Operating Instructions For Auto Beadloader

MATHEUS Industrie-Automation
Documentation: Automatic beadloader with FANUC Robot R2000 Customer: Goodyear Chile
A. No: 70/821 00 290
Matheus Industrie-Automation
Forstweg 1
54518 Osann - Monzel
O P E R A T I N G
I N S T R U C T I O N S
for
Automatic Beadloader
Serial No: 134-001

Year of manufacture: 2007
Messrs Matheus: Telephone: +49 6535/94478-0
Fax: +49 6535/94478-10
Customer service: Telephone: +49 6535/94478-22
Fax: +49 6535/94478-30
All rights to this documentation reserved.

Protected by copyright and competition law.
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Contents:
1 Work safety 3
1.1 Explanation of symbols 3
1.2 Safe working, setup and maintenance 5
1.3 Obligations of the operator 6
1.4 Machine and important components 7
1.5 Machine layout (schematic plan) 7
1.6 Machine designation 8
1.7 Power-operated machine sections 8
1.8 Emergency Stop functions 8
2 Assembly/Disassembly 9
2.1 Transport handling 9
2.2 Commissioning 11
2.2.1 Installation of the individual machine components 11
2.2.2 Surface condition and fixing 17
2.2.3 Robot gripper with gripper changing system 20
2.2.4 Machine overview 26
2.3 Electrical connection 27
2.4 Compressed-air connection 27
2.5 Switching on the machine for the first time, preparations for commissioning 28
2.5.1 Establishment of user-defined coordinate systems [USER Frames] 28
2.6 Decommissioning 30
3 Intended use 30
3.1 Materials 30
3.2 Purpose of the machine 30
3.3 Mode of operation of the machine in chronological sequence 31
3.4 General information on the intended use 31
4 Functional description 32
4.1 General 32
4.2 Spacer variants 32
4.3 Gripper checking routine 34
4.3.1 Identical/dissimilar bead mode 34
4.4 Functional sequence 35
5 Control elements 36
5.1 Control cabinet 36
5.2 Robot controller 37
5.3 Robot teach panel 40
5.4 Control desks 41
5.4.1 Control desk to left of access door 95-1 41
5.4.2 Control desk to right of access door 95-1 43
5.5 Control cabinet cooling unit 43
6 Operation 44
6.1 Bring robot into home position 45
6.2 Automatic mode 46
6.3 Operating sequence 47
7 Faults and troubleshooting 48
8 Maintenance 49
9 Technical data 50
10 List of subsuppliers 52
11 Hazard analysis 54
11.1 Normal operation 54
11.2 Maintenance and repairs 56
11.3 Setup and programming 58
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1 Work safety
1.1 Explanation of symbols
The following safety symbols are used in these operating instructions:
Work safety symbol
This symbol is used to draw attention to the possibility of injuries or fatal accidents
when operating instructions, work instructions, prescribed working procedures and
similar are not correctly adhered to or not followed. Observe this information and
exercise particular caution in these cases. Pass on all work safety information to
other users. In addition to the information in these operating instructions, the
applicable EU safety standards must also be taken into account. Failure to observe
this information can have serious consequences for health and also result in fatal
injuries.
Attention
This symbol accompanies information, directives, requirements and correct working

procedures in these operating instructions that must be observed in order to prevent
damage to machines or machine sections.
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Electrical voltage
This symbol can be found on the control cabinet and in those areas of the machine
where a danger through electrical voltage exists. Only specialists may carry out work
at these points. The symbol also accompanies relevant chapters in these operating
instructions.
Note
This symbol serves to draw attention to a specific action. It serves to draw attention
to information intended to facilitate working procedures and prevent possible
disturbances.
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1.2 Safe working, setup and maintenance
Personnel must not be present within the machine whilst the

operator initiates dangerous movements.
Refrain from any working methods that affect safety.
Responsible personnel must verify the correct functioning of protective and safety
devices prior to starting work on the machine.
Before switching on the machine, it must be ensured that no person can be

endangered when the machine starts. Observe warning signs and symbols on the
machine.
Do not remove any guards and covers from moving parts or render them ineffective.
Safety circuits must not be overridden or rendered inactive in any way.
Tools and other objects must not be placed in the area of the safety barrier.
Free access to control devices, in particular Emergency Stop buttons, must be

ensured at all times.
If it should be necessary to enter the robotic workcell with the

machine switched on, access is permitted only via the protective
door provided.
It is forbidden to enter the machine via one of the two rolling gates
that serve for loading the machine with beads.
Before carrying out electrical work, the main switch must be

switched off and the machine disconnected from the power supply.
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When removing safety devices for repair and maintenance

purposes, the machine must be shutdown in accordance with the
requirements and the main switch locked.
On completion of maintenance and repairs, the safety devices must

be refitted, tested for proper functioning and documented prior to
resuming production.
The machine should be inspected at least once per shift for

external damage and defects. This applies in particular to safety
devices.
In the event of irregularities, do not use the machine. Notify the supervisor.
In the event of air or oil leakage, stop the machine. Notify the supervisor.
In the event of unusual smoke development or noise, switch off the machine. Notify
the supervisor.
1.3 Obligations of the operator
Only authorised persons may work on this machine. The machine operator is
responsible for authorisation.
The machine operator must make these operating instructions available to operating
personnel and ensure that the operator has read and understood the same.
Reference is made here once again to the safety information relating to the robot and
contained in the FANUC documentation. This manual does not replace intensive
training in the handling of FANUC industrial robots. Observance of the safety
information contained in the FANUC documentation is a requirement.
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1.4 Machine and important components
The automatic beadloader is divided into the following functional groups:
2 carriage stations for the adjustment of feed carriages. Located on the feed
carriages, depending on the spacer size, are 1-2 spacer stacks with beads as
well as an empty position for destacking the empty spacers. A spacer stack
contains maximum 40 beads. The feed carriages are centred in the carriage
stations.
1 robot with bead and spacergripper which picks up the spacer with beads,
separates them and transfers the beads to the beadsetter via the local
beadloader.
1.5 Machine layout (schematic plan)
Fig. 1.5-1
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1.6 Machine designation
Designation: Automatic Beadloader with FANUC Roboter R2000

