Transcript
PC-Less MotoPick Conveyor Tracking System
OPERATOR’S MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.
Part Number: Revision:
172532-1CD 1
MANUAL NO.
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Copyright © 2015, Yaskawa America, Inc. Terms of Use and Copyright Notice All rights reserved. This manual is freely available as a service to Yaskawa customers to assist in the operation of Motoman robots, related equipment and software This manual is copyrighted property of Yaskawa and may not be sold or redistributed in any way. You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF files to another website, blog, cloud storage site or any other means of storing or distributing online content. Printed in the United States of America First Printing, 2015 Yaskawa America, Inc. Motoman Robotics Division 100 Automation Way Miamisburg, OH 45342 Phone: 937-847-6200 www.motoman.com
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Table of Contents
Table of Contents 1 Introduction ..................................................................................................................................... 1-1 1.1 Overview of MotoPick Conveyor Tracking System............................................................ 1-1 1.2 Main Feature...................................................................................................................... 1-1 1.3 Configuration of System and Preparation.......................................................................... 1-2 1.4 Specifications..................................................................................................................... 1-6 1.5 Precautions of Introducing the System .............................................................................. 1-8 1.5.1 Vision Device........................................................................................................ 1-8 1.5.2 Camera and Manipulator Installation Position .................................................... 1-11 1.5.3 Edit the Vision Program...................................................................................... 1-12 1.5.4 Using the Data Transmitting Function ................................................................ 1-12 2 MotoPick Support Tool Operation................................................................................................... 2-1 2.1 Main Window ..................................................................................................................... 2-2 2.2 Menu Bar ........................................................................................................................... 2-3 2.3 Tool Bar ............................................................................................................................. 2-6 2.4 Sub Menu Button ............................................................................................................... 2-8 2.4.1 Project Function ................................................................................................... 2-8 2.4.2 Monitoring........................................................................................................... 2-10 2.4.3 Online Setting ..................................................................................................... 2-10 3 Set Up ............................................................................................................................................. 3-1 3.1 Preparation ........................................................................................................................ 3-1 3.1.1 Layout Review ...................................................................................................... 3-1 3.1.2 Wirings between Devices ..................................................................................... 3-2 3.1.3 IP Address Setting................................................................................................ 3-8 3.1.4 PC Setup ............................................................................................................ 3-12 3.1.5 Camera Setup .................................................................................................... 3-15 3.1.6 Conveyor Settings .............................................................................................. 3-25 3.2 Setup ............................................................................................................................... 3-31 3.2.1 Confirm the Signal .............................................................................................. 3-31 3.2.2 Calibration .......................................................................................................... 3-32 3.2.3 Hand Setting and Home Position Registering .................................................... 3-52 3.2.4 Project Creation.................................................................................................. 3-54 3.2.5 Registration of Workpiece for Detection ............................................................. 3-78
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4 Playback Operation......................................................................................................................... 4-1 4.1 Normal Start-up.................................................................................................................. 4-1 4.2 Restarting the System...................................................................................................... 4-14 4.3 Change Project ................................................................................................................ 4-15 5 Online Setting (Motion Parameter Adjustment)............................................................................... 5-1 6 Monitoring ....................................................................................................................................... 6-1 6.1 Actual Production............................................................................................................... 6-1 6.2 Log ..................................................................................................................................... 6-3 6.2.1 How to Read the Logging Data............................................................................. 6-4 7 Restoration Procedures for the System Error ................................................................................. 7-1 7.1 Alarm.................................................................................................................................. 7-1 7.2 Emergency Stop Button is Pressed or External Emergency Stop Signal is Input.............. 7-1 7.3 Conveyor is stopped .......................................................................................................... 7-1 8 MotoPick JOB ................................................................................................................................. 8-1 8.1 MotoPick JOB .................................................................................................................... 8-2 8.1.1 JOB Configuration of MotoPick............................................................................. 8-2 8.1.2 Mechanism of MotoPick JOB Operation............................................................... 8-3 8.1.3 Important Reminder When Editing JOB................................................................ 8-5 9 List of Signal.................................................................................................................................... 9-1 9.1 MotoPick Ladder .............................................................................................................. 9-10 9.1.1 Deleted Lines from Standard Ladder.................................................................. 9-10 9.1.2 Added Lines to Standard Ladder ........................................................................ 9-11 10 Register....................................................................................................................................... 10-1 11 List of Variable ............................................................................................................................ 11-1 12 Troubleshooting .......................................................................................................................... 12-1 12.1 Related to Encoder ........................................................................................................ 12-1 12.2 Related to Vision............................................................................................................ 12-1 12.3 Related to Signal............................................................................................................ 12-2 12.4 Manipulator Operation ................................................................................................... 12-2 12.5 MotoPick Support Tool................................................................................................... 12-2
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12.6 Standby completion waiting ........................................................................................... 12-3 12.6.1 Whether the Camera Status is Set to Online.................................................... 12-3 12.6.2 Whether the Camera Status is Changed When Requesting Standby .............. 12-3 12.6.3 Whether the Camera JOB Name is Correct ..................................................... 12-4 12.6.4 Checking the Signals........................................................................................ 12-4 12.7 Robot JOB Stops at WAIT Instruction ........................................................................... 12-5 12.7.1 Setting PICK Priority to Picking Priority ............................................................ 12-5 12.7.2 Checking Whether the Data is Transmitted Normally....................................... 12-6 Appendix ...........................................................................................................................................A-1 Setting of the Connector BOXA-1 1 Connector BOX ..........................................................................................................A-1 2 Component Parts of Connector BOX .........................................................................A-2 3 Connector BOX ..........................................................................................................A-4 3.1 FS100 Terminal Block Wiring........................................................................A-5 3.1.1 Camera I/O, Sensor and Manipulator Hand Connection............................A-7 3.1.2 List of I/O Terminal Block Signal ................................................................A-8 3.2 Ethernet Device and Power Supply Device Wiring .......................................A-9 3.3 Encoder Pulse Distributor Wiring ................................................................A-10 4 Wiring Example in Connector BOX ..........................................................................A-11
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1 Introduction 1.1 Overview of MotoPick Conveyor Tracking System
Introduction 1.1
Overview of MotoPick Conveyor Tracking System MotoPick Conveyor Tracking system enables the manipulator applicable to the line, represented by picking and packing operations in food drug and cosmetic industries, in which the manipulator picks coming workpieces on the conveyor and places it in accordance with a designated pattern. This system requires an application software “MotoPick”. A software “MotoPick” is developed with aims of operating a conveyor tracking system which consists of vision devices, various sensors, conveyors with robots more effectively. A PC software, “MotoPick setup tool” (hereinafter referred to as “MotoPick Support Tool”) is used to construct this system.
