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Related Manuals for Bosch WS502
Summary of Contents for Bosch WS502
- Page 1 R901508696 Robotics Trainings System Version: 01-01 EN WS502 Instruction manual...
- Page 2 All rights reserved by Bosch Rexroth AG, also in case of registration of industrial property rights. We retain all powers of disposition such as the right to copy and forward.
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Page 3: Table Of Contents
Connection and controls on the control cabinet ....26 Pneumatic maintenance unit ............28 Technical data, Type plate ................ 29 Technical data .................. 29 Identification of the WS502 training system ........30 Operating and display elements ..............31 EMERGENCY STOP button ............31 Hand control VH2110 ............... 32 smartPAD hand control .............. - Page 4 Description of the coordinate system ..........55 11.5 mMS 4.0 attachment ................. 55 11.6 Connect the Bosch Rexroth mMS 4.0 with the WS502 training system 11.6.1 Modification of an existing mMS 4.0 for use with the WS502 training system ..............56 11.6.2...
- Page 5 Robotics Trainings System WS502 Bosch Rexroth AG 5/64 Contents 14.2.1 Operating materials, auxiliary materials, tools, measuring instruments ............... 61 14.2.2 Replacing parts ..............62 Disposal ....................62 EC – Declaration of Conformity ..............63...
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Page 6: About This Documentation
Information" chapter before you work with the product. Required and supplementary documentation In addition to these operating instructions for the (ready-to-use) WS502 training system the following additional documentation is also available: • “Teachware" teacher and student manuals and software contains exercises in accordance with the recommendations –... -
Page 7: Symbols
Robotics Trainings System WS502 Bosch Rexroth AG 7/64 About this documentation Safety information are structured as follows: SIGNAL WORD Type and source of the hazard Consequences of non-compliance Measures for averting danger • Warning symbol: Points out the hazard •... -
Page 8: Abbreviations
For example in explosion-protection areas or in safety-related parts of a control system (functional safety). Bosch Rexroth AG assumes no liability for damage in the event of improper use. The risks associated with non-intended use are the sole responsibility of the user. -
Page 9: Qualification Of Personnel
• the components are used in a different training system, • devices or sets are used that are not approved for the WS502 training system, • pneumatic pressure circuits are merged, •... -
Page 10: Transport, Assembly, Installation And Commissioning
Persons charged with working on the WS502 training system must be capable of understanding the information in this documentation as well as independently performing any details necessary due a possible lack of information based on their own professional qualifications. -
Page 11: Product And Technology-Specific Safety Information
Always deenergize the WS502 training system before you do any electrical work. Secure the plant/system from reconnection. Operate the WS502 training system only in a network with a functional RCD protective conductor or a protective ground. Manipulated and/or non-functional safeguards and protection equipment! Risk of serious injury! Immediately stop the system! ... -
Page 12: Obligations Of The Operating Organisation
• Guard on the cell The stated equipment is described in detail below. On the front and on the left and right side of the WS502 training system there is EMERGENCY STOP button an EMERGENCY-STOP button that must be easy to reach. - Page 13 There is a sliding door on the rear of the WS502 training system. It is provided with EMERGENCY-STOP door switches which safely shut down the system as soon as the sliding door is opened.
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Page 14: User Workstations
Bosch Rexroth AG Robotics Trainings System WS502 Safety information 2.10 User workstations Provide the following space for the WS502 training system to teach and learn the procedures on the WS502 training system: Abb. 1: WS502 training system space requirements Teaching stations... -
Page 15: General Information On Preventing Property Damage And Damage To Product
Robotics Trainings System WS502 Bosch Rexroth AG 15/64 General information on preventing property damage and damage to product General information on preventing property damage and damage to product NOTE The system stands under pressure and tension! Property damage! Do not loosen/remove any connected lines, connections and components ... -
Page 16: Scope Of Supply
Scope of supply Scope of supply The WS502 training system is supplied packed as a turnkey system. It stands on a sub-pallet and is held taut with non-metallic straps. It is packed in a foil and stands in a wooden crate which is closed on the front by a cover. The cover is fastened with nails or screws. -
Page 17: About This Product
The following sections of these operating instructions show examples of a variant of the WS502 training system and its components. There are a multitude of attachment units and sets available for the WS502 training system. These components make the WS502 training system a complete,... -
Page 18: General Plan
Robotics Trainings System WS502 About this Product General plan The WS502 training system consists of an aluminium profile frame with Makrolon panes, adjustable mounts for fixed assembly, a KUKA Agilus robot, hand control, control cabinet. Abb. 3: Agilus training system... -
Page 19: Agilus Industrial Robot
Robotics Trainings System WS502 Bosch Rexroth AG 19/64 About this Product Agilus industrial robot The Agilus Sixx is an industrial robot with six axes. The robot is equipped with a pneumatic gripper with an occupied control which is protected against damage by a collision coupling system. -
Page 20: Gripper On The Agilus Robot
20/64 Bosch Rexroth AG Robotics Trainings System WS502 About this Product 5.3.1 Gripper on the Agilus robot The Agilus robot is equipped with a pneumatic gripper with sensory occupied Pneumatics control. The pneumatic triggering of the gripper is made through the internal Agilus pneumatic functions. -
Page 21: Connections On The Agilus Robot
Robotics Trainings System WS502 Bosch Rexroth AG 21/64 About this Product 5.3.2 Connections on the Agilus robot The Agilus robot is equipped with a total of 3 pneumatic valves (3/2-way valves), Pneumatics i.e. with 6 connectors. Two of these connections are for the gripper function (opening and closing). - Page 22 22/64 Bosch Rexroth AG Robotics Trainings System WS502 About this Product Connections on the base All external connections of the Agilus robot are connected with the robot on the base. Abb. 8: Connections on the base of the Agilus robot...