Serial No: 134-001
Year of manufacture: 2007
1.7 Power-operated machine sections
All moving machine sections are driven either pneumatically or by electric motor.
These individually include:
- Rolling gates of the carriage stations

- Centering devices in the carriage stations
- Robot
- Robot gripper
Hydraulic drives are not used.
1.8 Emergency Stop functions
All Emergency Stop switches are centrally evaluated by the customer via a safety
PLC and shutdown all machine sections when actuated. Emergency Stop switches
are located on the robot hand-held operator panel, robot control cabinet and control
panel in the carriage station feed area.
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2 Assembly/Disassembly
2.1 Transport handling
The machine sections must be packed for transport so that they are adequately
protected against detrimental mechanical and climatic effects. For transport and
disassembly or assembly, the special instructions of the manufacturer must be
observed.
Individual components and large assemblies must be attached to lifting devices and
secured so that they do not constitute a hazard. Only suitable and technically perfect
lifting devices and lifting appliances with sufficient carrying capacity must be used.
Only experienced persons may attach loads and supervise crane drivers. The
supervisor must keep within the field of view of the operator or maintain voice
communication.
If the robot is transport by fork-lift truck, the forks must be inserted through the
pockets in the base frame. Any other method of transport of the robot using a
forklift truck is not permitted!
The carriage stations will be delivered in a pre-

assembled condition and have been packaged
onto a stabilised substructure.
To avoid torsions, that may have a bad

influence to the function, the carriage
station has to be carried with the Lifting gear
special lifting gear. The lifting gear has
to be mounted into the carriage station. The
lifting gear has two forklift pockets which have
to be used by carrying the carriage station with
the forklift.
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The lifting gear is applicable fort he left and the right carstation. There are two
different types of square pipes. One type always has to be mounted on the outer side
and the other always on the interior side. That means on the left side of the left
station the same square pipe has to be mounted like on the right side of the right
station! The two square pipes have to be connected with the two cross beams.
Lifting gear mounted in left station :
Square pipe 1
Cross beam
Square pipe 2
Lifting gear mounted in right station:
Square pipe 2
Cross beam
Square pipe 1
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2.2 Commissioning
2.2.1 Installation of the individual machine components
The robot is delivered already mounted on the robot base. The complete unit (robot
and base) must be aligned locally according to layout (drawing number 70/821 00
285) with respect to the bead setting machine and subsequently bolted in place. The
shear connectors and associated anchor rods are part of the scope of supply.
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The robot must only be operated when it is tightly bolted to the ground.
909 mm to centre of beadsetter
Fig. 2.2-1
2575mm to centre of beadsetter
1. The robot with base plate must be positioned as shown in the construction
drawing. The dimensions are shown in the respective construction drawing.
(Fig. 2.2-2/ Drawing No. 70/821 00 285)
2. After positioning the robot with base plate, it must be tightly bolted to the
ground using the anchor rods (M20) and associated shear connectors (resin-
anchored bolts) included in the scope of supply. (See Chapter 2.2.2, Surface
condition and fixing)
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Machine layout
Fig. 2.2-2
ATTENTION: The drawing is not true to scale!
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Fig. 2.2-3
3. The base plate of the right carriage station must be placed on the right side
of the robot base plate. In the area of the recess [3], the base plate rests
against the contour of the robot base plate.
The unit should initially be tightly bolted to the ground when all other
machine components have been installed and aligned as shown in the
layout.
4. The base plate of the left carriage station must be position on the left side
of the robot base plate. In the area of the recess [4], the base plate rests
against the contour of the robot base plate.
The unit should initially be tightly bolted to the ground when all other machine
components have been installed and aligned as shown in the layout.
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Fig. 2.2-4
5. Install and align the protective barrier. Place the robot control cabinet in the
specified position at the protective barrier [5].
Check the alignment of the individual machine components and correct the alignment
if necessary and subsequently bolt the machine to the ground at the specified points.
(Fig. 2.2.-6 / Drawing No.134-001-02-037)
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5 7 6
Fig. 2.2-5
6. The 4 guide rails of the carriage stations must be joined in the recesses
provided in the base plate, aligned and bolted in place. [6]
TIP! Join the guide rails in the recesses and bolt these only loosely. Drive a
spacer carriage into the carriage station in order to align the guide rails.
Recheck the dimensions before bolting in place.
7. Cable ducts removed for transport purposes must be refitted and the
respective cables connected as shown in the wiring diagram. The cable duct on the
ground leading to the control cabinet must be fixed in place.
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8. The metal covers above the rolling gates must be fixed in place and the
access door fitted.
9. When the machine has been fixed to the ground, the guide rollers for the
spacer carriages must be attached and adjusted. [7]
10. Once the machine has been installed and the USER frames of the carriages
have been adjusted, the gripper can be placed on a carriage, pushed in to the right
carriage station and fitted. (See fitting/removing gripper)
2.2.2 Surface condition and fixing
Evenness
To ensure that the carriage station functions correctly, the difference in level over the
entire carriage station area must be maximum 10mm. When preparing the concrete
flooring for the carriage stations, an adequately smooth surface must be ensured, as
the carriage stations connected with assembly plates are bolted to the concrete
flooring.
Floor type
If the machine is installed directly on the concrete, the pertinent building regulations
for the concrete quality (>= B25 according to DIN 1045) and the load bearing
capacity of the foundation must be observed.
Fixing the carriage station
The assembly plates are provided with through holes with a diameter of 14 mm.
Depending on the particular installation requirements, the components must be fixed
using split drive anchors or resin-anchored bolts.
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Material used
Split drive anchors: BTI Simplex anchors S-KA M12 x 100/M12 x 120/M12 x 140
Resin-anchored bolts: Wrth W-VD M12, Art. No. 0905412

Wrth W-VD M12 x 220 VZ, Art. No. 0905410121
Fixing the robot
The robot base plate or robot base is fixed using 8 M20 x 260 anchor rods and the
associated composite connectors (resin-anchored bolts). Protruding anchor rods can
be cut off above the nut with an abrasive cutting machine on completion of
installation.
Suitable for fixing are also anchors of the company Wrth
Composite connector: W-VD M20, Art. No. 0905420

