General Features

Manual Mode

The robot has the capability of being operated in manual mode where the human operator has complete control over the robot and can maneuver the robot to complete assigned work. The robot can only be powered on in manual mode and the operator has the choice of continuing in manual mode or switching to auto mode.

Auto Mode

In auto mode the system takes over and controls both the movement and the safety functions of the robot. Also in this mode, an operator can manually maneuver and instruct the robot on the desired travel path and can then place the robot in a location to initiate the travel task (“WalkThroughThenWork™”). In auto mode the system’s safety functions are engaged and working.

Hardware

MicroLogic PLC

Rockwell Automation’s MicroLogic PLC is integrated into the robot’s hardware and its primary function is to control and monitor power and hardware components such as the SICK proximity sensor, the contact bumper and the emergency stop function. If the SICK proximity sensor or contact bumper or emergency stop function are engaged, the PLC immediately stops the robot and shuts down the motor. For forty years PLCs have been the gold standard for control, sequencing, and safety interlock logic.

SICK Unit

SICK unit

SICK unit is an industrial-strength, CE-rated, field-tested laser sensor which has a customer defined detection envelope that creates both warning and full stop zones as the robot approaches an obstacle. The robot slows down in the warning zone as it nears the obstacle and will come to a complete halt in the stop zone if the obstacle remains in position and in the path of the robot. The length of both the warning and stop zones depends on the customer designated speed and load/weight capacity. Once the obstacle is cleared, the robot automatically resumes its journey along the designated path.

Contact Bumper

The contact bumper is hard wired to the PLC and if it comes in contact with an obstacle the PLC will immediately shut off the motor and hard stop the robot. This requires human intervention to restart the robot and resume its journey.

Emergency Stop Button

Emergency Stop Button is also hard wired to the PLC and if an operator presses the red emergency stop button the PLC immediately shuts down the robot. Again human intervention is required to restart the robot to resume its journey.

Software

When the robot has been turned on, the system performs its highest level self diagnostic test of the camera hardware, motors and odometry and if the system detects an error condition, an error message is shown on the display unit and the robot works only under manual control. In this condition, human intervention is required. The system provides diagnostics with instructions on how to correct the problem.

The system has a “watchdog” feature that monitors the performance of the robot’s internal software system programs and if, for example, the robot takes too long to perform a task, the watchdog displays the error, cuts power to the motors, and stops the robot.

The system can determine if system hardware components (odometry, SICK unit, bumper, etc.) are not properly connected or wired. In this case, the error is displayed and the robot can only be used in manual mode until the problem is fixed.

The system monitors the accuracy of the robot’s route on a designated path by utilizing internal rules (of path deviation) and stops the robot if it strays too far off path and breaks the rule.