CBSF CoboSafe Measurement System

Product Information

The CoboSafe-CBSF force measuring devices are part of a system and should be used in conjunction with CoboSafe-Vision, CoboSafe-Scan, and CoboSafe-Tek components. Before operating the device, it is important to read the manual and safety instructions thoroughly.

Specifications:

• Product Name: CoboSafe-CBSF Force and Pressure Measurement System
• Model Number: 325-2810-012-US-17
• Manufacturer: GTE Industrieelektronik GmbH
• Address: Helmholtzstr. 21, 38-40, 41747 Viersen, Germany
• Email: info@gte.de
• Phone: +49 2162 3703-0
• Website: www.gte.de

Product Usage Instructions

1. Safety Guidelines:

Before using the CoboSafe-CBSF, ensure you understand the intended use, necessary qualifications of personnel, and the operator’s responsibilities. Be aware of residual risks associated with using force gauges.

2. Brief Description:

The CoboSafe-CBSF is designed for force and pressure measurements within a specified system. It provides accurate readings when used correctly with the accompanying components.

3. Performing Measurements:

To perform a measurement with the CoboSafe-CBSF, follow the step-by-step instructions provided in the manual. Ensure proper setup and calibration before conducting any measurements.

4. Transmitting Data:

Measured data from the CoboSafe-CBSF can be transmitted wirelessly or via a USB port. Follow the guidelines for data transmission as outlined in the manual for accurate results.

FAQs

• Q: Can the CoboSafe-CBSF be used independently without the other components?
  • A: No, the CoboSafe-CBSF is designed to work in conjunction with CoboSafe-Vision, CoboSafe-Scan, and CoboSafe-Tek components for accurate measurements.

Force and Pressure Measurement System

CoboSafe-CBSF

325-2810-012-US-17
EN

Operating Manual
Force Gauges CoboSafe-CBSF

GTE Industrieelektronik GmbH Helmholtzstr. 21, 38-40 | 41747 Viersen, GERMANY | info@gte.de | Tel. +49 2162 3703-0 | www.gte.de

Operating manual: CoboSafe-CBSF Document version: 325-2810-012-US-17 ­ Translation from German­
Manufacturer and publisher: GTE Industrieelektronik GmbH Helmholtzstr. 21, 38-40 41747 Viersen Germany
Support-Hotline: +49 2162 3703-0 E-mail: cobosafe@gte.de
© 2024 GTE Industrieelektronik GmbH ­ This document and all illustrations contained therein are protected by copyright and may not be removed, altered or distributed without the express consent of the manufacturer!
Technical changes reserved!

PREFACE
This operating manual describes the operation of the CoboSafe-CBSF force measuring devices. The measuring method is part of a system and can only be used in conjunction with the following components: CoboSafe-Vision CoboSafe- Scan CoboSafe-Tek
Before beginning work of any kind, read this manual and the general safety instructions. Keep for later use!
Pay particular attention to the associated document “CoboSafe ­ General Safety Instructions” and the safety instructions and warnings in this document to prevent injuries and product damage. Keep this documentation at hand so that you can look it up if necessary. Share this documentation with future users of the product.
Associated with this manual is the document: CoboSafe ­ General Safety Instructions

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ABOUT THIS MANUAL

About this Manual

This manual describes operation of the CoboSafe-CBSF force measurement device. The measuring method is part of a system and may be used only in conjunction with the following components:
Software CoboSafe-Vision Pressure Measurement Set CoboSafe-Scan Pressure Measurement CoboSafe-Tek
Carefully and thoroughly read this document and the documentation for all of the systems to be used to become familiar with the product before using it.
To prevent injury and damage to the product, pay particular attention to the associated document “CoboSafe ­ General Safety Instructions” as well as to the safety and warning notes in this document. Keep this documentation nearby to serve as a reference when needed. Pass the documentation along to later users of the product.
The operating manual with safety instructions is a component of the measuring system and has to be stored near the measuring system, ensuring that it is accessible to personnel at all times.
Operating personnel must read the entire manual and be familiar with the product before beginning any work.
The fundamental requirement for working safely is consideration of all of the safety and warning notes as well as following the instructions in this and all related CoboSafe manuals.
In addition, the local accident prevention regulations and general safety regulations apply to the area of application of the measuring system.
The illustrations in this manual are intended to aid in fundamental understanding of the product. They may deviate from the actual model.
1.1 Symbols and Warnings in this Manual
1.1.1 Warnings
Safety and warning notes in this manual are indicated by symbols. The safety and warning notes are preceded by signal words indicating the extent of the hazard.
To prevent accidents, personal injury and property damage, comply with the safety and warning notes and proceed with caution.

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ABOUT THIS MANUAL

Warnings
DANGER WGAERFNAIHNRG CAUTION NOTICE

This combination of symbol and signal word indicates an immediately dangerous situation that will lead to death or severe injuries if not avoided.
This combination of symbol and signal word indicates a possibly dangerous situation that could lead to death or severe injury if not avoided.
This combination of symbol and signal word indicates a possibly dangerous situation that could lead to minor injuries if not avoided.
This signal word indicates a possibly dangerous situation that could lead to property damage if not avoided.

1.1.2 Explanation of Symbols
The following symbols are used in this manual to emphasize instructions, results, lists, notes and other elements:

Symbol

Explanation Introductory information relevant to safety

Z
1

Helpful tips and recommendations as well as information to ensure efficient and uninterrupted use Precedes instructions Step-by-step instructions. The instructions are numbered in the order of the respective steps.
Results of steps
References to sections of this manual and to other applicable documents
Lists with no specific order

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1.2 Appearance of Instructions The initial requirements in regard to personnel qualifications, personal protective equipment (PPE), special tools and materials are different for each step/process.
It is imperative that the specified requirements for all instructions are met.
The following illustration shows an example of how a set of instructions is structured.

