Running a 1.5 ton Industrial Robot With a Custom Open-source Controller part 1

GitHub: github.com/ExcessiveOverkill/...
CORRECTION: Odrives are actually designed to run PMAC motors, I'm still not quite sure why I am getting such a low final speed though, I was expecting ~6% faster.
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Patreon: / excessiveoverkill

[@pablomontoya8303]

Definitely balls of steel having that arm inside where it's well in range to smash through all of those floor joists lol

[@codeack101wlck]

Not like its gonna move where not programed it doesn't have a mind of its own

[@nicolassepulveda4878]

I mean, dude, for sure Hazard prevention is your topic. Out of the sarcasm, bad programming can happen, or failure can happen internally. That's why robotic arm setups have many panic stop buttons, also that's why there is a line on the floor so people is out of reach of the arm's movement range.

[@codeack101wlck]

@@nicolassepulveda4878 yeah I weld with a dual arm yaskawa everyday, unless your stupid and can't control your own actions of input into the robot suurrreeeeeee yeah it will smash through his wall, but I doubt anyone here is oblivious to their actions

[@codeack101wlck]

@@nicolassepulveda4878 the stops and guards are for auto operation, everyday i move arms that im standing next to you can respect a machine and still be safe

[@feolender2938]

@@codeack101wlck I just started using Yaskawa but not for welding. How did you get into that?

[@brandonmee-lee1695]

you're an absolute legend

[@yannpenhas9280]

What a challenge, man! It doesn't sound to be a piece of cake, but is definitely worth the effort! And the knowledge you get from this experience is priceless 👌

[@harrysvensson2610]

Trust me when I say that he's simplified a lot. Like, A LOT.

[@marks7502]

the planned obsolescence of these huge indestructible machines is shameful.

[@marksmod]

Jeez Louise, what a project. This looks like a full-time job

[@joels7605]

This is amazing! There is a huge market for aftermarket Fanuc retrofits. If you decided to sell that people would buy them like crazy for old CNC machines running Fanuc drives.

[@VladPalacios]

I want one

[@theaveragepro1749]

but also might risk legal action from Fanuc

[@paulie-g]

@@theaveragepro1749 On what basis? Reverse engineering for the purposes of compatibility is specifically legal in the US. No one whom Fanuc would hope to sell to would be using a homemade DIY solution instead.

[@mprotec1]

i want a hundred!

[@godetaalibaba2522]

I'm a robotic student and your video is full of interesting informations, thank you so much ! I had never thought about doing something like that, buying real industrial robot is awesome and I look forward to see the day I'll have the space and knowledge to do what you did there 👍

[@Make-Asylums-Great-Again]

JUST DOOOO IT, DOOOOOOO IT!

[@kelownatechkid]

Wow. Learning VHDL for a project like this is extremely dedicated! I am very impressed.

[@BlueJeebs]

First time I've heard of a practical use of FPGA-s that I'd be interessted in lol. Also the fact that you can get your hands on a robot like that is next level, if for nothing else, for practice. Just make sure it doesn't put a hole in the roof I guess lmao

[@Dangineering]

Whoa, instant sub. You are straight amazing. Electrical engineering still feels like black magic to me.

[@peterfitzpatrick7032]

Yep... instant sub here too... 😎👍☘️🍺

[@rok1475]

I hope you will one day develop this project into a business converting discarded robots into useful machines

[@Manofcube]

Great vid that shows what you're up against if you decide to acquire one of these units. Unless you want a forever-project, $5-10k sounds like what should be expected.

[@skybirdprojects5489]

This is an insane amount of skill and effort. Good job, and that is a wicked project!

[@Zauviir]

you are a hero! please keep us updated on the progress on spinning a custom pcb to control these, we use a few fanucs and i've always wanted to get a smaller one to tinker around with but i was worried about all the licensing bs.

[@sevendesign1805]

Brilliant work! You stand among the great! Way to push through! You're helping drive manufacturing for the everyday guys. I build machines and could totally use that controller. I just drove the cost on a part from a $1.05 to $.09 and we make a thousand of these parts a day minimum. We need to load the machine once a month while we maintain the ability to pull 1,600 off a day. "So we never have to load it and we're able to pull in $$ish?" Yessir. I'm stoked... I started electrical and mechanical and then found manufacturing. Building with my hands man.

