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Palletizing Solution - Instruction Manual

3.4.4. Mechanical and Electrical Installation

Tip

A minimum of two people is recommended to execute these steps.

Robot Installation

Info

A UR10 or UR10e cobot is required for the installation. The cobot is not included in the Robotiq Palletizing solution.

For robot installation, few cables need to be wired. The figure below resumes the identification of the column holes.

Summary of Contents for ROBOTIQ AX Series

Page 1: ...Robotiq Palletizing Solution AX Series for Universal Robots Instruction Manual ROBOTIQ PALLETIZING SOLUTION AX Series robotiq com leanrobotics org Original Notice 2022 Robotiq Inc...

Page 2: ...and Installation 26 3 5 Other Grippers 50 3 6 Installation for Universal Robots 52 3 7 URCap Package 52 3 8 Robot Configurations 58 3 9 License Agreement 61 4 Operation 64 4 1 Starting Up 64 4 2 Light...

Page 3: ...7 8 Spare Parts Kitsand Accessories 98 9 Troubleshooting 99 9 1 Palletizing Solution except the AirPick Gripper 99 9 2 AirPick Vacuum Gripper 103 10 Warranty 106 11 Harmonized Standards 108 11 1 Appli...

Page 4: ...Palletizing Solution Instruction Manual 4...

Page 5: ...is now orange l Updated Safety section to add information regarding Reduced mode l Updated Software section with more details for the pick position 2021 08 03 l Update of the Software section l Added...

Page 6: ...e of the Specifications section l Update of the Installation section Robot configurations 2020 12 16 l Update of the safety section l Update of the installation section l Update of the specifications...

Page 7: ...her for sale or not without prior written consent from Robotiq Under copyright law copying includes translation into another language or format Information provided by Robotiq in this document is beli...

Page 8: ...fully integrated with a linear axis pallet sensors and status lights An extra reach gripper bracket is also included in the Solution to extend the reach of an end of arm tool of 200 mm from the robot...

Page 9: ...inear axis Controller It allows for the simultaneous motion of both the axis and the robot during a palletizing action and the control of the pallet sensors and status lights 1 1 4 Pallet Sensors The...

Page 10: ...n Cup System includes a bracket a manifold air nodes port plugs bumpers tubing and additional suction cups Fig 1 2 Suction cup system Info Please refer to the Installation section for more information...

Page 11: ...ble to palletize boxes on large size pallets Please refer to the Extra Reach Bracket section for more details about the limitations of the extension bracket Fig 1 3 AirPick Vacuum Gripper Extra Reach...

Page 12: ...rder to use only one suction cup the single cup can be mounted right in the port of the vacuum generator 1 2 2 Auxiliary System with Multiple Suction Cups l A standard Suction Cup System can be attach...

Page 13: ...ams explain the logical operation of the Palletizing Solution based on the operator s actions as well as responses such as signals pallet and box sensor behaviors etc Please refer to the Status Lights...

Page 14: ...Palletizing Solution Instruction Manual 14...

Page 15: ...tion l Installation l Control l Maintenance l Inspection l Calibration l Programming l Decommissioning The present section is based on the following international standards and technical specification...

Page 16: ...n emergency conditions and not for normal condition stop Info The Solution is intended to be used with a UR10 or UR10e from Universal Robots Info Always comply with local state province and or federal...

Page 17: ...s are used for the suction cups Caution It is the installer operator s responsibility to ensure that all local safety measures and regulations are met The following non exhaustive list presents risks...

Page 18: ...bject is detected the Vacuum Gripper will go into a standby state 2 seconds after the e Stop button is pressed The AirPick Vacuum Gripper that comes with the Robotiq Palletizing Solution is connected...

Page 19: ...0 nominal 500 Protective stop 0 Stop Cat 2 Safeguard stop 0 Stop Cat 2 N A Stop Cat 1 and transition to Cat 0 Emergencystop N A Stop Cat 1 and transition to Cat 0 Reduced mode Please refer to the Univ...