1. Z Inspect and clean CoboSafe CBSF-75

Personnel

Personal Protective Equipment

Laboratory scientists System integrators

Protective gloves Safety shoes

Special Tools

Material

Set of Allen keys

Cleaning agent Soft, lint-free cloth

To provide reliable measured data, the measuring system has to

be regularly cleaned and inspected for external damage

1 Place the measurement system on a free, flat surface

The measurement system rests securely and cannot fall off.

2 …

Fig. 1: Example of instructions

Explanation of illustration “Example of instructions”
1. A triangle precedes the title of instructions or a step to be performed. 2. Indicates the qualification required of personnel to be able to safely perform the action
described. In the above example, the person performing the task has to be a laboratory scientist or a system integrator. For a description of the personnel qualifications, refer to chapter “Requirements of Personnel” in the general safety instructions.” 3. List of Personal Protective Equipment (PPE) required. In the above example, protective gloves and safety shoes have to be worn; chapter “Personal Protective Equipment” in

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FOR yOUR SAFETy
the general safety instructions. 4. If necessary: List of special tools required. A set of Allen keys is needed to check and
clean the device. 5. If necessary: List of consumables required. In the example above, a cleaning agent and
a soft, lint-free cloth is needed. 6. Introductory note on why action is required and what has to be kept in mind. 7. Step in the set of instructions. Always perform the steps one after the other and as de-
scribed. 8. Result of the previous step.
Z Always verify that the result is the same as what is described here.

For your Safety

The separate document “CoboSafe ­ General Safety Instructions” provides users with further information and must also be observed.
2.1 Intended Use
CoboSafe-CBSF force gauges (hereinafter also referred to as force sensors) are used to determine the forces occurring in collisions with collaborating robots. The force values are calculated in the device based on the underlying standards and publications. Please observe the instructions for use part ‘CoboSafe ­ General Safety Instructions’, chapter ‘Underlying standards and information leaflets’. The CoboSafe-Vision software is used to visualize and archive the stored measurement data. CoboSafe-CBSF may only be used for this purpose.
2.2 Qualification Required of Personnel
Only qualified personnel may work with the measuring and test system to avoid serious physical injury or considerable damage to property. Qualified are persons who are familiar with the commissioning and operation of robots. They must have the appropriate qualifications. They must be able to assess the work assigned to them, identify possible sources of danger, and take appropriate safety measures. The separate document “CoboSafe ­ General Safety Instructions” must also be observed.
2.3 Responsibility of the Operator
Please read the chapter of the same name in the corresponding document “CoboSafe ­ General Safety Instructions”.

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2.4 Residual Risk When Using CoboSafe-CBSF Force Gauges
Please read the chapter “Residual risks” in the corresponding document “CoboSafe ­ General Safety Instructions”.

Attention!
The measurement setup must meet requirements regarding stiffness and at the same time guarantee stability. Therefore, hard and stiff components must be used, which must be firmly connected to each other. Depending on the measurement setup, burrs, corners and edges can cause cut and impact injuries, for example when using aluminum profiles. Falling or tilting components of the measuring setup can cause injuries.

WGAERFNAIHNRG WGAERFNAIHNRG

Dangerous measurement setup Risk of injury due to improperly erected measurement setup! Establish measurement setup only with deburred compo-
nents. Upholster corners and edges. Secure measurement setup against unauthorized access. Wear specified protective equipment. Secure the measurement setup against tilting.
If the measurement setup is established using sharp edged components or has sharp corners, this can result in cuts and impact injuries. Tilting parts of the measurement setup (e.g., due to low stability) can cause impact and crushing injuries.
Falling components Risk of injury from dropping or dropping components! Keep order in the workplace. Keep work surfaces free for assembly and storage of
components. After use, store unused components as described in this
manual. Handle all components with care. Always hold the force sensors at the side for lifting and
positioning and make sure that the display and switch are not touched. Wear specified personal protective equipment.
Some components of the measuring system are heavy and hard. If force sensors, mounting adapters, transport cases, film rolls or the scanner are dropped, severe injuries up to crushing and bone fractures can result.

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BRIEF DESCRIPTION

Brief Description

The CoboSafe CBSF force gauges accurately check the permissible load thresholds for workplaces with human-robot collaboration (HRC). The handy devices are characterized by their small design, which allows easy integration of the force sensors into measurement setups – even in confined spaces. The device evaluates the force measurement, and the result is stored with the metadata ID, date and time. A wireless data connection can be established for data transmission. K1 damping elements are automatically detected by the CBSF, it also measures temperature and humidity.
Attention Only the specified measuring equipment may be used to perform a measurement. Measurement may not be performed when a configuration differs.

Scope of Delivery

CoboSafe-CBSF

or

1

2

3

CBSF-Basic

2 1

4

56

6

5

The CoboSafe-CBSF system consists of the following components:
Force sensors from the product series CBSF [1] K1 damping elements [2] Mounting adapter [3] USB charger with power cord [4] Transport case [5] USB flash drive containing CoboSafe-Vision software [6] Thermo-hygrometer (only for CoboSafe CBSF-Basic) [7]

3
74
Fig. 2: Scope of delivery

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SINGS AND LABELS

5 Sings and Labels The following markings shall be affixed to the CoboSafe CBSF:

CAUTION

Danger of Crushing The sign indicates a danger of crushing hands and fingers. Never touch the force sensor during measurement.

