UNNAMED HAPTIC DISPLAY REFERENCE MANUAL

Compiled by

Matthew Reed

Georgia Institute of Technology November 2003

SECTION 1

OPERATING INSTRUCTIONS

ROBOT OPERATING INSTRUCTIONS To Operate: 1. Plug in power supply. 2. Turn on force sensor. 3. Open Matlab 6.5 (desktop link). 4. Open dSPACE ControlDesk (desktop link). 5. Position robot in far right position. 6. In Control Desk:

a. Select “PL…” tab in leftmost window. b. Select “File Selector” tab in bottom window. c. In the same window, set the directory to C:/Matlab6p5/Work. d. In the right section of the bottom window, select the appropriate file and drag to the

ds1102 icon in the leftmost window. i. 4-Brake free gap SDOF velocity control: switchcontrol4.sdf ii. 4-Brake controlled gap SDOF velocity control: switchcontrol5.sdf iii. 4-Brake proportional velocity control: velocitycontrol2.sdf iv. 3-Brake free gap SDOF velocity control: switchcontrol4q.sdf v. 3-Brake controlled gap SDOF velocity control: switchcontrol5q.sdf vi. 3-Brake proportional velocity control: velocitycontrol2q.sdf

7. Program will automatically start running. If it does not, or you wish to restart the program, click on the green start button on the menu bar.

8. Click on the “Animate” button (5 to the right of the start button). 9. Click on “File” and open appropriate layout.

a. 4-Brake free gap SDOF velocity control: control4layout.lay b. 4-Brake controlled gap SDOF velocity control: control5layout.lay c. 4-Brake proportional velocity control: vcontrol2.lay d. 3-Brake free gap SDOF velocity control: control4qlayout.lay e. 3-Brake controlled gap SDOF velocity control: control5qlayout.lay f. 3-Brake proportional velocity control: vcontrol2qlayout.lay

10. Select “Yes” to load data connections if prompted. 11. Click on “View” “Full Screen”. 12. Edit Capture Settings (bottom right of layout).

a. In the “Length” textbox, enter “2”. b. Click on “Settings,” select “Acquisition” tab, select ‘Continuous,” click “OK.”

13. Rotate bottom base joint clockwise until endpoint trace jumps. Do not allow the top base joint to rotate.

14. Rotate the top base joint until the endpoint position jumps. 15. Robot is now ready to operate. Control initiates when the green circle is entered and shuts

off when the red circle is entered. 16. Controller parameters may be modified online

a. big = distance from desired path to boundary (used to generate desired velocity field) b. little = distance from desired path to gap boundary (used in free gap SDOF control) c. Ky = velocity control gain (5 is a good low gain)

17. Desired Path may be modified online a. Type “pbot” (for 4-Brake) or “qbot” (for 3-Brake) in the Matlab window.

b. Select controller in the first pulldown menu. c. Select “Change” in the second pulldown menu. d. Click on “G” to enter a line graphically or use the text boxes. e. Click “Add,” and then “Start.”

To Shut Down: 1. Push “Escape” key to exit full screen mode. 2. Click on “Edit” button (two to the left of “Animate”). 3. Click on the red stop button. 4. Close ControlDesk and Matlab. 5. Turn off force sensor. 6. Unplug power supply.

SECTION 2

MR FLUID BRAKES

Lord MRB-2107-3 Rotary MR Brake (4)

SECTION 3

AMPLIFIERS AND POWER SUPPLY

Advanced Motion Controls PS4X300W Power Supply (1) (same as PS2X300W with different base)

Advanced Motion Controls 12A8 PWM Amplifier (4)

25A Series

A-5

SERIES 25A SERVO AMPLIFIERS Models: 12A8, 25A8, 20A14, 20A20

Miniature Series

FEATURES: • Surface-mount technology • Small size, low cost, ease of use • DIP switch selectable: current, voltage,

velocity, analog position loop • Four quadrant regenerative operation • Agency Approvals:

BLOCK DIAGRAM:

ADVANCED MOTION CONTROLS

3805 Calle Tecate, Camarillo, CA 93012 Tel: (805) 389-1935, Fax: (805) 389-1165

25A Series

A-6

DESCRIPTION: The 25A Series PWM servo amplifiers are designed to drive brush type DC motors at a high switching frequency. A single red/green LED indicates operating status. All models are fully protected against over-voltage, over-current, over-heating and short-circuits across motor, ground and power leads. All models interface with digital controllers or can be used as a stand-alone drive. They require only a single unregulated DC power supply. Loop gain, current limit, input gain and offset can be adjusted using 14-turn potentiometers. The offset adjusting potentiometer can also be used as an on-board input signal for testing purposes when SW4 (DIP switch) is ON. SPECIFICATIONS:

MODELS

POWER STAGE SPECIFICATIONS 12A8 25A8 20A14 20A20

DC SUPPLY VOLTAGE 20 - 80 V 20 - 80 V 40 - 140 V 40 - 190 V

PEAK CURRENT (2 sec. Max., internally limited) ± 12 A ± 25 A ± 20 A ± 20 A

MAXIMUM CONTINUOUS CURRENT (internally limited) ± 6 A ± 12.5 A ± 10 A ± 10 A

MINIMUM LOAD INDUCTANCE* 200 µH 200 µH 250 µH 250 µH

SWITCHING FREQUENCY 36 kHz 22 kHz ± 15%

HEATSINK (BASE) TEMPERATURE RANGE 0 o to + 65o C, disables if > 65o C

POWER DISSIPATION AT CONTINUOUS CURRENT 24 W 50 W 70 W 100 W

OVER-VOLTAGE SHUT-DOWN (self-reset) 86 V 86 V 142 V 195 V

BANDWIDTH (load dependent) 2.5 kHz

MECHANICAL SPECIFICATIONS

POWER CONNECTOR Screw terminals

SIGNAL CONNECTOR Molex connector

SIZE 5.09 x 2.98 x 0.99 inches 129.3 x 75.8 x 25.1 mm

WEIGHT 10 oz. 0.28 kg

* Low inductance motors ("pancake" and "basket-wound") require external inductors.

25A Series

A-7

PIN FUNCTIONS:

CONNECTOR PIN NAME DESCRIPTION / NOTES I/O

1 +5V OUT O

2 SIGNAL GND GND

3 -5V OUT

Internal DC-to-DC converter, outputs regulated voltages of ±5 V @ 3 mA for customer use. Short circuit protected.

O

4 +REF IN

5 -REF IN

Differential analog input, maximum ±15 V, 50K input resistance.

I

6 -TACH IN

7 +TACH (GND) Maximum ± 60 VDC, 60K input resistance. I

8 CURRENT MONITOR OUT

This signal is proportional to the actual current in the motor leads. Scaling is 2A/V for 12A8 and 4 A/V for 25A8, 20A14 and 20A20.

O

9 CURRENT REFERENCE OUT

Command signal to the internal current-loop. The maximum peak current rating of the amplifier always equals 7.25V at this pin. See current limit adjustment information below.

O

10 CONTINUOUS CURRENT LIMIT

Can be used to reduce the factory-preset maximum continuous current limit.

I

11 INHIBIT

This TTL level input signal turns off all four power devices of the "H" bridge drive when pulled to ground. This inhibit will cause a FAULT condition and a red LED. For inverted inhibit inputs; see section "G".

I

12 +INHIBIT

Disables the amplifier for the "+" direction only. This inhibit will not cause a FAULT condition or a red LED.

I

13 -INHIBIT

Disables the amplifier for the "-" direction only. This inhibit will not cause a FAULT condition or a red LED.

I

14 FAULT OUT (red LED)

TTL compatible output. It becomes high during output short-circuit, over-voltage, over-heating, inhibit, and during "power-on reset". Fault condition indicated by a red LED.

O

15

P1

16 NC Not connected

1 -MOTOR Motor minus connection. O

2 +MOTOR Motor plus connection. O

3 POWER GROUND Power Ground. GND

4 POWER GROUND Power Ground. GND

P2

5 HIGH VOLTAGE DC voltage input. I

25A Series

A-8

SWITCH FUNCTIONS:

SETTING SWITCH FUNCTION DESCRIPTION

ON OFF

1 Internal voltage feedback On Off

2 It is recommended to leave SW2 in OFF position.

Shorts out the current loop integrator

capacitor.

Current loop integrator operating

3 This capacitor normally ensures "error-free" operation by reducing the error-signal (output of summing amplifier) to zero.

Shorts out the outer velocity/voltage loop integrator capacitor

Velocity/Voltage integrator operating

4 Offset / test. Controls sensitivity of the "offset" pot. Used as an on-board reference signal in test mode.

Test Offset

POTENTIOMETER FUNCTIONS:

POTENTIOMETER DESCRIPTION TURNING CW

Pot 1 Loop gain adjustment in voltage & velocity modes. Turn this pot fully ccw in current mode.

Increases loop gain

Pot 2 Current limit. It adjusts both continuous and peak current limit by maintaining their ratio (50 %).

Increases current limit

Pot 3 Reference gain. It adjusts the ratio between input signal and output variables (voltage, current, or velocity).

Increases reference input

gain

Pot 4

Offset / test. Used to adjust any imbalance in the input signal or in the amplifier. When SW4 (DIP switch) is ON, the sensitivity of this pot is greatly increased thus it can be used as an on-board signal source for testing purposes. See section "G".

N/A

25A Series

A-9

TEST POINTS FOR POTENTIOMETERS: See section “G” SET-UP: See section “G” for engineering and installation notes. OPERATING MODE SELECTION: These modes can be selected by the DIP-switches according to the chart in the functional block diagram: • Current Mode • Voltage Mode • IR Compensation Mode* • Tachometer Mode APPLICATION NOTES: *For IR compensation mode, a resistor must be added to location R8*. See the functional block diagram above and section “G” for more information. The combination of the resistor addition and the switches set for voltage mode will configure the amplifier for IR compensation mode. See section "G" for more information. See section G for more information on analog position loop mode. CURRENT LIMIT ADJUSTMENTS: These amplifiers feature separate peak and continuous current limit adjustments. The current limit adjusting Pot 2 adjusts both peak and continuous current limit at the same time. It has 12 active turns plus 1 inactive turn at each end and is approximately linear. Thus, to adjust the current limit, turn the potentiometer fully counter-clockwise, then turn clockwise to the appropriate value. If the desired limit is, for example, 10 amperes, and the servo amplifier peak current is 20 amperes, turn the potentiometer 7 turns clockwise from the fully counter-clockwise position. Pin P1-9 is the input to the internal current amplifier stage. Since the output current is proportional to P1-9, the adjusted current limit can easily be observed at this pin. Note that a command signal must be applied to the reference inputs to obtain a reading on P1-9. The maximum peak current value equals 7.25 V at this pin and the maximum continuous current value equals 3.63 V at this pin. The actual current can be monitored at pin P1-8. The continuous current can be reduced without affecting the peak current limit by connecting an external current limiting resistor R-lmt between P1-10 and P1-2. See table below.