1.2
Main Feature Followings are the features of MotoPick • Operability By using the MotoPick Support Tool, the conveyor tracking system can be easily setup. Also, adjusting of the robot operation is easily done by those who are not familiar with the programming pendant operating methods. • Scheduling Function In most of the production lines where picking and packing operations are employed, multiple manipulators are installed along the lines to handle a large amount of transferring products. To these manipulators, MotoPick conveyor tracking system can freely determine which manipulator to pick which workpiece. • PC-less system (while the system is in operation) This system does not require a PC during the operation. For this reason, no concern for a production system trouble attributing to the PC break down is necessary. However, the PC is necessary for setting up the system. Also, since more than two production lines can be constructed with a MotoPick Support Tool, it is no need to prepare a MotoPick Support Tool for each system when adding systems.
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1 Introduction 1.3 Configuration of System and Preparation
1.3
Configuration of System and Preparation Following is the system configuration of this system.
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1 Introduction 1.3 Configuration of System and Preparation Following table shows the constitution of the system and in charge party for preparation.
Parts
No.
Name
Prepared by
1. Software
1-1
Dedicated functions for MotoPick (PC less) Counter Board (Conveyor synchronized function board: JAPMC- PL2300R-E) included (one board)
Yaskawa
1-2
MotoPick Support Tool
2-1
Controller (FS100, FS100L)
2-2
Power supply cable
2-3
Programming pendant
2-4
Robot (FS100, FS100L corresponding model)
3-1
I/O module cable
3-2
Counter module cable (Conveyor synchronized board connecting cable)
3-3
Ethernet cable
4. Conveyor peripheral device
4-1
Encoder
5.Components of connector BOX
5-1
I/O terminal block
5-2
Counter terminal block
The connector BOX is prepared by customer1)
5-3
Ethernet hub
5-4
24V power supply
5-5
5V power supply
5-6
Circuit protector
5-7
Encoder pulse distributor
5-8
Socket (for encoder pulse distributor)
6-1
Camera
6-2
Camera cable
6-3
Camera I/O cable
2. Manipulator
3. Controller peripheral cable
6. Camera
6-4
Lens
7. Storage media
7-1
USB memory
8. PC, PLC
8-1
PC
8-2
PLC
9. Manipulator peripheral device
9-1
Robot mount
9-2
Robot hand
10. Conveyor
10-1
Conveyor (pick side)
10-2
Conveyor (place side)
10-3
Passage sensor
10-4
Camera mount
10-5
Light for camera
Yaskawa or Customer
Customer
1 For the connector BOX, refer to “Setting of the Connector BOX”.
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1 Introduction 1.3 Configuration of System and Preparation
Details of the components prepared by customer Parts
No.
Name
Specifications
3. Controller peripheral cable
3-1
I/O module cable
Controller specifications Connector: 10150-3000PE Shell: 10350-52A0-008 Terminal specifications Select appropriate connector
3-2
Counter module cable
Controller specifications Connector: 10140-6000EL Shell: 10340-3210-000 Terminal specifications Select appropriate connector
3-3
Ethernet cable
IEEE802.3/ab: Category 5 or higher is recommended.
4. Conveyor peripheral device
4-1
Encoder
Encoder I/F specifications I/F specifications of the specific board : Numbers of corresponding channel : 3CH Corresponding encoder type: Line-driver output (operation output: RS422 or equivalent) Note: It is not available for the open collector
5.Components of connector BOX
5-3
Ethernet hub
Necessary when using POE power supply camera. Other than above mentioned case, Ethernet hub is available.
5-7
Encoder pulse distributor
Prepare a distributor corresponding to the encoder's I/F specifications.
6-1
Camera
6-2
Camera cable
MotoSight series (Yaskawa made) In-Sight series (Cognex made)
6-3
Camera I/O cable
(In the MotoPick system, image taking instruction is made through the IO signals for the high reactivity)
6-4
Lens
Choose appropriate one in accordance with the camera or environment.
7-1
USB memory
6. Camera
7. Storage media
Capacity
512 MB to 4 GB USB memory whose capacity exceeds 4 GB is not available. Project data need to be stored in the storage media before changing projects.
Ambient temperature
0° to 60°C
Recommend
UDG4-DRJ series (Hagiwara Solutions Co., Ltd. made)
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1 Introduction 1.3 Configuration of System and Preparation
Parts
No.
Name
8. PC
8-1
PC
Specifications OS
Microsoft WindowsXP Professional SP3, Microsoft Windows7 Professional Edition (32 bit),
CPU
Intel (R) Core 2 Duo 2GHz or higher recommended
Memory
1 GB or more recommended
Hard disc
500 MB or more capacity recommended
Display resolution 1024 x 768 pixels or more 10. Conveyor
10-3
Set of tray detection sensor
(Operational specification) When objects are in front of the sensor, set this sensor to be “ON” and set it to be “OFF” when no object is in front of the sensor. Input pulse-type signal for when detecting.
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1 Introduction 1.4 Specifications
1.4
Specifications Followings are the operational specifications of the MotoPick system.
Manipulator
Controller type
Corresponds to the DX100 or FS100.
Maximum manipulator numbers to be connected
10 manipulators at maximum
Processing ability
Depends on conditions Processing ability of the manipulator (amount of workpieces to be handled) varies depending on the conveyor speed, amount of handling workpieces or environment (layout of manipulators and conveyors).
Accuracy of handling operation
Variance of ±1 mm (or more) may occur according to the conveyor speed, accuracy of workpiece detecting operation and other conditions.
Vision device Corresponding system
In-sight series system (Cognex made) Will be corresponding to other vision systems as needed.