Fig. 3: danger of crushing
Type plate The type plate is attached to the side of the CoboSafe-CBSF force sensor. The type plate contains the following data: Device type Spring constant (Spring Rate) Maximum Force Temperature range (Temp) year of manufacturing (year of M) Article number (Art.-Nr.) Serial number (Serial) Charging voltage
(input) CE label

Abb. 4: Type plate

The numerical appendix for the type designation corresponds to the indication of the spring constant.
Example: CBSF-150 = Force sensor with 150 N/mm spring constant.

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INFORMATIVE VALUE OF THE MEASUREMENT RESULTS
Inspection Date A label on the side of the measuring device indicates when the device has to be inspect and calibrate by the manufacturer. The year printed on the label is the year in which the next inspection is due. The month is indicated by the circle in which a month can be punched out.
Fig. 5: Label “Inspection Date”
This example shows a sticker that requires calibration in February 2018.
6 Informative Value of the Measurement Results The informative value of the results is limited exclusively to the specific contact situation measured. The values shown in the display of the CoboSafe-CBSF are not sufficient for an evaluation alone. The measured values can only be interpreted completely using the software CoboSafe-Vision and a pressure measuring process (CoboSafe-Tek or CoboSafe-Scan).
Selection of Measuring Points Information on the “Selection of measuring points” can be found in the chapter of the same name in the corresponding document “CoboSafe ­ General Safety Instructions”.

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INFORMATIVE VALUE OF THE MEASUREMENT RESULTS Qualitative curve of an impact force

1

3

4 2
5

Fig. 6: Curve of an impact force

Ft maximum transient force [N] [1] Fs maximum quasistatic force [N] [2] Quasistatic limit for relevant body region [3] Transient limit for relevant body region [4] Permitted force and pressure range [5]

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STRUCTURE AND FUNCTION COBOSAFE-CBSF 7 Structure and Function CoboSafe-CBSF 7.1 CoboSafe-CBSF-Force Sensors
2

1

3

4

6

6

7 5

Fig. 7: CoboSafe-CBSF

Measuring body [1] Measuring plate [2] Display [3] Pushbutton on rear panel [4] Base plate [5] Handle surfaces [6] Holder and mounting option for adapter. Threaded hole M4 x 8 mm. [7]

Dimensioned drawing of the base plate A dimensioned drawing of the base plate can be found in the appendix.

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STRUCTURE AND FUNCTION COBOSAFE-CBSF

7.2 Display
3
4

2

1

5 6

Fig. 8: Starting display

Charge level [1] Charging display [2] Time [3] Measurement number [4] Measured value display [5] Command line [6]

7.3 Menu Navigation
CBSF is operated by pressing the button on the back of the device briefly or for a longer time. Short keypress: Switch between menus and submenus Long keypress: Open menu; confirm selection; exit menu.
Switch on: Long keypress: CoboSafe-CBSF starts up when the pushbutton is released.

Operating mode:
When switched on, the CoboSafe-CBSF is immediately ready for measurement (REC). After the measurement has been completed, the results are displayed. Short keypress: Activate next measurement (in ‘manual’ mode). Long keypress: Menu opens in option ‘Shutdown’. Long keypress: Switch off CoboSafe-CBSF (Device switches off after 45 minutes auto-
matically)

Open menu:
Long keypress: Switch on CoboSafe-CBSF. Long keypress: Menu opens in option ‘Shutdown’. Short keypress: Move to the next menu. Long keypress: Switch to the submenu. Short keypress: Switch between the options in the submenu. Long keypress: Select the option and exit the submenu.

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Menu list and functions

Menu

Submenu

Function Switches off CoboSafe-CBSF

Manual
Auto
On
Off
Cancel
All Data
SVN: S/N: WL: Temp.: Humidity: Bat. V: Bat. A: Capacity: Free: Used: Last ID:

Press the button to activate measurement. Measurement begins when force reaches F > 20 N Measurement begins automatically when force reaches F > 20 N Switches on the wireless transmission
Switches off wireless transfer transmission
Cancels deleting
Deletes all stored measurements
Firmware Version Serial number of CoboSafe-CBSF Wireless ID Temperature display Humidity display Battery voltage in Volt Battery current in mA Capacity of the memory (quantity of measurements) Number of measurements still possible Number of measurements performed Last measurement number (ID) Exits menu and switch to operating mode

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STRUCTURE AND FUNCTION COBOSAFE-CBSF
7.4 Setting the Date and Time The date and time are set using the CoboSafe- Vision software. Before first use, connect the CBSF devices to the PC and start the software. Use the ‘CBSF Sync.’ function to program and update. Follow the instructions in CoboSafe-Vision to synchronize the date and time.
7.5 Measured Value Display The CoboSafe-CBSF force sensor outputs the measured values in the display after the measurement has been completed:

1 2 3

Fig. 9: Measured value display

Ft = maximum transient force[1] Fs= maximum quasistatic force [2] Number of the current measurement [3]

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STRUCTURE AND FUNCTION COBOSAFE CBSF- BASIC

Structure and Function CoboSafe CBSF- Basic

8.1 CoboSafe CBSF-Basic

Measuring Surface [1]

Enclosure [2]

Display [3]

Softkeys [4]

Handgrip [5]

Battery Compartment [6]

Fig. 10: CBSF-Basic

8.2 Menu Navigation CBSF-Basic

The force sensor is operated via 3 softkeys each, which can be assigned different functions in each menu. In the following menu trees, the softkeys are labeled F1, F2 and F3. Pressing the designated softkey executes a function, switches between setting options or navigates in menus.