Anchor rod: W_VD M20 x 260 VZ, Art. No. 09054126
Ground thickness
The ground thickness should be minimum 220 mm. The foundation must have the
appropriate load bearing capacity.
The carriage station and robot fixing points are shown in Fig. 2.2.6.
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Attention: The drawing is not true to scale!!!
Fig. 2.2-6
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2.2.3 Robot gripper with gripper changing system
Lock Measuring system
Gripper
changing
system
Fig. 2.2-7
The robot gripper can be adapted to the robot with the gripper changing system. The
gripper changing system is already fitted on the robot and gripper. For adaptation of
the gripper, the robot and gripper changing part must be joined and the gripper
changing system locked by turning 180 clockwise. A size 19 open-end spanner can
be used for this purpose. When the system is locked, the electrical and pneumatic
connections are automatically established.
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It is recommended to only adapt the gripper when the robot is tightly

bolted, connected and ready for operation so that it can be moved
into a "convenient" installation position.
For decoupling the gripper, it should be moved to a suitable support using the manual
functions of the robot. The gripper changing system can subsequently be released by
turning 180 anti-clockwise; electrical and pneumatic connections are automatically
disconnected at the same time.
Prior to releasing the system, the gripper must be secured against

falling. Air and power must be disconnected prior to decoupling.
For fitting or removing the gripper via the existing programs, the
USER frames must be setup for the left and right carriage. (See
Chapter 2.5-1).
Fitting the gripper
To fit the gripper, place the same in the centre spacer position of the 750 spacer
carriage so that the gripper changing system faces the centre of the cell and bring it
into position in the right cell.
In the SELECT screen, select the program J_GRMO. Select the T1 mode on the
controller via the key-switch and start the program. (SHIFT FWD) The robot stops
with the robot flange of the sixth axis in front of the gripper changing system. Check
that the gripper changing system is positioned exactly opposite to the gripper. Move
in Y+ direction (in WORD coordinate system) into the gripper changing system of the
gripper and lock the gripper changing system. Check for correct fixing. After fixing the
gripper, move in Z+ direction (in WORD coordinate system) until the gripper is
released. Open the compressed air on the robot arm and check the connection.
The program can subsequently be continued. The robot traverses to the home
position.
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Removing the gripper
Close the compressed air on the robot arm.

To remove the gripper, in the SELECT screen program select the program
J_GRDEMO. Select the T1 mode on the controller via the key-switch and start the
program. The robot moves towards the gripper rack above the centre spacer stack
of the 750 carriage; release the gripper changing system.
Carefully move the gripper manually back and forth to release it from the robot
flange. Caution! The gripper plate drops a few centimetres when released. For this
reason, hold the gripper plate and lower it carefully. Once the gripper is released, the
program can be continued (SHIFT FWD); the robot moves back into the home
position.
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Gripper overview
Fig. 2.2-8
1. Spacergripper
3. Pusher
2. Beadgripper
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1. The 4 spacergrippers serve for aligning the stack and gripping the
spacers.
2. The 6 beadgrippers serve for gripping the beads.
3. The spacer is separated from the bead with the pushers. The pushers
are used for scanning the stack height in search mode.
4. If a bead is in the gripper, the bead diameter is measured with the

integrated measuring system and compared with the setpoint value,
plus minus the given measuring tolerance. If the value is outside the
tolerance, the bead is identified as a reject and the robot traverses to
the reject position. The operator can subsequently remove this bead
and continue.
5. The gripper can grip beads with a diameter of 14 to 24 inches (356.62

to 622.81 mm). The gripper must be converted for larger diameters.
On the 750 spacer, beads with an inside diameter of 14" to 24" can be
gripped depending on the apex.
If beads with an inside diameter larger than 22 inches are used, the
beadgrippers must be fitted in the outer position. If beads with an inside
diameter smaller than 16 inches are used, the beadgrippers must be
fitted in the inner position. (See Fig. 2.2-9)
Beads from 14" to 22" are handled on the 750 spacers.

Beads from 16" to 24" are handled on the 900 spacers. When using the
900 spacer, the beadgrippers, spacergrippers and pushers must be
converted. (See Fig. 2.2-9)
6. In the gripping finger configuration for the 750 spacer, the pushers (4x),
beadgrippers (6x) and spacergrippers (4x) are located in the inner
position (black circle). In order to convert the grippers to the 900 spacer,
these must be moved outwards (red dashed circle). (See Fig. 2.2-9)
Always observe the safety instructions of FANUC Robotics! This

manual does not replace intensive training in the handing of
industrial robots. An exact description of operation of the robot is
contained in the documentation of FANUC Robotics.
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Gripper overview, conversion of gripping modules
Pusher
Beadgripper Spacergripper
Fig. 2.2-9
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2.2.4 Machine overview
1
7
5 4 3 2
Fig. 2.2.3.1 Machine overview
0 Station signal lamp (left, right)

1 Rolling gates
2 Right carriage station
3 Access protective door
4 Left carriage station
5 Maintenance unit, compressed air supply
6 Robot controller
7 Control cabinet
8 Robot
9 Protective barrier
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2.3 Electrical connection
The machine is delivered by the manufacturer ready to use.
Connection of the energy supply takes place according to the supplied diagram by
the customer. Only specialists may establish connections. Only establish connections
with the main switch off!
When carrying out installation or other work in the control cabinet, the
devices must be protected from falling objects (wire residues, wires,
metal chips) as these can cause a short-circuit.
The control must be installed in a moisture-free location. Protect the machine from
dirt and other damaging environmental influences.
Delivery of the machine takes place in modular units, consisting mainly of two
carriage stations, a robot with robot gripper mounted on a base as well as a robot
control cabinet. All control and load cables are single-ended pluggable. When
installing the machine locally at end customers, the electrical connections for the
robot are established on the robot base or for the carriage stations at the robot
control cabinet.
Ensure that any identical connectors are not interchanged.
Connectors must only be disconnected or connected with the operating

voltage switched off.
2.4 Compressed-air connection
The air pressure in the connecting pipe must be 6 bar and filtered. Air pressure
variations can impair the function of the pneumatic units.
The supply point for the machine is located at the maintenance unit on the right next
to the robot control cabinet. (Fig. 2.2.3-1)
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When carrying out repairs or maintenance work, the compressed-air supply must be
locked to prevent injuries. Depending on the position and condition of the gripper,
movements can be initiated through compressed-air inclusions in the system. When
disconnecting pressurised hoses, these can lash out and cause injuries; the
compressed-air must therefore always be shut-off prior to disconnection. This applies
similarly to pressurised motional units through spring force when opening the air
circuit.
2.5 Switching on the machine for the first time, preparations for
commissioning
Check the compressed air at the supply point.