Detection by Detecting method vision device (pick side/ place side)
Pattern matching, blob processing, or color recognition method (color recognition method is valid only when using a color recognizing camera) Note: Detection is available only when using In-sight series (Cognex made) corresponding image processing program obtained from Yaskawa.
Numbers of identifying type 5 types of workpiece at maximum (at 1 project) Note: Creation of more than two projects is available
Box/tray detection (pick side/ place side)
Conveyor
Accuracy of detection
Depends on the vision shooting conditions Note: Accuracy of detection of the model is affected by the resolution, lightening and other environmental conditions.
Maximum number of detecting workpiece
50 workpieces can be detected at maximum (in an image).
Detecting environment
Avoid the variation of illuminance because it can cause detection error of workpieces. To expect efficient operation, fencing all the equipment including the camera, lightening devices, etc is strongly recommended.
Detecting method
•Photoelectric sensor •Proximity sensor In this detection, detection is executed to the previously registered positions or postures of the pattern and the detection will not work properly to the unregistered patterns of positions or postures.
Signal for detection
Set this signal is set to be turned ON when there are trays to be detected and OFF when there is no tray on the conveyor. Also, input pulse-type signal when the tray is detected.
Tray/Box size
This system complies with the following sized trays: W 500 [mm] X D 500 [m] X H 500 [mm].
Maximum conveyor numbers to be connected
6 conveyors at maximum Note: In case connecting more than 3 conveyors, ask your Yaskawa representative.
Conveyor speed
This system can cope with the conveyor whose flowing speed or 60 m/min.
Control
•Conveyer start/stop •Conveyor speed deceleration Note: To control the conveyor, judge the conveyor controlling IO signals output from the manipulator with PLC, etc.
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1 Introduction 1.4 Specifications
Handling method Multi picking/placing operation
•Gripped by a vacuum gripper or a clamp gripper •Transfer workpieces parallel to conveyors •4 workpieces simultaneously at maximum. •4 types of workpieces at maximum •Continuous picking operation •Placing all workpieces once or placing each workpiece respectively are selectable.
Others
Application
MotoPick conveyor tracking system consists of the vision program, dedicated set-up software, application software in the controller, and move instructions (JOB). Use this system with the appropriate combination of constitution.
Example of a system
SUPPLEMENT
Pick side : Conveyor, Vision detection Place side: Conveyor, Passage detection (detection by inputting signal)
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1 Introduction 1.5 Precautions of Introducing the System
1.5
Precautions of Introducing the System Before introducing the system, processing abilities of the vision devices are to be into consideration besides that of the manipulator. In this chapter, items to be taken into consideration and installing conditions for the vision device are described.
1.5.1
Vision Device 1. Select a vision device and specify a view size. For the appropriate operation of the system, following two points are indispensable. • Selecting of an appropriate vision device to meet the target processing ability for the production line. • Specifying of the view size Conditions of the vision device are described below.
For the detection using the vision device, following un-equation should be satisfied. A.Intervals of image acquisitions > B. Image processing time + C. Data transmitting time A. Intervals of image acquisitions: Time intervals for accruing an image and next one. It is calculated by the following formula. (Vision size - Workpieces size) / Conveyor speed
B.Image processing time: Time from accruing an image from the vision device till finish processing it. It is subject to vary depending on the conditions such as calculating ability of the vision device, condition of the lighting or number of the registered model for detection or workpieces in the taken image, etc. for the shorter image processing time, registration of the simple and unique models for detection is recommended.
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1 Introduction 1.5 Precautions of Introducing the System C.Data transmission time: Time spent on data accruing for the controller from the vision. It is subject to change depending on the number of detected workpieces or connected manipulators. Unless these conditions meet, the system cannot detect the workpieces thoroughly and the manipulator could fail to convey the work pieces If it happens, take the following countermeasures. Broaden the view size
Lengthen the image taking intervals by broadening the view size. If it is broadened too much, the accuracy of detection may become less.
Shorten the image processing time Shorten the image processing time by adjusting the detecting conditions. Faster the arithmetic processing by upgrading the vision device specification can shorten the time.
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1 Introduction 1.5 Precautions of Introducing the System 2. Selection of the Lens and Adjusting of the Camera Height A lens for the vision device and its setting height is determined after vision device and its FOV are determined. Here in this manual, selection of the lens and setting of its height are explained taking In-Sight Micro1100 as an example. Suppose a FOV of 350mm is set along the conveyor flowing direction. The resolution of In-Sight Micro1100 is 640 x 480 pixels. Place the camera sideways along the conveyor flowing direction since the crossdirection of the camera view is longer than its height. Consequently, 350 mm x 262.5 mm is the realistic result for the FOV of In-Sight Micro1100. Based on this size, select the lens and calculate the height for setting the camera. The point to be considered first is the focal length of the lens. Following relationship exists between the focal length and the distance to the object (distance between the lens and the object) The size of the object = Focal length: Distance between the lens and the object
Suppose that a lens with its focal length of 12 mm is selected though the focal length varies depending on the specifications of the lens. The size of the CCD for In-SightMickro1100 is 1/3 inches (4.8 mm x 36 mm), the distance between the lens and the object can be calculated as follows. 4.8 mm : 350 mm = 12 mm : X mm X = 875 mm Based on this value, determine the setting height of the camera.
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1 Introduction 1.5 Precautions of Introducing the System 1.5.2
Camera and Manipulator Installation Position For writing workpiece position data to the manipulator, it takes the same period as the total time of taking image of the workpieces to detecting them and data transferring time. Data transferring time depends on the number of detected workpieces. It takes about 0.5 to 5 seconds for 1 to 50 workpieces. Therefore, the camera must be placed away from the manipulator for this time period. (Otherwise, it fails to detect some workpieces if taking an image at shorter intervals than the distance of above mentioned time period.) The distance from the end of the camera FOV to the end of the manipulator operating range is calculated by the following formula: (workpiece detection processing time + data transfer time) × conveyor speed. Example) Image detection processing time: 1.0 [sec] Data transmitting time: 0.5 [sec] Conveyor speed: 200 [mm/sec] Necessary minimum distance [mm] = (1.0 [sec] + 0.5 [sec]) × 200 [mm/sec] → 300 [mm]
CAUTION •
It is recommended to install a camera with the necessary minimum distance that includes some extra distance.