Fig. 11: Menu Navigation CBSF-Basic

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DAMPING ELEMENT K1 AND SPRING RATE K2

DAMPING ELEMENT K1 AND SPRING RATE K2

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DAMPING ELEMENT K1 AND SPRING RATE K2

Damping Element K1 and Spring Rate K2

The compression properties of, for example, muscle tissue to fat tissue or to surfaces of the body less covered such as fingers differ. Also, the biofidel property related to the pain sensation and the injury risk is different. The body resistance must also be taken into account.
Biofidel setup To create a biomechanical or biofidelic setup, specified compression elements K1 and K2 have to be used.
The damping elements K1 simulate the biomechanical property of body surfaces.
The spring rate K2 simulates the biofidelic body resistance.

The K1 damping elements are classified by Shore hardness. Colors are assigned to the different Shore hardness. The correct damping element is determined by the color:

Color Green Blue Red

Shore-hardness 10° Shore A +/- 7 30° Shore A +/- 5 70° Shore A +/- 5

The Shore hardness of the K1 damping elements can change with aging. The manufacturer recommends replacement after one year as part of the calibration service. If the K1 damping elements are exposed to special conditions such as high ambient temperatures or contact with solvent containing liquids, it may be necessary to replace them earlier.

Spring rate K2
The K2 spring rates are special springs built into the CoboSafe CBSF force sensors. They enable a correct simulation of the biofidelic body resistance. The springs (K2) of the manufacturer are all tested for suitability and are subject to strict selection criteria.

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Preparing for Measurement

The force sensors CoboSafe-CBSF are the fundamental device for force and pressure measurements. The measuring device is positioned at the collision points determined for the application. The additional damping element K1 is placed on the measuring surface, when this is defined in the test specification and included in the configuration of the measurement plan. Depending on the measuring plan, a pressure measuring film from the CoboSafe- Scan or CoboSafe-Tek system is placed on the damping element K1 or directly on the measuring plate (Fig. 9). The collision measurement is carried out with this setup.

Fig. 12: Measurement setup without and with K1 damping element

Keep in mind that CoboSafe-CBSF has to acclimate to the surroundings for at least two hours before beginning the operation.

10.1 Safety When Preparing a Measurement

CAUTION

Sharp edges Risk of cuts due to sharp edges!
Only establish the measuring setup with completely deburred components.
Wear personal protective equipment.
There is a risk of cutting injuries on edges that have not been deburred.

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WGAERFNAIHNRG

Tilting and falling components Risk of injury due to tilting and falling components of the measurement setup! Construct the measuring setup with care. If the setup with one person is not safely possible, get a
second person to help. Wear personal protective equipment.
Hard and heavy components (e.g., aluminum profiles) are often handled and joined while the measurement setup is being established. Until these components are firmly connected, they can tilt or fall, causing severe crushing and impact injuries.

CAUTION

Clamping point The clamping point is located in the red area between measuring surface and measuring body.
The force sensor must be held in position during the measurement by means of a mounting adapter.
The force sensor must not be fixed manually during the measuring process, otherwise there is a risk of crushing. During the measurement, e.g., fingers can be squeezed in this area.

Clamping Point

Fig. 13: Clamping point

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10.2 Defining Measurement Target
The collision scenarios have to be defined before measurement begins. Body zones where potential collisions between robot work site personnel and robots have to be identified. The collision positions and collision vectors result from the determined scenarios for which collision measurement has to be performed.
The definition of possible collisions and the choice of force and pressure sensor must be taken into account when preparing the measurement environment and selecting the measurement points within CoboSafe Vision. The collision positions determine the body localizations and, if necessary, the specific localizations.
When selecting the measurement points, it must be considered that only the respective contact situations can be measured and evaluated.

10.3 Preparing the Measurement Environment

WGAERFNAIHNRG

Requirements for the scaffold Risk of injury from tilting scaffold!
Ensure firm stand of the scaffold. Exclude the possibility of collision with other equipment
(e.g., forklift).
If the scaffold is not anchored sufficiently and tilts, crushing and impact injuries may result.
We recommend that the measurement setup and the support surface is constructed from aluminum system rails from reputable manufacturers and that profiles with a cross-section of at least 40 x 40 mm be used.
The specific structure depends on the defined objective of the measurement.

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WGAERFNAIHNRG

Dangerous situations when handling the scaffold Ensure the following points when erecting the scaffolding:
The contact surface for the force sensor must have a minimum spring constant of 2000 N/mm in the direction of the collision vector.
The pre-set position of the measuring point is guaranteed. Sufficient stability is ensured (e.g., by anchoring in the foun-
dation or support struts) to prevent tilting due to collisions and/or weight forces of the force sensor. Sufficient firmness is ensured to absorb the total weight of the measuring unit and the force resulting from the collision. To erect the scaffolding, always work in accordance with the according regulations on site. Wear personal protective equipment according to the instructions: Protective clothing, safety shoes, protective gloves and industrial safety helmet are necessary. Properly handle heavy and bulky parts with two persons or with lifting equipment.
Serious injuries from falling components are possible.

Use safety factor 3 for firmness calculations.

Requirements for the contact surface
The contact surface for the CoboSafe-CBSF force sensor must ensure a secure hold. If the measuring setup is manufactured as recommended using aluminum profile rails, the following minimum requirements for the contact surface are generally met:
The normal vector (Fig. 14/2) of the contact surface (Fig. 14/3) forms a line with the collision vector (Fig. 14/1).
The contact surface is flat. Do not use obviously curved surfaces. The minimum contact area is 80 mm x 80 mm.
If the mounting adapter is to be mounted in a groove of the aluminum profile rail, e.g., using sliding blocks, an additional free groove of at least 140 mm must be available.