[@SentientSpeckSeekingSapience]

Great video! I wish I had enough electronics/software knowledge to really understand everything you presented here. With the right attachments for the end of the arm, this robot would be handy for automotive rebuilders (imagine being able to quickly and easily manipulate the position/orientation of heavy parts during disassembly/reconditioning/assembly). It could also replace a miniature crane in certain applications, especially if the robot was made mobile by some means.

[@Torqu3e]

This is what hacking means in today's world. The vast spanse of knowledge in various domains like electronics, electrical, mechanical, software, hydraulics, CNC, troubleshooting skills, what not is required to make this happen. Kudos to unkerfuffling so much complexity and getting a working model. Hat tip good sir!

[@chromosundrift]

Respect. Mad skills. Thanks for publishing this inspiring adventure!

[@robertboateng-duah9555]

Nice! I was thinking that you could make the robot run faster by changing the mosfets that originally come with the o-drive. something that can handle 300V. You might probably have to design a new PCB for that, but it shouldn't be a big deal. This is really amazing and inspiring work!

[@apaskiewicz]

Just wow. Excessive overkill is right! This was inspirational. Thanks for making this video.

[@toma.3d]

I wonder, why have i not seen this on LinuxCNC forums? Or did i ? 😃 Magnificent job on bringing the beast back to life!

[@VvvDoubleDvvV]

Thats some perseverance man gj getting this far

[@JonWhitton]

Thanks for sharing. An impressive debug and re-engineering project

[@ravindrareddy8536]

This is amazing who would have thought to use odrive on such a big robot, genius

[@mathieufasquelle3159]

This is impressive ! Good job 👍🏻👍🏻

[@nico101]

Awesome video, im in the same project right now, but i already started the motor swap

[@newt2010]

I used to work for an integrator and used Fanuc robots for 5 years. For the past 23+ years, I have worked for Motoman ( Yaskawa). You have your work cut out for you, since you don't have the matched controller for that arm. Great work and way to DIVE in. Look forward to watching your progress. Cheers

[@MrWaalkman]

Been a minute since I worked on a Motoman. Ours was so old that I ended up buying an old 1.3M pixel camera with a CF slot in it so I could format the card properly (Motoman required a different version of FAT12 which Windows no longer uses).

[@RobertElderSoftware]

This was a really great insight into the world of industrial robotics. I find it amazing how, in recent years, industrial machinery like this that could theoretically produce thousands or millions of dollars worth of product over its lifetime can be bought for the same price as a month's worth of groceries. The inflation rate of basic necessities has been far greater than the inflation rate of heavy machinery like this. It makes me think that a surprise North American manufacturing boom might be one of the things that can save our economy.

[@antontudor5724]

So much work. You deserve a brake from “what is wrong this time?” .

[@ravindrareddy8536]

this is beyond impressive, good job

[@iewanvandenberg3972]

love the video! I really want to make the jump from mills into CNC with robot arms like you.

[@StripeyType]

HOLY MACKEREL. This is darn close to being an open source drop-in replacement for an R-J3

[@benripka6977]

Holy shit... Fantastic work. Thanks for sharing.

[@Clark-Mills]

Wow! Very nice work. Thanks!

[@anderslarsson7123]

Amazing project!

[@dougphillips5686]

This is the best project on youtube!

[@hibber2249]

For the record, roboguide ships with all the controller firmware variations so you could have downloaded that and then restored from a virtual robot while using the trial version and saved yourself the custom driver but this is cooler

[@avenuex3731]

Complexity of this sort is often due to layer caking solutions rather than working from first principles. Good luck on your project.

[@rusticagenerica]

Such an awesome video & channel !!

[@GameProgrammer79]

I am not sure if I understood the issues correctly but anyway was an interesting video from start to the end and it seemed the robo was working at the end.

[@CNC-Time-Lapse]

I used to work for FANUC North America. If maintained, these robots can last a looooong time. Industrial customers can order replacement parts directly from FANUC or an authorized FANUC dealer with a ZDT contract.