•
Too much distance between the camera and manipulator may cause less workpiece transportation accuracy.
•
Each manipulator can store up to 500 position data. When more than 500 data from detection to operation of the target are stored, data is overwritten from the oldest ones.
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1 Introduction 1.5 Precautions of Introducing the System 1.5.3
Edit the Vision Program The controller designated as the master of the vision program reads the value of the cell to which a symbolic tag, specified by the image processing program, is attached. For this reason, MotoPick would not work properly in case the name of the symbolic tag is modified. Be careful to the name when editing or creating the camera JOB.
Symbolic tag name Value Total_num
Total number of the workpieces detected at a trigger. 50 workpieces are detected at maximum.
Work*.Score
The score (correlative value) of the registered workpiece model which are detected.
Work*.X
Position of the detected workpieces (X,Y). X, Y mean the position on the user coordinates.
Work*.Y Work*.Angle
Amount of angle error of the detected workpieces over the registered model.
Work*.Type
Types of the detected work pieces
Note: “ * ” stands for 2-digit workpiece number (Work 01 to Work50)
1.5.4
Using the Data Transmitting Function When the external device reads and writes the variables of the controller used for JOB with using such as the data transmitting function, perform interlock with JOB as follows.
Variable P010
1. Write the variables.
2. After that, turn ON the interlock signal. External Device
The JOB confirms the interlock signal, and then uses the variables.
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2
MotoPick Support Tool Operation
MotoPick Support Tool Operation MotoPick Support Tool is required when setting up the MotoPick system. Basic operations of this MotoPick Support Tool are standardized with that of Windows applications for the improvement of operation. In this section, operation methods of the MotoPick Support Tool are explained. Following is the main window of the MotoPick Support Tool.
NOTE
As shown in the following table, available versions for the MotoPick Support Tool vary depending on the versions of the dedicated functions for the FS100 corresponding MotoPick. For this reason, use the MotoPick Support Tool delivered with the FS100. Version of dedicated functions for the FS100 MotoPick
Available version of MotoPick Support Tool
AP003B MP02.01A-00 or earlier
AP003B PC02.01A-00 or earlier
AP003B MP03.00A-00 or later
AP003B PC03.00A-00 or later
For the version of dedicated functions for MotoPick, refer to FS100 variable S098 or S099. And for the version of the MotoPick Support Tool, refer by selecting {Other} - {Version Information} under the MotoPick Support Tool menu bar.
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2 MotoPick Support Tool Operation 2.1 Main Window
2.1
Main Window Each menu on the MotoPick Support Tool main window and functions of each button are described here.
No. Item
Content
1
Menu bar
Refer to section 2.2 “Menu Bar”.
2
Tool button
Refer to section 2.3 “Tool Bar”.
3
Sub Menu
Press each button below to change the window to display the sub menu. •Project •Monitoring •Online Setting
4
Explanation of main menu Displays the details of the main menu selected by the sub menu button.
5
Explanation of sub menu
Displays the details of the sub menu button at which the mouse is pointing.
6
Sub menu display area
Displays the sub menu of the main menu selected by the sub menu button.
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2 MotoPick Support Tool Operation 2.2 Menu Bar
2.2
Menu Bar Each function of the menu bar are described here.
No. Item 1
Content
Menu bar
1.1 File(F)
Following operations are executed to the project data. •New •Open •Project Settings •Exit
1.2 Project(P)
Following operations are executed to the project incorporated into the system. •Change Project •Upload Project Data •Download Project Data •Start •Stop
1.3 Settings(S)
Set the following items to the MotoPick Support Tool. •Language •Saving destination of the project data (in the PC) •Programming pendant settings
1.4 Other(O)
Version information
Details of each menu • File menu New
Create a new project data
Open
Read an existing project data
Project settings
Allocate a number to each of the newly created project data. By switching the number, the project can be switched. Switch the project by following the procedures below. •Select {Project} - {Project Switch} under the menu bar. •Switch the project by an external signal For the details, refer to section 4.3 “Change Project”.
Exit
Terminate the window of the MotoPick Support Tool.
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2 MotoPick Support Tool Operation 2.2 Menu Bar • Project menu Change Project
Switch the project data
Upload
Acquire the project data from the external memory device connected to the FS100, and save it in PC.
Download
Acquire the project data from the PC, and save it in the external memory device connected to the FS100.
Start Stop
Start the MotoPick system Terminate the MotoPick system
• Setting menu AP003B PC03.00A-00 or later Language
Select a language for the MotoPick Support Tool
Application Folder Path
Specify a saving destination of the project data created by the MotoPick Support Tool. Only when changing the saving destination, change this setting. • When specifying a folder in Program Files as a saving destination, the application should be executed with administrator authority.
Log Max Line
Specify the maximum numbers of the lines output by the CSV file. Normally, it is not necessary to change.
Master R/C IP Address
Set the IP address of the controller to download the created project data. The recommended USB memory should be inserted to the controller to which the data is downloaded in order to save the downloaded data.
AP003B PC02.01A-00 or earlier Language
Select a language for the MotoPick Support Tool
Application Folder Path
Specify the destination of the project data saved by the MotoPick Support Tool. Only when changing the saving destination, change this setting. • When specifying a folder in Program Files as the destination to save, the application should be executed with administrator authority.
Log Max Line
Specify the maximum numbers of the log output by the CSV file. Normally, it is not necessary to change.
FTP server (P.P.)
Set the FTP server name Input an IP address of a P.P as a destination of the project data.
Destination of uploaded data
• CF card • USB memory
Destination of uploaded data on the CF 1)
If “CF card” is selected as the destination of the uploaded data, the data is saved in the folder specified by this menu. •A new folder is created for the uploaded data in case the specified folder is not found in the CF card.
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2 MotoPick Support Tool Operation 2.2 Menu Bar Destination of uploaded data on the USB *1
If “USB memory” is selected as the destination of the uploaded data, the data is saved in the folder specified by this menu. •A new folder is created for the uploaded data in case the specified folder is not found in the USB memory.
FTP account
Set an account for the FTP. Input “nx”.
FTP password
Set a password for the FTP. Input “nx”.