Check the set air pressures at the gripper (Z-stroke, gripping finger) and
carriage stations (pawl, locking mechanism) according to the inspection report.
Check the applied supply voltage in the robot control cabinet.
Switch on main switch.
New measurement and inspection of robot frames
Positioning of the robot in the room with respect to the programmed

points depends on the determined reference coordinates (frames).
Repositioning of the robot in the room or changing a frame changes the
reference to motions. Frames and local positioning of the robot must therefore
correspond.
2.5.1 Establishment of user-defined coordinate systems [USER Frames]
Workpiece accommodation depends on the coordinate system of the carriage, since

all positions are approached with a special coordinate system.
For setting up the coordinate system, a teach point exists with which 3 special points
on the carriage (see Fig. 2.5-1) must be approached and stored. (Three point
method). The point is attached to the gripper changing system.
The first point is an orientation point that must be programmed first. This is followed
by the point for X orientation which defines the direction in X-direction. The Y
orientation point is programmed last which defines the Y-direction of the frame. The
U-frame is determined in this way.
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Always observe the safety requirements of FANUC Robotics! This

manual does not replace intensive training in the handing of
industrial robots. An exact description for setting up the user-
defined coordinate system (USER-Frame) is contained in the
documentation of FANUC Robotics.
Y orientation point
Orientation point X orientation point
Fig. 2.5-1 USER frame setting up points
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2.6 Decommissioning
If replacements, adjustments, maintenance or repairs have to be carried out or

disassembly of the machine is planned, the machine must be switched off and locked
to prevent unauthorised reconnection.
3 Intended use
3.1 Materials
The machine is designed for:
Left beads
Right beads
Universal, i.e. identical beads with a minimum size of 14" or a maximum size of 24"
internal diameter.
Spacers
With the external dimensions 750 x 750 mm or 900 x 900 mm. The spacers serve as
workpiece carriers for the beads.
3.2 Purpose of the machine
Loading the local beadloader with left, right or identical beads.
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3.3 Mode of operation of the machine in chronological sequence
The operator moves a feed carriage loaded with spacers and beads into the
carriage station. Attention must be paid to the appropriate bead and spacer size.
Following acknowledgement of the carriage station, the rolling gate is closed.
The robot takes a spacer with bead from the respective stack and subsequently
deposits the spacer in the empty position provided.
The bead located in the gripper is placed in the locally waiting beadloader.
Depending on whether identical or dissimilar beads are used, the loader takes
spacer with bead for the left and right side of the beadloader from one and the
same carriage or from both carriages. (Identical beads = 1 carriage, dissimilar
beads = 2 carriages)
The robot takes a second spacer with bead from the respective stack, deposits
the spacer in the empty position provided. and loads the locally waiting
beadloader with the bead located in the gripper With the second bead, the
beadloader is complete, i.e. the beadsetting process can be started.
When all beads on the feed carriage have been processed, the feed carriage filled
with empty spacers can be removed from the machine by the operator and the
machine can be loaded with a full feed carriage.
3.4 General information on the intended use
Use for any other purpose is considered improper and not for the intended purpose.
MATHEUS Industrie-Automation disclaims all liability for any damage attributed to
such use.
The intended use includes
the observance of all information contained in the operating instructions as well as

the information signs on the machine components and the observance of inspection
and maintenance intervals.
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4 Functional description
4.1 General
4.2 Spacer variants
The automatic beadloader can be operated with two different spacer sizes and
therefore in two different operating modes:
1. Spacer size 750x750 mm

2. Spacer size 900x900 mm
A feed carriage for 750 x 750 mm spacers offers 3 positions for one spacer stack
respectively. When the machine is fed a new carriage loaded with beads, the first
position must be empty, as shown in the graphic. This minimises the time the robot
requires to detect the available stack for calculating its destacking routine and speeds
up the process.
Spacer carriage for spacer size 750x750
Position 1
Position 2
Position 3
Fig. 4.2-1
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A feed carriage for 900 x 900 mm spacers offers 2 positions for one spacer stack
respectively. When the machine is fed a new carriage loaded with beads, the first
position must be empty, as shown in the graphic. This minimises the time the robot
requires to detect the available stack for calculating its destacking routine and makes
the process quicker.
Space carriage for spacer size 900x900
Position 1
Position 2
Fig. 4.2-2
Destacking always takes place from the back to the front, i.e. from the gate
opening in the direction of the robot. For a 750 spacer carriage with 3 stacking
positions, this means that destacking takes place from position 2 to position 1
and subsequently from position 3 to position 2. For 1 900 spacer carriage with
2 stacking positions, destacking takes place from position 2 to position 1.
A spacer with beads must never stand in the first position. In this case, the
robot generates an error message and the carriage must be moved out of the
carriage station.
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4.3 Gripper checking routine
The gripping fingers for bead and spacergrippers must be fitted according to the
bead and spacer size. In order to exclude the possibility of incorrect fitting of the
gripping fingers, the robot checks via an external sensor the gripping fingers each
time a different spacer size (750/900) is selected or each time the type defined by the
higher-level control is changed. The external sensor is located on the protective
barrier of the machine. The robot moves the gripping fingers across the sensor. If the
gripper check is unsatisfactory, the robot stops with the generation of an appropriate
error message.
4.3.1 Identical/dissimilar bead mode
The automatic beadloader can be operated with identical or dissimilar beads.
With identical beads, the same bead is used on the left and right side of the
beadsetter. Differentiation is unnecessary; the left and right beads can be taken from
the same carriage.
For operation with dissimilar beads, a left bead is used on the left side of the
beadloader and a right bead on the right side. The machine is provided with 2 feed
carriages, whereby one carriage contains only left beads and the other only right
beads. Left beads are transferred with the feed carriage to the left carriage station
and right beads to the right carriage station.
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4.4 Functional sequence
The feed carriages loaded with spacers and beads are pushed into the carriage
station by the operator. The rolling gates close when the respective button is
pressed.
After starting the machine, the carriages are locked in the carriage station. A
plausibility check is carried out on the selected carriages. (Carriage check 750er/900)
The robot takes a spacer with bead from the feed carriage. separates bead and
spacer and deposits the empty spacer in the empty position of the same feed
carriage. The diameter check of the bead which serves for type verification takes
place by means of a measuring system on the gripper. The robot moves towards the
beadloader and transfers the bead to the right side of the beadloader. The same
sequence subsequently takes place for the left side.
With the identical bead mode, the carriages are processed in succession. With the
dissimilar bead mode, the carriages are processed simultaneously. The rolling gates
open automatically when both carriages are empty so that no more material is
available.
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5 Control elements
5.1 Control cabinet
The control cabinet in which the machine control is located is installed above the
robot controller.
Control cabinet arrangement
Fuses
Rolling gate
FANUC PLC
Terminal strip socket

