Industrial Robot Controller

MOTOMAN XRC
 New
A New Dimension
Dimension
New

1 Controller

3 Robots

6 Tasks

27 Axes

27 controlled servo axes

Synchronized operation of three

robots
Synchronized programming of three
robots including external axes
Multi-tasking Simultaneous operation
of six tasks

Simple programming and diagnosis due

to several software functions

Multi functional User friendly Compact

 Outlines of the XRC
Built-in transformer
Simple installation and setup by plug-
connections.
Used for robot in UP-series and SK-X, SP-X
and SV-X-series.
INFORM programming language
Expandable slots for optional boards
-Sensor function by XSL-board
-Welding interface MEW and XEW-board
-I/O-interface MIO-board
-Ethernet and Fieldbus board
XRC cabinets may be put on top of each
other or docked side by side
Fulfils the EC-directive incl. EMC and LVD
Made in Sweden
Advanced control system
Powerful 32-bit micro processor for rapid
data processing.
PLC-programs for different applications, for
example: arc welding and handling.
Advanced PLC-unit in the control system
with expanded program capacity and new
logical functions e.g. for controlling pneumatic
functions in fixtures.
Multi tasking makes it possible to run several
jobs simultaneously.
Digital servopacks with software controlled
speed and position feedback.
Shock detection function
This function stops the robot when it comes
into contact with an object. Robot or
peripherical devices can be protected in case
of accidental collision.
Maintenance functions
Remotely monitors maintenance function of
robot status through Ethernet network.
Production processing and quality control
monitoring can be managed from a central
control room. Maintains history of when and
who changed the robot job instructions.
design Expandable modular cabinet
Programming pendant
All programming functions are in one unit
with clear and large 12-line screen. Optimal
programming time is achieved while all
functions are available during programming.
The menu text can be switched between
several different European languages by a
simple key operation. The programming
pendant is equipped with a 3-position dead-
mans handle.
Communication
XRC like the previous control system for
MOTOMAN robots, is a technical data
solution that is PC-compatible allowing
common computer tools to be used for
creating, reading and editing jobs in a PC.
The flexibility of the control system makes it
possible to communicate with other systems
such as PLCs, host computers, vision
systems etc., through serial links, Ethernet,
digital I/Os and fieldbus.
The controller memory is also accessible
through a PC-card.
Path control
The robots working path is controlled with
consistent precision and quality. Even at high
speeds the robot will not vary from the
programmed path of travel.
XRC improves high speed welding, cutting
and sealing applications better than ever.
ARM control
Advanced Robot Motion Control improves
the quality and productivity by improved
servo response of the motion control.
Optimised acceleration/deceleration and
vibration control ensures the correct path
and cycle time. Speed is automatically
optimised for circles and corners. Collision
between robot, robot tool and other devices
is immediately detected to stop the robot
and protect it from damage.
 The new programming pendant

Command menu Status menu

Backlighted LCD
screen
Go to sub-menu
Switching of
coordinate
Go to
system type
predefined menu

Go to top menu Go to next menu

Cursor, navigation
key Emergency stop

Dead-mans handle
(at the back)
Enter selection

Switch menu
cursor area

Axis keys, for robot Teach lock, for

and external axis blocking the Play-
back panel

Programming and
test-run keys
Programming keys
Numerical and
Serial interface application function
RS-232C keys

Mode selection
Teach / Play
Emergency stop

Servo power ON
Start playback
Alarm signal operation

Remote operation Hold playback

operation


Large LCD-display with back-
lighting. High contrast for day-
light operation.

Top menu icons Cross shape cursor button for

instruction basic operations.
Open new jobs Call up jobs Operates by icons and pull-down
Copy job Rename jobs Delete menues make operation as easy
jobs Modify jobs Set Master job as using your personal computer.

Lightweight thermoplastic
Application, e.g. programming pendant reduces
Arc welding Spot welding fatigue.
Handling application or General
application Key allocation is based on
human engineering research.
Variable diagnosis Position The number of keys are
variables for robot, station and minimised for required
base axes functions only.

