May 12, 2017 | 1© 2017 YASKAWA CONFIDENTIAL INFORMATION ALL RIGHTS RESERVED | YEU_PPTX_Template_2017© 2017 YASKAWA CONFIDENTIAL INFORMATION ALL RIGHTS RESERVED | GLOBAL TEMPLATE
POWER & FORCE LIMITING (PFL)
APPLICATION GUIDE
HC10
May 12, 2017 | 2© 2017 YASKAWA CONFIDENTIAL INFORMATION ALL RIGHTS RESERVED | YEU_PPTX_Template_2017
APPLICATION SUMMARY
1. Power & Force Limiting (PFL) Function Example
○ Broadly describes what PFL is and how it can be used in a
simple Pick & Place application
2. Tool Setting
○ Describes how to properly configure a tool for a PFL-enabled
application
3. PFL Modules
○ Details each step for properly configuring a PFL-enabled
application with multiple zones
4. PFL Application with No Zones (Example)
○ Highlights the differences (configuration, settings) between a
PFL application with and without zones
5. Clamping Prevention
○ Describes how to configure a zone to stop the robot before
a clamping scenario occurs
May 12, 2017 | 3© 2017 YASKAWA CONFIDENTIAL INFORMATION ALL RIGHTS RESERVED | YEU_PPTX_Template_2017
CONTENTS
1. Power & Force Limiting (PFL) Function Example
2. Tool Setting
2.1 Basic Tool Setting (Manual & Automatic)
2.2 Tool Interference Setting
2.3 Tool Number – How To Program
3. PFL Modules
3.1 {SLC EXT. Signal Allocation}
3.2 {Robot Range Limit}
3.3 {External Force Limit}
3.3 {Speed Limit}
3.5 {Safety Logic Circuit}
4. PFL Application with No Zones (Example)
5. Clamping Prevention
Legend:
{Menu on Pendant}
[Membrane Button on Pendant]
Manual Reference Material
Important Note
“Term in Manual”
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1. POWER & FORCE LIMITING (PFL) FUNCTION EXAMPLE
• The PFL Function detects external forces using embedded sensing in the robot
• If an externally detected force exceeds a user-defined limit, the PFL Function will stop the robot
• To successfully program a Pick & Place application, two conditions must be met:
1. The normal external force produced by part contact (gripping or releasing) should not stop the
robot
2. {External Force Limit} and {Speed Limit} in Zones 1 & 2 should be lowered to avoid clamping
dangers
Pick: Place:
Zone 1
Zone 2
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1. PFL FUNCTION EXAMPLE
Pick:
Place:
Zone 1
Zone 2
PFL Setting Other Space Zone 1&2
External
Force
Limit
PFL Input Signal PFLIN01 PFLIN02
X (N) 100 50
Y (N) 100 50
Z (N) 100 50
Resultant (N) 100 50
Speed
Limit
Speed Input Signal MS-OUT01 MS-OUT02
Speed Limit (mm/s) 250 100
Part Contact & Impact Avoidance:
• Tool # Change (Example: MOVx Tool 0 -> MOVx Tool 1)
• A Tool # Change command will disable the PFL function for the
first 5mm of a programmed move to prevent a “pseudo-impact”
due to intended contact with a part (see more detail on Page 10)
External Force & Speed Limits:
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2.1 BASIC TOOL SETTING – MANUAL INPUT
• For a simple Pick & Place application to work properly, two different tool states must be considered
1. Gripper without part (Tool 0) 2. Gripper with part (Tool 1)
• In the current implementation for PFL, these states are treated as separate tools on the YRC1000
pendant (each with their own set of properties)
• Therefore, the weight of Tool 1 above should be the sum of the gripper & the part
Tool 0
Reference Material: YRC Instructions (178642-1CD) 8.3.1 Tool Data Setting
Tool 1
1
6kg
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2.
1.
