The SmoothTool X URCap software is intended for robotic welding applications using a Universal Robots robot arm. The SmoothTool X URCap is intended as an add-on or extension to new or existing robot welding cells. Robotic welding is associated with many potential hazards. The user must read, understand and comply with the instructions in this manual, the manuals of the power source, UR-robot, and the manuals of other components in the complete robot system. The integrator must ensure that the complete robot system complies with the laws and regulations of the area in which it is installed. The integrator must perform a risk assessment and take the necessary steps to minimize the risks. The user must comply with the safety regulations set in place by the integrator.
Smooth Robotics ApS does not take responsibility for injuries or damage resulting from unintended use of, misuse of, or failure to follow the instructions in this manual or the manuals of any associated components.
Unintended Use
Unintended use includes but is not necessarily limited to:
- Using the SmoothTool X URCap for any non-welding process, including but not limited to plasma cutting, laser cutting, brazing, or arc gouging.
- Using the SmoothTool X URCap in combination with other URCaps. See Use of Other URCaps.
- Executing a program without having completed and verified a dry run of the program first. The 3D viewer is a useful feature for visualizing programs, but must not be used as a substitute for a physical dry run.
- Running an existing program on a workpiece that differs from the one it was created and validated for, without first performing a new dry run to confirm the program still works as intended.
- Making any changes to the robot cell — including repositioning fixtures, recalibrating the TCP, remounting the robot, or modifying safety devices — without performing a new or updated risk assessment.
- Operating without completing the full setup and configuration process described in this manual.
- Using any SmoothTool X power source integration without having fully read and understood the manual for that integration and the manual of the power source itself.
- Using SmoothTool X with a power source that does not have an existing SmoothTool X power source integration. The only supported exception is the SmoothTool X retrofit kit and URScript callback integration, which is the only intended method for using SmoothTool X with a non-integrated power source. Before using either integration, the user must read and understand the relevant manual and perform a risk assessment to ensure that the power source setup can be safely operated using that integration.
- Allowing personnel who are not trained in both robotics and welding to create, modify, or execute programs.
- Modifying the program tree or welding parameters while the robot is in an active or running state.
Safety Requirements for Integration
This is the critical part.
You must clearly state:
- What safety measures the integrator must implement
- What you assume exists externally
Examples: - Emergency stop requirements
- Required guarding
- Required safety PLC / category (if applicable)
- Safe shutdown behavior
You are basically saying: “Our product is safe IF these conditions are met.”
Ventilation, exhuast and fume extraction
Welding fume is hazardous to health.
Placement of Control Devices
Optional control devices, such as the arc control box must be placed within reach of the operator, also if this means positioning it within the dangerous area.
Warnings
Automatic Control of Power Source
If the power source provides the option to receive emergency stop signal as input it must be connected to the safety circuit of the welding cell.
Warning
The SmoothTool X URCap software automatically controls the power source. The user and integrator are responsible for ensuring that this does not result in personal injury or material damage. The URCap does not enable the user to explicitly define when the arc of the power source is turned on or off — this is determined implicitly by the program structure.
When connected to a power source that provides the option to control the wire, the user must ensure the area around the welding torch is clear before running any program.
Use of Other URCaps
Warning
Smooth Robotics cannot guarantee that SmoothTool X will function correctly when used alongside other URCaps. Third-party URCaps may interfere with SmoothTool X and cause unintended behavior. To ensure SmoothTool X functions as intended, the use of other URCaps must be avoided unless strictly necessary. In particular, UR nodes and third-party URCap nodes must never be inserted inside any SmoothTool X sub-tree that controls welding — currently this applies to the Weld Seam sub-tree — as this is where the arc is automatically turned on and off.
Using the Robot’s Built-in Simulation Feature
Warning
If the robot’s built-in simulation feature is enabled while SmoothTool X is not also in simulation mode, the robot will not move from its initial position but will start welding regardless when the program is run. The user must ensure that the robot’s built-in simulation feature is never enabled without SmoothTool X also being in simulation mode.