outlet
Safety PLC
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Bead selection 750/900

5.2 Robot controller
Robot ready and HOME
Robot abort
Robot immediate stop
Emergency Stop
RS-232-C/USB
Power
Fault
Cycle Start
Fault Reset
Key-switch T1/T2
Main switch
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Bead selection switch 750/900
This switch is used to select the bead size. A gripper check is carried out when this
switch is pressed.
Robot ready and in HOME position
This indicator light shows that the robot is ready and in the HOME position.
Robot abort
This button serves to abort the robot program. Restarting is no longer possible. The
machine must be brought into the home position and the main program restarted.
Robot immediate stop
This button serves to immediately stop the robot. Restarting can take place by
pressing the CYCLE START button.
EMERGENCY STOP
Pressing the Emergency Stop button will immediately stop all machine sections. The
Emergency Stop buttons must be released by pulling out.
The Emergency Stop function must only be used in "emergencies". This button must
not be used to switch the machine ON or OFF as in normal operation. The
Emergency Stop function must be tested for correct functioning as a matter of
routine.
Power indicator light
This indicator light shows that the controller is switched on.
FAULT indicator light
This indicator light shows whether a fault is present at the robot.
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[CYCLE START] button
This button serves for starting the program via the robot controller (only active when
the setting "LOCAL" is selected in system/config. This indicator light also shows the
operating status of the robot.
[FAULT RESET] button
This button serves for acknowledging robot faults.
T1/T2/AUTO key-switch
This switch must be set to the position AUTO for operation in an automatic mode.
With the protective door circuit open, the robot cannot be moved in the setting AUTO
as the robot is interlocked on the hardware side.
In the setting T1, the protective door circuit is overridden on the hardware side. The
robot can now be moved at safety speed (5%). This setting is recommended for the
normal operator in order to avoid uncontrolled movements.
In the setting T2, the protective door circuit is overridden on the hardware side. The
robot can now be moved with the set override. This setting serves for testing under
real conditions and should be used only by trained specialists.
USB interface
This interface is intended for a USB stick for backing up robot data.
RS-232-C interface
This interface serves for data backup and communication.
Main switch
The machine is switched off with the main switch.
Attention! Voltage is still present on the main switch also when it is

switched off. Dangerous external voltages may also be present
when the main switch is off. This must be separately disconnected
from the external source.
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5.3 Robot teach panel
Override display
Suspension unit
Status LEDs
TFT display
Emergency Stop
button
Function keys
Hot keys
[Fanuc Menus]
Navigation TP On/Off
buttons
Shift key (2x)

[movement release]
Direction keys
Cartesian (-X, +X, etc.)
Axis spec. (-J1, +J1, etc.)
Enabling button
on the back
Stop button
[program processing]
Display change
Program step
Forward/Back
Single step
selection
Selection of traversing
coordinate system
Fault reset
Hot key
Number block [operator menu]
Hot key Traversing speed

[current position] Hot key Hot key override (in %)
[inputs/outputs] [Status menu]
Fig. 5.3-1 iPanel
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5.4 Control desks
5.4.1 Control desk to left of access door 95-1
96X1
Emer-
gency
STOP
Open
rolling gate
Close
rolling gate
Start
EMERGENCY STOP
Pressing the Emergency Stop button will immediately stop all machine sections. The
Emergency Stop buttons must be released by pulling out.
The Emergency Stop function must only be used in "emergencies". This button must
not be used to switch the machine on or off as in normal operation. The Emergency
Stop function must be tested for correct functioning as a matter of routine.
Open rolling gate
In automatic mode:
When the "Open rolling gate" button is pressed, the carriage in the station is released
first and the rolling gate subsequently opened.
Teach mode:
The rolling gate opens immediately when this button is pressed.
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Close rolling gate
In automatic mode:
When the "Close rolling gate" button is pressed, the carriage in the station is locked
first and the rolling gate subsequently closed when the robot is in the HOME position.
This button must be pressed and held when closing the gate for safety reasons.
Teach mode:
The rolling gate closes immediately when this button is pressed. This button must be
pressed and held when closing the gate for safety reasons.
Start
The machine can be acknowledged again and started (continued start) by pressing
the Start button if the program was not aborted.
If a reject bead is detected by the robot for example, it moves into the reject position.
The operator can now open the access door and remove the reject bead from the
gripper. After leaving the cell and closing the door, the robot resumes its automatic
sequence when the Start button is pressed.
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5.4.2 Control desk to right of access door 95-1
97X1
Open
rolling gate
Close
rolling gate
Door
request
Door request
Release of the maintenance doors can be requested with this button. The button
flashes when the request is being processed. When the button lights up, the doors
are released and can be opened. When the button is pressed, the doors are locked
again.
The access door can also be opened when the hand-held operator panel is switched
on.
5.5 Control cabinet cooling unit
The air conditioning unit is preset. The fan of the air conditioning unit operates
continuously and recirculates the air in the control cabinet.
If the temperature in the control cabinet exceeds 35C, the unit switches to cooling
operation.
Observe the operating instructions of RITTAL!
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6 Operation
These operating instructions supplements the general manuals of FANUC Robotics

with regard to the special requirements relating to this application.
All topics described in the operating, programming, electrical and

mechanical maintenance manuals are not part of this
documentation.
This manual does not replace intensive training in the handing of

industrial robots.
Observe the safety information in the machine manufacturer's

operating instructions and the safety information in the robot
documentation of FANUC.
44
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6.1 Bring robot into home position
As long as no complete program abort takes place, the robot reaches its home
position by processing the automatic program.
The robot can be moved into the home position via the hand-held operator panel
(teach panel).
- Set the mode selector switch to "Manual".