Current Limit Resistor (Ω) 15K 6.6K 3.4K 2.1K 1.2K 810 500 250 0

Continuous Current Limit % 90 % 80 % 70 % 60 % 50 % 40% 30 % 20 % 10 %

TYPICAL SYSTEM WIRING: See section "G".

25A Series

A-10

ORDERING INFORMATION: Models: 12A8X, 25A8X, 20A14X, and 20A20X X indicates the current revision letter. MOUNTING DIMENSIONS: See page F-7.

Power Supplies, Filter Cards & Shunt Regulators

E-7

PS2X300W SERIES POWER SUPPLIES

FEATURES: • Multiple primary windings:

either 120 VAC or 240 VAC, 50/60 Hz operation

• 24 VDC secondary output winding taps

• Low cost • Agency approvals:

BLOCK DIAGRAM:

ADVANCED MOTION CONTROLS 3629 Vista Mercado, Camarillo, CA 93012 Tel: (805) 389-1935, Fax: (805) 389-1165

Power Supplies, Filter Cards & Shunt Regulators

E-8

DESCRIPTION: The PS2X300W series unregulated power supplies have been designed to complement ADVANCED MOTION CONTROLS' servo amplifiers and to provide the user with a complete solution to single and multi-axes DC drive applications. These unregulated DC power sources are an acceptable solution for most applications as ADVANCED MOTION CONTROLS' servo amplifiers compensate for power supply output variations and AC ripple components. Series PS2X300W power supplies are designed to provide the best cost-per-watt value while mechanically hosting two of B15A, BE15A or 25A Series servo amplifiers. They have multiple primary windings for 120VAC and 240 VAC 50/60 Hz operation. These power supplies feature four identical secondary windings that can be connected in series or in parallel for different output voltages and currents.

MODEL

MECHANICAL SPECIFICATIONS PS2X300W

AC INPUT CONNECTOR (female three prong plug) AC cord (not supplied)

DC OUTPUT CONNECTOR Flying Leads

SIZE 9.00 x 5.75 x 3.47 inches 228.6 x 146.1 x 88.1 mm

WEIGHT 9 lb.

4.1 Kg.

ORDERING INFORMATION:

AMC PART NUMBER

Input Voltage (240VAC)

Input voltage (120VAC)

Output Voltage (VDC)

Nominal Output Current (Amps)

PS2X3H24 PS2X3W24 24 12

PS2X3H48 PS2X3W48 48 6

PS2X3H72 PS2X3W72 72 3

PS2X3H96 PS2X3W96 96 3

MOUNTING DIMENSIONS: See page F-23.

SECTION 4

OPTICAL ENCODERS

Dynamics Research Corporation HS30C176B15N5000 Quadrature Optical Encoder (2)

Note: This document is a recreation of the document found at www.drc.com/encoder/hollow/HS30.htm which no longer exists since Dynamics Research Corporation was acquired by GSI Lumonics. GSI has yet to post specifications for this product. Model HS30 Incremental Optical Rotary Encoder

• Hollow shafts will accept up to 0.75 in diameter shafts • 5,000 line disc with internal 5X cycle interpoloation • Small compact size • Flexible spring mount • Unique split collar shaft mount • Frequency response up to 100 kHz all channels

The Model HS30 is a high speed hollow shaft optical rotary encoder. The units unique split collar and flexible spring make installation of the HS30 very simple. The unit is available with disc resolutions up to 5,000 lines and internal cycle interpolation of 5X to generate up to 100,000 counts per revolution. The lare inside diameter bearing used on the HS30 will accept up to ¾ in diameter shafts. The HS30 series is ideal for applications which require a high resolution hollow shaft encoder.

SPECIFICATIONS ELECTRICAL • 4,096 OR 5,000 lines, higher line counts available

upon request Disk resolution range: • 4X or 5X

Internal cycle interpolation factors:

• Gallium aluminum arsenide LED rated for 100,000 hours MTBF

Light sensors: • Photodiodes Excitation voltage: • +5 VDC (± 5%) Maximum current draw: • Units without interpolation = 245 mA, units with

cycle interpolation 275 mA Output format: • Two count (A + B) in phase quadrature with an

optional ZR output Quadrature specifications: • 90° ± 30° tested at 10 kHz output frequency Symmetry specifications: • 180° ± 10° tested at 10 kHz output frequency Rise and fall times: • 1 microsecond (maximum) into 1,000 pF load Frequency response: • 100 kHz all channels, units with 4X, 5X, 50 kHz

input *250 kHz max output) Phase sense: • Channel A leads Channel B for clockwise

rotations of the shaft as viewed from cover side of an installed unit

Zero reference: • ¼ count channel cycle wide, once per revolution Output specifications: • Differential, TTL compatible RS422 line driver

signals Wire type: • Shielded 26 AWG cable with individual twisted

pairs an overall PVC jacket MECHANICAL Shaft angular acceleration • 105 radians/s2 (maximum) Available hub I.D.s • .75 in or 18 mm diameter, other shaft sizes

available upon request Maximum shaft run out: • Up to ± .005 in radial, ± .010 in axial Shaft perpendicular to mounting surface:

• Up to .005 in per inch

Moment of inertia: • 4 x 10-4 oz-in-s2 Bearing type: • #540 torque tube bearing, ABEC class 5 or better Maximum operating speed: • 6,000 rpm or maximum operating frequency

response of 100 kHz, whichever occurs first Angular acceleration: • 105 radians/s2 (maximum) Customers shaft O.D. tolerance: • Nominal -.0002 in (.005 mm) to -.0007 in (.018

mm) ENVIRONMENTAL Operating temperature range: • 0° to 70° C (32° to 158° F) Storage temperature range: • -25° to 90° C (-13° to 194° F) Shock: • 50Gs for 11 milliseconds duration Vibration: • 20 Hz to 2,000 Hz at 5Gs Humidity: • To 98% R.H. (non-condensing)

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

HOW TO ORDER

HS30

ZR

A

A

B

B

GZ 1/2 Cycle

GZ 1/4 Cycle

GZ 1/4 Cycle (Option 1)

Function Wire ColorChannel A+ OrangeChannel A- GreenChannel B+ YellowChannel B- Blue

Channel ZR+ BrownChannel ZR- Grey

+5 VDC RedCommon Black

N

T = Top Clamp B = Bottom Clamp, No Cover Hole C = Bottom Clamp With Cover Hole

SHAFT ID 5E = 5/16” 6E = 3/8” 7E = 7/16” 8E = 1/2” 0E = 5/8” AE=3/4” 08 = 8 MM 09 = 9 MM 10 = 10 MM 11 = 11 MM 12 = 12 MM 13 = 13 MM 14 = 14 MM 15 = 15 MM 16 = 16 MM 17 = 17 MM 18 = 18 MM 19 = 19 MM

CABLE TYPE 1 = 1.0 ft of cable3 = 3.0 ft of cable6 = 6.0 ft of cable

SUPPLY VOLTAGEB = 5 V C = 12 V D = 15 V

ZERO REFERENCE0 = w/o ZR 1 = ¼ cycle 2 = ½ cycle 4 = full cycle

ELECTRONICS TYPE 4 = 4X Interpolation 5 = 5X Interpolation 6 = Diff. Line Driver (RS422)

Cycles Per Shaft Revolution

Special Modifications Consult Factory

SECTION 5

FORCE SENSOR

Assurance Technologies FT 15/50 6-Axis Force and Torque Sensor

Assurance Technologies Force and Torque Sensor Controller

PRODUCT DESCRIPTIONThe F/T sensor system measures the full six components

of force and torque (Fx, Fy, Fz, Tx, Ty, Tz) using amonolithic instrumented transducer. The F/T transduceruses silicon strain gauges for excellent noise immunity.The use of silicon gauges allows the F/T transducer to havehigh stiffness and increased overload protection. Alltransducer models are available with either DAQ F/T orController F/T interfaces.

The DAQ F/T allows the transducer to connect to ananalog Data Acquisition (DAQ) card (PCI, USB, PCMCIA,etc.) making it easy to read sensor data with your PC orrobot controller. The F/T strain gauge signals areconditioned and transmitted to the DAQ card. Next, theATI DAQ software works with your computer to convertstrain gauge data into force/torque data. The DAQ F/Tconsists of a transducer, an interface board, a power supplyboard, a DAQ card, software and high-flex cables designedto shield against outside electrical noise.

The Controller F/T processes the F/T strain gaugeinformation and outputs serial and analog force/torque data.Controller functions provide tool transformations, peakcapture, biasing and discrete I/O.

BENEFITS AND FEATURESOverload protectionThe F/T transducer is extremely rugged and durable. Thetransducers factor-of-safety can be as high as 2700%,depending on model and calibration.

High signal-to-noise ratioSilicon gages provide a signal 75 times stronger thanconventional foil gages. This signal is amplified resulting innear-zero noise distortion.

High-speed outputF/T controllers can output data at rates up to 28.5kHz.This speed exceeds requirements of most robotic and datacollection applications.

Software Tool TransformationsTool transformations can translate and rotate the F/Treference frame.

Versatile OutputsPCI, Analog, USB, PCMCIA, Discrete I/O, Compact PCI,and more.

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ATIs products and knowledgeable staff were instrumental in allowing us to rapidly prototype our latest surgical roboticplatform. Because of their off-the-shelf solutions for miniature force and torque sensing, we were able to go from concept toworking prototype in months instead of years.

