marker (for disabling collision checks).................................................. 29
3.8.2 Setting Docking parameters in MiR – only for MiR firmware after 2.4.1 .................................. 30
3.9 Calibration of the MiR robot front laser (Optional) ................................................................... 31
3.10 Create docking station position ................................................................................................. 32
3.11 Global offset adjustment (Optional) .......................................................................................... 34
3.12 Calibration of individual docking station offsets (Optional) ...................................................... 39
3.13 Test of ROEQ supplied SICK safety zones ................................................................................... 41
3.14 Test of ROEQ supplied docking sequence .................................................................................. 42
4 Detailed presentation ................................................................................................................ 43
4.1 Product description .................................................................................................................... 43
4.2 Identification label ..................................................................................................................... 43
4.3 TMC300Ext ................................................................................................................................. 44
4.4 Lock bolt homing button ............................................................................................................ 45
4.5 ROEQ cart components .............................................................................................................. 46
4.6 ROEQ docking station components............................................................................................ 46
4.7 Troubleshooting ......................................................................................................................... 47
5 Technical specifications .............................................................................................................. 48
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5.1 TMC300Ext specifications .......................................................................................................... 48
5.1.1 TMC300Ext – dimensions drawing ............................................................................................. 49
5.2 Cart300 with rails – specifications ............................................................................................. 50
5.2.1 Cart300 with rails – dimensions drawing ................................................................................... 51
5.3 DS100/200P Ext Floor docking station – specifications ............................................................. 51
5.3.1 DS100/200P Ext Floor docking station – dimensions drawing ................................................... 52
6 Maintenance .............................................................................................................................. 53
6.1 Overview .................................................................................................................................... 53
6.1.1 Regular cleaning and inspection ................................................................................................ 53
7 Appendices ................................................................................................................................. 54
7.1 Declaration of conformity .......................................................................................................... 54
7.2 Formulas for calculating the global offsets of the robot ........................................................... 55
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1 Introduction
1.1 Intended readership
The purpose of this instruction manual is to support the system integrator. It assumes a basic level of knowledge regarding the setup process of the MiR robot and software interface. Furthermore, the installation process of both the TMC300Ext and Cart300 requires some level of software knowledge and craftmanship.
This instruction manual contains all necessary information about the installation and usage of TMC300Ext and related equipment.
1.2 Where to find information
On www.roeq.dk, Partner Portal (login required), a wide range of information can be found, e.g.: software updates, instruction manuals, Sick safety zones, 3D CAD files and more.
1.3 Revision history
Document version Date Description 2.01 (this version)
2020.12.17
Creation of docking stations with ROEQ GUI updated for current version of the ROEQ GUI. 2.00
2020.07.23
Product names update from “TMOZ” to “TMC300Ext” and from “CP300” to “Cart300” with rails.
Minor layout updates. 1.00
2019.10.16
First release
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2 Safety
Before installation and operation read the information in this section carefully and pay attention to the safety instructions and warnings.
The CE-approval has been given to the ROEQ system as delivered from ROEQ and installed on MiR100/MiR200. Any additional modifications will require a new risk assessment of the specific configuration.
2.1 Overview
This manual contains notices to be observed to ensure personal safety and to prevent damage to property. The notices referring to personal safety are highlighted in the manual by a safety alert symbol. The notices shown below are graded by signal words to indicate degree of danger.
The ROEQ products are intended to be used with MiR100/MiR200 robots.
Read the MiR manual carefully before commissioning the combined solution.
In the following some safety issues may be identical to sections of the MiR user guide.
2.2 Safety concept
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2.3 General safety instructions
This section contains general safety notes. Some safety notes are repeated or further specified in
other sections of the manual and further safety notes are present throughout the manual.
2.3.1 Warning notes
• Ensure proper mounting of load during transport
Danger of personal injury from overturning robot or falling load.
All accessories and loads mounted on top of the robot/cart should be fastened responsibly and meet specifications stated in section 6.
• Avoid leakage of fluid during transport
Danger of personal injury from leaking fluid.
Make sure that loads containing fluids do not leak during transport.
• Update maps to avoid hazards on the route
Danger of personal injury and/or damage to the robot.
Make sure to update maps to avoid driving in hazardous zones such as close to stairways.
• Do not drive vehicle irresponsibly
Danger of personal injury and/or damage to the robot.
The robot should not be driven over edges or in other ways operated irresponsibly.
• Where to place
Avoid driving in areas with obstacles and always keep all drive paths clean and free for obstacles.
Avoid placing docking stations on slopes.
Always check weight/speed/slope conditions before commissioning.
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2.3.2 Caution notes
• Do not use the robot or cart to transport people
Risk of personal injury and/or damage to the robot.
The robot or cart should never be used to transport people. This will revoke compliance with the applied standards.
• Avoid gradients above 5% on the route
Risk of personal injury and/or damage to the robot.
The surface grade (ramps etc.) cannot exceed 5% as this may cause the robot to skid.
• Only drive on even and dry surface
Risk of personal injury and/or damage to the robot.