Page 20: ...AxisStop Category 0 and 1 When a stop is required the robot and the linear axis start the process at the same time even if they are independent so the stopping time can differ l For robot information...

Page 21: ...Palletizing Solution Instruction Manual 21...

Page 22: ...commended environmental conditions l Do not operate the Palletizing Solution or even turn on the power supply before the device is firmly anchored and the machine area is cleared Make sure that the ai...

Page 23: ...your legs not your back If you can not lift an object alone ask for help or find another method to move it 3 1 Scope of Delivery l 1 x AX Series Palletizing Solution base including o 1 x Linear axis 1...

Page 24: ...mm hex key l 10 mm hex key Not included l Lifting equipment min capacity of 200 kg such as a gantry crane overhead crane jib crane chain block or forklift with a proper lifting hook l Power screwdriv...

Page 25: ...nce l Water No Other l Free from corrosive liquids or gases l Free from explosive liquids or gases Table 3 1 Environmental and operating conditions of the Robotiq Palletizing Solution Caution Use of t...

Page 26: ...an be activated until the pressure is fully released 3 4 Mounting and Installation 3 4 1 Visual Inspection The Robotiq Palletizing Solution is shipped on a pallet A wood crate is protecting the hardwa...

Page 27: ...ld them into place 2 Cut all the strapping material that retains the components and take all cardboard boxes out of the crate 3 Unscrew the four 4 bolts that retain the base into the crate 4 Take the...

Page 28: ...alletizing Solution Instruction Manual 6 Lift the foot base unscrew the piece of wood under the foot base Remove the piece of wood and descend the Solution slowly and carefully see the picture below 2...

Page 29: ...7 Position the column vertically Use the lift point to rotate the column Caution Be careful not to pinch the cables If necessary secure them before lifting and placing the column on the base 29...

Page 30: ...he base Info A hook is present at the top of the column Use it to lift the column 9 Secure the column on the base using the four 4 M10 screws provided Tighten to a torque of 50 Nm Caution Make sure to...

Page 31: ...of your choice you will need to move it to its final location afterwards You can use one of the two following methods to securely move the Solution 1 Using a forklift Pay attention to the center of gr...

Page 32: ...people is recommended to execute these steps Robot Installation Info A UR10 or UR10e cobot is required for the installation The cobot is not included in the Robotiq Palletizing solution For robot ins...

Page 33: ...e into the cable carrier up to the column There are two separate raceways You must use the same section as the coupling cable Push the cable into the column via the side hole and bring it out by the h...

Page 34: ...Palletizing Solution Instruction Manual Base Cover Plate 1 Remove the cover plate that will allow the cable management 34...

Page 35: ...the four screws on the top of the linear axis controller 2 Place the URcontroller on top of the linear axis controller and secure it with the four screws you previously removed Caution Do NOT plug th...

Page 36: ...truction Manual Power CablesConnections 1 Plug the power cable output of the linear axis controller into the URcontroller 2 Plug the robot power cable into the URcontroller 3 Connect the Teach Pendant...

Page 37: ...2 Then continue to chan nel the cable through the column and the base and bring it out from the other extremity of the base Info The safety signals wires sticking out of the linear axis controller ar...

Page 38: ...lution This procedure needs to be done before the AirPick Vacuum Gripper installation It will ensure proper functioning of the solution The goal is to properly align the column with the base by placin...

Page 39: ...Tool Position X value base reference to 333 35 mm Make sure the TCPis set to 0 the TCPmenu can be found in the Installation tab Warning Move the robot slowly and watch the movement to avoid collision...

Page 40: ...dditional reach is needed install the extra reach gripper bracket on the robot tool flange using four 4 M6 screws and tooth lock washers and align properly with the dowel pin Info Install the bracket...

Page 41: ...generator 2 Secure the manifold by inserting screws and tooth lock washers in a cross pattern to properly compress the O ring of the generator 3 Insert each suction cup with an O ring into an air node...

Page 42: ...l Using a 5 mm hex key secure the elbow collar assembly larger collar to the arm Account for the orientation and dis tance from the elbow D2 l Clip the mounting bracket of the elbow collar assembly on...