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Page 23: Cube Rack
About this Product Cube rack The WS502 training system is equipped with a sensor-monitored cube rack system for the "4Block" program included in the scope of delivery. The racks on which the cube can be positioned are located on the base plate in the working area of the Agilus robot. -
Page 24: Cube Chute
24/64 Bosch Rexroth AG Robotics Trainings System WS502 About this Product Cube chute The training system comes standard with the predefined "Rack” program. Here the robot removes a cube from the attached mMS 4.0 expansion module and places it in the available cube rack. After 3 cubes are stored the remaining cubes are taken out of the mMS 4.0, unloaded through a hole in the base plate... -
Page 25: Control Cabinet
Robotics Trainings System WS502 Bosch Rexroth AG 25/64 About this Product Control cabinet The control cabinet is equipped with see-through Makrolon doors for training practices. In the control cabinet are the electrical supply unit, XM2200 control with PROFINET extension modules and I/O extension module, the safety devices and additional safety devices and switching elements. -
Page 26: Connection And Controls On The Control Cabinet
Ethernet interface (RJ45). 4. Main switch The main switch is used to switch the power supply for the entire WS502 training system on or off. Individual elements in the control cabinet are energized even when the main... - Page 27 EMERGENCY-STOP and protective door circuit When operating the WS502 training system without predecessor module such as the Bosch Rexroth mMS module or without a subsequent module, the jumper plugs included in the scope of supply must be installed. To connect an expansion module: Remove the jumper plug ...
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Page 28: Pneumatic Maintenance Unit
28/64 Bosch Rexroth AG Robotics Trainings System WS502 About this Product Pneumatic maintenance unit Type key: RD AS1-ACC-G014/R480320321 Abb. 13: Maintenance unit Maintenance unit Cut-off valve Connection input side Connection output side Abb. 14: Maintenance unit; pneumatic circuit diagram... -
Page 29: Technical Data, Type Plate
50-60 Rated power Security Protective ground PE (multiple protective earthing or RCD protective switch) A-weighted continuous sound level dB (A) < 70 (at the workstation of the operating personnel during conveying) Tabelle 6: Technical data on the WS502 training system... -
Page 30: Identification Of The Ws502 Training System
Technical data, Type plate Identification of the WS502 training system The type plate of the WS502 training system is located on the control cabinet of the system. In addition, the specific characteristics of the WS502 training system are also stated here. -
Page 31: Operating And Display Elements
Remove the KUKA smartPAD from the training system installation site when it is not connected. In the event of danger to persons and the machine, you can shutdown the WS502 training system by pressing one of these buttons. Triggering the EMERGENCY-STOP button stops the movement of the robot. All processes are stopped immediately and hazardous currents are switched off. -
Page 32: Hand Control Vh2110
Abb. 18: Hand control VH2110 EMERGENCY STOP button Connection line connection OVERRIDE speed controller Confirm button Display with touch function The confirm button (5) is not needed for the operation of the WS502 training system and has no function. -
Page 33: Smartpad Hand Control
33/64 Operating and display elements smartPAD hand control The scope of delivery of the WS502 training system includes the smartPAD hand control. With the help of the smartPAD, different operating and setup functions of the Agilus robot can be executed. -
Page 34: Transport And Storage
Carefully open the plastic packing with the knife. Lift the WS502 training system carefully off the pallet with a forklift and take it out of the box. Remove cable ties and adhesive tape carefully and dispose of them properly. -
Page 35: Assembling The Vh2110 Hand Control
8.1.2 Assembling the VH2110 hand control The VH2110 hand control is supplied in a separate box with the connection cable and bracket. To mount the VH2110 manual control panel on the WS502 training system proceed as follows: Install the bracket at operating height to the vertical frame construction of the ... -
Page 36: Transport
Remove the compressed air supply. CAUTION Tipping hazard of the WS502 training system! It is possible that the centre of gravity is off-centre; the centre of gravity shifts depending on the attachments! Risk of injury when lifting and transporting! Secure the training system when lifting and transporting in order to prevent ... -
Page 37: Storage
