5129046
User instruction
2nd Edition
Collaborative Palletizer
RC10 version 2.2
Created by EBCCW 00:06
Created by EBCCW 00:06
96:05
Original instruction
English
Created by EBCCW 00:06
96:05
5129046
User instruction
Collaborative Palletizer
RC10 version 2.2
© Flexlink AB 2017
All Rights Reserved
No part of this program and manual may be used, reproduced, stored or transmitted in any
form or by any means without the written permission of FlexLink AB. The contents of this
manual are for informational use only. All information and specifications contained in this
document have been carefully checked to the best efforts of FlexLink AB, and are believed to
be true and accurate as of time of publishing. However, due to continued efforts in product
development FlexLink AB reserves the right to modify products and its manuals without
notice. The warranty will not apply if the instructions in this manual is not followed,
modifications are done without FlexLink PSD's permission or violations to intended use.
Created by EBCCW 00:06
Created by EBCCW 00:06
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FlexLink AB assumes no responsibility or liability on any errors or inaccuracies in this program
or documentation. Any kind of material damages or other indirect consequences resulting
from any FlexLink AB product part, documentation discrepancies and errors or non-anticipated
program behaviour are limited to the value of appropriate products purchased from FlexLink
AB.
The products are delivered to the customer at the "as is" state and revision level they are on
the moment of purchasing, and are declared in detail in the license agreements between
FlexLink AB and user. User accepts and is obliged to follow the guidelines stated in the
separate license agreement needed in using any parts of this product package. FlexLink is not
responsible for damage if service on the equipment is not performed in accordance with this
manual.
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Preface
FlexLink takes no responsibility for safety issues related to pallet handling.
FlexLink takes no responsibility for safety issues related to cartons falling from pallet.
Description of symbols used throughout the document and on the machine:
Table: Warning and prohibition signs
No stepping on surface
Stepping and climbing prohibited
Access restricted to authorized personnel
No entry zone
Warning for electrical hazard
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Created by EBCCW 00:06
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Warning for burn hazard
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Table of Content
1 Machine description...........................................2
1.1 Scope of delivery..................................................2
1.2 Orientation...........................................................3
1.3 Palletizer..............................................................4
1.4 Gripper.................................................................5
1.5 Conveyor..............................................................5
1.6 Machine with alignment plate..............................7
1.7 Machine with docking unit...................................7
1.8 Configurable parameters......................................8
2 Requirements....................................................9
2.1 Environment requirements..................................9
2.2 Usage requirements..........................................10
2.3 Work piece requirements...................................11
2.4 Fork lift requirements.........................................11
2.5 Pallet requirements............................................12
2.6 Floor requirements.............................................12
2.7 Electrical power supply requirement..................12
2.8 Space requirements...........................................13
3 Safety...............................................................17
3.1 General..............................................................17
3.2 Prohibitions........................................................18
3.3 Position of guards, safety devices and hazards...18
3.4 Robot safety.......................................................19
3.5 Personal safety equipment................................21
4 Unpacking, lifting and transporting...................22
4.1 Unpacking..........................................................22
4.2 Lifting and transporting......................................22
4.3 Transport mode..................................................23
4.4 Preparation for relocation of palletizer................23
4.5 Docking with alignment plate.............................24
4.6 Docking with docking unit..................................24
5 Assembly and installation.................................25
5.1 Space and floor preparation................................25
5.2 No entry zone delineation...................................25
5.3 Mechanical assembly.........................................28
5.4 Electrical installation...........................................30
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6 Settings............................................................31
6.1 Motor drive settings...........................................31
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6.2 Actuator parameterizing.....................................31
6.3 Vacuum pump....................................................32
7 Robot system software set-up.........................33
7.1 Robot program...................................................33
7.2 Installation file....................................................35
8 Calibration........................................................40
8.1 Setting the TCP..................................................41
8.2 Dotting operation...............................................43
9 Testing and validation.......................................49
9.1 Validation checklist example..............................49
10 Operation.......................................................50
10.1 No entry zone and operational areas.................50
10.2 Unskilled operator tasks...................................51
10.3 Authorized personnel tasks..............................52
10.4 Control box user interfaces..............................52
10.5 Front pulpit user interfaces...............................53
10.6 Machine states................................................54
10.7 Emergency stop...............................................55
10.8 Safeguard stop.................................................55
10.9 Resetting.........................................................56
10.10 Powering ON the robot system......................56
10.11 Initializing robot arm.......................................57
10.12 State normal...................................................58
10.13 Shutdown robot.............................................64
11 User interaction lamps and buttons................65
11.1 Error Codes......................................................66
12 Maintenance and house-keeping...................69
12.1 Performance....................................................69
12.2 Lockout-Tagout procedure...............................69
12.3 General............................................................69
12.4 Maintenance tasks executed by unskilled
personnel.........................................................70
12.5 Maintenance tasks executed by skilled
personnel.........................................................71
12.6 Suction cup condition check.............................71
12.7 Vacuum pump..................................................72
13 Definitions......................................................73
14 Change history...............................................74
15 References.....................................................75
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Machine description
1.1
Scope of delivery
Machine name:
Standardized collaborative palletizer RC10
Item number:
Layout Right
5128966
Layout Center-Right
5128967
Layout Center-Left
5128968
Layout Left
5128969
Machine plate location: Conveyor back pulpit.
The machine contains one conveyor and one palletizer with two pallet
positions.
Conveyor
Palletizer
Picture: Machine division
The conveyor receives one carton box at a time and transports it
collision-free downstream to end position - picking position.
Production capacity [pcs/min]: ≤ 8
The palletizer is designed for guiding the pallet into correct position,
automatic pallet detection and contains indications for pallet status. Its
design enables quick relocation.
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The robot arm of the palletizer picks one box at a time from conveyor
and puts it on pallet in the pattern selected by user. If no pallet is
available to receive next box, the gripper awaits above picking position.
The manual intervention is to serve the machine with empty pallets and
remove the fully loaded pallets.
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Gripper with safety shroud
Safety padding
Incoming flow
Robot arm
Pedestal/actuator
Control box
Picture: Machine overview
1.2
Orientation
Back
Right
Left
Front
Picture: Machine orientation
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1.3
Palletizer
The palletizer is autonomous and transportable. It is easily mechanically
disconnectable/connectable to conveyor by the docking unit option. An
industrial fast-connector is used for the power and controls signals for
conveyor. Docking and transporting is one man work.
Left pallet position
Docking unit
Pallet detection sensor
Pallet status beacons
Right pallet position
Picture: Palletizer overview
Picking accuracy [mm]:
±10
Palletizer height performance, h [mm]:
Pedestal:
h < 1200
Actuator:
1200 < h < 1700
Means for floor fixing: Bolt size M10
The palletizer is configured to have a pedestal or a vertical actuator for
the robot foot. The vertical actuator provides increased reach.