Page 43: ...ing bracket of the wrist collar assembly on the cable carrier align the bracket with the sticker shown in the pre vious chart 6 Use cable ties to attach the tubing and cable to the strain relief part...

Page 44: ...7 bar 6 5 bar for an AirPick with serial number V 01351 l We recommend using a local pressure regulator with a filter and an air dryer 11 Install the small cover on the side of the column with the pr...

Page 45: ...Follow the installation guidelines in the URmanual for Emergency stop or Safeguard connections Use the connector supplied by Robotiq for Safeguard connections l If the safeguard is not used add jumper...

Page 46: ...blocks of the robot controller Fig 3 2 Vacuum Gripper wiring to robot controller 4 Connect the USB cable to a USB port of the robot controller The figure below illustrates the device cable on the rob...

Page 47: ...the robot controller Connect the brown 24V blue 0V and black digital input wires to corresponding connectors in terminal blocks Info Follow the good practices of the cable management You can use the...

Page 48: ...ts Imperial Units Comments Pull out strength 5200 N 1180 lbf Ultimate value considering rated value with 4 1 safety factor 20 800 N 4720 lbf Shear strength 1400 N 320 lbf Ultimate value considering ra...

Page 49: ...of the box sensor s cable to the sensor 4 Reinstall the front base cover using the provided screws 10 5 Install the column cover using the provided screws 4 6 Connect the power cable to the power outl...

Page 50: ...f the software If your gripper does not fit the following models it can still work but Robotiq doesnot guarantee that there will be no collision The gripper model is depending on the box dimensions an...

Page 51: ...that an extra reach bracket is used A rectangular prism is then added at the end of the bracket according to the rules mentioned above Bracket representation Height Width Length Direction 31 5 mm 75...

Page 52: ...talling URCap Package section to configure the Palletizing Solution properly before operating and programming the device Info Upgrading to Copilot version 1 21 and above an update of the linear axis P...

Page 53: ...the zip of URCaps and extract them on the root of a blank USB stick l Insert the USB stick in the URteach pendant or controller l On the teach pendant tap the triple bar icon in the upper right corner...

Page 54: ...s compatible with the Palletizing URCap package l Go to www support robotiq com select Browse by product l Click on your Robotiq product page and then Universal Robots l Click on Software Robotiq prod...

Page 55: ...l Restart PolyScope to complete the URCap installation By doing so you accept the License Agreement that is detailed in the URCap Information text box see below for the License Agreement l When PolyS...

Page 56: ...ots l On the teach pendant tap the triple bar icon l Tap Settings l Select System in the navigation pane on the left l Select URCaps l In the Active URCapsbox select the URCap to uninstall l Tap the m...

Page 57: ...versal Robots l Go to Setup Robot l Tap URCapsSetup l In the Active URCaps box tap the URCap to unin stall l Tap the minus button to uninstall the URCap l Restart PolyScope to complete the uninstallat...

Page 58: ...sure the proper use of the solution 3 8 1 Joint Limits Some joint limits must be configured For e Series 1 Tap Installation Safety Joint Limits 2 Then unlock the section with the proper password and c...

Page 59: ...values for the Elbow will be 167 and 0 l The minimum and maximum values for the Wrist 3 will be 270 and 270 3 8 2 Configurable Outputs Some configurable outputs must be set For e SeriesUniversal Robot...

Page 60: ...Instruction Manual For CB SeriesUniversal Robots 1 Tap Installation Safety SafetyI O 2 Then unlock the section with the proper password and set the Output Signal config_out 0 config_out 1 at System E...

Page 61: ...functional with a specific product of the UR s Product 5 Licensor s Products means those products developed by the Licensor in the course of the Licensor s Business 6 UR s Products means those product...

Page 62: ...rranty on Software The End User expressly acknowledges and agrees that use of the Software is at the End User sole risk The Software is provided AS IS and without warranty of any kind THE LICENSOR AND...

Page 63: ...y legal action or proceeding between the Licensor and the End User for any purpose concerning this Agreement or the parties obligations hereunder shall be brought exclusively in a court of competent j...