1 CF and USB cannot be used simultaneously.
• Other menu Version Information
Display the software version of both MotoPick Support Tool and controller.
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2 MotoPick Support Tool Operation 2.3 Tool Bar
2.3
2
Tool Bar
Tool Button
2.1 Mode change
Change the mode (Refer to “” ) ON line:
2.2 2.3 2.4 2.5 2.6 2.7
OFF line:
Open
Read the selected project
New
Create a new project
Download
Acquire the project data from the PC, and save it in the external memory device connected to the FS100
Upload
Acquire the project data from the external memory device connected to the FS100, and save it in PC
System start
Start a project
System stop
Stop a project
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2 MotoPick Support Tool Operation 2.3 Tool Bar Depending on the mode, the functions of main menu button, menu bar, tool button are limited as shown in the tables below.
○: available, X: not available Main menu button Select mode Edit Project “New” “Edit” Project
OFF line For “New” and “Edit”
○ ○
Online Setting
X
Monitoring
X
Start/Stop
X
ON line
○ ○ ○ ○ ○
Menu bar Select mode File
•New
•Change Project
X
•Upload Project Data
X
•Download Project Data •Start
X
•Stop
X
Settings
•Settings
Other
•Version Information
○ ○ OFF line
ON line
•Project settings •Exit Project
○ ○ ○ ○
ON line
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
•Open
NOTE
OFF line
X
Tool button Select mode Change Project Open New
○ ○ ○
Upload Project Data
X
Download Project Data
X
Start
X
Stop
X
○ ○ ○ ○ ○ ○ ○
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2 MotoPick Support Tool Operation 2.4 Sub Menu Button
2.4
2.4.1
Sub Menu Button
Project
Change the window to the project creating window Manipulator’s motion patterns or projects with the system setting patterns are designated with this menu.
Monitoring
Change the window to the production information or log data displaying window
Online Setting
Change the window to the manipulator’s motion parameter changing window. This function is available while in the play back operation. (This function is available when the MotoPick Support Tool mode is “online”.)
Project Function Select {Project} in the sub menu to call up the project window. On this window, creation and edition of the project are available.
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2 MotoPick Support Tool Operation 2.4 Sub Menu Button
No. Item
Content
1
{New} button
Followings are the procedures for creating a new project data. 1, Master folder Designate a name of the master folder to manage the project data. Multiple projects can be stored in this folder. With the project changing function, they can be switched. 2, Designate a project data in the project created in the step 1. 3, Create a project data.
2
{Edit} button
Edit the project data. 1, Select a master folder Select a master folder to be edited from among the list of projects. 2, Select a project data from the master folder selected in the step 1 or create a new project data in it. 3, Edit the project data.
3
{Project Settings} button
Create a project management file. 1, Allocate a project number. Select a master. And allocate a project number to a project data in the master. 2, Switch the project Specify a project number set in the step 1 to switch the project.
There are three ways of creating a project. Choose one out of three as needed.
NOTE
• Setup Wizard With this wizard, the project is created in dialogical orders. This set-up method is recommended to those who are unfamiliar to the setup. • Normal Setup The project is created in non-dialogical orders. This set-up method is recommended to those who are familiar to the setup. • Custom Setup In this setup method, only the necessary parameters are set up. This set-up method is recommended to the experienced.
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2 MotoPick Support Tool Operation 2.4 Sub Menu Button 2.4.2
Monitoring Select {Monitoring} in the sub menu to call up the monitoring window. Actual production of the system or log data can be referred by connecting the MotoPick Support Tool to the manipulator in motion.
No. Item
2.4.3
Content
1
{Actual Production} button Display the actual production window.
2
{Log} button
Display the log window.
3
{Work Status Monitor} button
Currently not available.
Online Setting Select {Online Setting} in the sub menu to call up the online setting window. This online setting fine adjusts the manipulator’s motion during the play back operation.
No. Item
Content
1
Display the online setting window.
{Online Setting} button
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3
3 Set Up 3.1 Preparation
Set Up Before setting up this system, preparations for the following items are required. Once these preparations are done, no other than “play back operation” and “change project” operation is necessary during the normal production.
Regarding the version of the dedicated functions for MotoPick AP003B PC02.01A-00 or earlier, when starting up the controller, the programming pendant application window appears on the programming pendant window.
NOTE
To display the normal programming pendant screen, press {FS Screen}. For the operating method of the programming pendant application, refer to “Connect the programming pendant application with the controller. (It is unnecessary if the version of MotoPick is AP003B PC03.00A-00 or later.)”
3.1
Preparation Before setting up the system, followings are necessary as its preparation. • Layout review • Wirings between devices • PC set-up • Camera set-up
3.1.1
Layout Review 1. Manipulator layout MotoPick system is not equipped with the interference function between manipulators. For this reason, when installing the manipulators, layout them not to interfere each other, or set limits to their range of motion. 2. Selection and installation of vision device Vision device and lens are needed be selected and installed in accordance with the object for detection. Also, depending on the lens, distance between the object for detection and the vision device (vertical position of the camera) varies. For the details of vision device selecting method, refer to section 1.5.1 “Vision Device” and section 1.5.2 “Camera and Manipulator Installation Position”.
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3 Set Up 3.1 Preparation 3.1.2
Wirings between Devices In the MotoPick system, visions, sensors, manipulators or encoders are supposed to be connected if used. Follow the figure below and instructions of each device when wiring. For the actual wirings, refer to Appendix "Setting of the Connector BOX". 1. System Configuration The figure below shows an example of a system configuration using two manipulators and two conveyors.
Table 3-1: Outline of Wirings between Devices Ethernet
Connect each controller, the camera, PC (for setup) with using Ethernet cables through the hub.
Camera I/O
Connect it to one of the controllers. The connected controller becomes a master controller of the camera to control the camera for taking images.
Sensor signal
Connect it to one of the controllers. The connected controller becomes a master controller of the sensor to control the sensor.
Conveyor encoder signal
Connect it to the counter boards of all the controllers.
Conveyor home position signal
Connect it from the controller which is allocated as a camera master (or a sensor master) to the counter board of each controller.