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Fig. 14: Example: Robot with rail framework for mounting the assembly adapter
10.4 Robot Parameters

NOTICE

Set robot parameters Material damage due to high collision speeds, forces and pressures!
Only combine measurement units as described in this manual.
Carefully plan collisions and document the planning. Design collision kinematics carefully and iteratively. Always test at greatly reduced speeds first. Then slowly increase the speeds. Finally, achieve the intended operating conditions at the
collaboration workstation.
If the robot exceeds the application limits of the force and pressure sensors during the collision, material damage to the measuring system can result.

Consider robot operation safety settings from ISO/TS 15066.

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Guide travel path collision:

Personnel
Laboratory scientist System integrator Robot operator

Personal Protective Equipment
Protective equipment required by the robot manufacturer

The collision kinematics on the robot are determined by defining the robot parameters. The determination must be made according to the objective of the measurement.

Carefully plan the adaptation of the robot parameters. Consider the following: The vector of the robot movement is normal to the measuring surface of the sensor. Vector of the robot movement hits the measuring surface centrally Test collision movement without mounted force sensor.
Begin with strongly reduced speeds and slowly approach the realistic collision conditions.

Test measurement of the parameters The specified parameters must be checked in the course of the measurement with a test measurement and, if necessary, repeatedly adjusted.

10.5 Checking the Components
The smallest unevenness on the measuring surface can have an influence on the measuring result. Therefore, clean the measuring surfaces before a collision measurement. Please observe the instructions in the chapter ‘Checking and cleaning CoboSafe-CBSF’.

Personnel
Laboratory scientist System integrator

Personal Protective Equipment
Protective clothing Protective gloves Safety footwear

Material
Soft, lint-free cloth Detergents Reference weight

Impurities (e.g. sand grains or metal chips) in the measurement setup can lead to considerable exceedances of the limit value during pressure measurement. All contact surfaces must therefore be cleaned before measurement. Damaged components of the measuring system prevent reliable measurement and must be replaced.

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10.5.1 Testing Proper Functioning of Force Sensor Z Check the force sensor with a reference weight.

Fig. 12: Reference weight

1 Place CoboSafe-CBSF on a flat surface. The measuring surface must face up.

2

Carefully lower the reference weight onto the measuring surface and wait until the measurement begins.

Measurement start Measurement starts at 20 N!
The measurement is running. After 5 seconds, the measurement result can be transferred to CoboSafe-Vision and displayed. If the measured force corresponds to the weight force of the reference weight applied, the force sensor functions as intended. If the measured value deviates, the force sensor is damaged.
The CoboSafe CBSF has been tested to confirm proper functioning.

Damaged force sensor A damaged force sensor must not be used for measurement and must be replaced.

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10.5.2 Checking and Cleaning the Collision Surface of the Robot Z Check and clean the collision surface of the robot.

1 Use a clean cloth.

2

Clean the collision surface of the robot. In particular remove coarse particles e.g. grains of sand or metal chips.

3

Ensure that the scaffolding and the contact surface meet the requirements of the measuring setup

All components have been tested and cleaned as described.

10.6 Attach CoboSafe CBSF to Contact Surface

10.6.1 Attaching Mounting Adapter to contact surface

Z Attaching mounting adapter to contact surface

Personnel
Laboratory scientist System integrator

Personal Protective Equipment
Protective clothing Protective gloves Safety footwear Industrial safety helmet

1 Prepare the measurement as described

2

Connect the mounting adapter to the contact surface, e.g., screw it into the aluminum profile rails using slot nuts.

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Fig. 16: Mounting adapter
The mounting adapter is firmly connected to the contact surface.

10.6.2 Attach CoboSafe-CBSF to Mounting Adapter

Z Attach the CoboSafe-CBSF to mounting adapter

Personnel
Laboratory scientist System integrator

Personal Protective Equipment
Protective clothing Protective gloves Safety footwear

1 Release the locking mechanism of the mounting adapter
Fig.17: Release mounting adapter

2

Attach the force sensor to the bolts of the mounting adapter

Fig.18: Attach CBSF

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Fix the force sensor to the mounting adapter 3 using the thumbscrew.
Fig.19: Fix CBSF
4 Align the force sensor. Consider collision vector.
5 Close locking mechanism.
Fig.20: Locking
The CoboSafe-CBSF is firmly connected to the contact surface. The mounting adapter is firmly connected to the contact surface. The force sensor is fixed in its position and firmly connected to the mounting adapter. The surface normal of the measuring surface lies on a line with the collision vector. The measuring unit can be established.
10.7 Mounting the K1 Damping Element The measurement plan from the CoboSafe- Vision evaluation software specifies whether and which K1 damping element is to be used. The damping elements are recognizable by their color. Remove the K1 damping element from the case and place it on the measuring surface of the CoboSafe-CBSF.

Fig. 21: CoboSafe-CBSF with damping element K1

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10.8 Applying Pressure Measuring Film
When the damping element K1 has been correctly mounted on the force sensor – if required according to the measuring plan – the pressure measuring sensor (pressure measuring film) is positioned on the measuring surface. The pressure sensor must be securely positioned. Simple aids may have to be used for this purpose. For detailed information, please refer to the separate product instruction manual for the respective pressure measurement method.

