Product Specification PickMaster

Product Specification PickMaster
3HAC 5842-6
Version 2.30
Product Specification
PickMaster
1
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technologies AB, Robotics. ABB Automation Technologies AB,
Robotics assumes no responsibility for any errors that may appear in this document.
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damages arising from use of this document or of the software and hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation
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nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Automation Technologies AB, Robotics
at its then current charge.
© Copyright 2004 ABB
Article number: 3HAC 5842-6
Version 2.30
ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
1
Welcome to PickMasterTM 2.30 .....................................................................................................6
2
PickMaster Features......................................................................................................................7
2.1
Scope.................................................................................................................................................. 7
2.2
Applications and processes.............................................................................................................. 8
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
2.3
PC-interface .................................................................................................................................... 10
2.4
Integrated vision (optional) ........................................................................................................... 10
2.4.1
2.4.2
2.4.3
2.5
2.5.1
2.5.2
3
External Vision Model SDK ....................................................................................................................... 12
Post inspection............................................................................................................................................. 13
Detailed vision information and run time Vision Analyzer......................................................................... 13
Inspection ........................................................................................................................................ 14
Level I: Type categorization and reject by parameter variance profiles...................................................... 14
Level II (optional): Inspection area selection though combinations of models and criteria ........................ 14
2.6
External Sensor SDK (On request)............................................................................................... 16
2.7
Controller side process flexibility ................................................................................................. 16
Technical Specification ...............................................................................................................17
3.1
Product content .............................................................................................................................. 17
3.2
Software Package ........................................................................................................................... 17
3.2.1
3.3
3.3.1
3.3.2
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
3.4.9
4
Random flow .................................................................................................................................................8
Predefined flow .............................................................................................................................................8
Indexing conveyors and fixed work areas .....................................................................................................8
Double/multiple pick, single/double/multiple place......................................................................................8
Configurable Pick and place sorting order ....................................................................................................8
Mixing and sorting ........................................................................................................................................8
Camera Distribution (optional) .....................................................................................................................9
Load Balancing and bypassing......................................................................................................................9
Adaptive Task Completion (optional) ...........................................................................................................9
Robot stops and exceptions ...........................................................................................................................9
Compatibility............................................................................................................................................... 17
Hardware ........................................................................................................................................ 17
Included vision equipment .......................................................................................................................... 17
Required equipment .................................................................................................................................... 17
Specifications .................................................................................................................................. 18
Maximum configuration.............................................................................................................................. 18
Vision .......................................................................................................................................................... 18
Robot Controller and I/O signals................................................................................................................. 20
Robots ......................................................................................................................................................... 20
Conveyor tracking ....................................................................................................................................... 20
Operator’s panel connectivity - RIS (optional) ........................................................................................... 21
Remote support ........................................................................................................................................... 22
RobotWare .................................................................................................................................................. 22
Pick and Place process performance ........................................................................................................... 22
Specification of Variants and Options ........................................................................................25
4.1
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.3
4.3.1
4.3.2
PickMaster Options........................................................................................................................ 25
Basic Licenses ............................................................................................................................................. 25
Additional Licenses..................................................................................................................................... 26
PickMaster related Controller Options........................................................................................ 29
RobotWare Option ...................................................................................................................................... 29
Hardware options ........................................................................................................................................ 29
Examples of PickMaster configurations....................................................................................... 29
Use case 1.................................................................................................................................................... 29
Use case 2.................................................................................................................................................... 30
3
4.3.3
4.3.4
4.3.5
4.3.6
Use case 3.................................................................................................................................................... 31
Use case 4.................................................................................................................................................... 32
Use case 5.................................................................................................................................................... 33
Use case 6.................................................................................................................................................... 34
5
Spare parts ...................................................................................................................................36
6
Documentation.............................................................................................................................38
1 Welcome to PickMasterTM 2.30
Thank you for your interest in PickMasterTM. This document will give you an overview of the product
characteristics and how it can be used. PickMasterTM the PC-based control software from ABB is a plug &
produce high-end integration of our high performance S4Cplus robot controller and of all IRB types.
PickMasterTM is a configurator and cell controller of flexible packaging lines with moving conveyors.
For position recognition of random production flows as well as powerful quality inspection PickMasterTM
uses a reliable powerful vision system from Cognex. It enables recognition of a wide variety of both
regular and irregular shaped objects, which makes PickMasterTM the ideal tool for controlling packaging
robots in the Consumer Industry, but it also makes it well suited for generic vision robot guidance
applications.
PickMasterTM can control up to 8 robots and 8 cameras - simultaneously in the same application or
concurrently in independent cells. Each robot can track 6 conveyors simultaneously.
By the use of Remote Integration Services (RIS) PickMasterTM can be operated from any production
panels or automation system through an integrated support for field buses, TCP/IP, serial link or digital
I/O.
PickMasterTM gives you the benefit of:
•
Fast installation and configuration of one or multiple robots in an Ethernet network. No
programming is required.
•
Instant product change-over
•
Cell controller capability for extensive operational control of process and connected robot
controllers
•
Risk reduction offering a product-based repeat solution, configurable for a multitude of
operational cases.
•
High performance vision recognition and product quality inspection including digital CMOS
cameras with high resolution for the highest demands
•
Advanced information sharing between cameras and robots
•
Powerful sorting functions
•
Tailored robot controller ProcessWare for best cycle time performance through enhanced builtin high volume flow conveyor tracking and optimal position transfer pipe line
Self contained robots in a line
•
PickMasterTM 2.30 is a modular product, which can be composed to your special needs:
•
With integrated vision for full random operation, working with continuously moving conveyors
•
Without vision recognition as a tool for efficient production with guided product flows on
multiple conveyors
•
With integrated vision for random operation and absolute accurate positioning on indexed
feeders or trays
•
For efficient quality inspection and product categorization alone or together with position
recognition.
