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SAMPLE OPERATIONAL MANUAL ALISA AXTMAN

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SAMPLE OPERATIONAL MANUAL ALISA AXTMAN

  1. 1. VersaBuilt VBX-160 Operator’s User Manual 
 Operator Manual Version 1.1 VersaBuilt VBX-160 12/2015
  2. 2. 1 Overview 1............................................................................................................. 1.1 VBX-160 Overview 1...................................................................................... 1.2 Operator Manual Overview 1......................................................................... 1.3 Technical Support 1........................................................................................ 2 Safety 2.................................................................................................................. 2.1 Intended use of VBX-160 2............................................................................ 2.2 General Safety Precautions 2........................................................................ 2.3 Electrical Safety 2........................................................................................... 2.4 Operator Safety 3........................................................................................... 2.5 Robot Safety 4................................................................................................ 2.6 Modifications to Equipment 4......................................................................... 3 Introduction to the VBX-160 5............................................................................. 3.1 VBX-160 Cell 5............................................................................................... 3.2 VBX-160 Rack System 6................................................................................ 3.3 Rinse and Dry 9.............................................................................................. 3.4 Robot 10......................................................................................................... 3.5 MultiGrip Soft Jaws 12.................................................................................. 3.6 Air/Electrical Panel 13.................................................................................... 3.7 VBX-160 CNC Components 16...................................................................... 3.8 VBX-160 Positioning 17................................................................................. 3.9 The VBX Controller 19................................................................................... 4 Processing Parts with the VBX-160 30............................................................... 4.1 Preparing to process parts 30........................................................................ 4.2 Processing parts 31........................................................................................ 5 Recovery 45........................................................................................................... 5.1 Introduction 45................................................................................................ 5.2 Recovery Process 49..................................................................................... 6 Preventative Maintenance 52............................................................................... 6.1 Daily Maintenance 52..................................................................................... 6.2 Weekly Maintenance 54................................................................................. Operator Manual Version 1.1 VersaBuilt VBX-160 12/2015
  3. 3. 6.3 Monthly 55...................................................................................................... 6.4 Annually 55..................................................................................................... Glossary 56.............................................................................................................. Appendix 1 Status/Control Button Key 59............................................................ Appendix 2 Shelf Slot Color Key 63....................................................................... Appendix 3 Stack Light Status Key 64.................................................................. Appendix 4 Action Panel Messages 66.................................................................. Operator Manual Version 1.1 VersaBuilt VBX-160 12/2015
  4. 4. 1 Overview 1.1 VBX-160 Overview The VersaBuilt VBX-160 is a robotic machine tending system. This is a flexible system designed to automatically load and unload parts for processing in a CNC machine. The VBX-160 consists of a cell with a rack system, a robot that is located in the cell, a VBX Controller (VBXC) that interfaces with the robot and CNC, and a rinse and dry system to clean parts. The VBX-160 also utilizes MultiGrip vises and MultiGrip soft jaws (MGSJ) to hold and transfer parts. 1.2 Operator Manual Overview This VersaBuilt VBX-160 operator manual is written for equipment operators who are running jobs using the VBX-160 interfaced with a CNC. This operator manual describes how to set up and run jobs using the VersaBuilt VBX-160. This manual also describes how the operator should care for and maintain the VBX-160 equipment. Organization of the manual: The VersaBuilt VBX-160 operator manual is organized with the following chapters: • Safety • Introduction to the VBX-160 • Processing Parts with the VBX-160 • Recovery • Preventative Maintenance • Glossary • Appendices 1.3 Technical Support VersaBuilt: support@versabuilt.com (208) 269-9482 Business hours are Monday through Friday 9am to 5pm Mountain Time When you contact technical support, a picture of the screen, the error message and/or details such as how and when the error occurred will expedite the support process. Operator Manual Version 1.1 1 VersaBuilt VBX-160 12/2015
  5. 5. 2 Safety 2.1 Intended use of VBX-160 The VersaBuilt VBX-160 is intended to be used only by trained personnel in a professional machine shop environment. 2.2 General Safety Precautions Only authorized and trained personnel should operate this equipment. You must act in accordance with the operator manual, safety decals and instructions for safe machine operation. Read and understand all referenced safety manuals before operating equipment. Users must use appropriate eye and ear protection while operating the equipment. 2.3 Electrical Safety • The electrical power must meet the following specifications: Voltage: 208-240VAC/3Phase, 50/60Hz - Full load: 15 Amps - Largest load: 10 Amps • Attempting to run the machine from any other source can damage the equipment and void the warranty • The electrical supply must meet the rating of the robot as well as other devices. • Do not reset a circuit breaker until the reason for the fault is identified and remedied Operator Manual Version 1.1 2 VersaBuilt VBX-160 12/2015
  6. 6. 2.4 Operator Safety General Safety Information: • Do not operate the equipment unless the doors are closed and the safety circuit is functioning properly • Do not operate the VBX-160 without proper training • Clearly understand the different control requirements for operating the equipment; these include the safety circuit, Cycle Start, Feed Hold, DNC Sync, Part Stop and Op Stop • Do not attempt to alter the safety circuit sensors • Operator should locate the main power switch and be familiar with the operation of this switch • Use appropriate eye and ear protection while operating the VBX-160. ANSI-approved impact safety goggles and OSHA-approved ear protection are recommended • Use extreme caution when moving the VBX-160 cell, risks to personnel may include crushing, pinching, and severing as well as other bodily injury • Check for damage to parts prior to operating the VBX-160. Do not operate the VBX-160 if any of the components do not appear to be functioning correctly • Read and understand all safety information provided in this manual • Read and understand all relevant user manuals before operating the VBX-160, including manuals for Robot safety and operation of the CNC and additional components VBX-160/CNC Door Interlock Information: The VBX-160 and the CNC machine both have safety circuits that are intended to protect humans while allowing necessary communications to occur between the two systems for robotic processing. Haas CNC machines have a door interlock safety circuit that prevents the mill from operating when the CNC door is open. When the mill is processing, there is an interlock solenoid that energizes and pneumatically engages a piston that physically locks the CNC door to prevent it from being inadvertently opened. The VBX-160 has a safety circuit that connects sensors on the VBX doors and gate post where the VBX-160 can be pivoted away from the CNC. If any of these sensors are interrupted, the ‘motors on’ light on the robot arm will go out and robot motion will be stopped. There is a second sensor on the VBX-160 gate post that is interrupted when the VBX-160 is pivoted away from the CNC. This second sensor communicates to the CNC controller. If the CNC door is open and the VBX-160 cell safety circuit is open, then the CNC stops processing. If the CNC door is closed and a part is processing, the CNC will continue to process the part if the cell safety circuit is opened. Operator Manual Version 1.1 3 VersaBuilt VBX-160 12/2015