Fig. 22: Measuring setup with CoboSafe-Scan and CoboSafe-Tek
11 Performing Measurement
Once the measuring device is positioned properly, measurement can begin.
After completion of the first measurement, the results can be assessed in CoboSafe-Vision. If the permissible limit values are exceeded, measures must be taken to reduce the effects of force and pressure. Possible measures are for example changes of the robot parameters (e.g., the speed). If these measures are not sufficient, additional measures may have to be taken, such as buffers on sharp edges.
A new measurement is then performed at this collision point. The measurement is repeated until the corrective measures take effect and the results are below the limit values.

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PERFORMING MEASUREMENT

Test measurements The initial test measurements can be performed without pressure measurement to save consumables. The results of force measurement appear on the CBSF-XS display. If the application is such that the forces are below the threshold values, pressure measurement can be added.
Measurement numbers Each measurement is assigned a number. It is advisable to note the number of a completed force and pressure measurement on the CoboSafe- Scan pressure image. This enables it to be later correlated to the force measurement.

WGAERFNAIHNRG

Dangerous robot motion
Risk of crush and collision between robot and measuring device! The collision situation to be measured can be dangerous. Do not reach into the collision range during measurement
and keep a safe distance away from collision range. Perform collisions only with the properly prepared measur-
ing device. Body parts between the robot and the measuring device can be pinched or bumped.

11.1 Performing a Measurement with the CoboSafe-CBSF

Personnel
Laboratory scientist Robot operator System integrator

Protective equipment
Protective clothing Protective gloves Safety footwear Industrial safety helmet Protective equipment required by the
robot manufacturer

1

Make sure that the measurement is prepared as described (see chapter “Preparing the measurement”).

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PERFORMING MEASUREMENT

2

Switch on the force sensor by pressing the pushbutton

Fig.23: Pushbutton

3 Read and note the displayed measurement number.

4 5

Fig.24: Measurement number
Start robot movement. The robot moves in the intended vector and collides centrally with the measuring unit.
Wait until the CoboSafe-CBSF displays a message on the display indicating that the measurement has been performed. The measurement data of the force measurement are stored in the internal memory.

6 End the contact situation according to the instructions in the robot’s manual.

7 Remove and separate the measuring unit.

8 9

Carefully remove the microfibre cloth Carefully loosen fixing aids such as adhesive tape

10 Carefully remove the pressure measuring film. 11 Remove the K1 damping element and stow it in the transport case.

When using the measuring system CoboSafe-Scan: Scan films promptly! The film “C” of the pressure measuring system CoboSafe-Scan is reddish in the area of the contact. Film “C” must now be scanned promptly to quantify the measurement data. Please read the operating manual of CoboSafe-Scan.

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TRANSMITTING MEASURED DATA COBOSAFE-CBSF

Transmitting Measured Data CoboSafe-CBSF

The force measurements performed are stored and indexed in the CoboSafe-CBSF. The record receives the following information:
Date Time Measurement number Device type Damping element K1 used Ambient temperature during measurement Humidity during measurement
The data can be transferred wirelessly to CoboSafe-Vision or via USB cable. For more information, please refer to the ,,CoboSafe-Vision Operating Manual “.
12.1 Transmitting Measured Data CoboSafe-CBSF-Basic
The data set stored by CBSF-Basic contains only the measurement number and no additional data. Supplementary parameters are defined when importing into the CoboSafe-Vision software.
12.2 Wireless Data Transmission
To be able to transmit data wirelessly, wire transmission has to be activated by selecting “ON” in the wireless menu. Read to chapter “Menu Navigation” to learn about this. The range of wireless transmission is about 20 meters under normal conditions. It may be restricted by external factors. If transmission is restricted or not possible at all, use a USB cable for transmission.
Not with CoboSafe-CBSF-Basic!

12.3 Transmission via USB Port
Use the included USB cable to transfer the data. Plug the cable into the Micro-USB connection socket of the CoboSafe-CBSF and into the USB socket of the PC. For more information on data transmission, refer to the ,,CoboSafe- Vision Operating Manual “.
Only a shielded USB cable approved by the manufacturer may be used to connect the CBSF to the PC.

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MAINTAINING FUNCTIONALITy

Maintaining Functionality

The CoboSafe-CBSF force measuring devices should be inspected before and after measurement to ensure proper functioning. Look for apparent damage and excessive pollution. Never use a damaged device. If there is any uncertainty regarding proper functioning or precision, e.g., because the device has been dropped or shows damage, the CoboSafe-CBSF should be sent to the manufacturer to be inspected.

13.1 Maintenance Schedule

Inspection Interval

Maintenance Tasks

Personnel

Before each measurement Inspection and cleaning

Laboratory scientist, System integrator

After each measurement

Inspection and cleaning

Laboratory scientist, System integrator

After approx. 20 operating Charging batteries hours or when indicated

Laboratory scientist, System integrator

Annually

Calibration of CoboSafe-CBSF

Manufacturer or certified service personnel

Replacement of damping elements K1

Laboratory scientist, System integrator

Every 2 years

Replacing batteries

Manufacturer

After updating standards or If necessary, replace dam- Manufacturer

in case of wear

ping elements K1, firmware

update

13.2 Checking and Cleaning
Instructions for checking and cleaning CoboSafe-CBSF force sensors and K1 damping elements.

Personnel
Laboratory scientist System integrator

Personal Protective Equipment
Protective clothing Protective gloves Safety footwear

Materials Soft, lint-free cloth

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MAINTAINING FUNCTIONALITy

13.2.1 Checking and Cleaning CoboSafe-CBSF

Z Checking and cleaning CoboSafe-CBSF

Wipe the measuring surface and housing with a clean cloth. 1 In particular, remove coarse particles (e.g., grains of sand or metal chips).
If present: Remove adhesive residue.