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3 Set Up 3.1 Preparation 2. Ethernet Wirings The figure below shows an example of Ethernet wirings using two manipulators. MotoPick system requires manipulators, vision devices and PC to be on the same network. Configure the devices, which are connected by the Ehternet hub, etc. when used, to be on the same network. When the devices are connected by a hub, use PoE corresponding Ehternet hub, etc. depending on the specifications of the vision device.
NOTE
Network settings of MotoPick system should be performed in a local network. If the settings are performed in a global network, the communication load may prevent the system from working normally.
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3 Set Up 3.1 Preparation 3. Encoder Wirings The figure below shows an example of an encoder wirings using two conveyors. To execute a conveyor tracking operation, precise encoder pulses of each conveyor should be input to the robot controller. When sharing one conveyor with more than two manipulators, confirm that the pulses input to each controller are the same.
CAUTION •
There may be rare occasions that noise is mixed to the conveyor encoder due to ON/OFF of the servo or other reasons. For this reason, confirm that there are no noise influences to the encoder pulse by turning ON/OFF the servo several times after setup is done. In case a noise is found, use noise filters or troidal core or adjust the wirings.
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3 Set Up 3.1 Preparation 4. I/O Signal Wirings In this system, a certain controller (hereinafter referred to as “master”) directly receives signals from a vision sensor or other detecting sensors. And other controllers than the certain one (hereinafter referred to as “slave”) receive detecting results from the master. As for the method of wirings to the manipulator, it varies between the master and slaves of the sensors used. Also, a single manipulator cannot be designated as a master of several vision sensors. (1) Wiring for Vision Master In this section, an example of an wiring method between the vision sensor and a master/slave manipulator is explained. The figure below shows an wiring method when the vision is used to the conveyor (CV#1).
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3 Set Up 3.1 Preparation (2) Wiring for Passage Sensor Master In this section, an example of an wiring method between the a passage sensor and a master/slave controller is explained. The figure below shows an wiring method when the passage sensor is used to the conveyor (CV#2).
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3 Set Up 3.1 Preparation (3) Wiring for Two Manipulators The figure below shows an wiring example when two controllers are connected to a vision sensor and a passage sensor
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3 Set Up 3.1 Preparation 3.1.3
IP Address Setting IP addresses are necessary for connecting the controller to the vision sensor and the PC to the network. Follow the examples below for setting the IP address to the PC and the manipulator. For the subnet mask, set as follows. Subnet mask: 255.255.255.0 Device
IP address
PC
10.0.0.3
Camera
10.0.0.5
FS100 (Robot1)
10.0.0.11
FS100 (Robot2)
10.0.0.12
FS100 (Robot3)
10.0.0.13
FS100 (Robotx)
10.0.0.1x
FS100 (Robot10)
10.0.0.20
Programming pendant (Robot1)
10.0.0.31
Programming pendant (Robot2)
10.0.0.32
Programming pendant (Robot3)
10.0.0.33
Programming pendant (Robotx)
10.0.0.3x
Programming pendant (Robot10)
10.0.0.40
The network setting of the FS100 and the programming pendant before shipping are as follows. FS100 ■IP Address
:10.0.0.2
■Subnet mask
:255.255.255.0
SUPPLEMENT
Programming Pendant ■IP Address
:10.0.0.4
■Subnet mask :255.255.255.0
1. IP address setting for the PC Set the IP address appropriate for the PC. 2. IP address setting for the controller Set the controller IP address using the programming pendant. (1) Start-up the controller in the maintenance mode and change the mode to the management mode.
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3 Set Up 3.1 Preparation (2) Select {SYSTEM} - {SETUP} under the main menu.
(3) Select {IP ADDRESS} on the window and input the IP address.]
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3 Set Up 3.1 Preparation 3. IP Address Setting of Programming Pendant (1) Turn ON the power for the FS100 – The window switches to the window as shown below.
(2) Press {Transmission Setting} button. – Transmission Setting window appears.
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3 Set Up 3.1 Preparation (3) Input “IP Address” and “Subnet Mask”. (4) Press {OK} button. – Network setting process is executed. The hourglass icon appears while the process is being executed. Wait till the icon disappears. – Programming Pendant Startup window appears.
SUPPLEMENT
When {Cancel} button on Transmission Setting window is pressed, the window closes without executing the network settings and Programming Pendant Startup window appears. Also, when {Reset} button is pressed, IP address and Subnet Mask set before shipping appear.
In case the communication between the FS100 and the programming pendant is not established due to setting errors, try setting the communication with the value set before shipping first, then establish the network again.
NOTE
Set “1” to RSW1 on the FS100 main CPU board, then turn ON the main power for the programming pendant by pressing {Simple Menu} on the programming pendant. Both the FS100 and the programming pendant are startedup with the network setting set before shipping. (Refer to section 1.2.6.1 "Network Setting before Shipping" for the network setting before shipping.) Then, execute the network setting again and return the setting of RSW1 on the FS100 main CPU board from “1” to “0” and turn OFF the power for the programming pendant, then ON again.
4. IP address setting for the camera The setting of the IP address of the camera is explained in section 3.1.5 “Camera Setup”.
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3 Set Up 3.1 Preparation 3.1.4
PC Setup 1. System Requirements of the MotoPick Support Tool
OS
Microsoft Windows XP Professional SP3 Microsoft Windows 7 Professional Edition(32 bit) .NET Frameworks3.5 corresponding Microsoft Windows 8
CPU
Intel(R) Core 2 Duo 2GHz or higher recommended
Memory
1 GB or more recommended
Hard disk
500MB or more capacity recommended
Display resolution
1024 x 768 pixels or more
2. Installation of the MotoPick Support Tool (1) Start-up Windows (2) Set the Installation CD into the drive. (3) Execute “MotoPickSupportTool¥setup.exe”. (4) An installation program starts. Follow the instructions on the display. (This software is available to the PC in which Microsoft. NET Framework 3.5 is installed. If it is not installed yet, install it by executing “DotNetFX35\dotNetFx35setup.exe” stored in the CDROM drive.) (5) When set up of the MotoPick Support Tool is completed, the notation {YASKAWA} - {MotoPick Support Tool} are added after {Start} - {All Programs}. Also, a shortcut icon of MotoPick Support Tool execution file appears on the desk top window. 3. MotoPick Support Tool Software Upgrading Procedures (1) Start-up Windows. (2) Select {Start} - {Control Panel} - {Add and Remove Programs} to delete the old version MotoPick Support Tool software. (3) Install the new version of MotoPick Support Tool software by following the procedures described in step 2 “Installation of the MotoPick Support Tool” .