  7. 7. 2.5 Robot Safety Robot Dangers/Risks may include: Important! All personnel who are working within the range of the robot arm must read the ABB Robot General Safety manual and the ABB Robot Emergency Safety manuals before working in the range of the robot. These manuals contain important safety information specific to the robot. • Any moving manipulator is a potentially lethal machine • Robot movements are performed with great force and may seriously injure personnel/and or equipment located within the working range of the robot arm • Risks to personnel may include: crushing, entanglement, pinching, and severing as well as other bodily injury Robot precautions: • Orange light on robot indicates motors are on and robot can move at any time; avoid being between the robot arm and other objects • Robot moves can be unexpected • Gravity may cause any parts or objects held by the robot to drop • Opening any cell door stops robot motion • The robot brake release located on the back side of the robot should only be pressed by qualified service personnel or in an emergency • When the brake release button is activated it releases or deactivates the brakes on each robot axis, causing the robot to move freely Warning: this can cause the robot to collapse under its own weight. • The Robot Communication Cable allows the VBX controller to communicate with the robot controller Warning: the robot communication cable should never be plugged into an ethernet hub connected to a LAN with other computers attached 2.6 Modifications to Equipment • DO NOT modify or alter this equipment in any way • Modifications of the equipment without authorization from VersaBuilt could lead to personal injury and equipment damage • Modifications of the equipment without authorization from VersaBuilt will void the equipment warranty Operator Manual Version 1.1 4 VersaBuilt VBX-160 12/2015
  8. 8. 3 Introduction to the VBX-160 3.1 VBX-160 Cell The VBX-160 cell is the enclosure for the robot, the rack system, the robot controller and the IO panel. The cell is on casters and can be rotated away from the CNC to allow the operator access to the robot or to the interior of the CNC. The VBX Controller is mounted to the exterior of the cell on the operator’s side. An operator door allows access to the interior of the cell. The interior rack shelves are accessed through 2 exterior doors. The Robot Controller access panel and the IO access panel are located toward the bottom of the cell’s exterior. A stack light,which conveys the cell status, is located on the roof of the cell. Refer to appendix 3 for the stack light status key. FIGURE 3-1 VBX-160 CELL
 Operator Manual Version 1.1 5 VersaBuilt VBX-160 12/2015 Rack 2 DoorRack 1 Door VBX-160 Controller Screen Stack Light Operator Door Robot Arm Robot Controller Access Panel IO Access Panel
  9. 9. 3.2 VBX-160 Rack System
 The VBX-160 contains 2 racks with 8 shelves on each rack. The top shelf of each rack has 3 slots that are designed to hold the MultiGrip soft jaws. The remaining 14 shelves have slots designed to hold parts. Each of the part shelves is individually configurable to accommodate particular part sizes and shapes. A configurable shelf template is engraved with graduated markings to show where to place the part blanks for robot transfer. Part locators may be used on the shelves to allow operators to quickly locate parts. FIGURE 3-2 VBX-160 RACK SYSTEM
 Operator Manual Version 1.1 6 VersaBuilt VBX-160 12/2015 MultiGrip soft jaw storage on top shelves Parts stored on shelves below MultiGrip soft jaws
  10. 10. A. Shelf Template The shelf template is a sheet of material such as plastic that is engraved with graduated markings. The markings indicate where to place the material blanks for robot picking. A shelf template is positioned on the top of each shelf. FIGURE 3-3 SHELF TEMPLATE 
 Operator Manual Version 1.1 7 VersaBuilt VBX-160 12/2015 Shelf template detail showing graduated markings
  11. 11. B. Part Locator A physical part locator is an optional and completely customized feature that allows the operator to easily locate parts. While it allows for quicker part location, it is less flexible than the shelf template and does take time to change out when necessary. A part locator can be placed on each rack shelf. FIGURE 3-4 PART LOCATORS
 Operator Manual Version 1.1 8 VersaBuilt VBX-160 12/2015 3 PART LOCATOR STACKED 4 PART LOCATOR
  12. 12. 3.3 Rinse and Dry Rinse and Dry is the process used by the robot to rinse coolant and chips off of a finished part and then dry the clean part. The Rinse and Dry tank and air knife are located in the VBX-160 cell. A pump and filter are located in the tank. Note: The operator must insure that the rinse tank contains adequate rinse solution to properly clean parts. For wet machining, the recommended solution is 4 - 6 inches of water. (Optionally, one ounce of Dawn dish detergent and/or a rust inhibitor may be used in the tank.) Warning: Never allow the water to fall below the top of the pump. Inadequate water level may damage the pump. FIGURE 3-5 RINSE AND DRY SET UP 
 Operator Manual Version 1.1 9 VersaBuilt VBX-160 12/2015 Air Knife Water Valve Lever Rinse Nozzles
  13. 13. 3.4 Robot An IRB 140 6 Axis Industrial Robot is installed in the VBX-160 cell. The robot uses a MultiGripper to hold MultiGrip soft jaws. The robot uses the MultiGrip soft jaws to pick parts off of a shelf and place them in the MultiGrip vise within the CNC. After a part is machined, the robot removes the completed part and returns it to the shelf. The robot has a “motor’s on” light which indicates that the robot can move at any time. A brake release is located at the base. A drip tray is located between the robot and the CNC door to catch dripping coolant and chips. Warning: The brake release should only be pressed by qualified service personnel. Review 2.6 Robot Safety for more information about the brake release. FIGURE 3-6 ROBOT 
 Operator Manual Version 1.1 10 VersaBuilt VBX-160 12/2015 FIGURE Brake Release Motor’s on Light
  14. 14. FIGURE 3-7 ROBOT MULTIGRIPPER
 Operator Manual Version 1.1 11 VersaBuilt VBX-160 12/2015 MultiGrip Soft Jaws in the MultiGripper MultiGripper Plungers
  15. 15. 3.5 MultiGrip Soft Jaws 
 MultiGrip soft jaws (MGSJ) are field machinable jaws for holding a part. They are both the robot end effector and the part’s work holding in the MultiGrip vise. They have an interface for the robot MultiGripper and for the MultiGrip intermediate jaws in the MultiGrip vise. This allows for repeatable transfer of the MGSJ and the part into the CNC vises. MGSJ come in three versions, one for outer diameter (OD) clamping, one for inner diameter (ID) clamping and a pallet version.
 Part - The material to be processed by the CNC. The VBX-160 supports virtually any shape and material type. MultiGrip soft jaws - The robot end effector and the work-holding in the MultiGrip vise. They have an interface for the robot gripper and for the intermediate jaws in the MultiGrip vise. This allows for repeatable transfer of the MGSJ and part into the CNC vises. Offered in versions for clamping outer diameters (OD) or inner diameters (ID). MultiGrip Intermediate Jaws - Consist of a set of serrations and dovetails that clamp the jaws and part into the vise. MultiGrip Vise - Engages MGSJ and part for processing. The VBX controller is configured for OD or ID clamping for both the vises and the robot gripper.
 FIGURE 3-8 MULTIGRIP SOFT JAWS, MULTIGRIP INTERMEDIATE JAWS AND MULTIGRIP VISE 
 Operator Manual Version 1.1 12 VersaBuilt VBX-160 12/2015 Part MultiGrip Vise MultiGrip Intermediate Jaws MultiGrip Soft Jaws
  16. 16. 3.6 Air/Electrical Panel The air/electrical panel is mounted on a post near the cell. The panel controls the air and power supply to the VBX-160 system. The main power switch for the VBX-160 is located on the outside of the panel. The panel also has air pressure gauges for the CNC door opener/closer, vise 1 and vise 2. FIGURE 3-9 EXTERIOR OF THE AIR/ELECTRICAL PANEL 
 Operator Manual Version 1.1 13 VersaBuilt VBX-160 12/2015 Chuck 2 Air Pressure Chuck 1 Air Pressure Power Switch Air/Electrical Panel Gauges Air/Electrical Supply Lines
  17. 17. FIGURE 3-9 EXTERIOR OF THE AIR/ELECTRICAL PANEL CONTINUED 
 Operator Manual Version 1.1 14 VersaBuilt VBX-160 12/2015 Input Lines and Switches Input Power 1 110 VAC Air Shut-off Input Power 2 220 VAC
  18. 18. FIGURE 3-10 INTERIOR OF THE AIR/ELECTRICAL PANEL 
 Operator Manual Version 1.1 15 VersaBuilt VBX-160 12/2015 Terminal Blocks DeviceNet IO System VBX-160 Main Power Switch Air System Filter Circuit Breakers Air System Lubricators Vise Solenoid Valves Analog Regulators
  19. 19. 3.7 VBX-160 CNC Components The VBX-160 components that operate as part of the CNC include: • MultiGrip vise: A vise with MultiGrip intermediate jaws for clamping MultiGrip soft jaws • G-Code macros in CNC controller provided by VersaBuilt as well as customer provided FIGURE 3-11 MULTIGRIP VISE 
 Operator Manual Version 1.1 16 VersaBuilt VBX-160 12/2015
  20. 20. 3.8 VBX-160 Positioning The VBX-160 cell can be pivoted away from the CNC to allow operator access to either the robot or the CNC. If possible, wait for the robot to finish picking or placing parts. Unlock the gate pin and roll the cell away from the CNC. To resume processing, roll the cell back into position in front of the CNC and lock the gate post with the pin. The cell can also be moved completely away from the CNC: • Power down the VBX Controller • Turn off the power for air • Disconnect the control cables • Remove the pivot pin in addition to the gate pin. • The cell can be rolled to another location or moved with a fork lift using the fork lift tunnels. Note: When the cell is pivoted away from the CNC a safety circuit will be opened. The robot will not be able to move, but the CNC can continue processing as long as the CNC door remains closed. Refer to Chapter 2 section 2.4 to review information regarding the safety circuit. Warning! Use extreme caution when moving the VBX-160 cell; risks to personnel may include crushing, pinching, and severing as well as other bodily injury. Review the safety information in Chapter 2 prior to moving the VBX-160 cell. FIGURE 3-12 VBX-160 PIVOTED AWAY FROM CNC Operator Manual Version 1.1 17 VersaBuilt VBX-160 12/2015 VBX-160 Cell CNC Gate PostPivot Post