Diagnosis of external I/Os Dia-

gnosis of universal I/Os Diagno-
sis of direct I/Os Setting of I/Os

Tool data User coordinates

Robot position coordinates
Setting of cubes and software
limits Parameter setting System
diagnosis functions
System diagnosis functions
Software version Alarm history
System clock Counters

Back-up functions Load Save The programming pendant has

Verify Delete been awarded for its good design
and user friendly layout.

System settings Date/Time

Speed settings Setting group
combinations Operating/Teaching Ministry of International Trade and
conditions User ID Industry, Japan
 Technical specifications

Controller Programming functions

Configuration Free-standing, Enclosed type Coordinate Joint, rectangular/cylindrical, tool,
Dimensions 800(W)x900(H)x650(D) mm system user coordinates
Weight Approx. 170 kg Robot Motion Joint coordinates, linear/circular,
Cooling system Indirect cooling Control interpolation, tool coordinates
Ambient During operation 0 to +45 Speed setting Percentage for joint coordinates,
temperature During transport -10 to +60 0.1 mm/s units for interpolations,
Relative humidity Max. 90% (non-condensing) angular velocity for T.C.P. fixed
Power supply 3 x 400/415/440V AC, 50/60 Hz motion
Grounding Less than 100 ohm Program Control Jump, call, timer, robot stop,
Digital I/O General signals (standard) Instructions execution of some instructions
40 inputs and 40 outputs of which during robot motion
24 inputs and 24 outputs are free Modification of Adding, deleting, correcting (robot
4 direct inputs teaching point axes and/or external axes)
Communication RS-232C and PC-card Position control Manually forwards and backwards in
Positioning system Absolute encoder / Serial interface the job (even circular)
Drive units Servopacks for AC servo motor Speed adjustment Fine adjustment possible
Accel / Decel Software servo control I/O-function Discrete I/O control, pattern
Programming 5.000 steps and I/O processing
capacity 3.000 instructions Programming Interactive programming
(standard) 1.500 ladder steps Language Robot language: INFORM II
Display text English, Swedish, French, Spanish,
Italian, Finnish, German
Tool Centre Point Max. 24 and up to 24 external
Safety features TCPs
TCP-calibration Automatically calibrates parameters
Personal safety 3-position dead-mans handle for end effectors using master jig
Low speed in teaching mode
Teach Lock Mode Prohibits operation from operators
panel
Collision proof Doughnut-sector frame, cubic frame
frames Maintenance functions
Machine lock Test-run peripherial device without
robot motion Software time Control power-ON time, servo
Self-diagnosis Alarm and error messages displayed usage meters power-ON time, playback time, work
together with explanation time and operation time displayed
User Alarm display Possible to display alarm messages Alarm display Alarm messages and previous alarm
for peripheral devices records
I/O-diagnosis Simulated enable/disabled output
possible

Operators panel
Options
Buttons provided Mode, Start, Hold, Emergency stop
Servo power ON Digital I/O I/O-boards, total max. 256/256
MIO02: 32 inputs and outputs
MIO03: 16 inputs and outputs
Programming pendant XO102: 40 inputs and outputs
Analogue output 12 channel (MEW/XEW-board)
Material Reinforced thermoplastic Memory expansion Max 60.000 points for 6 axes
enclosure (up to...) and 20.000 instructions
Dimensions 200(W)x322(H)x65(D) mm 3.000 ladder steps
Weight 1.2 kg External axis Total max. 27 axes
Display 5.7 inch, 40 characters x 12 lines Enclosure IP54, by add on kit
Safety feature 3-position dead-mans handle classification
Interface RS-232C


Controller layout
Basic cabinet

MOTOMAN
XRC

900

800 650
725

Optional cabinets
XRC Controller cabinet is expandable by
adding extra modules (XOC-1 and XOC-2).
The extra cabinets are required for Twin and
Triple robot mounting, external axis
servopacks as well as optional functions
such as PLCs and safety systems.
The optional cabinets are docked with the
controller cabinet either on top or by the
side providing a tidy cable installation.
1800

MOTOMAN MOTOMAN
XRC XRC
1450

1600

 MOTOMAN XRC will be the
It is physically reduced to minimise space but is optimised

Optional units such as

servopacks for external axes,
optional I/O boards, welding
interface boards and fieldbus
boards may be mounted on the
back plate inside the cabinet.

Indirect cooling by means of a set of fans at

the rear makes it possible to place the
cabinet in confined places. The indirect
cooling also keeps pollution and dust out of
the cabinet.