37/64 Transport and storage CAUTION Tipping hazard of the WS502 training system! It is possible that the centre of gravity is off-centre; the centre of gravity shifts depending on the attachments! Risk of injury when lifting and transporting! Secure the training system when lifting and transporting in order to prevent ... -
Page 38: Assembly, Installation And Commissioning
Assembling the WS502 training system CAUTION Danger due to irregularities, deviations, faults, defects during assembly or testing! Risk of damage! Do not put the WS502 training system into operation, i.e. take it out of service immediately. Investigate the cause and repair the defects. -
Page 39: Check And Connect The Pneumatic Supply
Connect the power plug to the customer’s supply voltage socket-outlet (230V AC). Operate the training system WS502 only on an electrical grid with an operational residual current operated circuit breaker (RCCB) or protective grounding. The electrical supply of the WS502 training system is established. -
Page 40: Operation Of The Training System
• The electrical supply and installation is correct. • A function test has been performed. • There are no tools, cleaning rags or other objects on the WS502 training system. • Accessibility and the functioning of the EMERGENCY STOP button are guaranteed. -
Page 41: Predefined Robot Programs
10.4 Adjustment of the zero position on the mounted mMS If you want to run the WS502 training system with the mMS 4.0, check first to see whether the set positions for operating the rack match the end customer’s existing system. -
Page 42: Correction Of The Horizontal And Vertical Zero Position
42/64 Bosch Rexroth AG Robotics Trainings System WS502 Operation of the training system 10.4.1 Correction of the horizontal and vertical zero position Proceed as follows to correct the position: Press the Manual button Press the MoveTypJog button Set the speed override to minimum speed ... -
Page 43: Selecting The Operating Mode And Program
It is necessary that the mMS module of the first digital output is set to the WS502 training system. This is to prevent that the robot and handling of the mMS 4.0 intervene in the rack at the same time. -
Page 44: Stop Movement (Immediate Stop)
44/64 Bosch Rexroth AG Robotics Trainings System WS502 Operation of the training system 10.9 Stop movement (immediate stop) Proceed as follows to immediately stop the running program: Press the Reset/Abort button The program sequence is stopped immediately. After a program abort the robot is typically not in the home position. This message will appear on the display: 10.10 Perform home position run... -
Page 45: Move The Robot In Jog Mode
Robotics Trainings System WS502 Bosch Rexroth AG 45/64 Operation of the training system CAUTION Obstacles in the area of movement of the robot! Risk of damage to components! First move the robot gripper manually to a position from which the desired ... -
Page 46: Saving The Current Robot Position
46/64 Bosch Rexroth AG Robotics Trainings System WS502 Operation of the training system Press the MoveTypJog button. Press the World button to select the global coordinate system. Select the desired direction (+ / -) for the movement directions X, Y, Z, A, B, ... -
Page 47: Open / Close Gripper
Robotics Trainings System WS502 Bosch Rexroth AG 47/64 Operation of the training system 10.13 Open / close gripper The gripper can only be opened or closed in manual mode. To open the gripper of the robot manually, proceed as follows:... -
Page 48: Restore Operational Readiness After Gripper Collision
48/64 Bosch Rexroth AG Robotics Trainings System WS502 Operation of the training system 10.14 Restore operational readiness after gripper collision During movements of the robot in manual mode there may be collisions of the gripper with attachments or the cell. This triggers the gripper coupling which holds the gripper in place with the help of 4 spring-actuated balls. -
Page 49: Reset The Set Position Points To The As Delivered Condition
Turn the main switch to the "0 - Off" position. The Bosch Rexroth control is immediately switched off. The robot system is shut down through an uninterruptible power supply (UPS) and then turned off. After the cooling fan on the robot control cabinet has been switched off wait... -
Page 50: Description Of The User Interface
50/64 Bosch Rexroth AG Robotics Trainings System WS502 Description of the user interface 11 Description of the user interface 11.1 Main screen The system user interface is displayed on the VH2110 control panel. After the system is started up the main menu of the training system appears on the display of the control panel. - Page 51 Robotics Trainings System WS502 Bosch Rexroth AG 51/64 Description of the user interface Automatic Mode: 4Block: Button for selection of the “4Block" program Rack: Button for selection of the “Rack" program Automatic Start: Button to start the automatic mode Automatic Stop: Button to stop the automatic mode (cycle stop) Part Pos1-4: Busy indicator for the 4 racks of the "4Block”...