  21. 21. FIGURE 3-13 LOCKED CELL 
 VIEW OF DETAIL FROM CNC SIDE 
 Operator Manual Version 1.1 18 VersaBuilt VBX-160 12/2015 POST DETAIL Pivot Post VBX-160 Cell Pin PIVOT POST Pin Sensor Gate Post Gate Post VBX-160 Cell CNC VBX-160 Operator Side Gate Post Pivot PostGate Post Fork Lift Tunnels
  22. 22. 3.9 The VBX Controller The VBX Controller (VBXC) is the operator interface for controlling the VBX-160 system and the CNC via DNC sync. The VBXC operates with two primary screens: the Operation Screen and the Configuration Screen. The operator works primarily with the Operation Screen to enter and run jobs. The Operation Screen consists of various panels which are described in detail below. The Configuration Screen is typically used by a machinist to configure the VBX-160. The Configuration Screen is described in the Machinist User Manual. Tool Tips: Hover the mouse pointer over the various symbols and sections of the screen, and a pop-up tip appears and describes the element. FIGURE 3-14 VBX CONTROLLER Operator Manual Version 1.1 19 VersaBuilt VBX-160 12/2015 VBX-160 Controller Screen VBX-160 Controller Keyboard and Mouse
  23. 23. A. Operation Screen Overview The primary screen used by the operator is the Operation Screen. Using this screen, the operator manages jobs and controls processing with the VBX-160. The Operation Screen is accessed via the screen selection menu. The Screen contains 4 panels: Status/Control, Actions, Active Jobs, and Racks. Each panel is described in detail below. FIGURE 3-15 JOBS SCREEN Operator Manual Version 1.1 20 VersaBuilt VBX-160 12/2015 Tool Tips- hover the mouse pointer over the various symbols and sections of the screen and a pop-up tip appears. Screen Selection Menu Status/ControlPanel Active Jobs List Actions Panel Rack Status Panel
  24. 24. B. Operation Screen Panels 1. Status/Control Panel The Status/Control Panel appears at the top of all VBX-160 controller screens. The buttons that appear may change based on the current state of processing. The figures below show the Status/Control panel buttons in various states of processing. Note: Refer to Appendix 1 for a complete description of the Status/Control Panel buttons FIGURE 3-16 STATUS CONTROL PANEL SHOWING VBX-160 “READY TO PROCESS JOB” FIGURE 3-17 STATUS CONTROL PANEL SHOWING “PARTS PROCESSING” STATE Operator Manual Version 1.1 21 VersaBuilt VBX-160 12/2015 Start Processing Parts Op Stop DisabledDNC Connected Safety Circuit Closed Parts are Processing Robot Speed Vise Pressure Indicates Processing
  25. 25. FIGURE 3-18 STATUS CONTROL PANEL DURING RECOVERY WITH ACTIONS REQUIRED FIGURE 3-19 OP STOP STATUS Clicking on the Op Stop button accesses the options below: Op Stop disabled Op Stop enabled VBXC will feed hold when milling op has finished processing Part Stop enabled VBXC will feed hold when part has finished processing Operator Manual Version 1.1 22 VersaBuilt VBX-160 12/2015 Parts Processing Interrupted, Complete Red Tasks Reset the Robot Control Robot and CNC
  26. 26. 2. Racks Panel The Racks Panel provides a view of the VBX-160 racks. The Racks Panel shows the racks from two views. The In view shows the perspective of looking through the operator door. The Out view shows the perspective of looking through a rack door. The Racks Panel has a Templates button. Clicking on the Templates button will bring up a display that is used to select the template for each shelf. FIGURE 3-20 RACKS PANEL AND TEMPLATE SELECTION PANEL Operator Manual Version 1.1 23 VersaBuilt VBX-160 12/2015 View Selection
  27. 27. The VBX Controller uses symbols and colors to show the status of each slot in the Racks Panel, including the current location of MultiGrip soft jaws and parts: MultiGrip soft jaw slots: represented by rectangles on shelves 1 and 9 • MultiGrip soft jaws in vise: mauve • MultiGrip soft jaws on shelf: violet • MultiGrip soft jaws in gripper: purple • MultiGrip soft jaw slot is empty: white • MultiGrip soft jaw transferring: blue • MultiGrip soft jaw error: red • MultiGrip soft jaw cancelled: yellow
 Part slots: represented by circles or rectangles on shelves 2-8 and 10-16 • Part waiting in slot: violet • Part is milling: represented by pink • Part on shelf ready to unload: green • Part slot is empty: white • Part held by robot: purple • Shelf transfer: blue • Part error: red • Part cancelled: yellow
 Note: Refer to Appendix 2 for a complete shelf slot color key. Operator Manual Version 1.1 24 VersaBuilt VBX-160 12/2015 FIGURE 3-22 RACK DISPLAY OF PART SLOTS FIGURE 3-21 RACK DISPLAY OF MULTIGRIP SOFT JAW SLOTS Tool Tips- hover the mouse pointer over the various symbols and sections of the screen and a pop-up tip appears.
  28. 28. 3. Actions Panel The Actions Panel displays a list of actions for the operator to perform in order to keep the VBX-160 processing. Actions appear as tasks, and the tasks are color coded to indicate their urgency. Refer to Appendix 4 for an explanation of action tasks/messages that may appear in the VBX-160 Actions Panel. • A task highlighted in red in the Actions Panel stops production until the red task is completed • A task with a white background in the Actions Panel needs to be done, but it is not urgent. A white task will not stop the processing • A task highlighted in yellow is not urgent and will not immediately stop the processing, but it could cause processing to stop if it is not addressed soon • When the operator completes a task, selecting the Done button next to the task will remove it from the list • If a task references shelf slots, clicking on the Highlight button will put a blue highlight in the Racks Panel around the slots or symbols that are associated with that particular task • Change the size of text by clicking on the AA button FIGURE 3-23 ACTIONS PANEL FIGURE 3-24 ACTIONS TASKS WITH WHITE BACKGROUND FIGURE 3-25 ACTIONS TASK WITH RED BACKGROUND Operator Manual Version 1.1 25 VersaBuilt VBX-160 12/2015 Size Text
  29. 29. 4. Active Jobs Panel The VBX Controller lists and manages jobs in the Active Jobs Panel The operator enters new jobs, cancels jobs and reviews current jobs in the Active Jobs Panel. Jobs are processed in the order that they are entered in the VBXC The following information is entered or displayed in the Active Jobs Panel: • Order: an identifier for the job • Part: identifies the part number for the part that is being processed • Processing: identifies the number of parts that are currently in the cell for a specific job • Remaining: identifies the number of parts that are waiting to be loaded for a specific job
 Operator Manual Version 1.1 26 VersaBuilt VBX-160 12/2015 Add JobCancel Job FIGURE 3-26 ACTIVE JOBS PANEL
  30. 30. 5. Recovery Panel The operator can manually initiate the recovery mode from the feed hold state by clicking on Recovery in the Control Panel or by cancelling a job that is currently processing This is typically done if the operator detects a problem and needs to cancel the current processing. Recovery can also be initiated by the VBX Controller when a problem is detected. Once the system is in a recovery mode, a series of actions must be completed in order to exit recovery mode and resume processing. During Recovery, a Recovery Panel with control buttons is displayed in the top right section of the Operation Screen. The recovery tasks appear in the Actions Panel. Recovery buttons that appear as grey are unavailable in the system’s current state. Gripper is the only control available to use in the feed hold state. The other controls become functional during various states of recovery. FIGURE 3-27 RECOVERY PANEL Tool Tips - Hover the mouse pointer over the various symbols and sections of the screen and a tool tip will appear. FIGURE 3-28 TOOL TIPS Operator Manual Version 1.1 27 VersaBuilt VBX-160 12/2015
  31. 31. FIGURE 3-29 RECOVERY PANEL CONTROLS 
 Operator Manual Version 1.1 28 VersaBuilt VBX-160 12/2015 Home- Moves robot to its home position Arm- Control buttons to move the robot gripper along the cells x,y and z axes Wrist- Controls for wrist rotation and angle Float- Relieves pressure when the arm crashes into something and is pressing against it in a way that makes it difficult to move with the Arm or Wrist buttons. Movement- Adjusts the movement speed Gripper- Controls for open, close, float and release Wash- Controls to wash and/or dry part Door- Control buttons to open and close CNC door Vise - Control button to open and close vise, float or eject part from vise FloatHome
  32. 32. FIGURE 3-30 RECOVERY PANEL CONTROLS CONTINUED Operator Manual Version 1.1 29 VersaBuilt VBX-160 12/2015 Movement: Control for distance of robot arm and wrist movement Green dots may appear in the Recovery Panel. The dots help the operator determine the current status of various system components. A green dot next to the Home button in the arm control indicates that the robot is in the “home” position. A green dot in the gripper, door, wash or vise controls indicates current status.