•
Integration of customized external vision algorithms
•
Integration of external sensor systems (on request) other than the standard Cognex vision
system
PickMasterTM 2.30 runs with the S4Cplus robot controller and RobotWare - at least 4.0.100 or higher.
Required RobotWare software option is “Prepared for PickMaster” which includes all necessary software
options to interface PickMasterTM as well as efficient conveyor tracking.
PickMasterTM 2.30 is certified for Industrial IT Level 0.
2 PickMaster Features
PickMaster is tailored for advanced high speed picking of random object on moving conveyors. The
flexibility and modularity of the product makes it suitable for a wide range of customer applications,
including generic vision recognition integration for robot guidance. PickMaster is available for all robot
types.
2.1 Scope
•
Eight robots and eight cameras per PickMaster running together in one process or in a multitude
of independent concurrent processes on the same PC.
•
Eight work areas per robot whereof six conveyors
Examples of line configurations
•
Project execution is easily started and stopped from a single button in the PickMaster studio
interface. Individual robots can be controlled separately at any time and status changes are
reported back to PickMaster.
7
•
Line PLC and custom operator’s panel connectivity through TCP/IP, field buses, serial port and
discrete I/O. This option, called RIS (Remote Integration Services) gives full control over the
PickMaster packaging process and the individual robots.
•
Runtime process tuning of positions, motion path, dwell times, tool activation, etc.
•
Camera distribution and position information sharing as well as capability to control the work
capacity distribution of the robots.
•
Wide range of enhancements in the RAPID program through dedicated RAPID instructions.
•
Advanced sorting functions
2.2 Applications and processes
PickMaster can handle a wide variety of applications in packaging as it has integrated support for mixing,
sorting, collating, blister patterns, etc.
The way the robot shall pick and place from different work areas is easily enhanced by PickMaster
RAPID instructions. The order and priority including exception handling is possible to program with the
RAPID instruction set provided with PickMaster.
However, in most cases, no programming adoptions are needed at all. The PickMaster software package
contains predefined RAPID modules.
2.2.1
Random flow
This is the most flexible way of feeding products. There is no need for fixtures and many different
products or packages can be transported on the same feeders without mechanical adoptions.
2.2.2
Predefined flow
The products and place trays may be placed in predefined positions. With PickMaster many robots and
products with various patterns are easily configured and the process is executed with highest performance
and efficiency with included work area limit supervision.
2.2.3
Indexing conveyors and fixed work areas
In many cases the products are presented to the robots on indexed tables or indexing conveyors. In this
case conveyor tracking is not used, but the products may be random placed and vision recognition is then
needed.
2.2.4
Double/multiple pick, single/double/multiple place
If higher performance is required, double picking is easily configured. However, heavier special grippers
and a less flexible configuration are the disadvantages of this solution.
2.2.5
Configurable Pick and place sorting order
The items are normally picked and placed in direction of the production flow on the conveyors, i.e. first
in, first out. It is also possible to extract the items from the flow in any three dimensional direction.
2.2.6
Mixing and sorting
Single product types, generated by PickMaster can be selected and extracted from the inflow and diverted
to different positions.
Alternative operations can be executed if products or specific product types are missing from the inflow.
Trough watermarks signal it is easy to detect if objects if a queue is empty and thus requires new input.
Sorting directions makes it possible to optimize the capacity of the robot, i.e. to make sure the robot runs
the shortest distance, etc.
Clearance areas can be declared to reject touching objects.
2.2.7
Camera Distribution (optional)
Multiple robots can be connected to the same camera. This is useful to save hardware and installation
costs. It is essential that the objects are well separated and that neighbor objects are not touched by the
ones being picked or placed. Also the elasticity of the conveyors may lower the accuracy the further away
the robots are from the trigger point.
2.2.8
Load Balancing and bypassing
With simple drag and drop the load of a production flow can be balanced among multiple robots. The
position information is acquired at one initial point on the line either through a position trigger of
predefined positions or through a camera using the camera distribution option. The production can easily
be balanced with equal or biased loads on all robots involved. The function can bee used to avoid
upstream robots to consume most of the products on the conveyors and thereby leaving too little to the
other robots.
The Load Balancing function can also be applied on robots with individual trigger points (separate camera
or sensor per robot). Simply decide, how much of the passing production shall be used and bypass the rest.
2.2.9
Adaptive Task Completion (optional)
PickMasterTM can be configured to ensure that every object is picked and every position is filled as a joint
operation of multiple robots. Without the need to assign objects to specific robots, the ATC-function
makes sure one but only one robot consumes the position. This option can be used for progressively filling
cases, which pass multiple robots.
2.2.10
Robot stops and exceptions
A single robot can be paused, stopped or even powered down during production. The way the remaining
robots are reacting is configurable. If load balancing is used, the workload designated to a paused robot
can be redistributed automatically among the running robots. If ATC is used, the specific positions are
redistributed to the next robot.
9
2.3 PC-interface
Graphical components are easily introduced and edited by right mouse click
•
Plug-and-Produce installation and configuration limits on-site software and hardware
engineering to a few hours.
•
Graphical concept with line and project configurator. Studio application with workspace area,
symbolic line/project view, log and runtime vision display.
•
On-line context-sensitive help for fast navigation through the use of PickMaster, identical to the
User’s Guide paper copy
•
Fast project start-up (2-3s for the complete line)
•
Line information stored in (*.pml)-files, projects are stored in (*.pmp)-files
•
Immediate task change-over and fully automatic one button production start
•
Status control of process as well as individual robots
•
Definitions of single objects as well as single/multi-layer pattern and container
•
Pre-programmed RAPID-code down-loaded at process start
•
Several processes can be handled in concurrent and self-contained operations from one
PickMaster
•
Event logging to Microsoft Event Viewer database
•
Available in six languages: English, German, French, Italian, Spanish, Japanese1.