Wet and uneven surfaces may cause the robot to skid.
• Do not overload the robot or cart
Risk of personal injury and/or damage to the robot/cart.
Maximum payload for all ROEQ products are stated in section 6.
• Do not use the robot/cart on board ships
Risk of personal injury and/or damage to the robot.
Unstable surface caused by moving vessel may cause the robot to skid.
• Turn off the robot before removal or installation of the TMC300Ext
Risk of personal injury and/or damage to the robot or ROEQ equipment.
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2.3.3 Notices
• Indoor use only
Risk of damage to the robot and/or cart.
The robot and cart are made for indoor use only and should never be used outdoor.
• Avoid small objects on the floor in the robot’s area
Risk of property damage and/or minor damage to the robot.
The robot cannot detect obstacles lower than 50mm and may overrun smaller objects.
• Remove unwanted object from the floor in the robot’s area
Risk of inefficient execution of orders.
The robot will go around objects that are not part of the map, but this may influence the efficiency of the planned route.
• Avoid overheating of components
Risk of damage to the robot or robot components.
The ambient temperature in the robot’s environment must not exceed 50 degrees Celsius - 122 degrees Fahrenheit.
• Avoid exposure of the robot to excessively humid or dry environment
Risk of damage to the robot or robot components.
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2.4 Safety circuit
The TMC300Ext employs the safety circuit installed in the MiR robot. The same safety principles apply when a ROEQ top module is installed, as are valid when the robot operates in isolation. That is the robot is installed with optical safety zones so that if a person or other moving object enters these zones, the robot will be forced into emergency stop. To operate the robot with a ROEQ top module and ROEQ carts, the default safety configuration of the robot needs to be updated. The residual risks of this updated safety configuration are summarized in section 2.9.
When using ROEQ equipment that extends beyond the extend of the robot e.g. a top module or a top module with a cart, the robot will automatically change to larger footprint based on the size of the equipment. Changing to larger footprint and larger safety zones are managed by Sick Safety components.
MiR100/200 is designed with redundant electrical safety circuit including Sick Safety components. If any internal errors in the safety circuit occur, the robot will immediately go into emergency stop which means that all moving parts will be voltage free by mechanical disconnection. Only when the redundancy is provided, it is possible to reset the emergency stop and continue.
For more information, refer to MiR user guide and sections 2.5 and 3.6 in this instruction manual.
2.5 Safety system specifications
When equipping a MiR100/MiR200 robot with a ROEQ TMC300Ext top module it is paramount to install the enclosed updates for the SICK safety system.
The TMC300Ext exceeds the physical size of the MiR100/MiR200 robot and therefor the standard safety zones supplied by MiR does no longer suffice.
To uphold the safe behaviour and the general functionalities of the system, the proprietary ROEQ safety configuration must be installed.
After installing the ROEQ safety configuration, the TMC300Ext equipped MiR100/MiR200 robot will furthermore become able to automatically adjust the width of the safety zones when driving with or without carts.
See section 3.6 for detailed instructions on how to update the SICK Safety System.
2.6 Intended use
The ROEQ product portfolio of MiR accessories are intended to be installed onto a suitable MiR robot. Apart for ROEQ specific requirements stated in section 4.7, the use of the ROEQ products are restricted by the limitations provided by MiR.
The TMC300Ext is intended to be commissioned and used in indoor industrial environments where access for the public is restricted.
The TMC300Ext top module is intended for transporting e.g. euro pallets, and other large size cargo. The cargo must be placed correctly in the rails.
When using ROEQ top modules and accessories (carts, racks, etc.) the size of the robot with attached units can result in larger application than the robot itself. For ROEQ standard applications this is handled by changing the footprint by the ROEQ generated missions and changing safety zones by a built-in safety switch in the top modules.
In each installation, end-user applications that are mounted on the ROEQ standard accessories must meet the limitations of use of these or if the end user application require increased footprint or safety zones that has to be changed/implemented by the commissioning part before use of the products.
Also, it is the responsibility of the commissioning part/company to ensure that the full/entire/combined installation including, but not limited to; top modules carts, docking stations, receiving stations etc. are covered by a risk assessment before commissioning.
Combined machines (here robot and top module) must be fitted with a new identification label for the combined machine.
Depending on the environment (trained/non-trained personal) where ROEQ docking stations are to be used in, "Operating hazard zone" marking on floor might be required.
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2.7 Foreseeable misuse
The ROEQ product portfolio of MiR accessories are intended to operate in the same conditions as the MiR100/MiR200 robots.
For MiR robots foreseeable misuse – refer to MiR specifications/guidance.
Any use or application deviating from the intended use stated by ROEQ is deemed to be misuse. This includes, but is not limited to:
• Overloading of the robot and top applications
• Failure in commissioning robot and accessories
• Failure to make a risk assessment of the full installation
2.8 Risk assessment
The ROEQ product portfolio of MiR accessories are intended to operate in the same conditions as the MiR100/200 robots.