(Hold signal is released when teach panel is activated).
- The first line of the teach panel display must show ABORTED.
If this is not the case, the current robot program must be aborted.
On the hand-held operator panel (teach panel) press the [FCTN] and [ABORT ALL]
key.
- Take the teach panel and grip the deadman's switch on the back.
- Switch on the teach panel (ON).
- Move the robot manually.
Select the traversing mode via the [COORD] button (Joint = individual axes,
WORLD= linear XYZ). Set the override to a small percentage value (5 to 10%).
Retract the robot manually via the blue direction keys (+X,-X,+Y.....) and SHIFT until
it is located roughly in the home position or the robot is positioned in such a way that
it is able to traverse along a direct path to its home position without collision.
The [SHIFT] key must remain depressed during the traversing motion.
- Select the referencing program:

Choose the "Select" key.
In the selection list, choose the program routine "P_HOME" via the cursor direction
keys and confirm the selection by pressing the Enter key.
Press and hold the "SHIFT" softkey.
Press the "FORWARD" softkey.
The robot traverses to the home position. If there is a risk of collision, immediately
release the deadman's switch or Shift key. When the program has been processed
completely, the display must show Robot in home position. On the hand-held
operator panel (teach panel) subsequently press the [FCTN]und [ABORT ALL] key.
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Referencing carried out using the teach panel can damage the robot
and machine sections as the robot traverses directly to the home
position. A precondition therefore is that the robot is not subject to
any obstacles, enabling it to reach the home position without
collision.
6.2 Automatic mode
Interfacing to the higher-level machine control takes place via Device-Net.
Starting of the automatic program externally is realised via the standard program
selection, PNS-Select (Program Number Select).
The following preconditions must be fulfilled for starting the automatic mode:
- Main switch is switched on.

- Robot is switched on.
- The Emergency Stop circuit must not be interrupted.
- The protective doors must be closed.
- The mode selector key-switch must be set to AUTO.
- REMOTE must be set in System/Config for Master Selection.
- The robot must be in its home position.
- The selector switch on the teach panel must be switched off.
- No step operation must be selected.
- No fault must be present.
Behaviour in the event of a power failure: In the event of a power failure or

if the machine is switched off during operation, the robot stops in its currently
assumed position.
On reconnection of the power supply or after switching on the machine again, the
robot automatically interrupts the last active program and performs a referencing
routine after pressing the "Cycle Start" button. If the robot has spacers or beads in
the gripper, the service position is initially approached. The parts must then be
removed by the operator. Before the robot starts the next destacking cycle, a search
routine is performed.
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6.3 Operating sequence
- The operator loads the machine with beads located in the spacers provided via
a carriage. Attention must be paid to the appropriate bead and spacer size.
- With the gripping finger configuration for 750 spacers, bead internal diameters
from 14" to 22" can be gripped on a 750 spacer.
- With the gripping finger configuration for 900 spacers, bead internal diameters
from 16" to 24" can be gripped on a 900 spacer.
- Depending on whether a left or right bead is required, the robot takes a spacer
loaded with bead from the respective carriage.
- The robot grips the bead and places the spacer in the stacking position for the
empty spacer of the same carriage.
- The robot transfers the bead to the beadloader.
- When the beadloader is provided with a left and right bead, the sequence is
complete.
- If there are only 6 beads left on the just processed carriage, the signal lamp
above the rolling gate starts to flash.
- If the robot has set the empty spacers to maximum and there are no further
beads on the carriage, the robot continues to work with the other carriage.
When both carriages are empty, the signal lamps above the gates light up and
the rolling gates open automatically.
- The carriage filled with empty spacers can be removed again by the operator
and replaced with a full one.
- After a new carriage with beads is pushed into the cell and the locking station
locks, the rolling gates can be closed. The rolling gate button must be kept
depressed until the gate is closed.
- Each time the access protective door or a rolling gate is opened, a search
routine is performed as the state of the carriage may have changed and a risk
of collision exists.
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7 Faults and troubleshooting
Fault description Measure

Robot is not in home position Bring robot into home position
UO 7 = OFF
No type defined by PLC/Start not possible Comes from higher-level control
Control set to "left index closed"/Control Check compressed-air system, initiator,
DI[81] = ON mechanism
Control set to "left index open"/Control Check compressed-air system, initiator,
Control set to "left index advanced"/Control Check compressed-air system, initiator,
Control set to "left index retracted"/Control Check compressed-air system, initiator,
Control set to "left rolling gate open"/Control Check initiator, mechanism
DI[85] = ON
Control set to "left rolling gate closed"/Control Check initiator, mechanism
DI[86] = ON
Control set to "right index closed"/Control Check compressed-air system, initiator,
Control set to "right index open"/Control Check compressed-air system, initiator,
Control set to "right index advanced"/Control Check compressed-air system, initiator,
Control set to "right index retracted"/Control Check compressed-air system, initiator,
Control set to "right rolling gate open"/Control Check initiator, mechanism
DI[101] = ON
Control set to "right rolling gate closed/Control Check initiator, mechanism
DI[102] = ON
Control set to "beadgripper open"/Control Check compressed-air system, initiator,
RI[1] = ON mechanism
Control set to "beadgripper closed"/Control Check compressed-air system, initiator,
RI[1] = OFF mechanism
Control set to "spacergripper open"/Control Check compressed-air system, initiator,
Control set to "spacer-pusher retracted"/Control Check compressed-air system, initiator,
Control set to "spacer-pusher extended"/Control Check compressed-air system, initiator,
RI[3] = OFF mechanism
Control set to "spacer-pusher extended"/Control Check compressed-air system, initiator,
Control set to "spacergripper closed"/Control Check compressed-air system, initiator,
Control set to "beadcentering in home position"/ Check compressed-air system, initiator,
Control RI[8] = ON mechanism
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8 Maintenance
Machine components Maintenance Interval
Robot Minor maintenance 1 year