• The “Automatic Measurement” function can be used to automatically calculate tool
settings
• On the Top Menu, select {UTILITY} -> {W.GRAV.POS MEASURE} to use the function
Reference Material: YRC Instructions (179531-1CD)
8.3.3
2.1 BASIC TOOL SETTING – AUTOMATIC MEASUREMENT
*Note – At this time, YII
recommends manually
configuring tool
settings using accurate
CAD data for a given
end effector
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2.2 TOOL INTERFERENCE SETTING
• PFL function uses the {Robot Range Limit} module to
detect whether the entire robot body, including tool
interference (not the TCP position) enter a user-defined
zone
• These zones can be used to slow down or stop the robot
• Tool Interference must be defined to use the {Robot
Range Limit} module
• To enter the function:
{Main Menu} -> {ROBOT} -> {TOOL INTERFERE}
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2.2 TOOL INTERFERENCE SETTING
Reference Material: YRC1000 Options - Arm Interference with Specified Cubic Area Check Function (178679-1CD) 1.2.2 Tool
Interfere File
Window Details
1. Up to 5 models (cylinders & spheres) combined as the tool shape
2. “Point1” and “Point2” coordinate values: the position of the ends of each cylinder
3. “Radius”: radius of the cylinder and the sphere
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2.3 TOOL NUMBER – HOW TO PROGRAM
Pick:
Place:
MOVL P001 V=100 (Tool 0)
MOVL P001 V=100 (Tool 1)
DOUT OT#(x) ON
MOVL P002 V=100 (Tool 1)
Update the tool information on controller (same
position)
Turn the gripper ON
PFL is OFF during the first 5 mm move5mm
Notes:
• Tool No. information can only be updated during a motion command
(MOVx)
• “MOVx (Tool Update)” and “DOUT” are currently always used in
conjunction to achieve the Tool # change for the controller and the
gripper
• A Tool No. Change command (MOVx Tool 0 -> MOVx Tool 1) will disable
the PFL function for the first 5mm of a programmed move to prevent a
“pseudo-impact” due to intended contact with a part (*this is TUV
approved)
Use Together
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2.3 TOOL NUMBER – HOW TO PROGRAM
1. Press [SHIFT] + [TOOL SEL] to open the tool list
2. Jog the cursor to the desired used Tool No.
3. Press [SHIFT] + [TOOL SEL] again to finalize the
selection
Tool No. Select Window
Currently Selected Tool No.How to change Tool #:
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2.3 TOOL NUMBER – HOW TO PROGRAM
01
• Check all commands with Tool No. before executing the program
• The Tool No. for a selected line in the INFORM Editor can be read from the job header (see left)
• An easier way to check Tool No. for the entire job is to display the “Tool No. Column” (see right)
• How to Enable: {Top Menu} -> {DISPLAY} -> {ENABLE TOOL NO}
• If a Tool No. is wrong, jog the cursor to a specific line, select the intended Tool No., and overwrite the line ( [MODIFY] +
[ENTER] )
Tool No. for the Selected Line
Tool No. Column
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3. PFL MODULES
PFL Modules in {Safety Func.} Menu
1. {SLC EXT. Signal Allocation}
2. {Robot Range Limit}
3. {External Force Limit}
4. {Speed Limit}
5. {Safety Logic Circuit}
Reference Material: YRC1000 Options Instructions for Functional Safety Function (178949-1CD) for Details of Functional
Safety Function
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3. PFL MODULE SUMMARY CHART
Robot Range Limit External Force Limit
Signal: FS-OUTxx Signal: PFLINxx
Link
Safety Logic CircuitSLC EXT. Signal Allocation
Robot
Position
Output Input
PFL Force
Limit
Allocate
Signal: MS-OUTxx
Speed Limit
Input
PFL Speed
Limit
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NOT USED -> F-SAFE #1
FS-OUT01 Zone 1
FS-OUT02 Zone 2
• The {F-Safety Signal Allocation} module is used to
designate a signal “FS-OUTxx” as the output signal
of the {Robot Range Limit} module (this alerts the
system when the robot enters a zone)
• {Main Menu} -> {SAFETY FUNC.} -> {F-SAFETY
SIGNAL ALLOC}
• Jog cursor to the specific FS-OUTxx signal, and
press “select” to choose F-SAFE #1
For an application with 2 zones, define 2 FS-OUTxx signals:
3.1 {SLC EXT. SIGNAL ALLOCATION}
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3.2 {ROBOT RANGE LIMIT}
Robot Range
Signal X (mm) Y (mm) Z (mm)
Zone 1 FS-OUT01 400/600 -600/-300 0/300
Zone 2 FS-OUT01 400/600 400/600 -100/0
Note• The definition of inside the cube is not the TCP, but the
“robot body” and “tool interference”
• This example is based on ROBOT coordinates
Choose any 2 files (pg. 16) to save robot range limit data:
X
Z
Zone 1
Zone 2
Y
Origin
{Robot Range Limit} can be used to define a 3-dimensional area as a specific zone, where
the user can customize PFL settings (speeds, allowable forces, etc.)