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3 Set Up 3.1 Preparation
NOTE
As shown in the following table, available versions for the MotoPick Support Tool vary depending on the versions of the dedicated functions for the FS100 corresponding MotoPick. For this reason, use the MotoPick Support Tool delivered with the FS100.
Version of dedicated functions for the FS100 MotoPick
Available version of MotoPick Support Tool
AP003B MP02.01A-00 or earlier
AP003B PC02.01A-00 or earlier
AP003B MP03.00A-00 or later
AP003B PC03.00A-00 or later
For the version of dedicated functions for MotoPick, refer to FS100 variable S098 or S099. And for the version of the MotoPick Support Tool, refer by selecting {Other} - {Version Information} under the MotoPick Support Tool menu bar.
4. Installation of DirectX If the DirectX is not installed on the PC to be used, download the latest DirectX from the Microsoft web site and install it. For checking the version of DirectX, click {Start} on Windows, input "dxdiag" in the search box, and then press {Enter}. (For Windows XP, click {Run}, input "dxdiag" in the displayed dialog box, and then click {OK}.) DirectX Diagnostic Tool starts. Click the {System} tab to check the version. 5. Setting of the Saving Destination of MotoPick Project Data At the initial start-up of the MotoPick Support Tool, a saving destination (inside the PC) setting window for the created project data appears. Select the desalination and press {OK}. The destination can be changed by selecting {Setting} - {Application Folder Path} from the menu bar on the MotoPick Support Tool main window. 6. System Environment (1) Select {Settings} on the menu window.
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3 Set Up 3.1 Preparation (2) Set all the items in the System Environment window by following the table below. To validate the settings, it is necessary to restart MotoPick Support Tool. AP003B PC03.00A-00 or later Language
Select a language for the MotoPick Support Tool
Application Folder Path
Specify a folder path as a saving destination of the project data created by the MotoPick Support Tool. Only when changing the folder path, change this setting. • When specifying a folder in Program Files as a saving destination, the application should be executed with administrator authority.
Log Max Line
Specify the maximum numbers of the lines output by the CSV file. Normally, it is not necessary to change.
Master R/C IP Address
Set the IP address of the controller to download the created project data. The recommended USB memory should be inserted to the controller to which the data is downloaded in order to save the downloaded data.
AP003B PC02.01A-00 or earlier Language
Select a language for the MotoPick Support Tool
Application Folder Path
Specify a folder path as a saving destination of the project data saved by the MotoPick Support Tool. Only when changing the folder path, change this setting. • When specifying a folder in Program Files as a destination to save, the application should be executed with administrator authority.
Log Max Line
Specify the maximum numbers of the log output by the CSV file. Normally, it is not necessary to change.
FTP server (P.P.)
Set the FTP server name Input an IP address of a P.P as a destination of the project data.
Destination of uploaded data
• CF card
Destination of uploaded data on the CF 1)
If “CF card” is selected as the destination of the uploaded data, the data is saved in the folder specified by this menu. •A new folder is created for the uploaded data in case the specified folder is not found in the CF card.
Destination of uploaded data on the USB *1
If “USB memory” is selected as the destination of the uploaded data, the data is saved in the folder specified by this menu. •A new folder is created for the uploaded data in case the specified folder is not found in the USB memory.
FTP account
Set an account for the FTP. Input “nx”.
FTP password
Set a password for the FTP. Input “nx”.
• USB memory
1 CF and USB cannot be used simultaneously.
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3 Set Up 3.1 Preparation 3.1.5
Camera Setup The following is the explanation of the case when using an In-Sight series camera of Cognex K.K. When using other cameras, perform the setup using the document and tool of the camera to be used. 1. Installation of In-Sight Explorer Install In-Sight Explorer on the PC for setup with using the CD delivered with the MotoPick. 2. Add the Camera to In-Sight Network When the camera does not exist on the same network as the PC and the FS100, add the camera to In-Sight network. For adding it, follow the procedures below. Start In-Sight Explorer. After starting In-Sight Explorer, when the target camera is already displayed in the In-Sight network window, it means the camera already exists on the same network. In this case, this step is not necessary. Proceed to Step 3 “Setting of IP Address and the Port Number” . OFF the In-Sight status as shown in the figure below because it cannot be connected to the network while the status is ON.
(1) Select {System} - {Add Sensor/Device To Network} under the menu bar
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3 Set Up 3.1 Preparation (2) Select a camera to be added to the network.
(3) Settings of Camera IP Address Set the camera IP address in accordance with the system. Refer to section 3.1.3 “IP Address Setting” when setting it. 3. Setting of IP Address and the Port Number (1) Select {Sensor} - {Network Settings}.
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3 Set Up 3.1 Preparation (2) Input the IP address and the port number of the camera. IP address
: Set it referring to section 3.1.3 “IP Address Setting”.
Subnet mask
: Set it referring to section 3.1.3 “IP Address Setting”.
Telnet port
: 23
Note : In case the net work connection is not available, confirm that the status is Offline.
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3 Set Up 3.1 Preparation 4. IO Settings Between the FS100 and the camera, IO signals are used for the communication such as image taking instruction or completion of detection. For the appropriate operation of the system, set the IO of the camera following the procedures below. (1) Double click the icon of the target camera in the In-Sight network window. (2) Select {View} - {Spreadsheet} under the menu bar.
Note: In case if the spreadsheet is already indicated, {EasyBuilder} is found in the menu bar instead of {Spreadsheet}. At this time, procedures shown above is no longer necessary.
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3 Set Up 3.1 Preparation (3) Select {Sensor} - {Discrete I/O Settings} - {Output Settings} under the menu bar.
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3 Set Up 3.1 Preparation (4) Next, set the IO with which the signal is output. Select “Job Completed” to Line 0. and “Job Load OK” to Line 1.
(5) Press [Details], and then set the pulse length to each signal. Following is the basic settings. [Line 0: 100msec]
[Line 1: 100msec]
NOTE
When the image taking interval is short, the pulse length may have to be shortened. If the pulse length is too short, the FS100 cannot recognize the image taking completion signal of the camera, and the system cannot operate normally.