For information about MiR robots Risk assessment – refer to MiR specifications/guidance.
Always make sure to make a risk assessment in order to achieving a safe installation. Performing the risk assessment is the responsibility of the individuals who are commissioning the system (robot, accessories, top application, end-user interface) in the environment it will be used in.
2.9 Residual risks
The ROEQ product portfolio of MiR accessories are intended to operate in the same conditions as the MiR100/200 robots.
For Residual risks for the robot, refer to MiR specifications/guidance.
For the ROEQ top module, the residual risks and potential hazards outlined below has been identified. These must be considered during integration and commissioning of the product. Some suggestions for this are included in section 3.
2.9.1 Crush hazards
It is potentially possible for a person to position his body or body parts, e.g. hands and feet, in a fashion that could result in it getting caught/crushed by the robot while docking or undocking from stations.
Stay clear of the docking stations while the robot docks or undocks. Mark the docking stations as hazard zones, following the description in section 3.3.
The residual risk related to this has been deemed acceptable, as the docking zone is considered a hazard operating zone. Further, the robot docks at very low speed and is therefore easy to avoid.
2.9.2 Low speed collision hazards
The ROEQ TMC300Ext module is larger than the footprint of the robot. The size of the TMC300Ext thus implies that it is installed with an overhang with respect to the robot. To allow the robot to dock into docking stations and automatic chargers despite this overhang, the low speed safety zones around the front of the robot, does not cover the front of the top module, as the robot would otherwise go into emergency stop when getting close to a dock or charger. This is illustrated in Figure 1 where the front of the smallest zone is dashed, to indicate that it follows the edge of the robot, and not the edge of the top module. Notice that it is only the low-speed (< 20 cm/s) safety zones that do not include the front of the top module. The TMC300Ext is fully covered while the robot drives at normal speed.
The reduced low-speed safety zone implies that the robot will not stop if a person jumps in front of it while going at low speeds (<20 cm/s), as this person will not trigger the safety zones. This is only the case if the robot moves straight ahead such as to dock. If the robot starts to turn, as it usually would if it is navigating at low speeds, the safety zones are enlarged to cover the full TMC300Ext footprint.
The residual risk concerning this has been deemed acceptable as any collision would happen at very low speed, at which the damage is minimal, and the robot is easy to avoid.
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Figure 1 Safety zones with and without cart. The faster the robot moves, the larger the active safety zone becomes.
To prevent the robot from going into e-stop on account of the legs of the cart, two small cutouts have been made to the scanner zones when driving with a cart. These cut-outs are also shown in Figure 1.
These cut-outs imply that it is potentially possibly for a person to place his foot in a way so that it will be run over by the wheels of a cart.
The residual risk pertaining to this has been deemed acceptable, as it is highly unlikely that this will happen while the robot is moving, and if the robot is standing still, it will require an almost deliberate action of the person.
2.10 Directive conformity
The TMC300Ext has been designed and manufactured in accordance to EU directive 2006/42/EF - Directive of Machinery.
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3 Commissioning
A full installation involves following steps:
1. TMC300Ext mounting Section 3.5
2. SICK setup Section 3.6
3. Mounting of docking station Section 3.7
4. Setting parameters in MiR robot Section 3.8
5. Calibration of front laser (SICK) Section 3.9
3.1 E-Stop and Reset
Please note, that after installing the TMC300Ext on the MiR, the Emergency-Stop and the Reset button are now operated from the TMC300Ext. There are two (2) Emergency stop buttons on the TMC300Ext, one on the front panel and one on the rear panel. The Reset button is located on the rear panel.
Figure 2. Emergency stop button (to the left) and Reset button (to the right).
3.2 Safety zones
When using top modules for carts the robot will automatically change safety zones when carrying carts. This requires that the safety configurations supplied with the TMC300Ext are installed on the MiR robot and the function verified before using the MiR-ROEQ combination.
When the robot drives without cart the robot will use standard safety zones (Figure 1 left) but when driving with cart the robot will automatically change to enlarged safety zones (Figure 1 right).
Please note that it is always the responsibility of the commissioning part/company to ensure that the safety zones cover the size of the end-user application.
3.3 Alleviating crushing hazards
TMC300Ext includes docking stations at endpoints to collect/deliver carts. Despite various risk mitigations implemented in the design, safety zones, footprint etc. there is a potential risk of getting pinned between docking stations and the robot.
To avoid potential personal injuries, it is recommended to instruct the employees/personal that are using and or working close to the system. It is also recommended to mark the area in front of the docking stations as “potential hazard zones” e.g. by using “hazard” tape on the floor.
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Figure 3. Marking of potential hazard zones.
3.4 Use
After setting up the ROEQ system including generating missions by using the ROEQ program all general operations of the ROEQ system are controlled by missions in the MiR standard interface.
Figure 4. ROEQ software in the MiR interface.
In addition to this instruction manual, a number of videos for selected steps can be found on the enclosed USB-drive and on Partner Portal (www.roeq.dk). Log-in is required.