The palletizer contains sensors for automatic pallet detection.
The power supply enters the control box from the conveyor side. All
cables to field components are connected to control box through
chassis-mounted industrial fast-connectors to enable quick and easy
replacement and maintenance. Spare I/Os are distributed to an
industrial M12-connector.
The palletizer contains the teach pendant for the robot which has a
cable with sufficient length for the whole robot work area. The normal
position and bracket for the teach pendant is located on the back pulpit
on the conveyor.
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Safety paddings are mounted on robot elbows and robot head for
cushioning and are equipped with pressure sensitive devices which
safety stop the machine if activated.
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1.4
Gripper
Picture: Gripper
Picture: Gripper mounting plate
The end-effector is of Gripper class, non-mechanical type, holding the
work piece with four vacuum suction cups. The gripper is equipped
with a safety shroud. If put out of position it will cause an immediate
safety stop.
The suction cups are mounted in an X to provide means for adjustment.
Wing nuts fastens the suction cups to provide easy adjustment. The
suction cups are for cardboard boxes and comes in two different
configurable sizes.
Suction cup outer diameter [mm]:
Small size
35
Large size
52
Suction cup mounting slot [mm]:
1.5
Width
30 ... 240
Depth
37 ... 130
Conveyor
The conveyor is configurable for different height and length alternatives
and is divided into zones. Each zone carries one work piece. The
adjustable conveyor legs simplify levelling. The docking unit option
provides fast mechanical connection/disconnection of the palletizer.
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Back pulpit
No entry zone
prohibited sign
Stack lights
Teach pendant
Picking position
Picture: Conveyor overview
Foot adjustment [mm] ±40
Means for floor fixing Bolt size M8
The conveyor upstream end has sensor detection for incoming box.
Each zone stop position contains an end-position sensor. The picking
position's end position sensor signals to robot that a box is ready for
picking.
The conveyor back pulpit holds the teach pendant bracket, stack light
and No entry zone prohibition sign. The stack lights communicates the
general state of pallets.
Start
End
End
End
Box rdy
Four zone conveyor
Three zone conveyor
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Picture: Conveyor sensor location
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Two zone conveyor
1.6
Machine with alignment plate
A machine without docking unit is intended for fixed installation where
the frequency of docking the palletizer is low and contains an alignment
plate.
The alignment plate is designed for all conveyor position alternatives
and is placed under the conveyor to guide the palletizer into the correct
position.
Picture: Alignment plate
1.7
Machine with docking unit
The machine conveyor contains a beam that holds the guiding pin. The
beam position corresponds to the conveyor position selected. A
conveyor for center position has a short side beam. A conveyor for left
or right position has a long side beam.
The palletizer is equipped with the docking unit. The unit contains a
guiding fork and a lock on each side for precise locating.
The bumper included is used while moving the palletizer with fork lift
for protection against the sharp edges of the locks.
Picture: Docking unit
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1.8
Configurable parameters
Conveyor position
Number of conveyors
Number of conveyor zones
Robot foot position
Docking unit
Calibration unit
Gripper suction cup size
Conveyor height (mm)
Right
Left
[Right], [Center-right], [Center-left], [Left]
1
2 ... 4
[pedestal], [actuator]
[yes], [no]
[yes], [no]
[small], [large]
[700], [744], [774], [818], [862]
Center-Right
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Picture: Conveyor position alternatives
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Center-Left
2
Requirements
2.1
Environment requirements
General climate requirement
Temperature [°C]
Operating ambient temperature:
Storage temperature:
Humidity
Relative humidity [%]:
Altitude [m]:
Electrical power supply
Robot arm IP-class
Robot pendant IP-class
Control box IP-class
9
Indoor without direct sunlight
10 … 40
0 … 40
10 ... 70
0 … 800
Reference to electrical drawings.
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2.2
Usage requirements
2.2.1
Intended use
The machine is specifically made for automatic palletizing of carton
boxes from a fixed picking position. The boxes should be undamaged,
clean and square-shaped.
2.2.2
User requirements
General requirements:
• Adult
• Unskilled or Skilled (for definition - reference to ISO 12100:2010)
• Long hair, loose-hanging clothing and accessories that
can get entangled are prohibited.
Skilled:
• Typically electrician, maintenance personnel or specialists
• Definite technical knowledge
• Sufficient knowledge for reading technical information
• Ability to comprehend technical drawings
• Ability to read English text
• High safety awareness, competence and experience for
risks associated to the machine
• Authorized to enter No entry zone when safety precautions are met
Operator:
• Can be unskilled
• Limited to actions outside No entry zone
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• Successfully trained in machine including User instruction
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2.3
Work piece requirements
General
Undamaged, clean and rectangular cardboard box.
Mass [kg]
0.5 ... 8
Width [mm]
150 ... 400
Length [mm]
150 ... 600
Height [mm]
100 ... 500
Lift surface
Flat top-surface, corrugated material
Recommended Cardboard
box quality:
EUPS 110, BC-Flute (Double well, 7.0 mm) Brown/
Brown.
2.4
Fork lift requirements
Blade length [mm]
1400
Blade width [mm]
max 160
Picture: Machine geometry affecting fork lift selection
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2.5
Pallet requirements
Pallet dimension [mm]:
Length
1200 or 1219
Width
800 or 1000 or 1016
Max height of loaded pallet [mm]:
Pedestal version
1200
Actuator version
1700
2.6
Floor requirements
Conveyor top must be horizontal.
Strength
Sufficient for complete application weight
Conveyor floor level [mm]
± 30
Palletizer
Horizontal and flat with max ± 10 mm
difference to conveyor
2.7
Electrical power supply requirement
2.7.1
General
Phases
1
Short-circuit current capacity [kA]
10
Connection type
Terminals 2.5 mm2
Incoming power supply throughput type
Gland
2.7.2
Control box
Control box:
Voltage [VAC]
110 ... 240
Frequency [Hz]
50/60
220: < 6.7
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Nominal current [AAC]
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110: < 13.7
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2.8
Space requirements
2.8.1
Physical dimensions of robot cell configurations
Palletizer weight [kg]
300 (whereof robot arm 30 kg)
Height for all configurations [mm]
3000 (including robot and gripper and robot hoses)
Picture: Machine dimensions sideways conveyor
Picture: Machine dimensions straight conveyor
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Dimensions based on pallet size 1200x1000 mm
Product
Conveyor right
Conveyor left
Conveyor center-right
Conveyor center-left
2.8.2
Conveyor type
A
Width
[mm]
B
Length
[mm]
Two zones - 1512 mm
2582
2369
Three zones - 2117 mm
3187
2369
Four zones - 2722 mm
3792
2369
Two zones - 1512 mm
2582
2369
Three zones - 2117 mm
3187
2369
Four zones - 2722 mm
3792
2369
Two zones - 1512 mm
2560
3212
Three zones - 2117 mm
2560
3817
Four zones - 2722 mm
2560
4412
Two zones - 1512 mm
2560
3212
Three zones - 2117 mm
2560
3817
Four zones - 2722 mm
2560
4412
Space requirements for usage and maintenance
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Clearances around conveyor:
- 1 m on pulpit side
- 0.2 m on opposite side
Picture: Clearances for conveyor
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Clearances to avoid quasi-static contact
for robot:
- 500 mm around pallets
- 500 mm around picking position
Picture: Palletizer clearances, sideways conveyor
Picture: Palletizer clearances, straight conveyor
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Recommendation
A large open area in front of robot cell
enables safe and fast removal and
turning of loaded pallets from
palletizing positions.