2

Use a soft cloth to clean the display on the device as well. Verify that the screen is clearly legible.

3 Check measuring surface for external damage.

Damage to CoboSafe-CBSF If there is no damage apparent on the housing or the measuring surface, inspection is completed. Please contact the manufacturer in the event of damage.

Inspection and cleaning of the device are completed.

13.2.2 Inspecting and Cleaning Compression Elements K1
Z Regularly check your K1 damping elements
1 Check the surfaces of the compression elements K1 for external damage.
2 Clean the K1 damping elements, if necessary.
Bend the damping element slightly and check for porosity. 3 Porous damping elements show lasting cracking when bent. A porous damping
element K1 may not be used and must be replaced. Carefully wipe the surfaces of the compression elements with a cloth: 4 SH 10 and SH 30: Use a dry cloth. SH 70: Use a damp cloth. The damping element is free of impurities and ready for use.

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13.3 Recharging Batteries The specifications of the charger can be found in the manufacturer’s documents and on the type plate. If the specification does not correspond to the country-specific specifications and designs, the charger must be replaced. The technical data for charging voltage and maximum charging current must be observed.
Battery charging can be performed using the following options:
Charging by charger. The specifications can be found in the technical data. Charging via the USB port of the PC.
Cyclic Charging Charge the device at regular intervals, especially during prolonged periods of inactivity!
13.4 Replacing Batteries The battery cannot be replaced by the operator. In the course of annual calibration by the manufacturer, the batteries and their charging cycles are checked and replaced if necessary. Batteries are replaced at the latest every two years.
13.5 Calibration Calibration of the force sensors is necessary to ensure the measuring capability of the system. To have the measuring system calibrated, contact customer service. Customer service can name a contact person for you or coordinate the next steps. The measuring system can be mailed to the manufacturer to have it calibrated
13.5.1 CoboSafe-CBSF Inspection Date A label on the device indicates when the force measuring device has to be inspected and calibrated by the manufacturer; refer to chapter “Signs and Labels” (inspection date).
13.5.2 Calibration by a Certified Laboratory The force measuring device can be calibrated by a lab accredited according to DIN EN ISO/ IEC 17025. We recommend having calibration performed by the manufacturer. The calibration of the measuring unit for temperature and humidity is not possible.

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PROPERLy STORING COBOSAFE-CBSF
13.5.3 Temperature/Humidity The integrated thermometer and hygrometer are calibrated along with the CBSF measuring devices. If calibration is not possible for various reasons, an external suitable measuring instrument must be used to determine the parameters.
13.5.4 K1 Damping elements The damping elements K1 are checked by the manufacturer for compliance with their specification during calibration of the CBSF-XS. Otherwise, the damping elements K1 should be replaced when worn or at the latest once a year.
13.5.5 Spare Parts Use only original spare parts or parts approved by the manufacturer. Spare parts can be obtained from GTE Industrieelektronik GmbH. Please contact customer service for assistance.
13.5.6 Firmware Update Firmware is updated via the CoboSafe-Vision software (this does not apply to CBSF-Basic).
14 Properly Storing CoboSafe-CBSF Ensure prescribed storage conditions (Refer to chapter “Technical Data”) Always store CBSF-XS devices in the included transport cases. Store CBSF-XS devices such that they are not exposed to shaking or vibrations.

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DETECTING AND REMEDyING MALFUNCTIONS

Detecting and Remedying Malfunctions

Error description
Force measurement repeatedly exceeds limit values

Cause
Wrong selection of robot parameters.
CoboSafe-CBSF incorrectly calibrated
CoboSafe-CBSF defective

Remedy Adjust robot parameters
Have CoboSafe-CBSF calibrated Check CoboSafe-CBSF and have it repaired. Contact customer service

Personnel Laboratory scientist, System integrator Manufacturer
Manufacturer

Display on CoboSafe-CBSF is blank when device is switched on.

Batteries empty Batteries defective

No wireless data transmission.

1

Wireless deactivated.
Too much distance between CoboSafe CBSF and laptop.
Device not started successfully. Internal error

2

Module defective

3

Weight on device

before started

4

Memory full

Charge batteries,
Have CBSF checked and repaired. To do this, contact customer service Activate wireless
Use USB cable to transfer data.

Laboratory scientist, System integrator Manufacturer
Laboratory scientist, System integrator Laboratory scientist, System integrator

Restart device

Laboratory scientist, System integrator

Send device to manufacturer to be checked

Manufacturer

Device must be sent to the manufacturer to be repaired

Manufacturer

Restart the device

Laboratory scientist, System integrator

Delete stored measured Laboratory scientist,

values

System integrator

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TECHNICAL DATA

Technical Data

16.1 Technical Data Force Sensor CoboSafe-CBSF
Weight and dimensions (mm): Specification Weight Diameter Height Measuring surface Diameter Measuring surface Height
Performance data: Specification Measuring range CoboSafe-CBSF-10 Measuring range CoboSafe-CBSF-25 Measuring range CoboSafe-CBSF-30 Measuring range CoboSafe-CBSF-35 Measuring range CoboSafe-CBSF-40 Measuring range CoboSafe- CBSF-50 Measuring range CoboSafe-CBSF-60 Measuring range CoboSafe-CBSF-75 Measuring range CoboSafe-CBSF-150 Maximum pressure on measuring sur-face Measurement inaccuracy, typical Measuring error maximum, in measuring range (from end value) Sampling rate Supply voltage Current consumption Capacity of internal memory (single measurements)