2.4 Integrated vision (optional)
Leading Cognex vision technology on dedicated frame grabber boards and built-in algorithms provides
the integrated vision.
The vision system is capable of recognizing regular as well as irregular forms. This includes unwrapped
food like chicken, meat, etc or more geometrical accurate products or wrapped and packaged forms.
1
English is the standard language. See “Delivery Situation” and “Solution Bank” for the release of the translated
versions
The vision capability is optional in PickMaster 2. Efficient object search and inspection is provided by
Cognex MVS-8100, MVS-8504 and 8100D frame grabber boards, which plug into the PCI-bus of the PC.
The powerful vision search algorithms are executed on the MMX accelerated PC. They provide fast and
reliable robot guidance as well as concurrent inspection capability. A maximum of eight cameras can be
connected on one PC (2 MVS-8504 boards).
With PatMaxTM, many vision recognition tasks are easily solved, which normally require extensive
custom image processing or which may be impossible to solve. PatMaxTM is a patented method by
Cognex, which is top of the line in vision technology. PatMaxTM returns reliable, accurate and repeatable
2-dimensional positions and orientations.
List of vision features:
•
Concurrent camera acquisitions and vision processing on multiple cameras.
•
Fast image updates
•
Fast and accurate calibration, linear or higher order algorithms for short focal lenses
•
For geometric model search, enhanced use of PatMaxTM solves many difficult search tasks.
Well suited for geometric search of both regular and irregular shapes.
•
Sub score parameters for adequate fine tuning, e.g. items to find, score limit, contrast limit, area
overlap, clutter, scale, angle, granularity
11
•
Enhanced Blob modeling for fast and simple search operations without the need for taught
models can find many different types of objects based on pixel features like area, perimeter, etc.
•
Multiple models per object possible
•
Vision model import/export for bitmap editing of camera images. Allows corrective changes
the image by any paint or draw program in order to optimize the modeling.
•
Zoom, pan, etc of the camera view simplifies accurate modeling
•
Auto camera trigger
•
Quality inspection with reject and type categorization: level I
•
Quality inspection through multiple inspection areas: level II
Lower window shows runtime and live images.
•
2.4.1
Runtime vision analyzer
External Vision Model SDK
In addition to the built-in vision technology, PickMaster can be enhanced by any type of image
algorithms, which is called through an “External Vision Model Interface SDK”. The external functions
can execute on the same PC as PickMaster or on another computer. They can be used both as separate
self-contained models and as inspection models in Inspection II. See the separate interface specification
document for advanced integration “External Vision Model SDK”, provided with the PickMaster
software.
2.4.2
Post inspection
PickMaster can be configured for object recognition and inspection and connect an I/O signal in the robot
controller instead of a complete robot operation coordinated a conveyor. The function can be used to
inspect objects after they have passed the robot zone or before they enter and to take appropriate action
2.4.3
Detailed vision information and run time Vision Analyzer
The vision and inspection results can be checked in detail in runtime for each individual camera. The
images and results are saved in a buffer. The results can be saved to a file (.pmv) and analyzed online or
offline in a separate executable Vision Analyzer, which is also provided with the PickMaster software.
Camera information and time stamps for each camera acquisition are also saved with this file.
13
2.5 Inspection
Visual inspection capability is an enhanced use of the vision integration, used to verify the quality and
categorization of the products for picking or placing. It is also used for enhanced feature recognition and
accurate identification of similar looking objects (level II).
It is possible to identify untaught defects like scratches or burn marks.
Both inspection levels II and I can be used for quality inspection even if the positions are pre-defined.
The inspection results are sent with the positions to the robot controller, where the decision may be done
to pick and place accepted or rejected items.
PickMaster can pick only the accepted items or it can also be configured to pick out only the rejected
items.
2.5.1
Level I: Type categorization and reject by parameter variance
profiles
This inspection type is included in the camera option.
With Inspection Level I acceptance profiles can be defined and used as type categorization for a vision
model as a combination of the parameters.
Categorization is based on the geometric or blob model parameters, depending on the type of model used.
On blob models, histogram analysis can be applied.
For PatMax models, a boundary check and filtering is possible. A protected multi-edge area can be
defined around an item. This function will reject any objects of which the boundary area is touching or
overlapping another.
2.5.2
Level II (optional): Inspection area selection though
combinations of models and criteria
Level II inspection is accessible when the inspection option is included. The inspection models can be of
type geometric, blob, histogram, and length measurement or external models.
The level II inspection is used to inspect additional features inside a given area in relation to a base search
model. Multiple inspection areas can be evaluated at the same time and with different types of models.
The following types of inspection are available inside an inspection area:
•
Geometric: presence of taught features. Evaluates numbers of hits, positions and orientations in
relation to the base model. Inspection of labels, right side up, distinction of minor features for
type selection, etc are common use cases.
•
Blob: presence of untaught features by blob analysis. Evaluation of pixel size, numbers, etc is
possible. Untaught defects like burn marks on baked products, scratches other defects can be
detected after the object was found.
•
Histogram: inspection of the grey scale characteristics in the inspection area by tolerances in
mean value, standard deviation, etc of the pixel values.
•
Size: definition of size measurement lines and configuration of acceptance levels in mm.
15
2.6 External Sensor SDK (On request)
With the ESS any type of external external sensor systems can be integrated in PickMaster – both through
access in design time and by providing position information in run-time. The interfaces are based on the
Microsoft ATL COM concept and they are available on request.
The external sensor can be a 3D vision system or a bar code reader, e.a and it can reside on another
computer system.
ABB does not take any responsibility for the proper functioning of an external software and hardware.
The support is limited to the interface specification.
2.7 Controller side process flexibility
Optimized real-time control of positions and conveyors are provided by the RobotWare option “Prepared
for PickMaster” in the S4Cplus controller.