Cables for safety circuits, external axes

I/Os and other communication options
are easily connected at the bottom of
the cabinet. The plugs are well protected
behind a removable panel.


premier robot controller
for functions, simple operations and expandability

Free slot in the CPU rack for optional

boards e.g. Sensor or Ethernet board.

PC-card (PCMCIA)
interface for high
speed backup or Serial interface through RS-232C
robot job connector suitable for PC communication
transferring. i.g. backup of robot jobs remote control
Robot and system etc.
software upgrade.

Standard field networks are available:

Cables for robot motors and signal cable
are easily connected by plugs at the back of
the cabinet to increase flexibility.
Ethernet, Profibus, Interbus-S, Device-
NET, etc. Your manufacturing line can be
integrally controlled through your
existing network.

Main power supply line is

connected by CEE plug. Serial interface through RS-232C connector
in the programming pendant is suitable for
PC communications e.g. back-up of robot

jobs.
 Software functions
The Advanced Robot Motion function
improves quality and productivity for
applications where correct path and high
speed is needed e.g. Laser cutting, water jet
cutting, gluing and sealing application.
By integrated Collision Detection function
the robot tool, fixtures and jigs as well as the
robot arm itself are protected against damages.
Moment limits may be individually set.
The XRC System gives possibility to control
27 axes from one single CPU, three robots
with external axes could be used for
synchronuous motion or for individual jobs.
Using the Twin-Drive function, two external
servomotors may be used for synchronuous
drive of a heavy fixture or large track (e.g.
welding application).
Endless Rotation of robot axis (T-axis) or an
external axis. Normally a servo motor is
limited to one or two turns in each direction.
By this function wrapping/unwrapping proces-
ses or painting applications are improved and
no time consuming reset of the turning is
needed.
The XRC system can handle six tasks at the
same time Multi-Tasking such as robot
jobs, concurrent I/O master job. By means of
special commands programming and editing is
made easily.
Welding Parameters (welding current, wire
speed, weaving, etc.) for a special welding
power source may be saved in a data file
(charcteristics). Start conditions, end
conditions are easily added to the robot job
by calling ARCON/ARCOF-command, which
reduces the programming time.
Other parameters for welding may be set, such
as: Retry function and Restart function.
Of course, it is possible to set individual values
for voltage, current wire feed, etc. for a single
welding string.
Communication interface between XRC
system and e.g. a PC may be handled in
several ways. A PC-card (PCMCIA) slot is
integrated in the CPU-rack. This PC-card can
be used as backup of user memory (jobs) and
also for upgrading of system software. For
advanced communication the RS-232C serial
interface or optional Ethernet board is used.
This together with our PC software puts the
robot into your network. Robot jobs may be
down- and uploaded to the system from a
central computer. The robot can be remote-
controlled.
The Interrupt Job function is used when the
robot serves e.g. one or several tooling
machines. A signal from the machine makes
the robot to interrupt its job for a moment to
serve the machine and then returns to
maintain its main job, e.g. deburring.
The Search function is used when the
workpiece may vary in size or position e.g.
picked up from a pallet or roughly cut pieces
at welding application. The data from the
sensor adjusts the robot job.
In arc welding applications the COMARC
package (including: start point search function,
seam tracking and multi layer) increase the
productivity by decreasing the demands of the
accuracy of the workpiece. It automatically
adjusts the robot job due to the actual
conditions. Multi layer function reduces the
programming time in heavy welding
applications.
When the robot is used together with a
machine tool for placing the workpiece in the
chuck, the Servo Float function allows the
robot arm to float with torque control making
it flexible with external forces.
When using the External Reference Tool
Centre Point function, it is possible to
designate a point in space as the tool control
point. This function may be used when the
robot is holding the workpiece and the tool
fixed e.g. pedestal spot welding machine or
application nozzle for gluing or sealing.
PMT function can be used to correct position
data easily and accurately when the robot tool
inadvertently collides with periferial jigs or
walls and becomes deformed. The job position
data will be corrected according to the new
tool data automatically.
The actual position of the robot is memorized
by pulse data. These data can be shifted into
another coordinate system, Relative Job
function. This function is used to perform
exactly the same operation but in another
location or direction.
The Parallel Shift function simplifies
programming. One operation is shifted
(copied) a specified distance. A counter sets
the number of operations. The function is used
in e.g. palletising application. Any type of
coordinate system can be used.
The PAM function is used for manual
operation. During playback the programmed
position or speed, can be corrected easily. It is
not necessary to stop the robot as the
correction amount and speed is set from the
programming pendant. This function is used
when the workpiece is only roughly
positioned in the fixture and the operator
checks and corrects the position.
The TCP (Tool Centre Point) function, adjusts
the robot position according to the tool data.
This function reduces the programming time
e.g. it can be used in a painting application
where the first nozzle applies the primer coat
and after shifting the TCP, the second nozzle
applies the topcoat by running the job again.
The Analogue Output Corresponding to
Speed uses an optional analogue board to
supply a signal to control a glue or paint pump,
or similar when the amount of sealant or paint
must be accurately controlled.
The Conveyor synchronisation function
synchronises the robot motion to the speed of
the conveyor. By connecting the optional
sensor board to an incremental encoder on
the conveyor drive motor, the speed is
detected and the robot can adjust its speed to
suite. This function is used both when picking
up as well as placing the workpiece onto the
conveyor without stopping it.
The Press synchronises the robot motion
with the press machine, where an encoder
mounted on the press flywheel monitors the
position of the press. The robot motion is
halted when it may interfere with the press
motion and starts again when the press rises
and interference is avoided. I/O signals are not
needed and cycle time is optimised.
For Spot welding applications the Short
Pitch function is used to suppress the rapid
robot arm movements during the short pitch
traverse of the spot welding gun.
A number of Optional Boards can be added
to the XRC system, such as; -Sensor board,
-Ethernet board, -I/O board, -Analogue output
board and COMARC board.
Complex I/O installations are easily solved by
use of the Fieldbus Interface Board which
is designed for well known market brands
such as; Interbus-S, Device-NET and Profibus
etc. Digital I/O optional boards of various
types are easily installed to customise your
system (16/16, 32/32, 40/40).
 KNT ENGINEERING