Value Unit <> 790 g
80 mm 60 … 107 mm
80 mm 60 … 107 mm
Value Unit 20 … 300 N 20 … 500 N 20 … 400 N 20 … 500 N 20 … 500 N 20 … 500 N 20 … 500 N 20 … 500 N 20 … 500 N
1500 N/cm² ±1 % ±3 %
1 kHz 3,7 V (DC) 500 mA >100 piece

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Specification Interface, Type Spring constant CoboSafe-CBSF-10 Spring constant CoboSafe-CBSF-25 Spring constant CoboSafe-CBSF-30 Spring constant CoboSafe- CBSF-35 Spring constant CoboSafe-CBSF-40 Spring constant CoboSafe-CBSF-50 Spring constant CoboSafe-CBSF-60 Spring constant CoboSafe-CBSF-75 Spring constant CoboSafe-CBSF-150
Operating conditions: Specification Relative humidity, non-condensing Temperature
Storage conditions: Specification Relative humidity, non-condensing Temperature
16.2 Technical Data CoboSafe CBSF-Basic
Weight and dimensions (mm): Specification Weight Measuring surface diameter Measuring surface height Lenght incl. handle Width

TECHNICAL DATA
Value Unit USB/Wireless
10 N/mm 25 N/mm 30 N/mm 35 N/mm 40 N/mm 50 N/mm 60 N/mm 75 N/mm 150 N/mm
Value Unit 20 … 90 % RH +10 … +30 °C
Value Unit 20 … 90 % RH +10 … +30 °C
Value Unit 1400 g
80 mm 70 mm 310 mm 80 mm

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TECHNICAL DATA
Performance Data: Specification Supply voltage Measured curve memory Measuring range Maximum pressure, on measuring surface Measuring inaccuracy, typical value Measuring error, maximum ( in measurement range Spring rate (SI) Spring rate (SAE) Sampling rate Port, type Charging batterie Battery life Charging current
Operating conditions: Specification Relative humidity, non-condensing Temperature
Storage conditions: Specification Relative humidity, non-condensing Temperature

Value Unit 2,4 V 100 pieces
20 … 500 N 1500 N/cm2 ±1 % ±3 %
75 N/mm 428,26 lb/in
1 kHz USB-mini –
2 hour 8 hour 500 mA
Value Unit 20 … 90 % RH +10 … +30 °C
Value Unit 20 … 90 % RH +10 … +30 °C

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16.3 Technical Data Accessories
Specification Nominal voltage, primary side Nominal voltage, secondary side Charging current

TECHNICAL DATA
Value Unit 100 … 230 V (AC)
5V 0,7 … 1,2 A

16.4 Requirements for Measurement Setup
Mechanical requirements contact surface: Specification Stiffness measuring points Contact surface

Value Unit > 2000 N/mm 80 x 80 mm

Requirements bearing surface The stated values represent recommendations of the manufacturer.

16.5 Requirements for Temperature and Humidity Measurement

Temperature measurement: Specification Measurement inaccuracy

Value Unit ±5 °C

Humidity measurement: Specification Measurement inaccuracy

Value Unit ±3 % RH

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COSTUMER SERVICE

Costumer Service

Scope of customer service
Phone E-mail Postal address Further information

Mediation of authorized contact persons for the calibration
Spare part orders Assistance with problems with the measuring system
Customer service is available from Mo – Thu from 8:00 to 16:00 (08 AM ­ 04 PM) Fridays from 8:00 to 14:30 (08 AM ­ 02:30 PM) +49 2162 3703-0
cobosafe@gte.de
GTE Industrieelektronik GmbH Customer Service Helmholztstraße 21 41747 Viersen, Germany
www.cobosafe.com

Disposal

Improper disposal
Environmental damage due to improper disposal! Do not dispose of the measuring system in residual waste. Dispose of all components according to regulations at the
place of use. The measuring system contains components that can damage the environment if disposed of improperly.

18.1 Disposal by the Manufacturer
The measuring device can be returned for disposal by the manufacturer at the end of its service life. Contact customer service before sending the device.

Fig. 24: Disposal

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APPENDIX: DIMENSION DRAWING MOUNTING ADAPTER:

Appendix

: Dimension drawing mounting adapter: Dimension drawing of mounting options on the CoboSafe-CBSF for holding auxiliary tools (Drawing not to scale)

Lenght L [mm] 107 89 75,5 76 73,5 65 64 62 60 21 14 7

1 6

CUT A-A

Name COBOSAFE CBSF-10 COBOSAFE CBSF-25 COBOSAFE CBSF-30 COBOSAFE CBSF-35 COBOSAFE CBSF-40 COBOSAFE CBSF-50 COBOSAFE CBSF-60 COBOSAFE CBSF-75 COBOSAFE CBSF-150 K1-SET Damping element SHORE HARDNESS 10 D=80 (GREEN) K1-SET Damping element SHORE HARDNESS 30 D=80 (BLUE) K1-SET Damping element SHORE HARDNESS 70 D=80 (RED)

L

K1-Set Damping element Art.-Nr.: 325-2803-004

8 6

Item number 325-2801-050 325-2801-051 325-2801-052 325-2801-053 325-2801-054 325-2801-055 325-2801-056 325-2801-057 325-2801-058 325-2803-004 325-2803-004 325-2803-004

A

A

4x 8,5

L

102

105

7 2

7 6

Art.-Nr.: 325-2803-022

Mounting with mounting adapter

150

130

8 0

M4 – 6H 5 max.
Mounting without mounting adapter

2 x 4H7 5 max.

1 0 3 7
6 3 7 9

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References

• CoboSafe > GTE
• GTE Industrieelektronik GmbH

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