[@mediasurfer]

Excellent work, Sherlock!

[@PeteBrubaker]

Also, thanks for increasing the cost of robots as I was considering buying a robot. :)

[@osmininmaks]

Впечатляющая работа! Я долгое время работал с похожими, в буквальном смысле, роботами - Hyundai Hi5, Hi5A.

[@heyhoe168]

Best toy 30-years old boy could possibly get.

[@toast47624]

Mad skills! Well Done!

[@nicholaszimmer663]

I used that R2000 for mig welding at a factory. At floor level its only 4-5 feet tall. You could disable the machine guards to make adjustments. If you get in that things way, it will toss you like a rag doll. I'm 200 pounds!

[@bnol03686]

This is a crazy amount of work for a homemade fifi

[@okiiPL]

Great work!

[@johnpaulperro]

awesome work man!

[@Cybertruck1000]

Massive credit to you for tackling that box of worms..

[@instaboiidsg2117]

Wow sick!!! Dude you are a genius

[@user-yn2bc8hz2y]

wow, great job keep it up

[@vandliszt]

I am encouraged to buy one now.

[@PeteBrubaker]

Yo. 8:42. From 0 to hero right there. Nice work!

[@Know-Way]

Nicely done.

[@iliketobuildstuff7013]

there is a fanuc post-processor for fusion online, I haven't tested it personally, as I still can't get communication from any computer to the rj3 controller on the robot working yet.. definitely an interesting project though, good on you having the patience to go through all this I would have just bought another robot (to be fair that is probably part of the reason our shop has 3 idle robots at the moment though)

[@ExcessiveOverkill]

I looked into the available post processor a bit, I wasn’t too confident it would work. The only way I had to transfer files to the robot was an ancient flash card.

[@iliketobuildstuff7013]

@@ExcessiveOverkill yeah, my local fanuc guy has been awesome, and I talked with a few people online and go kfloppy all setup, but either my rs232 wiring or something else was never quite sorted so i didnt get file transfer working.. tbh its pretty far out of my element so wiring could very possibly be the problem..

[@max_eley]

Excellent video!!!

[@edencybernetic]

Amazing! I just saved a arcmate 100ib and r-j3ib controller with pendant from being scrapped. Id love to know exactly what 3phase converter and transformer you used, the vid still is hard to see. Wanting to use it for plasma cutting steel sheets if I can but am mega new to these robots. Any help would be appreciated. ❤

[@themattrixrevolution]

i'm a cnc machinist and understand cnc code pretty well but understanding and overriding robotic arms is kinda the next level above me. i know these are usually noncollaborative robots and not even sure if these come with a pendant.

[@briansites8476]

Great video. Where did desk chair come from?

[@beatrute2677]

channel name checks out.

[@XoftC]

Nice work!

[@bapshago]

Was contemplating taking on a similar project, now I’m a little nervous.

[@Roetz40]

Great Video!!

[@matsworld9386]

seriously impressive ..

[@anam-0077]

It's really owesome. It definetely needs a lot of time. Wondering java or c supports automation

[@rafa_br34]

Damn, good job.

[@TheFabricator03]

Great Job!

[@juhotuho10]

This is insane!

[@douggjoseph]

This is impressive.

[@rusticagenerica]

Guys who use a damn logical analyzer are just incredible

[@geraldozambrinjunior4667]

Parabéns 😀🇧🇷 ! São poucos que têm seu conhecimento.

[@Tokentools-weldersAu]

You have a massive brain - that is awesome :)

[@i_might_be_lying]

Amazing project and rundown of Fanuc servo interface. Thanks a lot for the video!

[@Meekmakerspace]

Is there gonna be more on this? I just purchased a arc mate 100i. I was planning on buying a matching rj2 controller and rewiring for 220v. With the thought in mind you can creat programs with the tech pendant.

[@ExcessiveOverkill]

Yeah I plan on revisiting it this spring/summer hopefully. It still needs a ton of work to be good though. As long as the controller has the software for that exact robot it should work, but they seem to be pretty picky.