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3.5 TMC300Ext mounting
This section describes the unpacking and mounting process of the TMC300Ext. Step Instruction Illustration 1.
Remove the inspection plate by unscrewing the T20 bolts highlighted on the illustration.
When the inspection plate has been dismounted, remove the yellow cable tie to free the 4 top module cables.
NOTE: Never lift the TMC300Ext in the Emergency Stops.
NOTE: Due to the size and weight of the TMC300Ext it is recommended that two persons lift it up from the packaging. 2.
Carefully lift the TMC300Ext from the crate and place it on an elevated platform (e.g. a table or pallet) to access the underside of the TMC300Ext.
3.
Remove the 4 bolt-access cover plugs by using a large flat-tip screwdriver.
4.
Remove the 4 white plastic M10 top nuts from the pre-mounted M10 bolts.
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5.
Place the TMC300Ext on top of the MiR100/MiR200 robot.
To connect the 10-pin connector and Wi-Fi cable, the TMC300Ext must initially be placed slightly towards the front of the robot as illustrated until adequate accessibility has been obtained.
6.
When the two cables have been properly connected, carefully slide the TMC300Ext towards the rear end of the robot until the ethernet- and 4-pin connectors align with the TMC300Ext base plate cut-out as illustrated.
7.
Fasten the TMC300Ext to the robot by tightening the four pre-mounted M10 bolts highlighted on the illustration using 6mm hex key.
Carefully connect the 4-pin and ethernet connector to the robot interface.
8.
After tightening the bolts and mounting all cables reinstall the 4 bolt-access cover plugs into the holes in the top plate and remount the inspection plate.
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3.6 SICK setup (Applies for ROEQ Cart300 solutions)
This describes the Sick Safe s300 laser scanner configuration to get started with the ROEQ cart system.
3.6.1 Connecting to the Sick Safe laser scanner system
Since the Sick Safe laser scanners are interfaced with their own software, Sick Flexi Soft Designer and Sick CDS software must be installed on the PC used for the SICK setup. All software necessary for the implementation of the TMC300Ext is included on the enclosed USB-drive. Sick Flexi Soft Designer utilizes CDS to configure the scanners.
Note: It is highly recommended to back up (upload) existing safety zones from the Main Module and both Front- and Rear laser scanners before transferring (download) the new safety zones. This is described later in this instruction.
Definition of terms in the Sick program:
• Download to scanner: Here the laser scanners are the units to be downloaded to (will be stored on laser scanners).
• Upload to PC: Here the PC connected to the robot (laser scanners) is the unit to be uploaded to (will be stored on PC)
3.6.2 Setting up COM settings (Sick scanners)
This section describes the procedure for getting connected to the Sick Safe laser scanner system.
These steps are also described in a video enclosed on the USB-drive.
9.
After installation of the TMC300Ext the Reset Button, Emergency Stop and Antenna are now situated on the TMC300Ext.
Step Instruction 1.
Log on to the robots Wi-Fi. 2.
Connect to the robot via web browser: mir.com Step Instruction Illustration 1.
Copy the content of the USB-drive to the hard-drive on the PC.
2.
Start the program Sick Flexi Soft Designer from the PC.
3.
A connection must be configured to connect the PC to the scanners.
Start the connection setup by clicking “Com settings”.
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4.
The connection settings window will appear. A TCP/IP connection is required between the PC and the scanners.
Click “Add TCP/IP connection profile”.
5.
To create the new profile, fill out the entry name and set the IPv4 address to 192.168.12.9, which is the IP of the scanners.
Click “OK”.
6.
Click the check mark to test the connection.
When the connection is accepted, mark the connection as default by double clicking the connection.
Click “OK” to terminate the setup.
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3.6.3 Backup of existing laser scanner configuration (front/rear scanners) Recommended
This section describes the procedure for taking backup of existing Sick configurations before transferring the ROEQ Sick configuration from the enclosed USB-drive to the Sick Safe laser scanner system.
Step Instruction Illustration 1.
Click “Connect” to connect to the main Module.
When the connection is done (takes some time), the SICK main Module will be ready for doing the backup.
2.
You may be prompted with a warning that the physical system is different than that of the configuration plug.
This is because the same safety configuration is suitable for different variations of the safety hardware.
Select “Continue upload with physical system configuration”.
3.
Select YES to: Do you want to upload the configuration on “SICK Flexi Soft main module FX3-CPU1”?
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4.
Double click the front laser (S300.CPU1[0].EFI1.1)
5.
Select “Read configuration from device”
6.
Repeat step 3 and 4 for taking backup of the rear scanner
Double click the rear laser (S300.CPU1[0].EFI2.1)
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7.
Finally select “Save as” in the project drop down window and save the original configuration on the PC.
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3.6.4 Uploading laser scanner configuration to Sick Safe laser scanners
This section describes the procedure for transferring ROEQ configurations from the enclosed USB-drive to the Sick Safe laser scanner system.
It is highly recommended that the files stored on the enclosed USB-drive are saved in a local folder on the PC used for the SICK setup, before continuing with the following step.