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Picture: Recommended open area
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3
Safety
Safety performance level:
PLd (ISO 13849-1)
The machine’s robot is collaborative:
• The robot is single mode operated and cannot be changed
into noncollaborative mode.
• The entire workspace is regarded as collaborative. No devices for
detecting human presence to avoid contact are required.
The severity level of the worst case injury is characterized by bruises
and grazes and happens if an operator against regulations enter the No
entry zone without taking safety precautions and is hit on lower legs by
the work piece.
3.1
General
• Robot safety checksum = DD8A.
• Robot safety checksum must be checked before machine start.
• Noise level < 69 dB (EN ISO 4871).
• Fork lifts must be used for lifting/transporting pallets
in/out of No entry zone.
• Pallets must be handled in front-to-back direction, never sideways.
• The palletizer is equipped with protective cover to protect user
from unhealthy housing temperature of vacuum pump.
• Use gloves or secure that the housing temperature of vacuum
pump has decreased to healthy levels before removing
protective cover.
• The robot generates heat during operation. Do not handle or touch
while in operation or immediately after. To cool down, turn off
power and wait one hour.
• The palletizer must be anchored to floor or clamped to conveyor by
docking unit to ensure picking accuracy.
• Robot workplace must be kept empty, clean and tidy.
• Conveyor side plates must be mounted to prevent damages to
equipment inside conveyor beam.
• In case of emergency - any of the emergency switches on front
pulpit or pendant on back pulpit should be used. Main switch
should not be used.
• The delineation of the No entry zone must be kept visible and clear
through all time.
• Power interruption or turned off main switch will cause lost vacuum
which makes the robot drop the work piece.
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• Parts of control box contains electrical power also when main
switch is turned off.
• The work piece's trajectory, the work piece's low height above
objects (h=30 mm) and the work piece's movement direction
makes a dropped work piece to be thrown so short it stays within
the No entry zone.
• Robot arm must be in transport mode to avoid tilting during
lifting and handling.
• The bumper must be used while moving palletizer.
3.2
Prohibitions
• User is not authorized to make changes to robot safety system.
• An invalid robot safety checksum prohibits machine start.
• Access to No entry area is prohibited except for authorized
personnel while machine is in safe state and required safety
precautions are made that eliminates all risks.
• Stepping or climbing on any machine part is prohibited.
• Stepping or climbing on pallets is prohibited.
• Emergency switches are not allowed to be used for normal stop.
• The main switch should not be used for emergency stopping to
avoid long recovery time.
• Electrical loads must be stopped before switching main switch off.
• Connectors are not allowed to be disconnected while electrically
loaded.
• The protective cover for vacuum pump is not allowed to be
dismounted in order to avoid exposure of unhealthy temperatures
of vacuum pump and to protect equipment from stepping and
hinder the operator to stand too close to robot arm.
• Cleaning by spraying water on machine is prohibited.
3.3
Position of guards, safety devices and
hazards
Safety devices:
• Emergency switches
• Reset button
• Main switch
• Protective cover
• Safety paddings
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• Gripper safety shroud
• Bumper (usage during transport)
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Safety paddings
Emergency
switch
Robot arm
Moving parts
Emergency switch
Gripper
safety
shroud
Reset button
Protective cover
Conveyor rolls
Entanglement risk
Main switch
Vacuum switch
Burn risk
Picture: Safety and hazard overview
3.4
Robot safety
Operator safety with regards to unintentional contact is based upon
passive and active methods.
3.4.1
Inherent robot safety or UR-robot
The collaborative robot system from UR is classified as a power and
force limited collaborative robot and incorporates the following
inherently safety-rated limiting functions:
• Inherently safe design of robot geometry (smooth surfaces,
rounded edges and corners).
• The torque limitation of the robot arm will cause an immediate
safety stop in case of collision.
• Limitation of moving masses and velocities (kinetic energy).
• Use of safety-rated soft axis and space limitation function for
certain sectors
• Password-protected settings
• Robot enabling device located on back of teach pendant
• Robot safety settings generates checksum.
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3.4.2
Robot system safety
The collaborative robot system is combined with additional safety
devices on robot elbows, head and gripper to further decrease the
machinery safety risk.
Ø 3600
Robot system total reach [mm]
(Robot: r=1300mm, Gripper and work piece: r<500mm)
Maximum approved torque [kg m/s]
40
Maximum approved velocity [mm/s]
1100
Maximum effective payload mL, Gripper [kg]
Total mass of moving parts of robot M [kg]
3.4.3
10
(of which 8 kg is related to work piece)
47
Safety-rated software space limitations
The robot system is equipped with safety-rated space limiting functions
such as safety barriers and software limits.
The safety barriers are permanent and create a cage for the robot to
move within. A breach by the robot will cause the robot to stop (stop
category 0, IEC 60204-1). The space enclosed must kept as small as
possible.
The software limits are dynamic and cause the robot to perform a stop
if any of them is passed while active (stop category 2, IEC 60204-1). The
dynamic left limit is active while the gripper is in pallet right area. The
dynamic right limit is active while the gripper is in the pallet left area.
The software limits must set to run along the pallets' long side closest
to robot foot.
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Picture: Safety barriers in red and software limits in yellow
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Picture: Layout of software safety limitations
3.5
Personal safety equipment
Personal safety equipment worn by all users:
• Safety shoes
• Safety glasses
• Safety gloves
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Unpacking, lifting and
transporting
4.1
Unpacking
The machine parts are delivered on pallets. Tools required for
unpacking: hammer, crowbar, fork lift truck.
Picture: Recommended tools for unpacking
4.2
Lifting and transporting
Palletizer weight [kg]
300
Required tool
Fork lift
Conveyor geometry and weight
Conveyor type
Length [mm]
Weight [kg]
Width [mm]
Two zones
1512
< 300
800
Three zones
2117
< 300
800
Four zones
2722
< 300
800
The robot arm should be in transport mode during all lifting and
transport.
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Picture: Palletizer in transport prior to movement
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The bumper should be mounted on palletizer to avoid damages on
docking unit and human injuries due to sharp edges on the docking unit.
Picture: Bumper
4.3
Transport mode
Transport mode is set using Freedrive mode.