(FANUC-Robotics)
Robot Major maintenance 1.5 years
(FANUC-Robotics)
Gripper Relubricate guide carriage 1 year
(Drawing No.134-001-01-Z01;
part 514,515) 6X
Grease: Multifak EP1, TEXACO
Only authorised specialists may carry out maintenance. The axis

drives of the robot must not be relubricated. Relubrication can
cause gear or motor damage.
For further information on maintenance of robot components, refer

to the operating instructions of FANUC Robotics!! This manual
does not replace intensive training in the handing of industrial
robots.
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9 Technical data
Operating conditions:
Site of installation up to 1000m above mean sea level

Vibration-free
No aggressive gases
Building Covered and closed
Ambient temperature 0-45C
Humidity max. 75 %
Compressed air 6 bar
Compressed air filtered
Ratings:
Load voltage 380V - 415V

Control voltage 24V DC
Power input: 13 kVA
Frequency 50/60Hz
Batteries 1.5V, type D
Right, left carriage station:
Length 3212.06 mm
Width 1399.52 mm
Height 2440.00 mm with protective barrier
Height 2772.00 mm max. Protective barrier
Robot with base plate in transport position:
Length 1691.00 mm Transport position

Width 1200.00 mm Base plate
Height 1978.00 mm Transport position
Weight 1800.00 kg with base plate
Gripper:
Length 994.14 mm
Width 790.00 mm
Height 490.50 mm
Weight 102.00 kg
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Controller with control cabinet:
Length 780.00 mm
Width 590.00 mm
Height 2300.00 mm
Weight 320.00 kg
Right, left carriage
Length 2776.00 mm
Width 1068.00 mm
Height 1061.00 mm
Weight 680.00 kg
The machine must not be operated or stored in an environment

subject to strong vibrations, fouling, temperature fluctuations,
moisture, splashing cutting oil or other foreign substances.
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10 List of subsuppliers
Subsuppliers Component
FANUC Robotics Deutschland GmbH Robot R-2000iA/125L

Bernhuser Strae 36
D-73765 Neuhausen a. d. F.
Germany
Tel. : +49 7158 9873 - 0

Fax : +49 7158 9873 100
Festo AG & Co. KG Pilot valve

Postfach Solenoid valve
73726 Esslingen
Ruiter Strae 82
73734 Esslingen-Berkheim
Tel: ++49 (0)711 / 34 70

Fax: ++49 (0)711 / 347 21 44
Rittal GmbH & Co.KG Control cabinet cooling unit

Auf dem Sttzelberg
35745 Herborn
Tel: 02772/505-0
Fax: 02772/505-2319
Rockwell Automation Motor protecting switch

1201 South Second Street Contactor
Milwaukee, Wisconsin 53204-2496 USA
Tel: (1) 414.382.2000 | Fax: (1)

414.382.4444
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Subsuppliers Component
Schmersal Holding KG Latched safety switch

Mddinghofe 30
42279 Wuppertal
Telephone: +49-(0)202 / 6474-0

Fax: +49-(0)202 / 6474-100
SICK AG T-slot switch

Erwin-Sick-Str. 1
79183 Waldkirch
Tel. +49 7681 202-0

Fax. +49 7681 202-3863
TORMAFA GmbH High-speed gate

Tor- und Maschinenschutz Fabrikate
Wissenschaftspark Petrisberg WIP
Max-Planck-Str. 6
54296 Trier
Tel: 0651 - 9790188

FAX 0651 - 9790187
mail@tormafa.de
HIWIN GmbH Guide carriage on gripper (514, 515)

Brcklesbnd 2,
D-77654 Offenburg
Tel: + 49 (0) 781 93278-0

Fax: + 49 (0) 781 93278-90
The requirements relating to the intended use and maintenance as well as

the safety requirements of the subsuppliers must be observed!
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11 Hazard analysis
11.1 Normal operation
Danger Dangerous situation Risk Protective measure Reference

standard
Entrapment, Automatic movements Injuries due to Protective barrier around EN 12100-1,
shearing, of the machine standing in the the entire operating area EN 12100-2,
impact components and operating area of of the machine EN 10218,
robot. the robot and dimensioned so that it is EN953, EN1088
automatic able to withstand the
movements of force of the robot.
machine Locking doors in normal
components. operation.
Entrapment, Locking of spacer Injuries through Locking of spacer feed EN 12100-1,
shearing feed carriages in pneumatically carriage only possible EN 12100-2,
carriage stations driven lifting with closed protective EN954-1
cylinders. zone. Safety circuit Cat.
4 for rolling gates and
maintenance door.
Entrapment, Entering the operating Injuries due to Protective barrier around EN 12100-1,
shearing, area of the robot and standing in the the operating area of the EN 12100-2,
impact beadloader. operating area of robot and beadloader. EN 10218,
the robot and Locking doors in normal EN953, EN1088
automatic operation.
movements of Information in operating
machine instructions:
components. - Access to robot cell
only permitted through
maintenance door!
- Before acknowledging
the maintenance door,
the operator must
ensure that there are no
persons in the robot cell!
Entrapment, Standing in the area Injuries through Safety contact strip
impact of the rolling gate standing in the stops downward
while the gate is being area of the rolling movement of the rolling
closed. gate while the gate and simultaneous
gate is being reversal of direction on
closed. actuation.
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The following protective measures are not included in the scope of supply
of MATHEUS, but must be provided locally by HARBURG
FREUDENBERGER.
Danger Dangerous Risk Protective measure Reference

situation standard
Entrapment, Entering the Injuries due to EN 12100-1,
shearing, operating area of standing in the Monitoring of the EN 12100-2,
impact the robot and operating area of danger zone by EN 10218,
beadloader through the robot and horizontally arranged EN954-1
the open protective automatic light barriers on the
barrier in the area of movements of transfer carriage and
the beadsetter machine safety contact mat in
during operation. components. the floor area. When
the light barrier is
interrupted or when the
safety contact mat is
actuated, the robot as
well as all automatically
operated machine
components are
stopped.
Information in operating
instructions:
- Access to robot cell
maintenance door!
the operator must
ensure that there are
no persons in the robot
cell!
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11.2 Maintenance and repairs