Patrick Jensen, Ph.D.,Assistant Professor of OpthamologyJohns Hopkins University

Multi-Axis Force/Torque Transducers

AATI IINDUSTRIAAL AAUTOMAATION2

TABLE OF CONTENTSQuick-Selection Guide . . . . . . . . . . . . . . . . . . . . . . . .3DAQ F/T System . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5Controller F/T System . . . . . . . . . . . . . . . . . . . . . . . . .6How To Select an F/T Transducer . . . . . . . . . . . . . . . .7Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Nano17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Nano25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Nano43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Mini40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Mini45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Gamma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Theta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Omega160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Omega190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Specification Nano17 Nano25 Nano43 Mini40 Mini45 Gamma Delta Theta Omega160 Omega190Description pg. 6 pg. 8 pg.10 pg. 12 pg. 14 pg. 16 pg. 18 pg. 20 pg. 22 pg. 24

Max Fxy 12 50 8 20 120 30 150 600 600 1600+lb (+N) (50) (250) (36) (80) (580) (130) (660) (2500) (2500) (7200)

Max Txy 4 50 4 40 160 100 600 3600 3600 12000+in-lb (+N-m) (0.5) (6) (0.5) (4) (20) (10) (60) (400) (400) (1400)

Weight 0.02 0.14 .09 0.11 0.20 0.56 2.0 11.0 6.0 14.0lb (kg) (0.01) (0.07) (.04) (0.05) (.09) (0.25) (0.91) (4.99) (2.72) (6.35)

Diameter 0.67 0.99 1.69 1.57 1.77 2.97 3.72 6.10 6.14 7.48in (mm) (17) (25) (43) (40) (45) (75.4) (94.5) (155) (156) (190)

Height 0.57 0.85 0.45 0.48 0.62 1.31 1.31 2.41 2.20 2.20in (mm) (14.5) (21.6) (11.5) (12.3) (15.7) (33.3) (33.3) (61.1) (55.9) (55.88)

Specifications include standard interface plates.

When Lear Corporation partnered with KUKA Robotics to develop the OccubotVI seat testing system, we envisioneda robot that allowed for simultaneous load and position control. The critical component to achieving true loadcontrol was a sensor that could interface in real time with the robot kernel and receive commands directly whilemaintaining full robustness and accuracy necessary to duplicate exact human loading with sufficient repeatability.ATI Industrial Automation was the only choice, not just for the Theta transducer, which handily met all our demands,but primarily because of the excellent support from their technical and sales staff. Their partnership in the projectwas a key factor in its success.

Terry OBannon, Sr. Engineer, Biomechanics and RoboticsLear Technologies, LLCSouthfield, Michigan

Specification Nano17 Nano25 Nano43 Mini40 Mini45 Gamma Delta Theta Omega160 Omega190Description

AATI IINDUSTRIAAL AAUTOMAATION 3

QUICK-SELECTION GUIDE

AATI IINDUSTRIAAL AAUTOMAATION4

DAQ F/T SYSTEMDAQ F/T Systems come in one of two configurations depending on the size of the transducer. The two configurationsand their comprising components are listed below.Internal Interface Board Configuration: Transducer with internal interface board electronics (Gamma and larger),transducer cable, power supply box, power supply cable, data acquisition board, and user computer.External Interface Board Configuration: Transducer without electronics (Nano and Mini), transducer cable,interface power supply box, power supply cable, data acquisition board, and user computer.TransducerThe transducer senses applied loading with six degrees of freedom (Fx, Fy, Fz, Tx, Ty, and Tz). Gamma and largertransducer models have the interface board inside the transducer while Nano and Mini transducer models require theinterface board to be housed in Interface Power Supply Box (IFPS). Output is uncalibrated. ATI Software must be usedto produce calibrated output.Transducer CableFor our Nano and Mini transducer models, the transducer cable is integral to the transducer. For other transducers thetransducer cable is attached with a connector. The transducer cable is a long-life flexible cable specially designed fornoise immunity. This durable cable protects the transducer signals from electrical fields and mechanical stress.Interface BoardThe interface board electronics receive transducer strain gauge signals and convert them to readable DAQ card signalsusing noise immunity technology. Each interface board is calibrated to work with a specific transducer. The interfaceboard is mounted in the Gamma and larger transducer models and is located in the Interface Power Supply Box (IFPS)for the Nano and Mini transducer models. Output is uncalibrated. ATI software must be used to produce calibratedoutput.Power SupplyThe power supply converts readily available five volt (275mA) power from the PC through the DAQ card connection toclean power used by the transducer. The power supply is mounted in a small box that connects to the transducer cable onone end and to the data acquisition card on the other. When not mounted on the transducer, the interface boardelectronics are included with the power supply.Power Supply CableThe power supply cable conducts five volt power to the power supply box or interface power supply box and transmitsthe transducer signals to the data acquisition card. The cable has a flexible long-life design with special noiseimmunity features.Data Acquisition (DAQ) CardThe data acquisition card plugs into your PC, receives the analog transducer signals via the power supply cable and (withATI software on your computer) converts them into data to be used by computer programs. Our data acquisition cards areavailable in a wide variety of configurations and supply power to the F/T system. In many cases, you can use an existingdata acquisition card.DAQ BNC AdapterThis adapter connects to any of our standard power supply cables and provides a male BNC connection to each of theDAQ transducer outputs. It also has banana plug inputs from which it draws power.DAQ Multiple Transducer IFPS BoxThis multiple transducer version of our standard Interface Power Supply Box provides power for the transducers as wellas grouping all of the transducer outputs on connectors that are easily connected to DAQ cards that can support multipletransducers.