While in transport mode the arm is aligned lengthwise and reduces
off-centre of gravity.
Picture: Palletizer in transport mode from above
4.4
Preparation for relocation of palletizer
Instruction:
1
Secure that the robot arm is in transport mode.
2
Disconnect palletizer from conveyor by disconnecting the
electrical connector.
3
Disconnect palletizer from conveyor mechanically.
4
Disconnect palletizer from floor anchoring points.
5
Lift and move palletizer enough to mount the bumper on
palletizer.
6
Lift and transport palletizer to new location.
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4.5
Docking with alignment plate
The alignment plate is used for palletizers without docking unit.
The plate is placed on the floor under the conveyor after the conveyor
is set and anchored to the floor in the correct position.
The conveyor is levelled before the palletizer is moved into position,
guided by the alignment plate.
Picture: Alignment plate
4.6
Docking with docking unit
Machines with docking units has a docking beam on the conveyor and
a docking unit mounted on the palletizer. The conveyor is moved into
the correct position, anchored to floor and levelled.
The docking unit's locks is preferably used by the operator that moves
the fork lift transporting the palletizer to make the guiding fork funnel on
the palletizer to hit the guiding pin on conveyor. Locking the palletizer
docking unit to the conveyor on each side of guiding pin secures
accurate positioning.
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Picture: Docking unit
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5
Assembly and installation
5.1
Space and floor preparation
The machine should be mounted in an open space without obstacles.
The floor must be in level and floor strength sufficient to withstand the
machine weight.
Picture: Spirit-level to secure flatness
5.2
No entry zone delineation
Tape for No entry zone delineation is included.
The size of the No entry zone depends on layout. The delineation shall
be taped to the floor and maintained to express the borders of the zone
at all time.
The clearance to pallet must be minimum 500 mm.
Picture: Delineation tape
Recommendation
Improve the effect of limits by using belt barriers
as complement to tape (not included in delivery).
Picture: Recommended optional equipment for improved delineation
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Conveyor back’s extension
The backside border runs in line
with conveyor backside.
Box
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Picture: Delineation geometry for sideways conveyor
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Box end
The backside border is immediately
upstream the picking position.
Box
Picture: Delineation geometry for straight conveyor
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5.3
Mechanical assembly
Machine delivery form:
- Palletizer front pulpit installed
- Palletizer actuator/pedestal installed
- Robot arm installed
- Gripper installed
- Conveyor legs separated from conveyor top
- Conveyor back pulpit tilted flat
The assembly and installation processes requires space. The mounting
area must be kept clear during assembly.
The mechanical assembly is started after the base is assembled in the
right position.
When mounted, the conveyor and palletizer must be horizontal. The
stability increases if the machine is fixed to floor.
5.3.1
Conveyor
Lift and hold conveyor top flat and make sure no robot hoses are
clamped to damage while the legs are raised and mounted.
When the legs are fixed, the conveyor is placed on the floor on its legs.
Subsequently, the conveyor leg height is adjusted (700, 744, 774, 818
or 862mm) and the back pulpit is mounted.
The conveyor's height setting must be synchronized with the robot arm
picking position geometry settings.
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Picture: Adjustable conveyor feet
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5.3.2
Robot hoses
Mounting distances [mm]
D1 = 320
D2 = 250
Picture: Conduit bracket assembly
Picture: Robot hose stretch designation
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Robot hose stretch lengths
Control box to head (pink)
Control box to foot (green)
A1: 65 mm
B1: 40 mm
A2: 160 mm
B2: 120 mm
A3: 1000 mm
B3: 1000 mm
A4: 900 mm
A5: 800 mm
A6: 580 mm
5.4
Electrical installation
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The machine's incoming voltage has a span of 110 to 240V. The vacuum
pump is configurable to for either 110 or 220V. The vacuum pump
voltage configuration must be verified before power is turned on for
machine.
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6
Settings
6.1
Motor drive settings
The motor speed can be adjusted on the motor driver. DIP-switches are
located behind the cover on the driver on picture below and enables
adjustment of speed. Reference to User manual, Interroll, Zone-control.
DIP-switch cover
Picture: Conveyor driver
6.2
Actuator parameterizing
This chapter is valid for units with actuator. The actuator controller must
be initialized and taught its end-positions by the hand-control unit which
is included in delivery.
6.2.1
Initialization of actuator
1
Press the up-arrow button and the down-arrow button
simultaneously and hold for minimum 5 seconds until the
controller sound alarm is ringing.
2
Release both buttons.
3
Press the up-arrow button to move the pedestal up-wards. A
sound alarm will be ringing. Keep pressing until the alarm shuts
down.
4
Press the down-arrow button to move the pedestal downwards
and keep pressing until the pedestal is in the bottom position.
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6.2.2
Position teaching of top bottom positions
1
Press the up-arrow button until the pedestal is in top position.
2
Press the square button + the 1 button. A short beep sounds and
the orange lamp lights up.
3
Press the down arrow button until the pedestal is at the bottom
position.
4
Press the square button + the 2 button. A short beep sounds and
the green lamp lights up.
The hand-control unit's orange lamp is on while the actuator is in top
position and its green lamp while in bottom position.
6.3
Vacuum pump
Created by EBCCW 00:06
Vacuum pump pressure should be set to maximum.
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7
Robot system software set-up
This chapter and its action are for skilled personnel.
The machine must contain the following:
• program file, including:
- pattern file
• updated Installation file, including:
- machine configuring variables
- calibration data
- robot safety settings
7.1
Robot program
The program (urp-extension) contains the logic behaviour of the
machine. Several programs can be stored in the memory whereof one
is loaded, adapted (setting machine configuring program variables) and
run.
The program is downloaded to the robot system from a tablet with the
FlexLink app Robot config. Thereafter the program must be loaded.
7.1.1
Load program
The program must be loaded after it has been downloaded to the
machine.
Instruction for loading a program:
1
In main menu, press Run program, which opens the Run page.
2
Press File and thereafter Load to open the file explorer.
3
After pressing Run Program, the Run tab appears. Press File and
thereafter Load to open the file explorer.
Picture: Load command on Run program screen
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4
Select the program of interest and press Open or double-click on
program name to load the program, which makes a set of control
buttons available.
Picture: Set of control buttons
Note
If the current safety settings are
different from those used by the
opened program, the changes must
be applied and the safety board
restarted.
Press Apply and restart. The robot
must be reinitialized. Follow the
steps in the Initialize section.
Picture: Information of difference in safety configuration
7.1.2
Pattern file
The pattern file, also called script-file, describes how the carton boxes
are placed on the pallet layer by layer.
Created by EBCCW 00:06
The pattern file is downloaded to the robot system from a tablet with
the FlexLink app Robot config.
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7.2
Files stored in robot home catalogue:
- default.installation
- default.variables
- popup_language.script
- robot_control_hw_21.txt
- robot_control_hw_21.urp
Installation file
The installation file is located in the robot home catalogue. It contains
all the application and situation dependent specific configuration
parameters such as locations, calibration data, machine configuring
variables and safety settings.