  33. 33. 4 Processing Parts with the VBX-160 4.1 Preparing to process parts Important! Review chapter 2 for safety precautions prior to working with the machinery. The following steps should be taken prior to processing parts with the VBX-160: • Review chapter 2 for safety instructions • Verify that the rinse tank (if being used for this process) is filled properly with clean solution and is free of chips • Verify that the MultiGrip vise, the MultiGrip soft jaws and the MultiGrippers are free of chips and do not show signs of wear • MultiGrip vise is installed in the CNC • CNC door pathway is free of chip build up • CNC spindle, walls and ceiling are free from drip build up • Chip output banding systems are enabled and have sufficient capacity to handle the parts to be processed • Sufficient CNC consumables such as coolant to process parts • Verify that the CNC has adequate tool life that is needed to process jobs • VBX-160 cell is in the locked position (refer to figure 3-13) • Verify that the required job programs are loaded into the CNC • Power on to cell • Turn air on to cell • Be prepared with specific job information, including: order ID part # part quantity Operator Manual Version 1.1 30 VersaBuilt VBX-160 12/2015
  34. 34. 4.2 Processing parts A. Power Power up: Verify that power is on for the following: • VBX Controller (VBXC) • Illuminated power button is on the central processing unit, (CPU) • Main power on Air/electrical Panel • CNC Power down: The VBX-160 should be powered down before it is unplugged or before the power supply is shut off. Failure to power down could corrupt the VBXC data. If the VBX-160 is currently processing parts and needs to be powered down: 1. Enter recovery mode 2. Complete DNC sync 3. Move robot home 4. Clear vise and MultiGrip soft jaws 5. Complete recovery tasks (refer to chapter 5 Recovery) 6. press the illuminated power button on the VBXC CPU If the VBX-160 is not processing parts and needs to be powered down, then press the power button on the VBXC CPU. B. Complete DNC Sync When using a Haas CNC: 1. Press the MDI button on the CNC until the CNC main screen shows 'Waiting For DNC". 2. Click on the DNC Sync button on the VBXC. 3. The VBXC asks you to verify that the correct CNC machining programs are in the CNC controller. (make sure they are loaded) 4. Click the Done button on the VBXC. 5. The VBXC asks you to "Start Cycle The CNC". 6. Press the green Cycle Start button on the CNC Controller. 7. The CNC screen shows that it's connected to DNC. 8. The green plug symbol appears in the Status/Control Panel indicating that the VBXC and CNC are synced. 
 Operator Manual Version 1.1 31 VersaBuilt VBX-160 12/2015 CPU
  35. 35. C. Create a Job in the VBX Controller step 1 In the Status Control Panel click on the Screen Selection Menu button and select Operation. Note: Typically the VBX controller will “rest” with the Operation Screen displayed, and this step will not be necessary. FIGURE 4-1 SCREEN SELECTION MENU BUTTON step 2 In the Active Jobs Panel, click on the + symbol to create a job. FIGURE 4-2 CREATE A JOB BUTTON Operator Manual Version 1.1 32 VersaBuilt VBX-160 12/2015 Create a Job
  36. 36. step 3 Click on Part and select a part from the drop down menu. step 4 Click on Order and enter an order ID. step 5 Click on Quantity and enter the # of parts required for this order. step 6 When all of the required information is entered in the appropriate fields, click on Save to complete and save the job entry. After the job is saved, the VBXC returns to the Active Jobs Panel, and the newly created job appears in the Active Jobs list.
 Operator Manual Version 1.1 33 VersaBuilt VBX-160 12/2015 Click here to save job information in the VBXC
  37. 37. D. Shelf Template Selection If you see this message after you add a job, then you need to select one or more shelf templates that are configured for the part. step 1 Verify that the required template(s) is on the shelf. step 2 Click on the Templates button in the top right corner of the racks panel. The Shelf Template Selection tool appears.
 Operator Manual Version 1.1 34 VersaBuilt VBX-160 12/2015
  38. 38. step 3 Using the Shelf Template Selection tool, locate the shelf or shelves that you would like to use for this part, and then locate the required template. Click on the dot that corresponds with the shelf and the template. Note: You cannot change a template that is being used for a job that is currently processing. The shelves for MGSJ cannot be altered or used for part templates. step 4 Once you have selected a template, the OK button is available. Click on OK when you have finished selecting templates. Note: If you add a job and the VBXC has assigned parts to a template, you should not change that template to one that does not work for those parts. If you change a template that is assigned to a job, then the VBXC gives you an actions task of selecting a template for that job again. You can not change the template for a job that is currently processing parts.
 Operator Manual Version 1.1 35 VersaBuilt VBX-160 12/2015
  39. 39. E. Loading MultiGrip soft jaws and parts to run a job When the VBX Controller (VBXC) determines that there is capacity to run a job, it lists actions or tasks for the operator to complete. The VBXC first lists actions relevant to loading the correct MultiGrip soft jaws (MGSJ) for the job, and then when those actions are completed, it lists actions to load parts for the job. Actions Related to Loading MultiGrip Soft Jaws (MGSJ) • Each action related to a MGSJ specifies a MGSJ part number and the designated shelf location • The VBXC allows MGSJ to be shared among jobs • Load each set of MGSJ into the assigned location following steps 1 through 4
 step 1 Review the shelf slots designated for the MGSJ by clicking Highlight. The VBXC highlights the designated slot locations with a blue outline. The task specifies which MGSJ should be loaded in each slot by using a part # to ID the MGSJ. step 2 Open the rack doors to access the shelves.
 Operator Manual Version 1.1 36 VersaBuilt VBX-160 12/2015 Click here to highlight locations
  40. 40. step 3 Place the MultiGrip soft jaws in the assigned location. Note: Place the MultiGrip soft jaws with the serrated side on the shelf and with the robot gripper interface facing into the cell so that the robot can pick up the MultiGrip soft jaws with the gripper. step 4 Click the Done button next to the completed action after each item in the actions list is completed. The VBXC removes the task from the Actions list. New tasks are displayed if they are required. Note: A green rectangle is displayed in the Racks Panel to indicate the location of the MGSJ on the shelf.
 FIGURE 4-3 PROPER ORIENTATION OF MULTIGRIP SOFT JAWS ON SHELF Operator Manual Version 1.1 37 VersaBuilt VBX-160 12/2015 MultiGrip Soft Jaws Shelf Gripper
  41. 41. Actions Related to Loading a Part Each action that is related to loading a part tells the operator: • The number of parts to load • The relevant part ID • The relevant order ID Load each part following steps 1-4 below: step1 Review the assigned shelf location for each part. Click on Highlight in the Actions Panel to highlight the locations in the Racks Panel. step 2 Place parts in the assigned slots using either the shelf template (shown) or a part locator to correctly align the center and side of each part. Be sure to properly orient rectangular part material. The jaws are designed to pick rectangular material from a specific orientation on the shelf. Note: The operator should verify that the material does not exceed height limits.
 
 Operator Manual Version 1.1 38 VersaBuilt VBX-160 12/2015 Designated part locations are highlighted Click here to highlight locations
  42. 42. step 3 Close and latch both rack 1 and rack 2 doors. step 4 Return to the VBXC, and click on Done for this task. The VBXC removes the completed task from the task list. New tasks are displayed if they are needed Note: A violet circle displayed in the rack panel indicates that the part is loaded on the shelf and waiting for processing
 F. Cycle Start In the Status Control Panel, click on the Cycle Start button. The robot begins processing. Check the Actions Panel for any additional actions/tasks. Note: A task that has a red background stops the processing. FIGURE 4-4 CYCLE START BUTTON Operator Manual Version 1.1 39 VersaBuilt VBX-160 12/2015
  43. 43. G. Monitoring Part Processing During part processing, the rack display uses various colors to indicate the current status of each slot in the racks. As the part or MGSJ move through the process, the slot color changes. Checking the racks display on occasion endures the maximum efficiency of the VBX-160 system. Refer to Appendix 2 for a complete shelf slot color key. FIGURE 4-5 PART PROCESSING SLOT COLORS Operator Manual Version 1.1 40 VersaBuilt VBX-160 12/2015 Purple circle indicates the part is held by the robot Bright pink circle indicates part is in vise and/or milling Green circle indicates the part has finished processing and is ready to unload Blue circle indicates the part is in transfer
  44. 44. H. Unloading parts or MultiGrip soft jaws from the VBX-160 cell When an Actions Panel message indicates that parts or MGSJ are ready to unload, follow steps 1-6 below. step 1 Review the slot locations of the parts or MultiGrip soft jaws that need to be unloaded. Note: When the Actions Panel displays a task telling the operator to unload parts or MultiGrip soft jaws, the slots for those items are green, and they are outlined with a blue highlight when the Highlight button is clicked with the mouse. FIGURE 4-6 ACTIONS SCREEN SHOWING A TASK TO UNLOAD PARTS FIGURE 4-7 RACKS PANEL SHOWING LOCATION OF PARTS TO UNLOAD. FIGURE 4-8 RACKS PANEL SHOWING LOCATION OF MGSJ TO UNLOAD Operator Manual Version 1.1 41 VersaBuilt VBX-160 12/2015 Task tells operator to unload parts Locations of parts ready to unload shown with highlighted green circles Locations of MGSJ ready to unload shown with highlighted green squares
  45. 45. step 2 Open the rack door that corresponds with the location of the completed parts or MGSJ. Note: If the robot is currently processing parts, it safety stops when the door is opened. step 3 Remove the parts and/or MGSJ from the shelf as indicated in the Actions list. step 4 Close and latch the shelf door. step 5 Locate the completed task in the Actions Panel and click on Done. The VBXC removes the completed task from the list. step 6 If the job requires additional parts, the VBXC prompts the operator with a new task in the Actions Panel. Note: Refer to Appendix 4 for an explanation of all action tasks/messages that may appear in the Actions Panel.