With Prepared for PickMaster the robot is configured to work together with a PickMaster PC.
Prepared for PickMaster contains a set of RAPID instructions, functions, variables and data types. There
are also predefined system and program modules as well as RAPID routines included in Prepared for
PickMaster. The RAPID modules are part of the project definition and downloaded to the robot controller
at project start-up. The RAPID modules may be adapted to fit specific application needs, but in most
cases, very little or nothing needs to be changed.
Prepared for PickMaster takes care of the communication, initialization enhanced conveyor tracking and
makes it possible to perform advanced mixing, sorting and collating as well as exception handling as
timeout or error handling.
Functions for executing service routines directly from PickMaster are also included.
See PickMaster User’s Guide for the full set of instructions.
3 Technical Specification
3.1 Product content
PickMasterTM 2.30 Software package
PickMasterTM 2.30 Hardware
PickMasterTM 2.30 User’s Guide
3.2 Software Package
PickMasterTM 2.30 includes
•
PickMaster 2.30 software with line and project configurator, vision modeler, inspection
modeler (optional), event logging, production panel, Remote Integration Services (RIS)
(optional)
•
PickMasterTM Vision Analyzer
•
Cognex Vision Software CVL 6.2
•
PickMaster SDK
-External Model
-External Sensor2
•
License manager
3.2.1
Compatibility
Projects made in PickMasterTM 2.30 are not compatible with PickMasterTM 1.x versions and vice versa.
PickMasterTM 2.30 is compatible with Cognex MVS-8120.
3.3 Hardware
3.3.1
Included vision equipment
•
Vision PCI board Cognex MVS-8100 (single camera)
•
Vision PCI board Cognex MVS-8504 (four cameras)
•
Digital Vision board Cognex 8100D: complete vision kit including 1-3 digital CMOS cameras
and 10 m camera cables. The cameras can be ordered with normal or high resolution.
•
Camera breakout cable.
•
Trig/Strobe PCI board for MVS-8100: four pairs of secure opto-isolated trigger/strobe signal
connections. Each trig/strobe pair has separated 24 VDC and ground connections.
•
I/O adapter for MVS-8100
•
I/O card for MVS-8504
3.3.2
Required equipment
Robot Controller
2
•
M2002 S4Cplus
•
At least one 24 V Digital I/O board
On request
17
•
0..6 Encoder Interface board for ‘Prepared for PickMaster’
•
BaseWare 4.0.100 or later
•
Option ‘Prepared for PickMaster’
PC
PickMaster runs on Windows 2000 Professional or Windows XP on a regular Pentium III PC.
Recommended is 1.5 GHz or higher for best performance in CPU-demanding applications (many cameras,
inspection, etc).
Single Vision System requires two free PCI-slots per vision system. Analogue multi vision system and
Digital Vision system requires one PCI-slot per card. Ethernet network board are required for all vision
cards. Additionally one additional free slot is needed if a RIS field bus cards is used.
The PC should be equipped with a monitor of at least 17 inches with minimum resolution 1024x768
pixels. Recommended is a resolution with 1280x1024 pixels.
PickMaster was tested on IBM.
Cameras and cables
See chapter on vision below
3.4 Specifications
3.4.1
Maximum configuration
•
One PickMaster/PC
•
Eight robots/PickMaster
•
Two vision cards/PickMaster
•
Eight cameras/PickMaster
•
Eight work areas/robot
•
Six conveyors/robot
3.4.2
Vision
•
Search tools PatMaxTM /Blob
•
Vision quality inspection tools Level I and Level II (optional)
•
Linear and non-linear calibration
•
Camera acquisition time and transfer rates: typically 50-200 ms on a high performance PC.
Complex models can affect performance.
•
Up to eight simultaneous camera acquisitions
Hardware
The Cognex vision system is available in three different vision hardware configurations, the MVS-8100,
MVS-8504 and the 8100D(digital frame grabber). The vision boards are mounted on the PCI-bus of the
PickMaster PC.
MVS-8100 and MVS-8504 are analogue vision cards. MVS-8100 is used for single camera applications,
whereas four simultaneous cameras can be connected to MVS-8504.
Vision boards MVS-8120 already installed with PickMaster 2.x are compatible to run on Win 2000/XP
and PickMaster 2.30.
Maximum two vision boards can be plugged into the PC. MVS-8100 and MVS-8504 can be used
together.
Additional equipment not supplied with PickMaster for analogue vision cards: cameras, camera cables
There is always one trig/strobe I/O board needed for each MVS-8100 vision board. The trig/strobe I/O is
also mounted on the PCI-back plane.
The MVS-8504 uses an I/O card, which is prepared for DIN rail mounting outside the PC.
MVS-8100D is a digital vision card, which supports 1-3 camera. Cameras (normal or high resolution) and
cables are supplied with PickMaster for the digital vision card.
Performance
The image recognition time and transfer time for one type of objects in a scene is typically about 50-250
ms. Variations occur depending on the complexity and geometric accuracy of the models as well as if
inspection is included.
The vision recognition and inspection perform the most CPU consuming calculations on the PC.
Recommended is to use state of the art powerful PC’s to avoid restrictions in speed or performance loss.
Accuracy
The vision absolute accuracy is 1/40 pixel. This makes it possible to obtain accuracy levels of a few 1/100
mm. To obtain the total positioning accuracy and repeatability, the following parts are contributing to the
total result:
•
Camera resolution and field of view
•
Accuracy of the calibration sheet. This is very much dependent on the type of the reproduction
technologies (printing) to obtain the calibration blob pattern
•
Lens distortions affect the peripheral positions. Non-linear calibration calculation give the best
result
•
The robot repeatability
•
Conveyor accuracy. Highest accuracy is achieved when indexed feeders are used and the
camera is mounted inside the working area.