Step Instruction Illustration 1.
Open the project:
Project → Open → choose the project file “ ROEQSICKMiR100V2.0.0_cp300.fsp” or “ ROEQSICKMiR200V2.0.0_cp300.fsp”
from the SICK-folder on the USB-drive.
Note:
Be sure to select the configuration suitable for your robot model and serial number.
2.
Click “Connect” to connect to the main Module.
When the connection is done, the SICK main Module will be ready for transferring the desired safety zones.
Remark:
You may be prompted with the same hardware warning as described previously.
Choose “Continue upload with physical system configuration” as before.
3.
Click “Transfer the configuration” to transfer the new safety zones to the main Module and the two S300 laser scanners.
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4.
Make sure that both S300 scanners and the main Module are marked and click “OK”.
The password for uploading the new safety zones is:
SICKSAFE
5.
Please check the configuration protocol carefully for both scanners and proceed by clicking “Release”. These can be saved if needed.
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6.
Although the old main Module is verified, click “yes” to download the new configuration, and run the new head device.
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7.
Verify the new checksum by clicking “yes”.
8.
Mark the option for Authorized Client user group and click “OK”.
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For further information, see Flexi Soft Gateway Operating Instructions chapter 4. 9.
Select “Upload and verify result”
And “Yes” to finalize the process.
Remark:
If you have previously uploaded a ROEQ safety configuration to the robot, the “Upload and verify result” button may not be visible. In this case, confirm that the configuration is already verified. This is written in the lower right corner of the Flexisoft window.
10.
Select “Disconnect” before closing the program.
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3.7 ROEQ cart and docking station mounting
This section describes the unpacking and mounting process of the ROEQ cart and docking station.
Step Instruction Illustration 1.
Fasten the docking station firmly to floor.
2.
The docking station must be anchored to an even/smooth surface.
Make sure the docking station is parallel to the floor and levelled vertically.
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3.
The bottom plate of the docking station has 6xØ8,2 mm anchor holes.
To access these, the back plate of the docking station must be removed.
4.
If manual undocking is needed, turn the two handles on the docking station 90° and pull the cart away from the docking station.
Remove
Remove plateplate
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3.8 Setting parameters in the MiR robot
A few parameters need to be updated in order to optimize the docking with the ROEQ system.
3.8.1 Setting the distance to marker (for disabling collision checks)
Step Instruction Illustration 1.
Connect to the robot via web browser: mir.com
2.
In the MiR web interface, go to:
System → Settings → Docking and click
“Show advanced settings”.
3.
Change the value in “Distance to marker for disabling collision checks.” to 2.
Note: This will allow the robot to dock to a docking station when equipment is attached.
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3.8.2 Setting Docking parameters in MiR – only for MiR firmware after 2.4.1
Step Instruction Illustration 1.
In the MiR web interface, go to: System → Settings → Docking and click “Show advanced settings”.
2.
Change the value in “Parameter for driving more straight during docking” to 0.01
Note: This will ensure that the robot drives more straight while docking.
3.
Change the value in “Relative move target when docking to markers.” to 1.5
Note: This will ensure that the robot drives more straight while docking.
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3.9 Calibration of the MiR robot front laser (Optional)
It might be necessary to perform a calibration of the front laser scanners (Sick) to obtain a more stable docking performance.
These steps are also described in a video enclosed on the USB-drive.
Step Instruction Illustration 1.
Start the calibration of the robot by calibrating the front and rear scanner.
Go to: System → Robot setup → Calibrate front scanner
2.
Additional information for calibration of laser scanner
• Reset the scanners before the calibration
• Measurements are made from the outermost glass of the laser scanners (not the metal plate underneath the scanners)
• All four swivel wheels shall be orientation in same directing prior to calibration and throughout the calibration (For front scanner calibration drive the robot a little forward prior to calibration to align the wheels. For rear scanner calibration, drive the robot a little in backwards prior to calibration)
• Measurements are in meters with three decimals
• Iterate until there are no red figures left
• Reset the scanners and reboot the robot if there are no improvements in the calibration after 5-6 iterations, start over from step 1 if this occur, otherwise “wrong” calibration will be accumulated
• After calibration, the MiR must be restarted
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3.10 Create docking station position
In order to create a docking station, the MiR user interface is used.
These steps are also described in a video enclosed on the USB-drive. Step Instruction Illustration 1.
Drive the robot manually to the desired docking station. The robot needs to be within a distance of 1 meter approximately.
2.
Use the built-in MiR function to create a marker. The icon can be found at the top of the MiR map.
3.
Choose VL-marker and use the button in the bottom of the window to detect the VL-marker.
IMPORTANT
The name of the VL-marker must be “ROEQ_Docking X os_cart”
Where Docking is spelled with a capital letter, X is the name of the station, and can be both letter and numbers
If this naming convention is not followed, the ROEQ program for calibrating docking stations will not be able to find the new docking station.
4.
Run the supplied ROEQ program.
5.
Choose “Add new docking station”
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6.