 I. Multiple Jobs Multiple jobs can be entered and saved in the VBXC. The VBXC works from the top of the job list down to fill slots.It begins a new job and prompts the operator to place parts or MGSJ on the shelf when slots are available for processing. The system is designed so that the operator can load and/or unload parts when they are available. There is no need to wait for an entire job to be completed before clearing the finished parts related to that job. The VBXC alerts the operator if a different template is needed for a job. FIGURE 4-9 MULTIPLE JOBS LISTED IN THE ACTIVE JOBS PANEL 
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  46. 46. J. Cancelling a Job An existing job is cancelled by using the Edit Job List button in the Active Jobs Panel. You can cancel a job anytime after it has been saved. The elements of a saved job can not be edited. If the elements need to be changed, then cancel the job and re-enter it with the desired changes. Follow steps 1-4 below to edit the job list. Note: When a job is cancelled while a part is held by the robot and/or a part is in a vise, the VBXC enters Recovery mode. This enables the system to be restored to a normal state and the job re-entered if desired. If there is no part currently held and/or in a vise, then the job is simply cancelled and normal processing continues for other active jobs in the VBXC. To stop a part from processing, click on the Op Stop button to access the Part Stop button. Click on the Part Stop button to stop the part from processing. Click on it again to resume processing. The button then becomes the Op Stop button again. step 1 Click on the Edit Job List button in the top right corner of the Active Jobs Panel. The VBXC displays a list of all active jobs. step 2 Find the job that you need to cancel. Review the job information to validate that it is the correct job to cancel. If the information matches, then click on the Cancel button next to the job. To exit the edit mode without canceling a job, click on the Done button in the top right corner of the Active Jobs Panel. Operator Manual Version 1.1 43 VersaBuilt VBX-160 12/2015
  47. 47. step 3 Refer to the Actions Panel for tasks associated with canceling a job. Tasks may include unloading parts or unloading jaws. The slots of cancelled parts are yellow in the rack panel. Additional tasks may be Recovery related and involve actions such as removing items from the gripper and/or vise and moving the robot arm to Home. Refer to “Chapter 5 Recovery” for information related to these types of tasks if the VBXC enters recovery mode after a job is canceled. FIGURE 4-10 TASKS ASSOCIATED WITH CANCELING A JOB FIGURE 4-11 RACKS PANEL SHOWING LOCATION OF CANCELED PARTS Operator Manual Version 1.1 44 VersaBuilt VBX-160 12/2015
  48. 48. 5 Recovery 5.1 Introduction Important! Review chapter 2 for safety precautions prior to working with the machinery. A.Initiating Recovery Recovery occurs when the robot stops processing in response to an error or the operator initiates recovery by either clicking on the Recovery button or cancelling a job that is currently processing. The Recovery button is visible on the Status/Control Panel when the system is in a feed hold state. If the operator is initiating recovery, they must first click on the Feed Hold button to access the Recovery button. Once recovery is initiated, the actions for recovery are displayed in the Actions Panel. All recovery related actions must be completed before processing can begin again. Initiating the recovery state clears the current processing state of the VBX Controller. This cancels all parts and MultiGrip soft jaws that are held by the robot or in the vises. Communication with the robot and CNC is reset. FIGURE 5-1 FEED HOLD BUTTON AND RECOVERY BUTTON FIGURE 5-2 INITIATING RECOVERY MESSAGE Operator Manual Version 1.1 45 VersaBuilt VBX-160 12/2015
  49. 49. FIGURE 5-3 RECOVERY ACTION MESSAGES Note: For a complete list of action messages, please see Appendix 4 Operator Manual Version 1.1 46 VersaBuilt VBX-160 12/2015
  50. 50. B. The Recovery Panel When recovery is initiated, a Recovery Panel appears in the Operation Screen. FIGURE 5-4 RECOVERY PANEL Note: For a complete description of the Recovery Panel buttons, please refer to Chapter 3, section 3.9-B5. Operator Manual Version 1.1 47 VersaBuilt VBX-160 12/2015 Control For Movement and Speed Robot Home Button Robot Arm Controls Robot Wrist Controls Gripper Controls Door Controls Wash Controls Vise Controls
  51. 51. C. Using the Status/Control Panel Buttons During Recovery When recovery is initiated the icons on the Status/Control Panel change. Control buttons that are used to reset the robot and enable robot and CNC commands become available. Clicking the Enable button enables the robot to move. When the robot is enabled, the Pause button appears. Pause is used to pause the CNC and robot commands. The status icons indicate that processing has been interrupted, DNC is disconnected and part stop is enabled. FIGURE 5-5 STATUS /CONTROL PANEL AFTER RECOVERY INITIATED Note: For a complete description of the Status/Control Panel buttons, please see Appendix 1 Operator Manual Version 1.1 48 VersaBuilt VBX-160 12/2015 DNC Disconnected Part Processing Interrupted Part Stop Enabled
  52. 52. 5.2 Recovery Process A. If the operator is initiating recovery: step 1 Click on the Feed Hold button to stop processing Step 2 Click on the Recovery button, Step 3 The VBXC confirms that you wish to continue to recovery. Click OK. Note: All parts that are currently processing are cancelled when the system goes into the recovery mode. After the recovery mode is initiated by either the operator or the VBXC, the operator must complete steps 4-10 to complete and exit recovery so that processing can resume. B. For all recovery situations: Complete the tasks in the Actions Panel. The Actions Panel lists out the 4 primary steps to complete and the tasks that are associated with each step are listed in order below the first pane. Step 1: Enable the cell by clicking on the Enable button. This allows robot and CNC commands. Now the operator can control the robot movements as well as the CNC door. Note: Use the Pause button if there is a need to pause robot and CNC commands. The operator can toggle between Enable and Pause as needed while in recovery mode. Only the gripper open/close buttons are operable when the system is paused. The Recovery Panel buttons appear grey when they are not currently operable. Operator Manual Version 1.1 49 VersaBuilt VBX-160 12/2015
  53. 53. Step 2: Return the robot to the home position. This is done with the buttons on the Recovery Panel. Clicking on the home button returns the robot to home unless the robot has been in a collision or in the event that the MultiGrip soft jaws are entangled with a shelf or vise. These types of situations are referred to as movement errors. Note: In the case of a movement error: • Use the arm jog buttons when the arm or something that the arm is holding is in contact with an obstacle. Once the arm is no longer in contact, then the home button can be used. • The movement slider controls how much the arm and wrist jog buttons move the robot. Use the smallest movement increment when moving the arm out of a collision state. Additional motion errors or collisions may occur during this process. This is normal; proceed slowly and move the arm away from the point of contact using the arm and wrist jog buttons. • Use the gripper buttons to release the MGSJ if necessary. Do not drop the MGSJ on the floor or onto other objects or people when releasing them from the gripper. It may be helpful to have a second person available to catch the MGSJ when they are released from the gripper. Step 3: Complete a DNC sync. Refer to chapter 4, section 4.2B to review the steps for DNC sync. Once the CNC controller is in DNC mode, click the done button next to the task on the VBXC. If the sync is successful, then the prompt disappears from the screen, if the prompt remains, retry the steps. Step 4: Address and clear the listed errors. Put away anything held in the gripper and/or vise. There are two ways to do this: • Manually with the controls,(open, close, float) • Using the eject button. The eject button will have a green dot by it if it is available for use. When the eject button is used, the robot puts the MGSJ and/or parts back on the shelf. Operator Manual Version 1.1 50 VersaBuilt VBX-160 12/2015 Eject Buttons
  54. 54. • Continue clearing any errors that are listed in the Actions Panel. Step 8: Verify that all of the recovery actions are completed,and click on Done. The VBXC exits recovery mode and is ready to resume normal processing. The VBXC exits recovery mode in a feed hold state. Step 9: Click on Cycle Start to exit the feed hold state and begin processing parts. Note: For a complete description of recovery messages/signals, refer to Appendix 4.