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Page 52: Position Data Screen
0: The robot approaches each point, briefly stops and then continues Done: Green: Movement command to approach the position point was transmitted by the Bosch Rexroth control to the robot controller Red: No movement command sent InPos: Green: The robot has reached the position... -
Page 53: Changing A Position Data Record
Robotics Trainings System WS502 Bosch Rexroth AG 53/64 Description of the user interface Display box: Text display for instructions and error messages Main menu function buttons: Main Screen: Displays the main screen Setup screen: Opens the setup screen 11.2.2 Changing a position data record A list with all existing position records is shown in the position data screen. -
Page 54: Setup Screen
Rack Turn Overview: The Rack Turn Overview section displays the storage locations of the Bosch Rexroth mMS 4.0 (from 0/0 to 2/4). In order to service a location (position gripper in front of storage position, move into the storage position, close gripper, move out of the storage position), Positions 23, 24, 25, and 26 were stored in the system. -
Page 55: Description Of The Coordinate System
Abb. 27: mMS 4.0 training system NOTE Operation with mMS 4.0 The operation of the WS502 training system is possible either with an attached mMS 4.0 or with the sliding door closed. The scope of delivery of the WS502 training system includes attachments for the detection and mounting of the mMS 4.0 to the training system. -
Page 56: Connect The Bosch Rexroth Mms 4.0 With The Ws502 Training System
11.6.1 Modification of an existing mMS 4.0 for use with the WS502 training system Mount the Bosch Rexroth mMS 4.0 on the rear of the training system. On the rear there is a sliding door for intervention into the storage module by the robot. For the operation of the training system either the sliding door is closed or the mMS 4.0 must be installed. -
Page 57: Connect The Mms 4.0 With The Training System
Description of the user interface 11.6.2 Connect the mMS 4.0 with the training system Mount the Bosch Rexroth mMS 4.0 on the rear of the training system. On the rear there is a sliding door for intervention into the mMS 4.0 by the robot. - Page 58 58/64 Bosch Rexroth AG Robotics Trainings System WS502 Description of the user interface Connect the frame elements on upper rear right with a second mounting bracket. The WS502 training system can now be operated with the mMS 4.0.
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Page 59: Help In Case Of Faults
13 Service and inspection This chapter covers the service and inspection work that may be performed by personnel trained on the WS502 training system. Maintenance and inspection work that can only be performed by specifically trained and qualified personnel are described in chapter 14. -
Page 60: Service And Inspection Plan
60/64 Bosch Rexroth AG Robotics Trainings System WS502 Service and inspection 13.2 Service and inspection plan The following table lists the jobs, first by the service intervals and then by assemblies/components. Maintaining the intervals is mandatory. When? What? Where? Comments... -
Page 61: Maintenance Work
WS502 training system maintenance schedule Tabelle 9: 14.2.1 Operating materials, auxiliary materials, tools, measuring instruments The following are required to work on the WS502 training system: • Protective work clothing according to regulations Auxiliary equipment • Cleaning and care products: cleaning cloths... -
Page 62: Replacing Parts
Repair wear only if the WS502 training system is located at a site that is safe for the personnel – there is no risk to health (falling down, slippery due to moisture, etc.). -
Page 63: Ec - Declaration Of Conformity
Robotics Trainings System WS502 Bosch Rexroth AG 63/64 EC – Declaration of Conformity 16 EC – Declaration of Conformity Bosch Rexroth AG Drive & Control Academy As per Machinery Directive 2006/42/EEC Bahnhofplatz 2 As per Low Voltage Directive 2014/35/EC D-97070 Würzburg, Germany... - Page 64 64/64 Bosch Rexroth AG Robotics Trainings System WS502 EC – Declaration of Conformity Bosch Rexroth AG Drive & Control Academy Bahnhofplatz 2 97070 Würzburg, Germany Phone: +49 9352 18-1920 Fax: +49 9352 18-1040 eMail: training@boschrexroth.de www.boschrexroth.com/training R901508696 (Version 01-01 EN) ©...