Choose “TMC300Ext” from the drop-down menu
Remark:
The rest of the options refer to other ROEQ products. Contact ROEQ sales department for information on these products.
7.
Select the docking station you created in step 3.
Next click “Create docking station”. A new VL-marker is created and the offsets and entry points for both markers is set to ROEQ’s predefined values. If these values or points are changed, the docking sequence will not work.
“Create all stations” will install all uninstalled docking stations. An uninstalled station is defined as a station that consists of the original VL-marker position and no belonging missions.
8.
The entry point for the docking station is predefined to be at a distance of 1.5 metres from the final destination. Make sure not to change the entry point of the docking station. Always click cancel at the edit page of the docking station. The entry point will be changed even if the values are not changed.
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3.11 Global offset adjustment (Optional)
These steps are also described in a video enclosed on the USB-drive. 9.
In the MiR interface, mir.com.
Go to setup/missions.
Select the “ROEQ Utility” mission group and run the “ROEQ_OS_Footprint mission”
This mission will change the current footprint of the robot to fit the TMC300Ext.
Info
Please note that the docking station (docking points) generated here are only stored in the active map on the MiR robot.
If multiple maps are used docking points must be generated in the individual maps/sites.
Step Instruction Illustration 1.
This adjustment will minimize variation in end position between the individual robots.
Three measurements, a, b and c, should be carried out 5 times each.
2.
On each side of the front of the TMC300Ext, locate the bend of the black steel trim
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3.
Measure out a distance of 35 mm from the bended black steel edge and make a mark on the top plate of the module
4.
Repeat the process on both right and left side in the front end of the TMC300Ext.
5.
Draw a line between the two points using e.g. paper-tape that may be removed afterwards
6.
Mark the mid-point of the robot
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7.
Drive the robot into a docking station by select the docking station on the Map and select “GO TO”.
(without a cart)
8.
Place a straight object across the gap in the docking station, e.g. a ruler or similar, to provide a reference for measuring distance.
9.
Mark the centre of the Docking station.
10.
Measure the a-value.
a-value = distance from point marked on the TMC300Ext front left corner to the docking station.
(Robot x-direction)
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11.
Measure the b-value.
b-value = distance from the point marked on the TMC300Ext front right corner to the docking station.
(Robot x-direction)
12.
Measure the c-value.
c-value = distance from mark made on the TMC300Ext centre to Docking station centre.
(Robot y-direction)
y ← positive direction (positive c- value)
y → negative direction (negative c-value)
13.
Repeated the procedure five times (dock into docking station five times and measure a, b and c- values).
An example of the fifteen measurements is given to the right. Docking #
a
b
c 1
68.23 mm
64.67 mm
-1.05 mm 2
71.31 mm
68.48 mm
-1.23 mm 3
73.56 mm
70.41 mm
-2.92 mm 4
68.48 mm
64.87 mm
-1.41 mm 5
68.65 mm
64.85 mm
-0.88 mm
14.
Calculate the means 𝑎̅, 𝑏̅
and 𝑐̅ as 𝑥̅=15⋅Σ𝑥𝑖5𝑖=1
𝑎̅
𝑏̅
𝑐̅
70.05 mm
66.66 mm
-1.50 mm
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15.
Use the supplied ROEQ program.
Note:
The ROEQ program v4.9.5 is for MiR v2.6.0 and up.
For a version of the ROEQ program compatible with older MiR versions, contact the ROEQ support team.
16.
In the top left corner click “Calibration”.
17.
Type the calculated means [mm] from above steps. Finish by clicking “Calibrate robot”.
18.
Restart the robot to implement new global offsets.
19.
Note: If you operate more than one robot, this calibration should be performed with the same Docking station for all robots.
Info
Same procedure applies for floor mounted docking station and docking stations with
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3.12 Calibration of individual docking station offsets (Optional)
Individual calibration of a docking station can be performed if uneven performance is discovered on one or few docking stations. Measurements are carried out in same way as in the previous section.
docking bolts (shown here).
Optional
The calibration can be done manually:
In the MiR web interface, go to System → Settings → Calibration
Specify the new global offsets, using the 4 most significant decimals, and save the changes.
Step Instruction Illustration 1.
Use the supplied ROEQ program.
Note:
The ROEQ program v4.9.5 is for MiR v2.6.0 and up.
For a version of the ROEQ program compatible with older MiR versions, contact the ROEQ support team.
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2.
Click “Update existing docking station”.
3.
From the dropdown menu choose the docking station selected for calibration.
(If you have chosen an ID above 30, you will need to modify the range of stations the program searches for. Use the “Modify range” button for this purpose.)
4.
Supply the program with the mean values from the measurements of a, b and c in millimetres [mm].
Finish by clicking “Calibrate docking station X Y”. This will update the offsets for the individual docking station.
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3.13 Test of ROEQ supplied SICK safety zones
Step Instruction Illustration 1.
Run the “ROEQ_Get cart ID“ mission. The mission can be found under Setup → Missions and in the ROEQ cart mission group. The robot should now get the cart. Wait for the robot to leave the docking station.