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  55. 55. 6 Preventative Maintenance 6.1 Daily Maintenance Important! Review chapter 2 for safety precautions prior to any maintenance activities. Complete the following tasks at least daily, or more often if indicated: A. Rinse and Dry system • Inspect the rinse and dry nozzles looking for proper adjustment to keep solution contained in the tank • Empty and refill rinse solution daily or more often if needed • Inspect the tank filters and remove debris or replace if needed • Fill rinse tank with enough water to cover the pump. (Optionally, a solution of Dawn dish detergent or rust inhibitor and water may be used.) • Do not use solvents in the rinse solution • Rinse tank replacement pump filters: Manufacturer: McMaster-Carr Manufacturer Part #: 2514K28 Description: 600 or 800 microns, High Capacity Tie-on Mesh Filter Bag, polyester, 11” diameter, 24” high VersaBuilt Part #: 5001210 B. Inspect MultiGrippers, intermediate jaws and MultiGrip soft jaws • Look for signs of wear • They should be free of chips or other debris • If dry machining, then lubricate the MGSJ cross pin with silicone spray (fig. 6-1) C. Inspect the VBX-160 Cell • Clean off chips, coolant and any debris D. Inspect robot • Inspect robot cabling, look for wear/damage • Clean chips, coolant and debris from the robot E. Inspect Vises • Clean out chips and other debris FIGURE 6-1: MGSJ CROSS PIN Operator Manual Version 1.1 52 VersaBuilt VBX-160 12/2015
  56. 56. F. Chip Management Chip management is extremely important. Monitor chip accumulation and remove as needed. Keep these tips in mind for chip management: • Clear chips from MGJ, intermediate jaw and part. Chips between the MGJ and the Intermediate Jaw or between the part and the MGJ can have a detrimental effect on processing efficiency. • Empty the chip output system before starting extended processing. • Chips fall onto the vise when they dry out. Blow chips off surfaces on and above the vise. • 5th axis vise sensors are sensitive to chips. Vise wash should rotate vise and blast out chips. Blow accumulations of chips away from vise. • Periodically blow out door tracks. Chips can accumulate in door tracks preventing the door from moving and stopping production. • Wash bucket is critical to chip management between part and MGJ and between MGJ and intermediate jaws. • Vise wash is critical to managing chips between MGJ and intermediate jaws that will cause concentricity and flatness errors. Operator Manual Version 1.1 53 VersaBuilt VBX-160 12/2015
  57. 57. 6.2 Weekly Maintenance Complete the following tasks at least weekly, or more often if indicated: A.Robot Controller Air Filter Maintenance The Robot Controller air filter is located on the outside of the cell below the operator door. Inspect the filter for dirt and debris. If the filter is dirty, then remove and replace. Manufacturer: McMaster-Carr Manufacturer Part #: 2209K611 Description: Pleated Panel Air Filter, Merv 8, 10 x 10. Trade size, 1” thick, pack of 2 VersaBuilt Part #: 5001257 FIGURE 6-2 ROBOT CONTROLLER AIR FILTER B. Air/Electrical Panel • Inspect air filter and fill lubricators on air/electrical panel Operator Manual Version 1.1 54 VersaBuilt VBX-160 12/2015 Filter
  58. 58. 6.3 Monthly Lubricate vises • Use a grease gun with a needle grease tip • Grease 2 points on the right side of vise, 1 point on the back and one point in front • Pump the grease on 1-2 times then open and close the vise and repeat 1-2 times for each point • If a grease point overflows, then it is full 6.4 Annually • Inspect robot damper axes 2,3 and 5 • Inspect robot timing belts • Oil change: gear box axes 5 and 6 • See ABB documentation for additional information on IRB-140 Annual maintenance B. Intermediate jaws • Lubricate intermediate jaws, by applying … to surface. • Clean out chips and other debris C. Air/Electrical Panel • Inspect air filter and fill lubricators on air/electrical panel Operator Manual Version 1.1 55 VersaBuilt VBX-160 12/2015
  59. 59. Glossary Action List: A list of actions for the operator to perform to keep the VBX-160 processing. Active Job List: A list of jobs that are currently active in the VBX-160 system. Air/Electrical Panel: Supplies air and power to the VBX and the door vise control circuit. Air Knife: blows air on the finished part to clean and dry. Brake Release: A button on the back side of the robot. When this button is activated it releases or deactivates the brakes on each robot axis, causing the robot to move freely. Note: this can cause the robot to collapse under its own weight. This button should only be pressed by qualified service personnel. CNC Pneumatic Door Control: Opens and closes CNC door to allow robot access. Configuration Screen: This is where the system and parts are configured. Accessed via the screen selection menu. Cycle Start Button: This button is visible when the system is in a feed hold state. It is used to start or continue processing. DNC Cable: A cable that connects the VBX controller to the CNC for communication. DNC Sync Button: This button is used to tell the VBX-160 controller that the DNC connection to the CNC has been interrupted. For example: when the CNC is reset. Using this button will activate the DNC synchronization process. Door Open/Close Sensors: Allow the VBX-160 to determine if the door is in the open or close position. Drip Tray: A tray that is located in front of the robot to catch dripping coolant. Feed Hold Button: This button is visible when the system is processing. It is used to pause processing. Gate Post: The post that locks the cell in position for processing. Grease Zerk: Fitting for adding grease to the MultiGrip vise. Gripper: The part of the robot that engages the MultiGrip soft jaws or pallets. Gripper Float Button: When this button is activated, if the robot is holding MultiGrip soft jaws, it will drop them. Gripper Interface: The side of the MultiGrip soft jaws with MultiGrip pins. Gripper Sensors: Sensors on the gripper that help the robot identify if MultiGrip soft jaws are attached and if a part is being held. Operator Manual Version 1.1 56 VersaBuilt VBX-160 12/2015
  60. 60. Intermediate Jaws: Intermediate jaws are bolted to the vise and interface with MultiGrip soft jaws or pallets. IO Access Panel: Located on the CNC side of the VBX-160 cell, provides access to robot IO wiring panel for service. Job: The processing of one or more preconfigured parts in the VBX-160. Jobs Screen: The main screen on VBX-160 controller, allows operator to manage jobs and control the VBX-160. Accessed via the screen selection menu. Machinable Face: The top portion of the MultiGrip soft jaws or pallet that will be machined to hold a part. Manual Vise Valve: A handle valve that allows the vise to be opened or closed manually. Note: handle must be returned to center position to allow the robot to control the vise. Motor’s On Light: A light on the upper robot arm. When this light is illuminated the robot motor is on, and the robot can move at any time. MultiGrip soft jaws: Machinable jaws for holding a part. MultiGrip soft jaws come in two versions, one for outer diameter (OD) clamping and one for inner diameter (ID) clamping. MultiGrip Vise: A vise with MultiGrip intermediate jaws for clamping MultiGrip soft jaws or pallets. Operator: A person trained to load, operate and maintain CNC machines and VBX-160s Pallet: A one piece version of the MultiGrip soft jaw used for fixturing multiple parts or parts that cannot be reliably picked from the shelf. Requires the operator to secure the part to the pallet. Part Family: A group of similar parts that can be processed with the same MultiGrip soft jaws or pallets and tooling. Part: Generally referring to material to be processed. Part Locator: A sheet with cutouts to easily locate a specific part size and shape accurately on the shelf. Pivot Pin: A pin that connects the VBX-160 cell to the pivot post. Pivot Post: The hinge where the cell rotates from the CNC. Pivoted: When the cell is pivoted away from the CNC to allow access to the CNC or robot. Power Cable: A black cable that supplies power to the VBX-160 cell from the air/electrical panel. Pre Op: An operation to cut probing features for a second op and a dovetail interface for a first op MultiGrip soft jaw. Probing: Using a CNC tool to measure the location of a part in the CNC or the size or shape of a machined feature of the part. Operator Manual Version 1.1 57 VersaBuilt VBX-160 12/2015
  61. 61. Recovery Button: This button is used by the operator to manually initiate recovery mode to clear the current processing state of the controller, typically after an error has occurred. Rack System: The racks contained in the VBX-160 cell. The cell contains two racks with 8 shelves on each rack Recovery State: When the robot stops processing in response to an error. Red Task: A task highlighted in red in the Actions Panel; it is urgent. The robot will stop processing until the red task is completed Rinse Bucket: A bucket that holds a cleaning solution and a pump for washing the finished part. Robot Communication Cable: A cable that allows the VBX controller to communicate with the robot controller. Note: the robot communication cable should never be plugged into an ethernet hub connected to a LAN with other computers attached. Robot Controller Access Panel: A removable panel on the operator side of the cell that provides access to the IRC5 Compact Controller. Safety Sensor: The VBX-160 cell has 4 sensors. one on each door and one on the gate post Safety Stop: When a door is opened or if the robot has a hard collision, the robot will enter a safety stop state. In the safety stop state, the robot is unable to move and the motors on light will be off. The safety stop state will need to be cleared by the operator to continue processing. Screen Selection Menu: Located in the upper left hand corner of all screens. The menu has a drop down list to select one of the following screens: jobs, configuration. Shelf: there are a total of 8 shelves on each rack in the VBX-160 cell Shelf Slot: The location on a shelf where the robot will pick a part or pallet. Shelf Template: A black plastic sheet engraved with graduated markings to show where to place the material blanks for robot picking. A shelf template is positioned on the top of each shelf. Signal Cable: A yellow cable that connects low voltage signals between VBX-160 cell and air/ electrical panel. Vise Sensors: Used to determine if the vise is holding a part. VBX-160 Cell: The enclosure of the robot and all of its components VBX Controller: The operator interface for controlling the CNC. White Task: A task highlighted in white in the Actions Panel, needs to be done, but it is not urgent. A white task will not stop the robot. Yellow Task: A task highlighted in yellow is not urgent and will not immediately stop the processing, but it could cause processing to stop if it is not addressed soon. Operator Manual Version 1.1 58 VersaBuilt VBX-160 12/2015