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3.2 {ROBOT RANGE LIMIT}
Settings (bottom-left)• File Valid Cond: VALID
• Alarm: OFF (Only Output Signal, Does Not Stop Robot)
• Monitor Target: OUTSIDE (Keep Normal Working Under Monitor)
• Coordinate: ROBOT (Suggested for This Example)
• Shape Type: CUBOID
• Point1 / Point2: Coordinates (mm) of Cube Vertex for Zone 1 & Zone 2
• Output Signal: FS-OUT01 for Zone 1, FS-OUT02 for Zone 2
Note
• Output Signal FS-OUTxx should be defined in the {F-Safety Signal Allocation}
module before it is used. Otherwise, the signal will not be available for selection
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External Force
Signal Situations X (N) Y (N) Z (N) Resultant (N)
PFLIN01 Factory Default 100 100 100 100
PFLIN02 Lower in Zone 1&2 50 50 50 50
• PFLIN01 is the factory default setting of PFL Function
• PFLIN02 are the settings to lower the limits in Zones 1 & 2
Note
• The maximum external force allowed for setting is 300N
{External Force Limit} is the module used to define and save
force limit settings
Choose any 2 files to save external force limit data:
3.3 {EXTERNAL FORCE LIMIT}
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Settings(top-left)
• File Valid Condition: SIGNAL (gets signal from {Safety Logic Circuit})
• Control Group: R1
• Limit (Each Axis): INVALID for all
(bottom-left)
• External Force Limit: Force Threshold in XYZ Direction & Resultant
• Input Signal bit0: “PFLIN01”, “ON” (bit 1,2,3,4 leave blank) for undefined zones
“PFLIN02”, “ON” (bit 1,2,3,4 leave blank) for Zone 1 & 2
• Output Signal: *Leave blank*
Note• In File No. 1, the factory default setting for FILE VALID COND is “VALID”. This
field must be changed to “SIGNAL” for this example. Otherwise, a file with
“VALID” will override all other files.
3.3 {EXTERNAL FORCE LIMIT}
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Speed Limit Signal Situations Speed (mm/s)
MS-OUT01 Factory Default 250
MS-OUT02 Lower in Zone 1&2 100
Note• PFLIN01 is the factory default setting of PFL Function
• PFLIN02 are the settings to lower the limits in Zones 1 & 2
3.4 {SPEED LIMIT}
{Speed Limit} is the module used to define
and save speed limit settings
Choose any 2 files to save speed limit data:
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Settings(top-left)
• File Valid Condition: SIGNAL (Get signal in Safety Logic Circuit)
• Control Group: R1
• Limit Speed: *Enter the desired speed limit*
• Detection Delay Time: 0 (+1) sec
(bottom-left)
• Input Signal bit0: “MS-OUT01”, “ON” (bit 1,2,3,4 leave blank) for undefined zones
“MS-OUT02”, “ON” (bit 1,2,3,4 leave blank) for Zone 1 & 2
• Output Signal: *Leave blank*
Note• The {Speed Limit} module will slow the robot down to a user-defined speed limit (if
active speed is higher). If the robot speed is still higher than the limit after the user-
defined delay time, the PFL function will stop the robot. Minimum delay time is 0 (+1)
seconds.