AATI IINDUSTRIAAL AAUTOMAATION 5

DAQ SOFTWAREATI provides DAQ F/T software components that you can use to build your application aswell as a sample application program. The software components are optimized for highspeed data transfer and include an Automation Server and C library as described below.

Software Component FeaturesThe Automation Server ATIDAQFT is a Windows ActiveX component that performs the core operations of the DAQ F/Tsystem including: reading calibration files configuring the transducer system converting transducer signals from any data acquisition system into force and torques performing tool transformationsATIDAQFT can be used in development platforms that support ActiveX or Automation containment, including:LabVIEW, Microsoft® Visual Basic, Visual Basic for Applications, and Visual C++.

For non-Windows operating systems, ATI also provides a C Library with the same features.Application ProgramThe Windows DAQ F/T application program displays graphical and numerical force and torque output for Windows 95and later Windows operating systems. Visual Basic 6.0 source code is provided as an aid in creating additional

9105-N1PCI 16-bit PCI 28.5K Datasets/second

9105-N1CPCI 16-bit CPCI 14.2K Datasets/second

9105-N2CPCI 12-bit CPCI 28.5K Datasets/second

9105-N1PCMCIA 16-bit PCMCIA 28.5K Datasets/second

9105-N2PCMCIA 12-bit PCMCIA 28.5K Datasets/second

9105-N2USB 12-bit USB 14.2K Datasets/second

9105-N1ISA 16-bit ISA 14.2K Datasets/second

ATI DAQ CARD P/N RESOLUTION BUS MAXIMUM THROUGHPUT

Maximum Throughput is dependent on the overall speed of the computer system.

DAQ CARDSOur DAQ F/T System works with our DAQ cards shown below or with differentially-ended or single-ended analog inputs on your DAQ hardware; however, differentially-ended inputs are preferred for the best noise immunity.

DAQ F/T System

Transducer

Power Supply Cable

Power Supply or InterfacePower Supply (for Nano/Mini

Transducers)DAQ Card-PCI, PCMCIAcPCI or USB

Transducer Cable

The DAQ F/T outputsamplified, conditioned straingauge signals to a dataacquisition card - not forceor torque data.ATI software(included) running on thehost computer performscomputations to convert thestrain gauge voltage datainto force/torque data.

You must acquire all sixstrain gauge channels inorder to calculate any of theforces and torques.

Note:

AATI IINDUSTRIAAL AAUTOMAATION6

CONTROLLER F/T SYSTEMThe Controller F/T system comes in one of two configurations depending on the size of the transducer. The twoconfigurations and their comprising components are listed below.Internal Mux Board Configuration: Transducer with internal mux board electronics, transducer cable, controller, andpower cord.External Mux Board Configuration: Transducer without electronics, transducer cable, mux box, mux cable,controller, and power cord.

TransducerThe transducer force and torques applied in six degrees of freedom (Fx, Fy, Fz, Tx, Ty, and Tz). Gamma and largermodels have on-board electronics (known as the mux board) and Nano and Mini models require these electronics to be ina separate housing (known as the mux box).

Transducer CableFor our smaller transducers (Nano and Mini series) the transducer cable is integral to the transducer. For othertransducers, the cable is attached with a connector. This durable, long-life, flexible cable protects the transducer signalsfrom electrical fields and mechanical stress.

Mux BoardThe mux board electronics connect directly to the transducer's sensing elements and provide high-level output signals.Each board is calibrated to work with a specific transducer. The board is mounted in the transducer when possible.When not possible, as in the Nano and Mini transducers, the board is located in the mux box.

Mux CableSystems with a mux box will also require a mux cable. The mux cable is a highly flexible long-life cable.This durable cable protects the transducer signals from electrical fields and mechanical stress.

ControllerThe controller interfaces with the transducer or mux box to process the transducer data into useable force and torque dataand to provide high-level functions like tool-transformations and threshold detection. The controller is powered bystandard 115VAC/230VAC power. This intelligent controller communicates over an RS-232 serial port and can alsooutput loads via analog voltages. Its optically isolated discrete I/O port connects easily into many industrial applicationsand responds to user-programmed threshold conditions.EuroCard ControllerThis small card provides all the functions of our regular Controller in a small package ideal for integration into systemswhere space is limited. All signals to and from the card are available on the industry standard 96-pin connector. To usethis card, it must be plugged into a mating connector that provides regulated DC voltages and connections to an ATI muxtransducer.

Controller F/T System

Transducer7.6m Standard Cable9105-C3-025F-R

Controller

Legacy Analog Output

Discrete I/O

RS-232Communication

Power Input

A Mux box is addedbetween transducer and

controller for Nanoand Mini models

Analog Output

OPTIONSWhile our standard systems provide all the necessarycomponents for measuring force and torque, we also haveavailable options which may aid in interfacing the F/T sensorsystem with special applications.

Interface PlatesAll F/T transducers come with standard interface plates. TheNano and Mini series and Omega190 transducers havethreaded hole patterns machined into both sides that are usedfor attaching to the customer's equipment. All othertransducers have a threaded hole pattern on the tool side anda blank plate on the mounting side. The blank plate ismachined by the customer to accommodate specificmounting requirements.