  62. 62. Appendix 1 Status/Control Button Key CONTROL BUTTONS The Control Buttons appear in the upper right corner of the VBX Controller. The control button display will change based on the current state of the VBXC.They are operable independent of other activities on the screen except when modal dialogs are displayed. DNC Sync: This button is visible when the system in in a feed hold state. The operator uses this button to tell the VBX Controller (VBXC) that the DNC connection to the CNC has been interrupted. This will initiate the DNC synchronization process. The VBXC controls the CNC via DNC. Cycle Start: This button is visible when the system is in feed hold state. It is used to start or continue processing. Within recovery mode, commands which cause movement of the robot arm or CNC will be disabled (greyed out) until Cycle Start is invoked. Recovery mode gripper manipulation is available while the cell is in a feed hold state. Outside of recovery mode, Cycle Start will start or continue part processing if there are parts ready for processing. Cycle Start will be disabled if the safety circuit is open. Feed Hold: This button is visible when the system is processing. It is used to pause processing. When feed hold is initiated, the VBXC will stop sending actions to the robot and CNC. The CNC will complete its current action before stopping. Operator Manual Version 1.1 59 VersaBuilt VBX-160 12/2015
  63. 63. Recovery: This button is visible when the system is in feed hold state. The operator uses this button to manually initiate recovery mode to clear the current processing state of the VBXC. It will cause parts and MultiGrip soft jaws held by the robot or in vises to be cancelled. It also resets communication with the Robot and CNC. It can also be useful while in recovery mode to reset the robot should it become unresponsive. Enable: This button appears in recovery mode. Clicking on this button will enable robot and CNC commands. When Enable is clicked, the button will change to Pause. Pause: This button appears in recovery mode after the enable button has been clicked. Clicking on pause will pause robot and CNC commands. When Pause is clicked, the button will change to Enable. Reset: This button appears in recovery mode. Clicking on this button will clear any pending robot motions and get the robot back to a starting state. This is useful in the rare case when the robot becomes unresponsive. For example: If you tell the robot to eject the vise, but the robot is unresponsive, then you can clear that command using the Reset button.This button will not move the robot arm to the home position. The robot arm is moved in the Recovery Screen. Operator Manual Version 1.1 60 VersaBuilt VBX-160 12/2015
  64. 64. STATUS ICONS The status icons icons appear at the top of the screen to the left of the control buttons. Status icons communicate the status of the cell. Op-Stop Disabled: op-stop is disabled. Click icon to cycle op-stop modes. Op-Stop Enabled: Single op enabled. The VBXC will feed hold itself when a milling op has finished processing. Click icon to cycle op-stop modes. Op-Stop-Part Stop: Part Stop enabled. The VBXC will feed hold itself when a part finishes processing. Click icon to cycle op- stop modes. Rack Light On/Off: Click on the light bulb to turn the rack lights on or off, Black light bulb indicates that light is turned off. White light bulb indicates that the light is on. Safety Circuit Closed: The cell safety circuit is closed. This status is required to move the robot or initiate CNC operations. Safety Circuit Open: The cell safety circuit is open. This is caused by cell door or pivot sensors being opened. The cell cannot begin processing until the safety circuit is closed. Error Action: An error has occurred. Refer to the Action Panel for tasks related to the error Robot Speed: shows current speed of the robot. 
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  65. 65. DNC Connected: The VBXC is synchronized with the CNC DNC connection. DNC Disconnected: The VBXC is not synchronized with the CNC DNC connection. The VBXC detects DNC disconnect by testing the DNC connection before sending a command to the CNC. DNC disconnect is also caused by invoking DNC sync. When this is active, there will be DNC sync actions in the action list. Running: The system is processing parts. This icon will be present when the VBXC is processing parts from the rack. It remains present in the feed hold state. Vise Pressure: These gauges show the current pressure for the vises. The vise pressure can be adjusted in part configuration. The gauges are always visible in the Status/Control Panel. 
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  66. 66. Appendix 2 Shelf Slot Color Key Note: Key includes color/slot status Red/error The slot had an error Blue/transferring The part is on the shelf waiting for op to op transfer. Blue Violet/waiting the slot has a part/ MultiGrip soft jaws on the shelf waiting for processing Green/part done The part is complete, on the shelf waiting to be unloaded Purple/holding the part/MultiGrip soft jaws is held by the robot Yellow/cancelled The part is cancelled and held by the robot Bright Pink/milling The part/MutliGrip soft jaws from the slot is currently milling White/empty The slot is empty Mauve/in vise The part is in the vise Operator Manual Version 1.1 63 VersaBuilt VBX-160 12/2015
  67. 67. Appendix 3 Stack Light Status Key Operator Manual Version 1.1 64 VersaBuilt VBX-160 12/2015 Action List System State Messages: These are messages that will appear in the action list which reflect the overall state of the VBX Controller Message Color/Image Action Buttons System State Description Press Cycle Start to begin processing parts Press Cycle Start to continue processing parts Press Enable to begin controlling the robot and CNC. Initializing. Please wait... Red None Shut Down This message can appear while the VBX Controller software is starting up. The part processing server is shutting down. Please wait.... Red None Shut Down This message will appear while the VBX Controller is shutting down The part processing server is shut down. Restart to proceed. Red None Shut Down This message will appear while the VBX Controller is shut down. Connecting to robot controller. Please wait... The cell is in test mode. Exit tests to proceed. Red Done Test This message will be displayed when the VBX cell is in development testing mode. It should not appear in normal operation.
  68. 68. The stack light on the roof of the VBX-160 cell indicates cell status as follows: Illuminated Green: Running Illuminated green and blinking: Running, but in feed hold Illuminated red and flashing: Error has occurred Not illuminated: Idle Operator Manual Version 1.1 65 VersaBuilt VBX-160 12/2015
  69. 69. Appendix 4 Action Panel Messages Action List System State Messages Message Color/image Action Buttons System State Description The robot controller firmware must be updated to be compatible with this application. Use the teach pendant or Robot Studio to restore the controller backup called UPDATE. Red Done Update This message appears when the robot controller software version is incompatible with the VBX Controller software version. Contact Technical Support if you see this message. The robot controller firmware is updating to be compatible with this application... Red Done Update This message appears when the robot controller software version is incompatible with the VBX Controller software version. It indicates that the VBX Controller is updating the robot controller software. This should only take a few minutes. Part processing or other robot actions are not available while this message is present. Operator Manual Version 1.1 66 VersaBuilt VBX-160 12/2015
  70. 70. Verify that the vises in the CNC are cleared of parts and jaws. There was a communication error between the VBXC and the robot controller. • Verify that the Ethernet connection between the VBXC and the robot controller is connected. • Shut down the VBXC, then turn off the power to the cell air/ electrical panel for 60 seconds, then turn it back on. • If the problem persists, call technical support. Red None Recovery When the VBX Controller experiences errors communicating with the robot controller, it enters recovery mode with this message. Attempting to exit recovery mode from this state will retry robot communications. If robot communications are successful, this message will be cleared and the normal recovery exit process will proceed. If robot communications are still unsuccessful, this message will persist. Try using the Reset button in Recovery to clear any pending robot motions and get the robot back to a starting state. Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 67 VersaBuilt VBX-160 12/2015
  71. 71. The system is entering recovery mode. Red Done Recovery The system has encountered an error or the user has manually invoked an error and the system is working on entering recovery mode. This message may appear briefly while the system enters recovery. The following actions must be performed to exit recovery mode: • Enable the cell • Move the robot arm to CNC home. • Reconnect DNC. • Address and clear the listed error actions. White Done Recovery This message is present while the VBX Controller is in recovery mode. It tells the user what general steps need to be performed in recovery. Other action messages will indicate specific actions to be addressed. Selecting Done invokes a check that the steps listed have been performed and a self test. If successful, the VBX Controller will exit recovery mode. If not successful, the user will be prompted by pop- up dialog of the actions to be performed. Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 68 VersaBuilt VBX-160 12/2015
  72. 72. Initiate DNC mode on the CNC control panel. Red Retry Recovery, Running, Idle Message requesting that DNC communications be established or re-established with the CNC. Press the Done button in the actions list to begin the DNC connection process. Start cycle on the CNC. Message requesting that the CNC Cycle Start button be pressed on the CNC to complete the establishment of DNC communications. The robot has an emergency stop. • Verify robot estop buttons are reset. • Verify teach pendant interface is terminated. Red None Recovery, Running, Idle This message indicates an emergency stop on the robot. This can be caused by the eStop button on the front of the robot controller enclosed in the robot controller compartment or by the estop button on the teach pendant if attached. Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 69 VersaBuilt VBX-160 12/2015