The robot program is reading data from an installation file with a specific
name stored in a specific location. The robot system can contain several
installation files, but the active file must have the name and location
that the program expects.
The calibration data of an installation file cannot be extracted and copied
into another installation file. Calibration has to be carried out for each
individual machine. Reference to Calibration chapter.
7.2.1
Machine configuring variables
The program configuring variables must be updated before the robot
system software can be set into Run.
The variables which configures the behaviour of the machine and must
be set before the machine is started.
Picture: Program robot button
Setting instruction:
1
From main page, go to Program robot page.
2
Press Variables in the left list.
3
Set values according to tables in next chapter.
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Picture: List of installation variable values
7.2.2
Machine configuring variable setting
Name
Value
Note
Cnt_global
-
Carton box picking counter
i_dry_run
False
Carton box dry on/off
i_size_pallet
0.155
Contains manually filled in pallet height if i_meas_pal=false [m]
i_size_pedestal
0.502
Electric pedestal stroke length [m]
i_size_robot
0.720
Height between floor and robot foot [m]
i_size_safety
0.04
Height between box and gripper on pallet [m]
i_size_safety_c
0.06
Height between box and gripper [m]
i_weight_gripper
1.8
Gripper weight [kg]
Size_pallet_mem
-
Contains result value of executed automatic pallet height detection
Name
Conditional value
i_meas_pal
Manual pallet height setting
Automatic pallet height detection
for each new pallet
False
True
Name
Created by EBCCW 00:06
i_language
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Conditional value
Select language
English, German, Polish, Portuguese, Swedish, French
36
Name
Conditional value
i_elec_pedest
Fixed pedestal
Electrical actuator
True
False
Name
i_pallet_euro
Name
Conditional value
European pallet
US pallet
True
False
Conditional value
i_pos_conveyor
Layout 1
Layout 2
Layout 3
Layout 4
1
2
3
4
Conveyor layouts
Picture: 1. Right, 2. Left, 3. Left-center, 4. Center-left
Variable i_size_conveyor
Contains the height H between floor and carton
box bottom surface.
Variable Size_pallet_mem
Contains result value of executed automatic pallet
height detection.
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Carton box
in picking
position
Conveyor
Floor
Picture: Distance H
7.2.3
Safety settings
Safety barriers and software limits has to be set (included in default
installation file) before the machine is taken into operation.
Instruction for Right and Left layouts
Normal mode
Force [N]
Power [W]
Speed value [m/s]
Momentum (torque) [kg m/s]
150
250
1.1
40
Reduced mode
Force [N]
Power [W]
Speed value [m/s]
Momentum (torque) [kg m/s]
100
200
0.75
20
1
Set Safety barriers front, left and right (red) to run along pallet
borders.
2
Set Safety barrier in the back (red) to run just along the backside
of box in picking position.
3
Set the software limits (orange) to run along the inner pallet
borders.
Box
Created by EBCCW 00:06
Picture: Safety barriers and software limits of Right or Left layout
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Instruction for Center-Right and Center-Left layouts:
1
Set Safety barriers front, left and right (red) to run along pallet
borders.
2
Set Safety barrier in the back (red) to run just along the backside
of box in picking position.
3
Set the software limits (orange) to run along the inner pallet
borders.
Box
Picture: Safety barriers and software limits for C-L and C-R layouts
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8
Calibration
This chapter is advanced and carried out by skilled personnel.
Calibration process
Main switch OFF
Mounting tool
Placing plate
Main switch ON
Dotting operation
Setting TCP
Main switch OFF
Dismounting tool
Removing plate
Picture: Calibration process steps
Calibration makes sure the geometrical relation to the picking position
is known by the robot system. A calibration has to be executed every
time the picking position and robot arm has been moved in relation to
one another. Subsequently the robot system will loose picking accuracy
when calibration is neglected after the geometrical relation has been
changed.
The execution requires entering the No entry zone and measures to
secure safety.
Picking position
Robot
foot
Created by EBCCW 00:06
Picture: Foot and picking position relation
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The list below of safety precautions for calibration do not hinder
additional measures:
• The workspace is cleared from all personnel not participating in
calibration process.
• Calibration must be executed by skilled personnel only.
• Main switch must be turned off while mounting/dismounting
calibration tool and placing/removing calibration plate.
• Calibration tools are not allowed to be mounted during
normal operation.
• Reduced robot speed.
• No other than FlexLink calibration tools designed for the specific
machine are allowed to be used.
Picture: Gripper with mounted calibration tool
A mounted calibration tool and calibration plate has to be used when
calibrating the robot system. The calibration tool is pike-shaped and
therefore will the calibration activities have to be carried out with great
caution. The tool is mounted before the dotting process is started and
is removed when the results of the dotting process are saved.
How to mount the tool depends on the tool selected. Reference to
Calibration tool, Assembly instruction.
8.1
Setting the TCP
With reference to the selected calibration tool's Assembly instruction,
find the tool's vertical D-value.
The D-value is the distance from the bottom surface of robot head and
the tip of calibration tool. Different tools have different designs and are
mounted in different ways.
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Robot
head
Calibration tool tip
Picture: Distance D
Setting instruction
1
Turn on main switch.
2
Turn on robot controller on the teach pendant.
3
Reset robot safety system.
4
Set the robot system into Normal state (green status lamp on
pendant).
Created by EBCCW 00:06
Picture: Normal state
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5
Press Program robot button in main menu
6
Select the tab Installation, thereafter TCP Configuration.
42
Picture: Program robot button
7
Select the TCP_1 configuration and press Set as default to
activate it.
8
Set X-, Y-, Rx-, Ry- and Rz-values to 0.
9
Set Z-value equal to the Calibration tool D-value.
10 Set the payload value to 1.8 kg (Note: picture contains wrong
value).
Picture: Scroll down TCP list
8.2
Dotting operation
During the actual calibration the calibrating tool makes "dotting" against
the calibration plate in three locations in the picking position and the
geometrical coordinate result is stored in the robot system's installation
file.
The safety system needs to be kept intact to avoid interrupting the
calibration process. The safety shroud on gripper needs extra attention
for certain calibration tools.
There are four different directions the carton box can approach the
picking position. The carton boxes are aligned against a sliding surface
before reaching the end-stop surface to create a well-defined picking
position. The alignment surface is always the surface nearest the robot
for sideways approach.
The picking position geometry is recorded as a "Feature" named "frPick".
The three dotting points:
• Pick_0, crossing between sliding and end-stop surface
• Pick_Y, for the Y axis direction/end-stop surface
• Pick_X, for the X axis direction/sliding surface
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The calibration plate must be used. Neglecting the plate will result in a
vertical offset error.