[@BalloonSchool]

That looks so cool :)

[@Shadoweee]

Algorithm has blessed You lol. Great video, You should post an update or something :) What did You plan on using it for? Just for fun?

[@camilonavarro7943]

Really impressive

[@derekleclair8787]

Seriously awesome!

[@srihari767]

You are awesome 💯😎 I have some experience in yaskawa 6 axis robot i can release how much effort you put on it.

[@chronokoks]

I always thought there is some dark magic involved in running such robots servos as the dynamics are complex and you need smooth motion, small following error and reduce things like harmonics and etc. I read up a book on servos and the math was quite heavy :D

[@JoseJimeniz]

What was even cooler, back when i worked at Fanuc, was the "float" mode. You can grab the end of the robot arm, and push it around. It will sense you pushing on it and "let" you push it. Obviously you're not strong enough to actually move it, but like a toddler holding your hand, it sense the tiny force you put on the arm and move in that direction. It's also quite impressive to watch the raw encoder values with with the robot sitting still, and just touch the end of the arm. The encoder is so precisce that it can register the imperceiptible movement you add.

[@butterbaybiscuits8694]

Good robots, terrible company. Nice work!

[@graealex]

What a rabbit hole...

[@asnaeb2]

Haha wtf I've used the ABB EGM interface and was already triggered on how much work it was to get it to run properly but this is a whole new level of external robot control

[@alo1236546]

Did you try robotdk and stepper motor

[@jameslucarelli7172]

Dude this is totally awsome. I have a question tho. I got almost exactly the same servo motor a while ago. I have no idea how to work it. Just the motor no robot. How would i do that?

[@ExcessiveOverkill]

You can use an Odrive if you’re alright with like 15% speed, the encoders actually have quadrature pulse output internally if you open them up so you can hook them directly together. If you want full speed you’d need to find a servo amplifier rated for the same voltage and that can accept quadrature input.

[@mytuberforyou]

This is very interesting- I am wondering what prevents making a program that accounts for the difference between kinematics set A (controller) and set B (actual robot)? There are off-the-shelf 6 and 8 axis kinematics modelers, maybe more, if you know the length of each offset in Robot A (the controller is programmed for) and B (shown in your schematic) I think it would be workable. Or at least possible.

[@alexanderpettit2969]

There are different communication methods between joints and the CPU on various robots, those require more work than simply translating between two vector spaces. These vary in timing, power requirements, and overall data architecture.

[@Petardozord]

Carefull with that.

[@blinkbright]

Imagine programming one of those crazy industrial robots to play with a video game controller. Everything starts out quaint and innocent. But then the robot loses a life in whatever game it ends up playing, and the video ends with the robot violently bashing the controller and chucking it through a window. I genuinely think that'd be the funniest thing to watch!

[@ricokonratt]

Love your work! Thank you for sharing!

[@percival23]

Would this be overkill for an automated litter box cleaner? My cat poops a lot and those clumps are surprisingly heavy.

[@petermuller608]

Impressive!

[@BriannaJohnsonDazedAndConfused]

Very cool.🤖

[@gregstarr2]

What is a robot like that typically used for

[@hakanloyan3483]

which programs do you use for motion planning ? Like MoveIt ?

[@zyxwvutsrqponmlkh]

Very nice, if you can come up with a package that replaces the original Fanuc controller boxes I'm sure it would have a decent sized market.

[@dgb5820]

I got lost after 1 minute but pretended to be smart by continued to watch to the end

[@brainimplants]

Amazing work I love it thanks for sharing. I wonder if you gave up on the fanuc servo amplifier too easily. The optical fiber connection shouldn't be so difficult to tap into. Maybe it's just ethernet and you can wireshark the packets? Someone out there has information on that protocol.

[@ExcessiveOverkill]

I think it is some custom realtime protocol, I have a large capture of it saved from when the controller was still together. I'll add it to the github repo if anyone wants to have a go at it. I asked around all the forums and found zero mention of it.

[@Sicaine]

Impressive work so far. Quite inspiring. But, listen, just imagine your workshop in style of batmans R&D Cave ;D (your lights spaced reminded me about the room)