  73. 73. The safety circuit is active. 1. Pivot cell to CNC. 2. Verify that cell doors are secure. 3. Check the door sensors for alignment and damage. 4. Check safety circuit for damage. Red Done Recovery, Running, Idle The cell safety circuit is open. This is caused by cell door or pivot sensors being opened. The cell cannot begin processing until the safety circuit is closed. Press Cycle Start to continue after closing doors. The robot controller is in manual mode. Turn the key on the robot controller, (inside the controller compartment) to automatic mode. Red Done Recovery This message appears when the key on the front of the robot controller enclosed inside of the robot controller compartment is set to manual operation. The key must be set to automatic before processing can continue. There was a collision. The robot collided with an object. The system enters Recovery mode. The robot must be brought back to its home position before processing can continue. Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 70 VersaBuilt VBX-160 12/2015
  74. 74. There was a motion error. The robot collided with an object. The system enters Recovery mode. The robot must be brought back to its home position before processing can continue. There was a fumble error A part was fumbled in the jaws. If the fumble occurred while picking or placing the part within the CNC, processing will continue unless too many fumble errors occur. If the fumble happens in the CNC, processing will stop to protect the CNC from a loose part. Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 71 VersaBuilt VBX-160 12/2015
  75. 75. The pneumatics self test failed. 1. Check the sensed actuator for mechanical damage. 2. Use the pneumatics control buttons in the recovery panel to check the movement of the sensed actuator. 3. Check the condition and adjustment of the indicated sensor. 4. Check the condition of the wiring to the indicated sensor. 5. If a gripper sensor had a float error, verify that the gripper stays open and stays closed when floated. 6. For further information, see the Pneumatics Adjustment and Troubleshootin g Guide Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 72 VersaBuilt VBX-160 12/2015
  76. 76. There was an error moving the CNC door. Check the door movement and sensors. Red None Recovery If the CNC door is commanded to open or close and the corresponding sensor does not indicate completion of the action within ten seconds, this error will be generated. Exiting recovery mode will perform a system self test and clear this error on successful test. Waiting for vise pressure to stabilize… There was a vise pressure error. Red None Recovery The system was unable to achieve a target pressure on the vises. Exiting recovery mode will perform a system self test and clear this error on successful test. Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 73 VersaBuilt VBX-160 12/2015
  77. 77. Check the supply pressure and check the pneumatic systems leaks. There was a communication error between the VBXC and the robot controller. • Verify that the ethernet connection between the VBXC and the robot controller is connected. • Shut down the VBXC, then turn off the power to the cell at the sell air/electrical panel for 60 seconds, then turn it back on. • If the problem persists, call technical support. Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 74 VersaBuilt VBX-160 12/2015
  78. 78. There was a communication error between the VBXC and CNC communication hardware. • Verify that DNC RS232 communication hardware is connected and undamaged. • Shut down the VBXC, then turn off the power to the cell at the cell air/electrical panel for 60 seconds, then turn it back on. • If the problem persists, call technical support. Red Done Highlight Recovery This message indicates that the VBX Controller was unable to open its local RS232 port. This can be caused by hardware failure or system misconfiguration. Restart the VBX Controller to exit this state. There was a sensor error. Check the sensors on the gripper and vises. Red None Recovery There are a few places where the robot sensors are checked during part processing where unexpected reading can be attributed to a mechanical failure of the cell as opposed to the state of the part being processed. Exiting recovery mode will perform a system self test and clear this error on successful test. Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 75 VersaBuilt VBX-160 12/2015
  79. 79. A system error has occured. Shutdown system and restart. • Shut down the VBXC, then turn off the power to the cell at the cell air/electrical panel for 60 seconds, then turn it back on. • If the problem persists, call techinical support. Red None Recovery This message indicates that the VBX Controller has detected an unexpected state of the VBX Controller software or the robot controller software. Power cycling the cell may clear this error. Report these errors to VersaBuilt technical support. An IO error has occurred on the robot controller. • Check for damage to control and sensor wiring. • Check for damage or modifications to air/electrical panel wiring. • Shut down the VBXC, then turn off the power to the cell at the cell air/electrical panel for 60 seconds, then turn it back on. • If the problem persists, call technical support. Done Highlight Action List System State Messages Message Color/image Action Buttons System State Description Operator Manual Version 1.1 76 VersaBuilt VBX-160 12/2015
  80. 80. Action List Single Slot Messages The part from shelf ( ) slot( ) had an error. • Remove the part from the cell. Red Done Highlight Recovery The part had an error. Remove the part from the cell. The part from shelf ( ) slot( ) had a motion error. • Remove the part from the cell. Red Done Highlight Recovery The part had a motion error. remove the part from the cell. The part from shelf ( ) slot ( ) had a collision error. • Remove the part from the cell. Red Done Highlight Recovery The part had a collision error. Remove the part from the cell. The part from shelf ( ) slot ( ) was fumbled. • Remove the part from the cell. Red Done Highlight Recovery The part was fumbled (dropped). Remove the part from the cell. Unable to pick part from shelf ( ) slot ( ). • Remove the part from the cell. Red Done Highlight Recovery The robot was unable to pick the part from the shelf. Remove the part from the cell. There was an error milling the part from shelf ( ) slot( ) in vise ( ). • Use the vise open/close buttons to manually remove the part, or • Use the “remove items from vise” button to have the robot place the part in the jaws on the shelf. Red Done Highlight Recovery There was an error from the milling program for the part. Remove the part from the cell. Operator Manual Version 1.1 77 VersaBuilt VBX-160 12/2015
  81. 81. Remove the part in the gripper from the cell. • Use the gripper open/close buttons to manually remove the part, or • Use the “place held items” button to have the robot place the part in the jaws on the shelf. Red Done Highlight Recovery There is a part in the gripper which needs to be removed from the cell. The user can either manually remove the part by floating the gripper or automatically by using the “place held items” (eject) button. Remove the part in vise from the cell. • Use the vise open/close buttons to manually remove the part, or • Use the “remove items from vise” button to have the robot place the part in the jaws on the shelf. Red Done Highlight Recovery There is a part in the vise which needs to be removed from the cell before proceeding. The user can either manually remove the part by using the manual vise valves or automatically by using the “clear vise” (eject) button. Replace cancelled jaws on shelf ( ) slot ( ). Red Done Highlight Recovery Cancelled MultiGrip soft jaws in the gripper or vise need to be placed in their shelf slot. Jaws from shelf ( ) slot ( ) had an error. • Replace the jaws on the shelf. Red Done Highlight Jaws from shelf ( ) slot ( ) had a motion error. • Replace jaws on the shelf. Red Done Highlight Recovery The robot was moving the MultiGrip soft jaws and had a motion error. Place the MultiGrip soft jaws back in their slot. Jaws from shelf ( ) slot ( ) had a collision error. • Replace Jaws on the shelf. Red Done Highlight Recovery The robot was moving the MultiGrip soft jaws and had a collision error. Place the MultiGrip soft jaws back in their slot. Operator Manual Version 1.1 78 VersaBuilt VBX-160 12/2015
  82. 82. Jaws on shelf ( ) slot ( ) are holding a cancelled part. • Remove the part from the cell. • Replace the jaws on the shelf. Red Done Highlight Recovery When the robot places cancelled MultiGrip soft jaws which are holding a part on the shelf, the cancelled part must be removed from the cell. The jaws from shelf ( ) slot ( ) were fumbled. • Replace the jaws on the shelf. Red Done Highlight Recovery The robot tried to pick up the MultiGrip soft jaws but was unsuccessful. Place the MultiGrip soft jaws back in their shelf slot and press the done button. There are canceled jaws from shelf ( ) slot ( ) in the gripper. • Use the gripper float button to manually remove the jaws, or • Use the “place held items” button to have the robot place the jaws on the shelf. Red Done Highlight Recovery There are MultiGrip soft jaws in the gripper which need to be placed in their shelf slot before proceeding. The user can either manually place the MultiGrip soft jaws on the shelf by floating the gripper or automatically by using the “place held items” (eject) button. Operator Manual Version 1.1 79 VersaBuilt VBX-160 12/2015
  83. 83. There are canceled jaws in vise ( ) from shelf ( ) slot ( ). • Use the vise open/close buttons to manually remove the jaws, or • Use the “remove items from vise” button to have the robot place the jaws on the shelf. Red Done Highlight Recovery There are MultiGrip soft jaws in the vise which need to be placed in their shelf slot before proceeding. The user can either manually place the MultiGrip soft jaws on the shelf by floating the gripper or automatically by using the “clear vise” (eject) button. Unload completed jaws from shelf ( ) slot ( ). White Done Highlight Recovery, Running, Idle The MultiGrip soft jaws in the slot are no longer needed for processing of active jobs. Remove the MultiGrip soft jaws from the shelf and select the done button on the action. Operator Manual Version 1.1 80 VersaBuilt VBX-160 12/2015
  84. 84. Action List MultiSlot Messages Unload ( ) of completed part ( ) for order ( ). White Done Highlight Recovery, Running, Idle Unload the completed parts from the cell and confirm via the Done button. Unload ( ) of canceled part( ) for order( ) White Done Highlight Recovery, Running, Idle Unload the cancelled parts from the cell and confirm via the Done button. Load jaws ( ) onto shelf ( ) slot ( ) for order ( ). White Done Highlight Recover, Running, Idle Load MultiGrip soft jaws for a job. Load ( ) ( ) for order( ). White Done Highlight Recovery, Running, Idle Load parts into the slots for processing. The ( ) for job ( ) requires an additional slot of one of the following shelf templates before it can be queued to run on the system. White Done Highlight Recovery, Running, Idle There are not sufficient template slots configured in the cell (available or not) for the job to ever run. The template shelf must handle tall parts • ( ) No pending actions. Operator Manual Version 1.1 81 VersaBuilt VBX-160 12/2015

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