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3 Set Up 3.1 Preparation 5. Indication of the Spreadsheet This setting enables indication of the spreadsheet at the time the vision program is started up. (1) Select {View} - {Spreadsheet} under the menu bar.
Note: In case if the spreadsheet is already indicated, {EasyBuilder} is found in the menu bar instead of {Spreadsheet}. At this time, procedures shown above is no longer necessary.
(2) Select {System} - {Options} - {Job View} under the menu bar.
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3 Set Up 3.1 Preparation (3) Tick “Make Spreadsheet View the Default View” check box.
6. Setting the Camera to be in Online at Start-up To externally communicate or instruct the image taking instruction to the camera, the camera should be set to Online. Followings are the method to set the camera to be in online at the start-up. (1) Select {Sensor} - {Startup} under the menu bar.
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3 Set Up 3.1 Preparation (2) Set “” to {Job} and tick the online check box.
7. Save the image processing program A sample program of the image processing program available in MotoPick system is also installed in MotoPick installation CD. To use the program, save the camera JOB “002-1.job” or “002-1C.job”, which is installed in the MotoPick installation CD, into the camera. By drugging and dropping the desired file to the icon of the target camera in the In-Sight network window, the JOB can be saved in the camera.
NOTE
Save the camera JOB “002-1C.job” for the color camera and “002-1.job” for the non-color camera.
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3 Set Up 3.1 Preparation 8. Settings of Image Taking Method The image taking method of the vision program is described here. (1) From the menu of In-Sight Explorer, click {File} → {Open Job} to open the target job. (2) Double click the cell A0 (image) of the camera JOB to open the spreadsheet. (3) Set “Camera” to {Trigger} and “Overlapped” to {Buffer Mode}.
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3 Set Up 3.1 Preparation 3.1.6
Conveyor Settings In order to make the manipulator track the workpiece on the moving conveyor, it is needed to set the conveyor information in the conveyor COND FILE of the controller. In this section, setting methods of the conveyor COND FILE is described. For the setting details of the conveyor COND FILE, refer to "FS100 OPTIONS INSTRUCTIONS FOR CONVEYOR SYNCHRONIZED FUNCTION".
1. USED STATUS Select a term from either USED /UNUSED. Set it to "USED". 2. PORT NO. Specify a channel from which data is acquired. Specify the port number by following the No. shown below. Conveyor name File No.
Port No.
CV1
1
CN1
CV2
2
CN2
CV3
3
CN3
CV4
4
CN4
CV5
5
CN5
CV6
6
CN6
3. ENCODER SIGN FORWARD/BACKWARD the encoder sign. Set the sign so that the values of the pulse and speed of the conveyor become positive on the programming pendant window when the conveyor starts its operation.
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3 Set Up 3.1 Preparation 4. POS RESOLUTION Set the resolution of the encoder. Measure the resolution by following the procedures below. The conveyor resolution is defined as below. “Conveyor resolution = Conveyor sift value / Encoder pulse” [µm/pulse] This is a measuring example of a conveyor resolution where a marking is put to the conveyor. 1. Put a marking on both belt and frame at the upper stream conveyor. From the sift value of the marks, presume the resolution.
2. To display the conveyor shift value (pulse) on the programming pendant window, execute “SYSEND instruction”, a robot job, and input the conveyor home position signal. Input a home position signal by following the JOB below.
By turning ON the following universal outputs, the conveyor home position signal can be input. According to the conveyor to be used, change the signal which is output at DOUT in the JOB above.
Conveyor
Home pos. No.
CV#(1)
OUT#11
CV#(2)
OUT#12
CV#(3)
OUT#13
CV#(4)
OUT#14
CV#(5)
OUT#15
CV#(6)
OUT#16
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3 Set Up 3.1 Preparation 3. Select {ROBOT} - {CV MONITOR} on the programming pendant window.
4. Select {POSITION} from {PAGE} which is displayed at the lower right of the programming pendant window. And then, press [SELECT].
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3 Set Up 3.1 Preparation 5. Confirm that “0s” are set to {CURR POS(PULSE)}.
6. Move the conveyor and stop it just before the marking disappears. (Move the conveyor as long as possible.)
7. Measure the distance between the markings which have been put in the explanation (1) in step “4. POS RESOLUTION”.
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3 Set Up 3.1 Preparation 8. By the current position (pulse) on the programming pendant window, divide the shift value measured at the above mentioned measurement. The quotient is regarded as the conveyor resolution (μm/pulse). The quotient is regarded as the conveyor resolution (µm/pulse). Note: Do not refer the current position (mm) on the programming pendant window at this time. Note: If the current position (pulse) on the programming pendant window is a negative value, reverse the setting of "ENCODER SIGN" in the conveyor COND FILE, and perform this setting again from the beginning. Note: If the current position (pulse) on the programming pendant window remains 0, execute the following operations. • Execute the JOB created in the step 2 again to output the conveyor home position signal. • Check the wirings of the encoder and conveyor home position signal. • Re-install the concurrent IO stored in the delivered CD. (It is stored in the System folder in the delivered CD)
9. Write the measured conveyor resolution into the corresponding conveyor COND FILE.
Perform this operation to all the conveyors to be used. Also, perform the same settings to the conveyor COND FILEs of all the controllers connected to the same conveyor. The conveyor resolutions are used in section 3.2.4 “Project Creation”
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3 Set Up 3.1 Preparation
CAUTION There may be rare occasions that noise may influence the conveyor encoder value due to ON/OFF of the servo or other reasons. For this reason, confirm that there are no noise influences to the encoder pulse by turning ON/OFF the servo several times after setup is done. In case a noise is found, use noise filters or troidal core or adjust the wirings.
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3 Set Up 3.2 Setup
3.2 3.2.1
Setup Confirm the Signal Confirm the connections between devices before setup operations, or operations may not be executed properly. 1. Confirm the wirings Devices may be damaged if input/output is confirmed before connection is properly established. Confirm the connection prior to the input/output confirmation. 2. Confirm the signal Confirm the signal of all the devices used. Followings are the examples of devices normally used.