3.4 {SPEED LIMIT}
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• The {Safety Logic Circuit} module is used to define
the logic relation between signals from different PFL
function modules
• Each line has 2 Inputs & 1 Output
• Input1 and Input2 can be Positive or Negative (NOT)
• AND / OR logic can be inserted between Input1 and
Input2
3.5 {SAFETY LOGIC CIRCUIT}
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3.5 {SAFETY LOGIC CIRCUIT} EXPLANATION
Safety Input PFL Function
Force 1 Speed 1
Force 2 Speed 2
Zone 1 Zone 2 Force 1
Graphic Description (just for explanation):
Note
• Line 1: #1 FSBIN01 is the Input on functional safety board (short
circuit from factory), and MS-OUT54 is PFL function status
• For monitor target of robot range limit is “Outside”, “NOT FS-OUTxx”
means robot enters Zone XX
• Lines 2 & 4: When the robot is outside of Zone 1 and Zone 2, the PFL
function will use the first external force and speed limit files
• Lines 3 & 5: When the robot is inside of Zone 1 or Zone 2, the PFL
function will use the second external force and speed limit files
Zone 1 Force 2
Zone 2
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4. PFL APPLICATION WITH NO ZONES (EXAMPLE)
{SLC EXT. Signal Allocation}
{Robot Range Limit}
{External Force Limit}
{Speed Limit}
{Safety Logic Circuit}
If a JOB has no special zone requirements (meaning PFL settings will remain the same throughout the
duration of the application), then the {SLC EXT. Signal Allocation} & {Robot Range Limit} modules are
not used
{External Force Limit}
• Choose one file and enter the required external force limits
• File Valid Condition: Signal->VALID (overwrite other files)
• The “Input Signal” (pg. 19) field will no longer appear
{Speed Limit}
• Choose one file and enter the required speed limit
• File Valid Condition: Signal->VALID (overwrite other files)
• The “Input Signal” (pg. 21) field will no longer appear
{Safety Logic Circuit}
• Only keep the first line: #1FSBIN01 -> MS-OUT54
• (Ensure MS-OUT54 status is ON)
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5. CLAMPING PREVENTION
Define a Zone to Prevent Clamping:
• Only {Robot Range Limit} module is needed
• Build a new {Robot Range Limit} file
Settings
• File Valid Cond: VALID
• Alarm: ON (Stop the Robot)
• Monitor Target: OUTSIDE
• Shape Type: CUBOID
• Point 1 / 2: Vertex of Cube
• Output Signal: *Leave blank*
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APPENDIX: TORQUE SENSOR CALIBRATION
PFL function takes use of the data from embedded sensors in the robot arm to calculate
and analyze the external force.
If the PFL function is not working properly or the user experiences alarms during
handguiding, a Torque Sensor Calibration process may be required.
1. Change security level to “YASKAWA” mode
2. Turn OFF PFL function
3. Jog robot back to Second Home Position
4. Correct the torque sensor data
Torque Sensor Calibration can only be conducted under YASKAWA mode (USB License Key
needed).
Four Steps to finish the Torque Sensor Calibration:
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APPENDIX: TORQUE SENSOR CALIBRATION
1. Change security level to “YASKAWA” mode (torque sensor data can only be read under YASKAWA
mode):
• Insert the USB License Key to the pendant
• Enter Security Mode window ( {Main Menu} -> {SYSTEM INFO} -> {SECURITY} )
• Press [INTERLOCK] + [SELECT] keys on keyboard
• Enter the Password, and press [ENTER]
Security Mode Window Enter Hided “YASKAWA” Mode
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APPENDIX: TORQUE SENSOR CALIBRATION
Enter Password YASKAWA Mode Display
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APPENDIX: TORQUE SENSOR CALIBRATION
2. Turn OFF PFL function (avoid singularity prevent during jogging robot back to Second
Home Position):
• Enter Safety Logic Circuit ( -> {SAFETY FUNC.} -> {SAFETY LOGIC CIRCUIT} )
• Add “NOT” logic before “#1 FSBIN01”
• Do not forget to turn PFL ON after calibration
Add “NOT” logic before “#1 FSBIN01” PFL is OFF
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APPENDIX: TORQUE SENSOR CALIBRATION
3. Jog robot back to {Second Home Position}:
• Enter Second Home Position Window ( -> {ROBOT} -> {SECOND HOME POS})
• Keep pressing “FWD” key until all differences in the positions are 0.0 deg.
Enter Window Second Home Position Window
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APPENDIX: TORQUE SENSOR CALIBRATION
4. Correct the torque sensor data
• Enter {PFL DIAGNOSIS} window (-> {SAFETY FUNC.} -> {PFL DIAGNOSIS})
• Change Input # to “9”, and record the data from 0 to 5, and from 10 to 15.
• Enter {TORQUE SENSOR ORG POS} window (-> {SAFETY FUNC.} -> {TORQUE SENSOR
ORG POS})
• Update the axis SLURBT data in CH1 (0 – 5) & CH2 (10 - 15)
Enter Window Change Input to “9”
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APPENDIX: TORQUE SENSOR CALIBRATION
The reading of Torque Sensor is sensitive and may change within a small range.
The user should approximate the average value, and enter data 0-5 into CH1 and
10-15 into CH2 respectively.
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