2.
The cart should now be attached to the robot. Put a box besides the attached cart to check if the robots state is changed to “emergency state”.
3.
Make sure that the box is touching the cart.
4.
If the robot does not change state to “emergency state”, the SICK zones will have to be reinstalled.
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3.14 Test of ROEQ supplied docking sequence
Step Instruction Illustration 1.
Drive the robot to a random position a few meters away from the VL-marker. Use the joystick, located in the upper right corner of the MiR control panel (See icon in illustration).
2.
Run the “ROEQ_Get cart ID“ mission. The mission can be found under Setup → Missions and in the ROEQ cart mission group. The robot should now get the cart. Wait for the robot to leave the docking station.
3.
The robot should now be attached to the cart. Manually drive the robot around for a short while. Then drive the robot to a new position a few meters away.
4.
Run the “return cart” mission.
Info
Please note that the missions generated by the ROEQ program are only stored in the active map on the MiR robot.
If multiple maps are used docking points and missions has to be generated for each maps/sites.
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4 Detailed presentation
4.1 Product description
The TMC300Ext is an accessory for the MiR100/200 which allows the robot to transport ROEQ carts and other ROEQ products.
The TMC300Ext works in conjunction with the software embedded on the MiR robot and acts as an extension of the robot’s autonomous capabilities.
After installing the TMC300Ext on Top of MiR100/200 the robot can attach and detach itself to the ROEQ cart and deliver it at locations specified by the user.
The TMC300Ext is fully compatible with MiR100 hardware version 2.0 and MiR200 hardware version 1.1 and newer versions.
4.2 Identification label
The identification label of the TMC300Ext is placed here:
ROEQ ApS
Kobbervænget 5
DK-5492 Vissenbjerg
Denmark
Serial number: XzzzyyyAxxxxnnnnn
Made in Denmark 2018
- CE ROEQ ApS declares that TMC300Ext meets the
requirements of the applicable EC directives. See Declaration of conformity in Appendix 7.1.
- Serial number A unique serial number is given to all CE approved ROEQ products.
• X refers to the product variant
o 1 = top module carts
o 2 = top module lifter
o 3 = top module rack
o 4 = permanently attached cart
o 5 = extended
• zzz states the hardware version
• yyyAxxxx is the ROEQ product code
• nnnnn is the sequential number
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4.3 TMC300Ext
Pos. Description Pos. Description 1
Emergency stop button 5
Top plate 2
Protective guard 6
Access lid 3
Mounting bolt access plug 7
Lock bolt 4
Wi-Fi antenna 8
Protective side fender
Pos. Description Pos. Description 1
Lock bolt homing button 3
Connection access 2
Reset button 4
I5 override button 5
Top nut for thread protection
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4.4 Lock bolt homing button
This section describes how to use the lock bolt homing button to manually retract the locking bolts (see Table 1).
Table 1:Top view of ROEQ Top Module with locking bolts in retracted position (picture A) and in extracted position (picture B): Note: The depicted product is TMC300.
If needed, the lock bolts can manually be retracted by using the lock bolt homing button.
The lock bolt homing button is placed at the rear end of the MiR robot, underneath the left corner of the top module (see Table 2).
Table 2:Placement of the lock bolt homing button, marked with a red circle. Note: The depicted product is TMC300.
Picture A Picture B
Picture A Picture B
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4.5 ROEQ cart components
Pos. Description Pos. Description 1
Caster wheel 4
Corner attachment point 2
Cart main frame 5
Locking mechanism attachment point 3
Docking bolt interface (optional) 6
Ball docking interface (optional)
4.6 ROEQ docking station components
Pos. Description Pos. Description 1
Docking bolt 4
Docking station front plate 2
Docking bolt housing 5
V-marker for MiR 3
Docking bolt release handle
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4.7 Troubleshooting
For the operator to be able to retract the locking bolts, the MiR robot must not be in a state of emergency. The lock bolt homing button (section 4.4) is only functionally when the robot is ready to operate.
If the lock bolt homing procedure has been interrupted during execution or the homing button is not responding, the TMC300Ext must determine the lock bolts point of origin.
This is done by pressing and holding the homing button for 5 seconds. Release the homing button and the TMC300Ext will begin to determine the lock bolts point of origin.
If this procedure has been carried out successfully, the homing button is now functional.
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5 Technical specifications
5.1 TMC300Ext specifications
General specifications related to the dimensions and performance of TMC300Ext installed on MiR100 or MiR200
Communication
Connection between TMC300Ext and MiR
Ethernet, TCP/IPv4
Dimensions
Length
1200 mm (emergency stop buttons not included)
Width
606 mm
Standard height
78 mm
Height above floor after installation on MiR
430 mm
Weight (without load)
45 kg
Color
Machined aluminium and matt black Environment
Ambient temperature range
+5 degrees Celsius to 50 degrees Celsius (humidity 10-95% non-condensing)
IP class
IP 20 Safety compliance and approvals
Compliance with
CE certified Loading specification
Max height from floor to Top
1800 mm (Top camera required)
Centre of gravity
Lower than 900 mm above the floor
Centre of load mass
As close to robot centre as possible - eccentric loading can cause undesirable performance and mission failure.