Cameras and cables
All camera types, which are approved for use with Cognex MVS-8100 and 8504 boards, can be used with
PickMaster. For moving object on conveyors, cameras with full frame shutter and progressive scan are
recommended. PickMaster has been tested with Sony XC-55, Hitachi and HR-50
A high-resolution camera is only possible in conjunction with MVS-8504. A compatible camera, with
progressive scan is the JAI CV-A1high-resolution camera.
The camera cables can be ordered through Cognex with the following specifications:
300-0239-30 for MVS-8100 (the last figure represents the cable length in ft)
19
300-0136-30 for MVS-8504 (also compatible with MVS-8120) Sony XC55 and Hitachi
300-0316-30 for HR-50
Trig-Strobe Board
For each vision board (MVS-8100) one trig/strobe I/O board is required for connecting the camera trigger
and strobe signals to the S4Cplus system. The vision board and the I/O board are connected through a
ribbon cable.
The DSQC 524 Trig-Strobe board adapts the vision system I/O (5 VDC) with the I/O of the robot
controller (24 VDC). Each trig-strobe pair is separately powered with 24 VDC and connected to ground,
which makes it possible to connect to more than one robot controller in parallel.
Trig/strobe ribbon cable
Ribbon cable connection between vision board and trig/strobe board.
Trig/strobe adaptor
When using MVS-8100 single camera vision board an additional I/O converter is required for the ribbon
cable connection.
I/O card
When using MVS-8504 an I/O card for the trig/strobe is required. This is a standard component from
Cognex.
3.4.3
Robot Controller and I/O signals
The robot controller must be equipped with at least one Digital I/O-board, e.g. DSQC 328 or similar. As
an example, one DSQC 328 with 16 in and 16 out signals can handle one robot with four cameras and four
conveyors if no other signals are occupied.
The detailed use of required I/O signals is as follows:
•
Gripper vacuum and blow: two signals per vacuum tool
•
Conveyor synchronization (during calibration): one signal per conveyor
•
Position generator trigger, e.g. camera: one signal per work area, e.g. pick and place area
•
Conveyor start and stop order: one signal per conveyor if this function is used
Detailed hardware connection diagrams are shown in the User’s Guide.
3.4.4
Robots
Approved for use on all robot types.
3.4.5
Conveyor tracking
Continuously moving conveyor belts are the preferred way to feed items and packages. It gives a high
flexibility since the robot can operate on the items on the fly for the full time they are within the working
area of the robot.
Speed
The system has been tested with a maximum conveyor speed at 1400 mm/s with an IRB 340 without
vision recognition. The capability to follow conveyors at high speeds is dependent on the acceleration and
speed limitations of the actual robot. When changing the speed of the conveyors, i.e. when using them for
stop and go, the accuracy is decreased dependent on the acceleration and deceleration slopes. Indexing
feeders cannot be used for regular conveyor tracking.
On conveyors with vision recognition the speed is limited by the following factors:
•
Camera trigger frequency. The vision model search time and position transfer time limits the
trigger frequency. For an average time of 250 ms the maximum frequency is 4 Hz.
•
Motion blurs. On high-speed conveyors the camera shutter time needs to be very short which
again requires very good light.
Drive Unit
External drive units connected to I/O controls operate the conveyors. Drive units like the ABB AC300 has
a 24V I/O interface allowing forward, backwards, and stop operations, speed preset, and increment and
decrement.
Encoder
One or more encoders measure the position of a conveyor. Usually an encoder is placed close to an
identification and operation area in order to minimize errors caused by the elasticity and inaccurate
guidance. The encoder measurement sample rate is configured in the robot controller and by default set to
20 ms.
The interface board DSQC 377 handles one encoder. It is possible to connect one encoder to two interface
boards.
The encoder should be of type Open collector PNP output, two phases with 90 degrees phase shift, voltage
10-30V3 and current 50 - 100 mA.4
The pulse ratio from the encoder should be in the range of 5000 - 10000 pulses per meter of conveyor
motion (See wiring diagrams in 3HAC 15497-2 User’s Guide). The pulses from channels A and B are
used in quadratures to multiply the pulse ratio by four to get the counts. This means that the control
software will measure 20000 - 40000 counts per meter for an encoder with the pulse ratio given above.
Reducing the number of measured counts below 20000 will reduce the accuracy of the robot tracking.
Increasing the number of measured counts beyond 40000 will have no significant effect as inaccuracies in
robot and cell calibration will be the dominating factors for accuracy. The encoder board (DSQC 377) is
able to handle min 500 and max 50000 counts per meter.
The maximum frequency is 50 kHz (may occur with high conveyor speed and many pulses per meter).
The encoder should be connected to the robot by a screened cable to reduce noise.5
The number and speed of the conveyors are CPU-consuming factors on the S4Cplus controller. Maximum
six conveyors may be attached. Maximum four encoder boards may be connected inside the cabinet
together with one I/O board.
3.4.6
Operator’s panel connectivity - RIS (optional)
PickMaster can be operated remotely by use of the option RIS (remote integration services). With this
option, PickMaster can be operated from a remote place like an operator’s panel, thus making it possible
to integrate PickMaster in the overall line control also protecting the once designed and fine-tuned
projects from being changed by an operator. RIS provides the runtime interface as well as the
configuration menus to set up the command codes.
The available RIS interfaces:
•
Field bus connection. PickMaster includes a generic driver interfacing the Hilscher field bus
card series. Hilscher field bus cards, which plug into the PCI-bus of the PickMaster PC, support
all major field bus standards6. See www.hilscher.com for the field bus card product range and
specifications.
3
Normally supplied by 24 VDC from DSQC 377
4
Lenord-Bauer Gel 260-V-02500A001
5
If this cable is long, the inductance in the cable will produce spike pulses on the encoder signal, which may, over a
period of time, damage the opto-couplers in the encoder board. The spike pulses can be removed by installing a
capacitor between the signal wire and ground for each of the 2 phases. The capacitors should be connected to the
terminal board where the encoder is connected and not on the DSQC 377.