In some installations, a secondary plate on one or both sidesof the transducer is necessary in order to allow access to allfasteners. If a secondary plate is required, it must beprovided by the customer.

Custom InterfaceATI can help you design and fabricate interface plates neededfor a nominal price. Please contact an ATI salesperson foradditional information.

Temperature CompensationThe F/T transducer has a gain-shift error of approximately0.16%/°F (0.29%/°C) from the calibration temperature of72°F (22°C). The Basic temperature compensation optionminimizes this error for temperatures around roomtemperature. We recommend this option with all Nanotransducers and with any sensor that will be used wheretemperature may vary.

Dual-Calibration For Controller F/T SystemWith this option, one transducer can use two calibrations.A manually-operated switch allows the selection of either oftwo gain settings. Each gain setting is paired with uniquecalibration information that the user can download into thecontroller. This allows the use of one calibration for a lowpayload with high resolution, and the other calibration for alarger payload with a lower resolution.

ExampleThe expected maximum measured load is 98N (10Kg) of forceand the end-effector is 25cm long. The moment generatedwould be 24.5N-m.

The best F/T would be a Delta/SI-330-30 (330N, 30N-m)which can handle the 24.5N-m moment. The maximumsingle-axis moment rating (Txy) of this model is 230 N-m,which should be sufficient for overload situations.

Note: The published payloads of robots are typically themaximum load the robot can handle at published positionalresolution. The robot can actually handle much larger loads, butwith some loss of positional repeatability. During a crash bothinertia and the sudden deceleration can generate large loads.Robots are typically overpowered for an application, and therobot is capable of exerting loads many times its rated loads.

You may decide to select a transducer with a lower payloadwith the understanding that this will increase the chances ofdamaging the transducer during a crash.

We highly recommend the use of a robotic crash protection orbreakaway device such as ATI's Protector as an added measureof F/T transducer protection in all robotic applications.

HOW TO SELECT AN F/T TRANSDUCERI. Calculate expected moment and forcesMoment capacity is usually the determining factor inchoosing the best transducer model for your application.The end-effector attached to the transducer as well as thetasks being performed will generate forces on thetransducer, which will result in a moment. The moment isthe applied force (dynamic and static together) multipliedby the distance from the transducer origin to the point atwhich the force is applied. It is important to also consideroverload conditions beyond the normal operating forcesand moments the transducer will experience.

II. Identify transducer strengthUse the Quick-Selection Guide on page 3 to compare themeasuring ranges of the transducer models available.

III. Verify resolutionNext, the required resolution should be considered.A fine resolution requirement can conflict with atransducer chosen based on moment capacity.Transducers with larger ranges have coarser resolutions.

IV. Inspect other transducer specificationsCompare the detailed specifications of the chosentransducer to those of your application requirements tobe certain the chosen transducer is appropriate foryour application.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AATI IINDUSTRIAAL AAUTOMAATION 7

Fx, Fy (lb) 1/160 1/2560 1/80 1/1280 1/40 1/640

Fz (lb) 1/80 1/1280 1/40 1/640 1/20 1/320

Tx, Ty (in-lb) 1/80 1/1280 1/40 1/640 1/20 1/320

Tz (in-lb) 1/80 1/1280 1/40 1/640 1/20 1/320

Fx, Fy (+lb) 7.5 15 30

Fz (+lb) 25 50 100

Tx, Ty (+in-lb) 25 50 100

Tz (+in-lb) 25 50 100

Fx, Fy (N) 1/40 1/640 1/20 1/320 1/10 1/160

Fz (N) 1/20 1/320 1/10 1/160 1/5 1/80

Tx, Ty (N-m) 1/500 1/8000 3/1000 3/16000 1/200 1/3200

Tz (N-m) 1/500 1/8000 3/1000 3/16000 1/200 1/3200

AATI IINDUSTRIAAL AAUTOMAATION18

GammaI highly recommend ATIs force/torque transducers to anyonewho needs a reliable, pre-calibrated, easily programmabletransducer. It is a truly versatile plug-and-play system.Prof. Francisco Valera-CuevasNeuromuscular Biomechanics LaboratoryCornell University, Ithaca, NY

The Gamma F/T transducerThe transducer and the standard mounting adapterare made of high-strength aircraft aluminum.

BENEFITS AND FEATURESExtremely High strength! Precision machined from high-strength aircraft aluminum.! Maximum allowable overload values are 7.8 to 27 times

rated capacities.High Signal-to-Noise RatioSilicon strain gauges provide a signal 75 times stronger than conventional foil gauges. This signal is amplified, resulting in near-zero noise distortion.