situation standard
Entrapment, Robot movements Entering the Release of EN 12100-1,
shearing, outside operating area of movements via EN 12100-2,
impact programmed paths the robot during enabling and EN 10218
traversing and operating buttons,
gripper motions. reduced speed (see
also robot manual),
operation only by
trained personnel,
information in
operating instructions.
shearing, with the protective operating area of movements via EN 12100-2,
impact door open the robot during enabling and EN 10218
traversing and operating buttons,
gripper motions. reduced speed (see
also robot manual)
Entrapment, Compressed air Air can escape Main air valve (local) EN 12100-1,
shearing, available also when when pneumatic for maintenance and EN 12100-2
impact protective door is lines are repair purposes.
open disconnected. Information in
Unexpected operating instructions:
movements through
pressure loss.
Electric shock Maintenance and Contact with live Main switch, EN 12100-1,
repair of electrical parts. information sign, EN 12100-2,
components information in EN60204-1
operating instructions:
Electric shock Components live Contact with live Earthing of all EN 12100-1,
due to malfunctions parts. machine components. EN 12100-2,
EN60204-1
Locked in the Locked in the Injuries through Information in EN 12100-1,
machine after machine on starting movements of robot operating instructions: EN 12100-2,
access through and machine - Access to robot cell EN 10218
maintenance component on only permitted
door unexpected starting through maintenance
of the machine. door!
- Before
acknowledging the
maintenance door,
the operator must
no persons in the
robot cell!
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FREUDENBERGER.

situation standard
Locked in the Locked in the Injuries through EN 12100-1,
machine after machine on starting movements of Monitoring of the EN 12100-2, EN
access through robot and danger zone by 10218, EN954-1
the open machine horizontally arranged
protective component on light barriers on the
barrier in the unexpected transfer carriage and
area of the starting of the safety contact mat in
beadsetter machine. the floor area. When
operated machine
components are
stopped.
instructions:
maintenance door!
the operator must
cell!
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11.3 Setup and programming
Dangerous Reference
Danger situation Risk Protective measure standard
shearing, outside programmed operating area of movements via EN 12100-2,
impact paths the robot during enabling and operating EN 10218
traversing and buttons, reduced
gripper motions. speed (see also robot
manual), operation
only by trained
personnel, information
in operating
instructions.
shearing, with the protective operating area of movements via EN 12100-2,
impact door open the robot during enabling and operating EN 10218
traversing and buttons, reduced
gripper motions. speed (see also robot
manual)
Locked in the Locked in the Injuries through Information in EN 12100-1,

machine after machine on starting movements of robot operating instructions: EN 12100-2,
access and machine - Access to robot cell EN 10218
through component on only permitted through
maintenance unexpected starting maintenance door!
door of the machine. - Before
acknowledging the
maintenance door, the
operator must ensure
that there are no
persons in the robot
cell!
During programming
or setting up the robot,
the operator takes the
teach panel in the
machine, the TP has
an EMERGENCY
STOP button.
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FREUDENBERGER.

situation standard
Locked in the Locked in the Injuries through EN 12100-1,
machine after machine on starting movements of Monitoring of the EN 12100-2, EN
access through robot and danger zone by 10218, EN954-1
the open machine horizontally arranged
protective component on light barriers on the
barrier in the unexpected transfer carriage and
area of the starting of the safety contact mat in
beadsetter machine. the floor area. When
operated machine
components are
stopped.
instructions:
maintenance door!
the operator must
cell!
During programming or
setting up the robot, the
operator takes the
teach panel (TP) in the
machine, the TP has an
EMERGENCY STOP
button.
59

Operating Instructions For Auto Beadloader

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MATHEUS Industrie-Automation

Serial No: 134-001

All rights to this documentation reserved.

1.1 Explanation of symbols

The following safety symbols are used in these operating instructions:

Work safety symbol

This symbol accompanies information, directives, requirements and correct working

1.2 Safe working, setup and maintenance

Personnel must not be present within the machine whilst the

Refrain from any working methods that affect safety.

Before switching on the machine, it must be ensured that no person can be

Free access to control devices, in particular Emergency Stop buttons, must be

If it should be necessary to enter the robotic workcell with the

Before carrying out electrical work, the main switch must be

When removing safety devices for repair and maintenance

On completion of maintenance and repairs, the safety devices must

The machine should be inspected at least once per shift for

1.3 Obligations of the operator

1.4 Machine and important components

The automatic beadloader is divided into the following functional groups:

1.5 Machine layout (schematic plan)

1.6 Machine designation

Designation: Automatic Beadloader with FANUC Roboter R2000

1.7 Power-operated machine sections

- Rolling gates of the carriage stations

Hydraulic drives are not used.

1.8 Emergency Stop functions

2.1 Transport handling

The carriage stations will be delivered in a pre-

To avoid torsions, that may have a bad

Lifting gear mounted in left station :

Lifting gear mounted in right station:

2.2.1 Installation of the individual machine components

909 mm to centre of beadsetter

2575mm to centre of beadsetter

ATTENTION: The drawing is not true to scale!

2.2.2 Surface condition and fixing

Fixing the carriage station

Resin-anchored bolts: Wrth W-VD M12, Art. No. 0905412

Fixing the robot

Suitable for fixing are also anchors of the company Wrth

Composite connector: W-VD M20, Art. No. 0905420

Attention: The drawing is not true to scale!!!

2.2.3 Robot gripper with gripper changing system

Lock Measuring system

It is recommended to only adapt the gripper when the robot is tightly

Prior to releasing the system, the gripper must be secured against

Fitting the gripper

Removing the gripper

Close the compressed air on the robot arm.

2. The 6 beadgrippers serve for gripping the beads.

4. If a bead is in the gripper, the bead diameter is measured with the

5. The gripper can grip beads with a diameter of 14 to 24 inches (356.62

Beads from 14" to 22" are handled on the 750 spacers.

Always observe the safety instructions of FANUC Robotics! This

Gripper overview, conversion of gripping modules

2.2.4 Machine overview

Fig. 2.2.3.1 Machine overview

0 Station signal lamp (left, right)

2.3 Electrical connection

The machine is delivered by the manufacturer ready to use.

Ensure that any identical connectors are not interchanged.

Connectors must only be disconnected or connected with the operating