6
Currently supported field buses: Profibus; Interbus; Can; DeviceNet; SDSM (Smart Distributed System);
ASIM/Universal Protocol (RS232/422/485)
21
•
TCP/IP, accessible from any programming language from the PickMaster PC or any other
computer in the Ethernet network
•
Serial RS232 interface. PickMaster is accessible through commands over a RS232 serial
connection to the PickMaster PC.
•
Digital I/O interface. PickMaster supports digtal boards from Advantech, the 16 I/O PCI-1750
and the 32 I/O PCI-1756. See www.advantech.com.
RIS include interfaces to configure the commands to run PickMaster. RIS is configured per PickMaster
project and the following interfaces are exposed:
Project commands:
•
Open
•
Close
•
Start
•
Stop
Status: Project running/Stopped/Configuration Error/No License/Error
•
Robot commands for selected robot
3.4.7
•
Start
•
Pause
•
Stop
•
Reset E-stop
•
Pick rate
Remote support
PickMaster is delivered with remote support capability. It is recommended to order the PickMaster PC
with a dial-up connection possibility (modem) to make the application easily accessible for remote
support. The dial-up connection may also be established on another PC in the PickMaster network. It does
not necessarily need to be the same PC as where PickMaster is installed.
3.4.8
RobotWare
RobotWare 4.0.100 or later is necessary to run in the robot controller S4Cplus, with the option Prepared
for PickMaster included.
Prepared for PickMaster
Prepared for PickMaster is the RobotWare option installed in the robot controller. Each robot controller in
a PickMaster line needs the Prepared for PickMaster option, which includes all necessary functions for
conveyor tracking, communication with PickMaster and running stereotype pick-and-place movements.
The enhanced conveyor tracking included in Prepared for PickMaster can track six conveyors
simultaneously.
The option Prepared for PickMaster is exclusively offered together with PickMaster.
3.4.9
Pick and Place process performance
The performance is here described on an IRB 340 as a realistic process case for complete cycles with
varying distances and real gripping and dropping time. The performance can both be higher and lower
depending on the products and grippers.
In the diagram below the grip and drop time is 35 ms each.
Pick Rates PickMaster/IRB340
100 g
500 g
1000 g
2000 g
200
180
187
182
170
160
150
140
139
130
Pick Rate [ppm]
127
120
117
118
118
107
107
100
97
86
80
74
65
60
40
20
0
25/100/25
25/305/25
25/500/25
25/700/25
Cycle Length [mm]
Z-Offset ppm reduction
35
30
Reduction of ppm [%]
25
20
100 mm
305 mm
500 mm
700 mm
15
10
5
0
10
25
75
Additional Z-Offset [mm]
When the z-offset is varied the performance is influenced as described in the diagram above.
For performance on other robot types, see robot documentation.
Conveyor tracking repeatability
The tracking error for an IRB340 described as conveyor repeatability is valid for each pick and place
position separately and under the assumption that the speed is kept constant.
23
Conveyor speed
[mm/s]
Repeatability
[mm]
100
1
250-500
2
500-800
5
800-1400
15
Table 1: Conveyor repeatability for IRB 340
The above figures are considering a belt with small speed deviations
The robot acceleration capability is an important parameter for determining the accuracy and maximum
conveyor speed. With lower maximum acceleration limits, the capability to follow and to coordinate with
the speed is limited.
4 Specification of Variants and Options
4.1 PickMaster Options
PickMaster can be composed from a set of options in order to tailor the product scope to the needs of the
production line and the processes. PickMaster can run with or without vision.
PickMaster is licensed through basic licenses and additional licenses. For each order of the product
PickMaster, one, but only one basic license is required.
The integrated vision system is available with five vision card alternatives. Up to two vision cards options
may be defined with one PickMaster.
PickMaster 2.30 is hardware compatible with PickMaster 1.x. Upgrade licenses from PickMaster 1.x to
PickMaster 2.30 can be ordered as well as additional options as an extension to an existing PickMaster
2.30.
4.1.1
Basic Licenses
42-6
Basic PickMaster license
This option does not include any robot or vision options. To be able to run a PickMaster the necessary
Additional options have to be selected separately.
Physical items delivered with this option:
•
PickMaster software box
42-8
Upgrade license from PickMaster 1.1 to PickMaster 2.30
This option requires a valid PickMaster 1.1 license and must be installed on the same PC as the former
PickMaster 1.x, from which it will inherit the same functional options. The product reference for the
existing PickMaster 1.1 will be asked for when ordering this option.
Physical items delivered with this option:
•
PickMaster software box
42-7
Extension license for additional licenses on PickMaster 2.30
This option requires a valid PickMaster 2.x license and must be installed on the same PC as the former
PickMaster 2.x and the new additional options will be accumulated to the existing options. The product
reference of the existing PickMaster 2.x will be asked for when ordering this option.
No licenses are included in this option.
No physical items are delivered with this option.
42-4
Demo Unit
License to use PickMaster for 400 days with all options included and the accumulated production time is
limited to 2 hours. After that time PickMaster has to be shut down and restarted.
The option is intended for use in test, evaluation and training purposes. No additional options are required.
25
Physical items delivered with this option:
•
PickMaster software box
•
Cognex MVS-8504 four-camera frame grabber board
•
Camera break-out cable
•
I/O card
One free PCI-slot is required on the PC. Maximum number of cards is two.
4.1.2
Additional Licenses
559-1
Lic. for one robot
License to use one robot. Maximum number of robots is eight
On each connected robot, the RobotWare option “Prepared for PickMaster” is required.
No physical items are delivered with this option.