The dotting points must be carried out in order:
1
Pick_0
2
Pick_Y
3
Pick_X
Picture: Dotting points due to layout
Created by EBCCW 00:06
Dotting instruction for Pick_0
1
Press the Features tab
2
Press frPick.
3
Press the "Pick_0" point and then Change this point button, which
cause the Move-page to appear.
Picture: Dotting point selection
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4
On Move page, the arrows can be used for movement and the
speed can be reduced to be more precise with the slide bar in the
bottom.
Recommendation
Use Base setting feature in top
right corner.
For more information - reference
to UR10 User Manual.
Picture: Feature Base selection
5
Activate Freedrive mode by pressing the black button on the back
of pendant.
6
While in Freedrive mode, move the tool manually to position
Pick_0 into the corner against the flat calibration plate surface.
7
Execute sub-routine Coordinate mating as below.
Picture: Pick_0 dotting point
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Sub-routine Coordinate mating
1.
Set coordinates: Rx=3.14, Ry=0, Rz=0;
In case a pop-up window appears which asks to go to Initialization
screen when any of the coordinate fields are selected, it means the
robot system never was set to Normal state in the first place.
Press "Go to Initialization screen" and make the robot system go into
Normal state before continuing.
2. The robot system assess if the physical position of the gripper is
close enough to the filled-in coordinates.
In case the robot system assess the physical position to be too far away
from filled-in coordinates, it will open the Move Robot into Position
screen.
- Press Auto to run the gripper into position and finish with OK which
cause the Move screen to appear.
Created by EBCCW 00:06
8
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On Move screen, press OK when the arm location is correct, to
make the Installation screen to re-appear.
46
Dotting instruction for Pick_Y
1
Under frPick, press the Pick_Y and press the Change this point
button which cause the Move page to re-appear.
2
On Move page, move the arm as for Pick_0, to the Pick_Y position
along the end-stop surface a minimum of 100mm away from
Pick_0 position and make sure the tool tip reaches the calibration
plate.
3
Execute sub-routine Coordinate mating.
4
Press OK when the arm location is correct, which will make the
Installation page return.
Picture: Pick_Y dotting point
Dotting instruction for Pick_X
1
Under frPick, press Pick_X and press the Change this point button
which cause the Move page to re-appear.
2
On the Move page, move the arm as for previous points, top the
Pick_X position along the sliding surface a minimum of 100mm
upstream the corner Pick_0 position. Make sure the tool tip
reaches the calibration plate.
3
Execute sub-routine Coordinate mating.
4
Press OK when the arm location is correct, which will make the
Installation page to return.
Picture: Pick_X dotting point
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Dotting finalization
1
All three coordinates are now found, but unsaved.
2
On Installation screen, press TCP configuration to open the Setup
for the Tool Center Point page.
3
Select TCP in the Avaliable TCPs scroll down list and press Set as
default.
Picture: Setup for the Tool Center point
4
Press Load/Save to the left which opens the Load/Save robot
installation to file page.
5
Press the Save button to save the three coordinates into the
installation, which disables the button.
6
Leave Program mode.
Picture: Load/Save to file
Created by EBCCW 00:06
The machine is now calibrated and ready to be turned off for restoring
it to normal operation.
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9
Testing and validation
The machine is not allowed to start for production (put into service)
before validation has been passed successfully. Incorrect settings or
incorrect application program can cause dangerous situations.
Validation is required before operation. All validation procedures are
executed by skilled personnel.
9.1
Validation checklist example
VALIDATION PROTOCOL
Signature
........................................................................
Date
........................................................................
Validated unit
........................................................................
Test points
Test
Failure test/
Safety validation
Expected result
Pass/
Failed
Comments
1
No entry zone delineation
-
2
Incoming voltage
-
3
Correct recovery after power loss
4
Payload setting
5
Robot program loaded
6
Safety barrier settings
-
7
Software limits settings
-
8
Velocity settings
-
9
Torque settings
-
Normal and reduced mode
10
Acceleration settings
-
Normal and reduced mode
11
Emergency switch front
System emergency stop
12
Emergency switch back (pendant)
Robot emergency stop
13
Collision on gripper shroud
System emergency stop
14
Collision on robot arm
Protective stop
15
Collision on safety padding elbow 1
Protective stop
16
Collision on safety padding elbow 2
Protective stop
17
Collision on safety padding head
Protective stop
18
No box detected in picking position
Alarm
19
Suction cup function in general
-
20
Missing pallets check
Lamp indications
21
Both pallets full check
Lamp indications
-
Normal and reduced mode
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10
Operation
10.1
No entry zone and operational areas
The No entry zone prohibits access to everyone who is not authorized.
A breach is a violation to the regulations of the machine.
Box
Box
Picture: No entry zone
Created by EBCCW 00:06
The operational areas are in the front and back of machine and are
related to the removal/insert of pallets and start/stop of machine.
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Picture: Operator areas (S=Starting/stopping, P=Pallet handling)
10.2
Unskilled operator tasks
Unskilled operators should in no case enter No entry zone while main
switch is on. All tasks to be carried out are located outside No entry
zone or when the main switch is off.
Pallets must be inserted and
removed by fork lift.
Pallets must be inserted and
removed length-wise.
Picture: Fork lift direction restriction
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Maintenance, house-keeping/Cleaning
Periodic maintenance tasks are executed on gripper and conveyor while
machine is stopped and main switch turned off.
Undocking/docking, lifting and transporting palletizer
Main switch should be off before and during docking, undocking, lifting
and transporting.
Actions to solve production hinders inside No entry zone
Unskilled operators calls for skilled, authorized personnel to solve
problems inside No entry zone. Examples: stuck carton box, dropped
carton box.
10.3
Authorized personnel tasks
Skilled and authorized personnel are approved to enter No entry zone
with main switch on when required safety precautions are carried out
to eliminate all risks.
Set robot into transport position
The robot needs to be powered and in Freedrive mode to make the axis
of the arms possible to move manually into correct transport position.
10.4
Control box user interfaces
Devices:
• Main switch
• POWER ON lamp
The main switch turns off incoming power to machine and hinders the
user from entering the box without turning off incoming power. Orange
coloured remain powered despite turned off main switch.
Created by EBCCW 00:06
The POWER ON white lamp indicates 24VDC power and ventilation fan
are powered.
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10.5
Front pulpit user interfaces
The front pulpit contains the front emergency switch and the resetbutton.
Picture: Front pulpit initiators
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10.6
Machine states
Legend:
Power off
Start
Standby
Power on
Brake release
Robot system power on
Automatic run
Ready
Manual run
Freedrive enable
OFF
States:
5 - Freedrive
4 - Normal
3 - Idle (Brake release)
2 - Power off
1 - Machine power on
0 - Machine power off
ON
SHUTDOWN ROBOT
Created by EBCCW 00:06
Picture: Machine state diagram
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10.7
Emergency stop
To emergency stop the machine, press any of the two emergency
switches. When then machine is emergency stopped, all dangerous
motions will be immediately put into safe state.