ROBOTIC SYSTEMS

ROBIA SUOMI

ROBIA

MOTOMAN
MOTOMAN
ROBIA

MOTOMAN

MOTOMAN MGM SPOL

MOTOMAN
GEIGER HANDLING
MOTOMAN
MOTOMAN
MESSER SAG REHM
MOTOMAN
RISTRO
MOTOMAN

MOTOMAN

KOUVALIAS INDUSTRIAL ROBOTS

MOTOMAN ROBOTICS EUROPE AB a YASKAWA company

Box 504 SE-385 25 Torss Sweden
Tel: +46-486-48800 Fax: +46-486-41410
www.motoman.se
Group Companies: France: MOTOMAN Robotics, Nantes +33-2-40131919, Germany: MOTOMAN Robotec, Allershausen +49-8166-90-0
MOTOMAN Robotec, Frankfurt +49-6173-6077-30, Great Britain: MOTOMAN Robotics, Banbury +44-1295-272755, Italy: MOTOMAN Robo-
tics, Modena +39-059-280496, Netherlands: MOTOMAN Benelux, Breda +31-76-5424278, Portugal: MOTOMAN Robotics, Porto +351-14968160,
Reg 7P-03-07-01INT

Slovenia: RISTRO, Ribnica +386-61-861113, Spain: MOTOMAN Robotics, Barcelona +34-93-6303478, Sweden: MOTOMAN Robotics Europe,
Torss +46-486-48800 MOTOMAN Mecatron Robotic Systems, Kalmar +46-480-444600
Distributors: Czech Republic: MGM Spol, Tabor +420-361-254571, Denmark: Robia, Vejle +45-79428000, Finland: Robia Suomi, Turku +358-
22145600, Greece: Kouvalias Industrial Robots, Kallithea +30-1-95892436, Hungary: REHM Hegesztstechnika, Budapest +36-12562012,
Israel: KNT Engineering, Kfar Azar +972-39231944, Norway: Robia, Hokksund +47-32252820, South Africa: Robotic Systems, Bertsham +27-
114943604, Switzerland: Geiger Handling, Schwarzenburg +41-31-7343111 Messer SAG, Dllikon +41-18471717