558-1
Lic. for one camera
License to use one camera with inspection level I. Maximum number of cameras is eight. The license is
compatible with all vision hardware choices.
No physical items are delivered with this option.
551-1
Inspection
License to use one camera with inspection level II. Maximum number of cameras is eight. Each of this
option requires one 558-1, i.e. this option adds on to the camera license.
No physical items are delivered with this option.
295-1
Remote Integration Services (RIS)
This option is used to run PickMaster from a remote operator’s interface. Software for field-bus
connectivity is included in this option.
No physical items are delivered with this option.
560-1
Analogue Single Vision
Single camera vision. Each of this option requires at least one 558-1.
Physical items delivered with this option:
•
Cognex MVS-8100 single camera frame grabber board
•
Trig-strobe I/O board with ribbon cable
•
Trig-strobe I/O converter
Two free PCI-slots are required on the PC. Maximum number of vision cards is two.
562-1
Analogue Multi Vision
Vision integration for multiple cameras. Each of this option requires at least one 558-1.
Physical items delivered with this option:
•
Cognex MVS-8504 four-camera frame grabber board
•
Camera break-out cable
I/O card
•
One free PCI-slot is required on the PC. Maximum number of cards is two.
554-1
Digital Single Vision
Designates the choice of a digital single camera system. If this option is selected one of 563-1 or 564-1
must be selected.
No physical items are delivered with this option.
563-1
Standard single
Digital single vision board including one camera with normal resolution. Each of this option requires at
least one 558-1.
Physical items delivered with this option:
•
Cognex 8100D 1 Channel card
•
Cdc 50 camera
•
Camera Cable
•
Trig/Strobe cable
One free PCI-slot is required on the PC. Maximum number of cards is two.
564-1
High Resolution single
Digital single vision board including one camera with high resolution. Each of this option requires at least
one 558-1.
Physical items delivered with this option:
•
1 Cognex 8100D 1 Channel card
•
1 Cdc 200 camera
•
1 Camera cable
1 Trig/Strobe cable
•
One free PCI-slot is required on the PC. Maximum number of cards is two.
555-1
Digital Double Vision
Designates the choice of a digital double camera system. If this option is selected one of 565-1 or 566-1
must be selected.
No physical items are delivered with this option.
565-1
Standard double
Two cameras with normal resolution will be delivered with the digital double vision card. Each of this
option requires at least one 558-1.
Physical items delivered with this option:
•
1 Cognex 8100D 2 Channel card
•
2 Cdc 50 cameras
27
•
2 Camera cables
•
2 Trig/Strobe cable
One free PCI-slot is required on the PC. Maximum number of cards is two.
566-1
High Resolution double
Two cameras with high resolution will be delivered with the digital double vision card. Each of this option
requires at least one 558-1.
Physical items delivered with this option:
•
1 Cognex 8100D 2 Channel card
•
2 Cdc 200 cameras
•
2 Camera cables
•
2 Trig/Strobe cables
One free PCI-slot is required on the PC. Maximum number of cards is two.
556-1
Digital Triple Vision
Designates the choice of a digital triple camera system. If this option is selected one of 567-1 or 568-1
must be selected.
No physical items are delivered with this option.
567-1
Standard triple
Three cameras with normal resolution will be delivered with the digital triple vision card. Each of this
option requires at least one 558-1.
Physical items delivered with this option:
•
1 Cognex 8100D 3 Channel card
•
3 Cdc 50 cameras
•
3 Camera cable
3 Trig/Strobe cables
•
One free PCI-slot is required on the PC. Maximum number of cards is two.
568-1
High Resolution triple
Three cameras with high resolution will be delivered with the digital triple vision card. Each of this option
requires at least one 558-1.
Physical items delivered with this option:
•
1 Cognex 8100D 3 Channel card
•
3 cdc 200 cameras
•
3 Camera cables
•
3 Trig/Strobe cables
One free PCI-slot is required on the PC. Maximum number of cards is two.
523-1
Camera Distribution
License to distribute the results from cameras to multiple robot work areas.
The number of licenses designates the maximum number of additional work areas, which can share the
result from a camera with the first work area. The maximum number of licenses is eight, which also
corresponds to unlimited number of distributed work areas.
No physical items are delivered with this option.
524-1
Adaptive Task Completion
License to distribute positions dynamically between robot work areas. When a robot misses a position, the
following robots will handle it. Used to make sure that no position is lost. If the positions are distributed
from a camera, at least one option 523-1 is required.
No physical items are delivered with this option.
260-1
User’s guide English
Physical items delivered with this option:
•
One printed User’s Guide copy in English
4.2 PickMaster related Controller Options
The following options need to be ordered for the robot controller operating with PickMaster.
4.2.1
RobotWare Option
257-1
Prepared for PickMaster
Each robot operating with PickMaster requires Prepared for PickMaster. The option contains all necessary
functions to interface PickMaster and to run enhanced conveyor tracking on up to six conveyors.
4.2.2
Hardware options
80-1/135-1
Encoder Interface Unit for PickMaster (internal/external)
For each conveyor connected to the robot controller, one encoder board for PickMaster is required. This
option is only software supported together with PickMaster.
201
At least one digital I/O board or similar is required for exchanging signals between PickMaster and the
robot controller. See hardware description for the number of signals required.
4.3 Examples of PickMaster configurations
This chapter describes some installation cases and their related PickMaster options.
4.3.1
Use case 1
Eight robots along two conveyors with predefined product positions
29
Basic license
Quantity
Option
1
42-6
Basic license
Additional licenses
Quantity
Option
8
559-1
Lic for one robot
(1
295-1
RIS if remote operator’s panels are used)
(x
260-1
x copies of the printed User’s Guide)
Robot options per robot: i.e. the quantity multiplies by 8.