Result: The robot change status to Robot emergency stop. A dialogue
window on teach pendant opens. The reset-lamp on front pulpit lights
up.
Picture: Pop-up window
Recovery:
1
Release all emergency switches.
2
Press reset, whereas the blue lamp turns off and robot state
changes to OFF.
3
Press Go to initialization screen in the dialogue window on
pendant.
4
Re-initialize machine.
10.8
Safeguard stop
If the gripper safety shroud is moved out of position or any of the safety
paddings are activated, the machine will carry out an immediate safety
stop.
Result: The robot changes status to Safeguard stop. The robot stays in
state Normal.
Recovery:
1
Put safety shroud back into position and undo pressure on safety
paddings.
2
When the reset-button is pressed, the machine will automatically
resume.
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10.9
Resetting
Emergency stopping, activating safety paddings or moving gripper
safety shroud out of position will cause the robot to execute a safety
stop.
A safety stop will turn on the blue reset pushbutton lamp.
Before the machine can be reset, the cause of the tripping has to be
fixed. Thereafter the reset-pushbutton can be pressed which will make
the machine ready for restart.
10.10
Powering ON the robot system
Before the robot is switched on, the safety system must be reset.
Instruction:
- Switch on the robot by pressing the power button on the
teach pendant.
- The system takes about one minute to start up.
- The state will change to Booting and thereafter Power off
conditioned no alarms are present.
OFF
ON
SHUTDOWN ROBOT
Created by EBCCW 00:06
Picture: Turning on the robot system
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10.11
Initializing robot arm
10.11.1
Turning ON robot arm
Instruction:
- In state Power off, initialize robot arm by pressing
button ON.
- The robot initially changes state to Power on,
and thereafter to Idle.
OFF
ON
SHUTDOWN ROBOT
Picture: Safety and hazard overview
10.11.2
Starting robot arm
When in state Idle, the robot is ready to start.
Instruction:
- In state Idle, start the robot by pressing START.
- The robot initially changes state to Brake release while the
arm makes small movements (shivering) and thereafter
changes state to Normal.
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Picture: Initialize robot screen
10.12
State normal
In state Normal, the robot arm is ready to move automatically
(automatic palletizing).
OFF
ON
SHUTDOWN ROBOT
Picture: Normal state (Production state)
A correct payload must be set before the arm is moving. Fill in the
correct value in the Current payload field.
Created by EBCCW 00:06
To finalize initialization, press OK, which brings back main menu.
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Picture: Initialization finalization
10.12.1
Running a program - Automatic production
Setting a program into run causes the machine to go into automatic
production.
The correct way to start running a program is without a box in the
gripper. Starting to run a program with a box in gripper will cause an
error.
The Pause button is used to pause the program temporarily when it
is running. The program execution and the robot arm halts where
they are when this button is pressed.
The Play button is used to run the program.
Buttons not used during normal
operation
Back: Program goes back one step.
The Stop button is used to stop the program definitively.
Forward: Program forward one step.
Instruction for how to run program
Warning
Pressing the play button more than
once may result in the program
failing to run.
1
Press the Play button once. The robot controller takes around 5
seconds to launch the program.
2
The first operation in the program is arm initialization. If the robot
is not in the home position, the user will be prompted to initialize
the arm. The robot arm is moved back to program home position.
Press and hold the Auto button to move the arm.
Warning: This first movement of the robot arm must be
supervised continuously by the user to avoid hazardous collisions
between the arm and its environment.
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Picture: Automatic movement into position
3
When the robot reaches the home position, the Cancel button
disappears and the OK button appears in its place. Press OK to
return to the Run Program menu. You must press the Play button
again.
Picture: Robot motion finished
4
Once the Play button is pressed the program starts running.
5
Two prompt screens will appear depending on the machine
status.
- One screen will prompt the operator to enter how many
layers are full on the pallets that are in the machine. If there
is no full layer on the pallet, enter "0".
Created by EBCCW 00:06
- A second screen will prompt the operator to enter how
many boxes are on the top layer which is not full. If all
layers are full, enter "0".
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Picture: Number of layers prompt
6
Another prompt screen will appear if two pallets are in the
machine when the program starts running. It will ask which pallet
the operator wants to complete.
Process for machine starting with one pallet on either side:
a. Prompt screen asking for full layer count.
b. Prompt screen asking for number of boxes in
incomplete layer.
c. The machine starts without any further operation.
Machine starting with pallets on both sides:
a. Prompt screen asking for full layer count on the
right pallet.
b. Prompt screen asking for number of boxes in incomplete
layer on the right pallet.
c. Prompt screen asking for full layer count on the left pallet.
d. Prompt screen asking for number of boxes in incomplete
layer on the Left pallet.
e. Prompt screen asking on which pallet the robot should
place boxes.
f. The machine starts without any further operation.
When the last prompt has been answered, the robot starts its cycle.
The arm moves to the picking area and waits for an available location on
the pallet and an available box to pick. When the program is running, a
variable tab is available on the Run Program menu. It can be used to
check the variable state for debugging.
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Picture: Variable status
10.12.2
Stopping a program
Instruction:
- Press Stop button on the Run tab screen. The program
status will switch to Stopped.
Picture: Stop button
If the program is stopped when the robot has a box in the gripper, the
box should be removed and placed back on the box conveyor.
10.12.3
Freedrive
Freedrive mode allows the user to change to position of the robot arm
manually. The mode can be activated while in state Normal. The mode
is entered by pressing the Enable-button on the backside of teach
pendant and left by releasing the button.
Created by EBCCW 00:06
10.12.4
Modes
There are four operating modes which are represented by four tabs at
the top of the screen.
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Picture: Tab position
Tabs
- Run tab. Program control handling.
- Move tab. Position data, tool
coordinates and manual run control.
- I/O-tab. Input and output status.
- Log tab. Robot settings.
Picture: Tab overview
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10.13
Shutdown robot
The command Shutdown robot in the main menu cause the robot to
return to state Machine power on where robot system is switched off.
OFF
ON
Created by EBCCW 00:06
SHUTDOWN ROBOT
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11
User interaction lamps and
buttons
Light stack
Light stack
Green
Red
Fixed
2 pallet workable (not full & both present)
Flashing 1 pallet workable (other full or absent)
Fixed
0 pallets workable (2 full pallets or no pallets present)
Flashing -
Pallet status light
Each pallet position has its own pallet status beacon with green and red
lamp.
Pallet status light
Green
Red
Fixed
Pallet workable (in progress or empty)
Flashing
-
Fixed
Pallet not present
Flashing
Pallet full
Picture: Pallet status light location
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Reset button
Blue lamp ON: Safeguard or emergency stop
Picture: Reset button location
11.1
Error Codes
11.1.1
No case detected in the Gripper
Situation: This stop usually occurs when the box is dropped during the
place to pick cycle.