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5.1.1 TMC300Ext – dimensions drawing
Figure 5.
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5.2 Cart300 with rails – specifications
The TMC300Ext works in a setup were the cargo extends up to 1200 mm. E.g. with the ROEQ Cart300 with rails mounted on top:
The following specifications are additions to the general specifications stated in section 5.1
Dimensions
Cart length
800 mm
Rails length
1236 mm
Cart width
800 mm
Rails width
836 mm
Cart height
484 mm
Rail height
523 mm
Weight (without load)
35 kg
Color
RAL 7001 - silver grey
Corner attachment points
M10x1.5 mm Payload
Cart payload
150 kg for MiR100
300 kg for MiR200
Weight distribution
Payload shall be evenly distributed around the centre of the cart.
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5.2.1 Cart300 with rails – dimensions drawing
Figure 6.
5.3 DS100/200P Ext Floor docking station – specifications
The following specifications are additions to the general specifications stated in section 5.1
Dimensions
Length
250 mm (383 mm including docking bolts)
Width
800 mm
Height
430 mm
Weight
18 kg
Color
RAL 7001 - silver grey
Anchor points
6 x 8.5 mm
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5.3.1 DS100/200P Ext Floor docking station – dimensions drawing
Figure 7.
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6 Maintenance
6.1 Overview
The following maintenance schedules give an overview of regular cleaning and part replacement procedures.
NOTE: The stated intervals are indicative and depend on the operating environment and frequency of usage of the robot.
6.1.1 Regular cleaning and inspection
This table gives an overview of maintenance tasks for all ROEQ products. Part Maintenance Interval TMC300Ext General
Clean the TMC300Ext on the outside with a damp cloth.
Do not use compressed air.
As needed Locking bolts
Clean the bolts with a dry cloth to maintain correct function
Every 2-3 weeks / as needed Side wear protection plate
Inspect the side protection plates for damage/wear to maintain correct docking function.
Every month / as needed Cart General
Clean the cart on the outside with a damp cloth.
Do not use pressure cleaning.
As needed Wheels
Remove dirt with a cloth, and make sure nothing is preventing the wheel from turning.
Inspect the wheels to ensure correct function.
Every month / as needed Locking mechanism
Inspect the spring activated lock arm inside the locking mechanism to ensure correct function.
Every month / as needed Docking Station General
Clean the docking station on the outside with a damp cloth.
Do not use compressed air.
As needed
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7 Appendices
7.1 Declaration of conformity
Declaration of conformity according to the EU Machinery Directive 2006/42/EC, Annex II 1. B
Manufacturer:
ROEQ ApS
Kobbervænget 5
DK-5492 Vissenbjerg
Technical file compiled by:
Martin Ziemann Junker
ROEQ ApS
Kobbervænget 5
DK-5492 Vissenbjerg
Description and identification of the machinery
Generic denomination
TMC300Ext
Function
Logistics accessory for application on MiR100 and MiR200 autonomous robot, designed to be operated in conjunction with the operating system delivered by Mobile Industrial Robots.
By adding ROEQ specific operation routines to the mission list, the operator will be able to command the robot to pick up and deliver ROEQ designed carts and pallets and thereby executing multiple logistic tasks with the use of one robot.
To be able to operate with a ROEQ cart attached a modified version of the laser scanner software is installed on the robot.
Model
ROEQ 265A2000 V1.0
Serial number
X100265A200000010 and higher
Commercial name
TMC300Ext
This product is expressly declared to fulfil all the relevant provision of the following EU Directives or regulations:
2006/42/EC
-
Applied harmonized standards reference
DS/EN 60204-1:2006
Safety of machinery - Electrical equipment of machines - Part 1: General requirements.
DS/EN ISO 12100:2011
Safety of machinery - General principles for design - Risk assessment and risk reduction.
DS/EN 349
Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.
Vissenbjerg 2018-04-01
Signature
Benni S. Lund
R&D Manager
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7.2 Formulas for calculating the global offsets of the robot
These formulas are used for calculating the global offsets of the robot in relation to the calibration.
𝑂𝑟𝑖𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑜𝑓𝑓𝑠𝑒𝑡=tan−1𝑏̅−𝑎̅800
𝛼=tan(𝑂𝑟𝑖𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑜𝑓𝑓𝑠𝑒𝑡)∙(8002−𝑐)
𝛽=𝑎−𝛼
𝑥 𝑜𝑓𝑓𝑠𝑒𝑡=(𝛽−(435−435⋅cos(𝑂𝑟𝑖𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑜𝑓𝑓𝑠𝑒𝑡))−70)1000
𝑦 𝑜𝑓𝑓𝑠𝑒𝑡=𝑐̅+435⋅sin(𝑂𝑟𝑖𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑜𝑓𝑓𝑠𝑒𝑡)−1000