TYPICAL APPLICATIONS! Real-time force control! Haptics feedback! Prosthetic device testing! Robotic assembly! Automotive part testing

English-Calibrated Sensing Ranges US-7.5-25 US-15-50 US-30-100

Resolution F/T System Type CON DAQ CON DAQ CON DAQ

Fx, Fy (+N) 32 65 130

Fz (+N) 100 200 400

Tx, Ty (+N-m) 2.5 5 10

Tz, (+N-m) 2.5 5 10

Metric-Calibrated Sensing Ranges SI-32-2.5 SI-65-5 SI-130-10

ResolutionF/T System Type CON DAQ CON DAQ CON DAQ

Contact ATI for complex loading information. Resolutions are typical. CON = Controller F/T System, DAQ = 16-bit DAQ F/T System

X-axis & Y-axis force (Kx, Ky) 52x103 lb/in 9.1x106 N/m

Z-axis force (Kz) 100x103 lb/in 18x106 N/m

X-axis & Y-axis torque (Ktx, Kty) 93x103 in-lb/rad 11x103 N-m/rad

Z-axis torque (Ktz) 140x103 in-lb/rad 16x103 N-m/rad

Fxy +270 lb +1200 N

Fz +910 lb +4100 N

Txy +690 in-lb +79 N-m

Tz +730 in-lb +82 N-m

Fx, Fy, Tz 1400 Hz

Fz, Tx, Ty 2000 Hz

Single-Axis Overload English Metric

Stiffness (Calculated) English Metric

Resonant Frequency (Measured)

AATI IINDUSTRIAAL AAUTOMAATION 19

Physical Specifications English MetricWeight 0.56 lb 250 g

Diameter 2.97 in 75.4 mm

Height 1.31 in 33.3 mm

Specifications include standard interface plates.

COMPANY PPROFILEATI Industrial Automation is a world-leading

developer of Automatic Tool Changers, Multi-AxisForce/Torque Sensing Systems, ComplianceDevices, Robotic Crash Protection Devices andRobotic Deburring Tools. Our products are foundin thousands of successful applications aroundthe world.

Since 1982, our engineers have beendeveloping cost-effective, state-of-the-art productsand solutions to improve manufacturing productivity.

Our Mission is to provide customers aroundthe world with high-quality robotic peripheraldevices, tooling and sensors that enhance customerprofitability by increasing the effectiveness, flexibility,safety and productivity of their automationapplications. We accomplish this throughcontinuous improvement of existing products,product customization and new product innovation.

Our engineering-centric staff focuses onproviding customer solutions.

Pinnacle Park, 1031 Goodworth Drive, Apex, NC 27539 USATel: +1.919.772.0115 E-mail: info@ati-ia.comFax: +1.919.772.8259 www.ati-ia.com

PRODUUCT PPROFILERobotic Crash Protection DeviceProtector Designed to prevent damage to robotic end-effectorsresulting from robot crashes. Features include: Automaticreset, high-repeatability, large moment rotation and lowcost.

Robotic/Automatic Tool ChangerQuick-Change A high-precision rugged device that automatically changestooling. Patented fail-safe locking mechanism uses No-Touch LockingTM technology, allowing plate separationwhen locking.

Robotic & CNC Deburring ToolsSpeedeburrA series of high-speed robotic air tools that chamfer anddeburr aluminum, plastic and steel parts using floatinghead technology, providing a fast cycle time and anaccurate, clean cut.

Multi-Axis Force/Torque SensorF/TMeasures six axes of forces and torques applied to roboticend-effectors. High overload protection and high signal-to-noise ratio.

Automated Assembly Alignment DeviceCompensator An insertion device using Remote Center Compliancetechnology, that helps assembly machines automaticallyalign close-fitting parts, preventing jamming and galling.

Robotic Rotary JointUnlimited Rotation of Robotic ToolingA device that allows unlimited rotation of end-of-armtooling without tangling or twisting robot lines. Utilizesadvanced slip-ring technology to pass electrical andpneumatic signals from robot to tooling..

......................................................................................................................................

OUUR QQUUALITY PPOLICYATI Industrial Automation strives to provide

customer satisfaction through on-time delivery,continuous improvement of quality and reliability,and a constant focus on innovation and profitability.

9205-05-1001-11 April, 2003

© Copyright by ATI Industrial Automation, Inc. 2003. All rights reserved.

SECTION 6

MACHINE DRAWINGS

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SECTION 7

HARDWARE

Size Location Quantity Total1/2-13 x 1 Bottom Base to Table 2 2

Washer to Bearing to Handle Shaft 1Washer to Bearing to Joint Shaft 1Bottom Base to Support 4Back Base to Support 6Bottom Base to Back Base 5Back Base to Brake Mount 4

5/16-24 x 1.5 Handle Disk to Arm AE/BC to Brake 8 85/16-24 x 1.25 Arm BC to Bearing Housing (3-Brake Only) 4 45/16-24 x 3/4 Brake Mount to Brake 8 8

Collar to Arm 16Back Base to Bumper 2

1/4-20 x 5/8 Joint Shaft to Arm CD 4 4#10-24 x 1 Upper to Lower Bearing Housing 4 4

#10-24 x 7/8 Shaft to Arm CD to Force Sensor Mount 4 4Positioning Ring 2Handle Shaft 1

Size Location Quantity Total1/4-20 x 5/8 Handle Disk to Arm ED 4 4#10-24 x 1/2 Force Sensor to Force Sensor Mount 4 4

Size Location Quantity TotalHandle Shaft 1Joint C shaft (3-Brake Only) 1

Size Location Quantity TotalCollar to Brake Shaft 4Positioning Ring to Brake Shaft 2

3/16 x 1.00 6

Angular Contact Ball Bearings

1.000 x 2.000 x .500 2

Gib Head Keys

Flathead Screws

Socket Head Cap Screws

3/8-16 x 1.5

#10-24 x 1/4

19

3

1/2-20 x 1.0 2

1/4-20 x 1 18