Possible causes of the fault:
• Torn or damaged suction cups
• Damaged vacuum switch
• Clogged suction cups or vacuum generator
• Holes in the picked box
Reset procedure: Press the Stop Program button and then press the
Play button to restart the program. Follow the steps described in the
Run a program section of this manual.
Created by EBCCW 00:06
Picture: Alarm message
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11.1.2
No Vacuum Detected on Gripper
Situation: This stop occurs when the vacuum switch fails to detect a
box in the gripper during the picking operation for 3 seconds.
Possible causes of the fault:
• Torn or damaged suction cups
• Damaged vacuum switch
• Clogged suction cups or vacuum generator
• Holes in the picked box
Reset procedure: Press the Stop Program button and then press the
Play button to restart the program. Follow the steps described in the
Run a program section of this manual.
Picture: Alarm message
11.1.3
Please Remove Case From End effector
Situation: This error occurs when the program starts running with a box
in the gripper.
Reset procedure: Press the Stop Program button. Remove the box from
the gripper and place it in picking position. The vacuum output can be
switched off on the I/O tab. Then press the Play button to restart the
program. Follow the steps described in the Run a program section of
this manual.
Picture: Alarm message
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11.1.4
Robot not allowed in this area
Situation: This fault will only occur when the robot enters an inactive
pallet zone.
Example: If the robot is palletizing the right pallet it is not
authorized to enter the left pallet zone. An entry to the left
pallet zone will cause the error to trip.
Reset procedure: Press the Stop Program button and then press the
Play button to restart the program. Follow the steps described in the
Run a program section of this manual.
Picture: Alarm message
11.1.5
Protective Stop
Protective stop is also called Force stop.
Situation
The Protective Stop fault appears when the robot has
detected excess resistance on any of its 6 axes.
Reset procedure
Press the Enable Robot button and then press the Play
button to resume the program execution. The robot will
continue from where it tripped. Homing is not required
for restarting.
If Protective stop occurs during the homing procedure, the robot likely
believes a box is in the gripper.
Created by EBCCW 00:06
Measure: Change the payload value on the Initialization
screen. Press the File button and then the Initialize button,
or press the coloured dot beside the File button.
Picture: Alarm message
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12
Maintenance and housekeeping
12.1
Performance
Robot cabling lifetime [cycles]
min. 4 000 000
Required suction cup check interval
10 000 cycles
Vacuum pump filter [months]
3
Control relay type
SSD-type
12.2
Lockout-Tagout procedure
Instruction:
1
If the machine is in automatic production - let the gripper finalize
the placing of the carton box.
2
Stop the program when the gripper is empty by pressing the Stop
program button.
3
Go to main menu and select Shutdown robot.
4
The robot system will shutdown and machine state change to
state Machine power on.
5
Switch off the control box main switch located in the box front.
6
Power supply is disconnected.
7
Wait 5 seconds for the vacuum pressure to disappear.
8
Lock the main switch with padlock in OFF-state.
9
The machine is ready and safe for maintenance.
12.3
General
• Use a damp cloth to clean photo eyes and reflectors.
• Use a dry, clean, non-fluffy cloth to clean conveyor rollers and any
machine part in contact with product.
• Keep all parts in contact with product clean.
• Use efficient vacuum cleaners to clean dry areas of floors, walls,
and machine interior and exterior.
• Clean floors and walls using highly persistent disinfectants.
• Maintain the delineation of robot workplace limits.
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12.4
Maintenance tasks executed by unskilled
personnel
Unskilled personnel tasks
Periodicity
Components
Maintenance
Conveyor rollers
Check the cleanliness
X
Photo eyes and reflectors
Clean optics
X
Suction cup fastening
Check tightening (wing nuts)
X
Suction cup condition
Clean. Check wear.
X
Workspace delinearization
Keep clear and visible
Actuator base bolts
Check tightening
X
Robot base bolts
Check tightening
X
15 days 1 month 1/2 year
Created by EBCCW 00:06
Picture: Bolt checkpoints
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70
X
12.5
Maintenance tasks executed by skilled
personnel
Table 1: Skilled personnel tasks
Periodicity
Components
Maintenance
Fan filter of control box
Clean
Safety system
Inspect
X
Vacuum system
Inspect
X
12.6
15 days 1 month 1 year
X
Suction cup condition check
The gripper parts must be regularly checked during the machine's
service life to prevent possible damage. A special cycle has been set up
in the program. When the system starts, the cycle counter is checked.
If more than 10,000 cycles have been performed since the previous
check, the cycle is executed.
The robot arm moves to the inspection position (above the conveyor)
and a popup appears on the Teach pendant screen. The operator must
check the gripper parts.
Picture: Check message
Instruction:
• If all the gripper parts are in working order
1. Press Continue button
2. Follow the next steps to start the program.
• If some gripper parts are damaged
1. Press Stop Program button.
2. Turn off main switch.
3. Replace the damaged parts.
4. Switch on main switch and start machine.
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12.7
Vacuum pump
Following actions are for skilled personnel only.
Created by EBCCW 00:06
Vacuum pump maintenance routine:
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1
Replacement of vanes every 3000 hours of use.
2
Inspection and cleaning of filter every 40-200 hours of use.
72
13
Definitions
Effective payload
Tooling and work piece mass
Freedrive mode
Mode in which the robot arm's position can be changed manually
Robot Config
Software tool for defining pallet pattern
Safety checksum
Individual number for every possible safety settings combination
TCP
Tool center point
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14
Change history
Created by EBCCW 00:06
Change history
Edi
Change
1
Document created
2
General improvements
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Note
74
15
References
Reference to technical library on www.flexlink.com which contains
downloadable documentation:
http://www.flexlink.com/en/home/support/technical-library
Name
Doc item no.
Note
Declaration
5129045
Control box
5127921
110V/220V power supply
External connections
5127926
110V/220V power supply
Spare parts instruction
5129047
Assembly instruction
5129156
Calibration tool kit 5126067
Assembly instruction
5125245
Safety paddings elbows 5129389
Assembly instruction
5125246
Safety paddings robot head 5129390
Assembly instruction
5125244
Gripper 5124176/5124577
Vacuum system
5128037
User instruction
5129046
English - original
User instruction
5129370
Swedish
User instruction
5129371
Norwegian
User instruction
5129372
Finnish
User instruction
5129373
Danish
User instruction
5129374
German
User instruction
5129375
French
User instruction
5129376
Czech
User instruction
5129377
Polish
User instruction
5129378
Dutch
User instruction
5129379
Italian
User instruction
5129380
Spanish
User instruction
5129381
Hungarian
User instruction
5129382
Portuguese
User instruction
5129383
Chinese
User instruction
5129384
Japanese
User instruction
5129385
Thai
User instruction
5129386
Indonesian
Robot config manual
5129368
75
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