Quantity
Option
1
257-1
Prepared for PickMaster
2
80-1/135-1
Encoder Interface Unit for PickMaster (internal/external)
4.3.2
Use case 2
One robot along conveyors with one camera
Basic license
Quantity
Option
1
42-6
Basic license
Additional licenses
Quantity
Option
1
560-1
Analogue Single Vision
1
559-1
Lic for one robot
1
558-1
Lic for one camera
(1
295-1
RIS if remote operator’s panels are used)
(1
551-1
If Inspection is used on the camera)
(x
260-1
x copies of the printed User’s Guide)
Robot options per robot
Quantity
Option
1
257-1
Prepared for PickMaster
2
80-1/135-1
Encoder Interface Unit for PickMaster (internal/external)
4.3.3
Use case 3
Two robots along conveyors with six cameras
31
Basic license
Quantity
Option
1
42-6
Basic license
Additional licenses
Quantity
Option
2
562-1
Analogue Multi Vision
2
559-1
Lic. for one robot
6
558-1
Lic. for one camera
(1
295-1
RIS if remote operator’s panels are used)
(x
551-1
Inspection on x cameras)
(x
260-1
x copies of the printed User’s Guide)
Robot options per robot: i.e. the quantity multiplies by 2
Quantity
Option
1
257-1
Prepared for PickMaster
3
80-1/135-1
Encoder Interface Unit for PickMaster (internal/external)
4.3.4
Use case 4
One robot along indexing feeders with three digital cameras (normal resolution).
Basic license
Quantity
Option
1
42-6
Basic license including one robot
Additional licenses
Quantity
Option
X
556-1
Digital Triple Vision
1
567-1
Standard resolution
1
559-1
Lic. for one robot
3
558-1
Lic. for one camera
(1
295-1
RIS if remote operator’s panels are used)
(x
551-1
Inspection on x cameras)
(x
260-1
x copies of the printed User’s Guide)
Robot options
Quantity
Option
1
257-1
4.3.5
Prepared for PickMaster
Use case 5
Four robots along conveyors with two cameras
Basic license
Quantity
Option
1
42-6
Basic license
33
Additional licenses
Quantity
Option
1
562-1
Analogue Multi Vision
4
559-1
Lic for one robot
2
558-1
Lic for one camera
6
523-1
Camera Distribution
(1
295-1
RIS if remote operator’s panels are used)
(x
551-1
Inspection on x cameras)
(x
260-1
x copies of the printed User’s Guide)
Robot options per robot: i.e. the quantity multiplies by 4
Quantity
Option
1
257-1
Prepared for PickMaster
2
80-1/135-1
Encoder Interface Unit for PickMaster (internal/external)
4.3.6
Use case 6
Four robots along conveyors with four cameras and ATC
Basic license
Quantity
Option
1
42-6
Basic license
Additional licenses
Quantity
Option
1
562-1
Analogue Multi Vision
4
559-1
Lic for one robot
4
558-1
Lic for one camera
1
524-1
Adaptive Task Completion
(1
295-1
RIS if remote operator’s panels are used)
(x
551-1
Inspection on x cameras)
(x
260-1
x copies of the printed User’s Guide)
Robot options per robot: i.e. the quantity multiplies by 4
Quantity
Option
1
257-1
Prepared for PickMaster
2
80-1/135-1
Encoder Interface Unit for PickMaster (internal/external)
35
5 Spare parts
3HAC 021476-001
PickMasterTM 2.30 Software
3HAC 15492-1
Cognex vision board MVS-8100M type A.
Single camera frame grabber vision board.
3HAC 021516-001
Cognex vision board MVS-8504
Vision frame grabber board for maximum for maximum four simultaneous cameras
3HAC 021515-001
Cognex camera connection breakout cable
Brake out box used for MVS-8504 to connect up to four camera cables.
3HAC 021514-001
Cognex I/O card for MVS-8504 card
3HAC 10846-1
Trig strobe I/O DSQC 524
Conversion board for four pairs of trig and strobe signals. Converts 5VDC TTL signals to 24 VDC signals
and vice versa. All signals are stabilized and opto-isolated.
3HAC 11530-1
Ribbon cable with 40-pin connector used for trig/strobe I/O DSQC 524.
3HAC 15493-1
I/O Adapter
Trig/strobe I/O signal connection adaptor including ribbon cable with 10-pin connector. Used to connect
MVS-8100 to the ribbon cable for the trig/strobe I/O DSQC 524.
3HAC021474-001
Camera cdc 50
Normal resolution camera for Cognex Digital Vision system
3HAC021475-001
Camera cdc 200
High resolution camera for Cognex Digital Vision system
3HAC021517-001
Vision 8100D1
Cognex Digital Vision system for one camera (normal or high resolution)
3HAC021518-001
Vision 8100D2
Cognex Digital Vision system for two cameras (normal or high resolution)
3HAC021519-001
Vision 8100D3
Cognex Digital Vision system for three cameras (normal or high resolution)
3HAC021520-001
Vision cable outlet 1
Cable outlet for Vision 8100D1
3HAC021521-001
Vision cable outlet 2
Cable outlet for Vision 8100D2
3HAC021522-001
Vision cable outlet 3
Cable outlet for Vision 8100D3
3HAC021677-001
Camera Cable
Camera cable for connection between cable outlet and camera
3HAC 021488-001
User’s Guide in English
Printed user documentation in English.
37
6 Documentation
The following documents are part of the PickMasterTM product:
3HAC 5842-6
Product Specification PickMasterTM 2.30 (this document)
Getting Started
PickMasterTM 2.30 Getting Started, English, included in 3HAC 021476-001PickMaster Software 2.30.
3HAC 021488-001
PickMasterTM 2.30 User’s Guide English, also available as PDF and HTML on-line help with the product
Cognex vision system documentation
Included on the PickMasterTM CD
PickMasterTM External Vision Model SDK
Software interface description for the integration of external vision model algorithm.
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