Page 64: ...Toolbar checkbox 4 Select the digital input for the box sensor 5 Test the box sensor and the digital input Tap the I O tab and place an object in front of the box sensor to validate if the sig nal cha...

Page 65: ...ed but Copilot has not established the communication yet with the linear axis controller l Tap Installation URCaps Copilot Linear Axis and click on Scan button RED Solid An axis error happened l Tap I...

Page 66: ...e system is idle OR l The pallet is not detected and the system is idle Place a new pallet WHITE Solid l The linear axis is activated and brake is released l The Robotiq Controller PLC is connected to...

Page 67: ...Copilot Configuration Then a Select the Palletizer model used i In the Configuration tab under Palletizing Solution select Linear Axis b If required deactivate the Use Copilot to manage a soft speed t...

Page 68: ...mit the linear axis range outside of the Palletizer node Therefore caution must be observed when operating the linear axis with the ActiveDrive toolbar or the Linear Axis move node 3 In the ActiveDriv...

Page 69: ...q Palletizing Solution is set this way 2 On the Teach Pendant tap the Program button 3 Select URCapsin the navigation pane on the left 4 Tap the Palletizer button Info To use the palletizer node in it...

Page 70: ...sparameter you have to set the box s l Width A l Depth B l Height C l Payload l If you have labels that need to be oriented on your pallets check the Set label orientation box o You can choose the sid...

Page 71: ...instance will be a Position the robot tool flange connector on side A same side as the robot wrist as shown in the picture above Robot joints should be positioned as close as possible to the center o...

Page 72: ...you will have to a Select the desired pallet l Right or left l Both pallets b Determine the dimensions of the l Front l Side l Height 10 The PALLET and BOX parameters are now completed Click on PATTE...

Page 73: ...B Make sure to select the desired ones l Click on Edit to configure your pattern o Configure the pattern you chose A B or both i Click on the button to add boxes ii Use the arrows to move and positio...

Page 74: ...r Sequence to modify it 12 Three 3 of your parameters are now set Complete your configuration by clicking on the SETTINGSbutton 13 For this configuration set tool speeds and accelerations with the box...

Page 75: ...e empty palletizing mode of full depal letizing mode l If the program is interrupted the current status number of boxes processed on each pallet will be kept l If the program is saved the status will...

Page 76: ...e box at 90 is checked to allow a gripper rotation of 90 around the Z axis for trajectory optimization It can be unchecked if it is not possible for the gripper to pick the box at 90 degrees compared...

Page 77: ...is to a specific position It can be used inside or outside the Pal letizer node You can command the axis to move at a 1 Fixed position 2 Relative position the position is relative to the current posit...

Page 78: ...ng Script Functions 1 Palletizing functions are made available in the Script drop down menu 2 Tapping on the Script Code textbox f x then on the drop down Function menu gives access to the script func...

Page 79: ...ction returns True the event is recorded in the URLog tab The rq_linear_axis_disable False function returns True when it succeeds and returns False when it fails the program is not stopped The event w...

Page 80: ...lder The Add between layer folder will not be executed Declaration rq_set_pallet_completed Return value There is no return value associated with this function 5 3 Vacuum Gripper Behavior Workpiece gri...

Page 81: ...nless specified all dimensionsare in millimeters The following subsections provide data on the various specifications for the Robotiq Palletizing Solution 6 1 Technical Dimensions 6 1 1 Linear AxisBas...

Page 82: ...6 1 2 AirPick Vacuum Gripper Fig 6 1 AirPick general dimensions 82...

Page 83: ...Palletizing Solution Instruction Manual 6 1 3 Extra Reach Bracket 83...

Page 84: ...6 1 4 Bracket for Two 2 Suction Cups Fig 6 2 Two air nodes bracket s dimensions 84...

Page 85: ...Palletizing Solution Instruction Manual 6 1 5 Bracket for Four 4 SuctionsCups Fig 6 3 Four air nodes bracket s dimensions 85...

Page 86: ...ximum pallet height filled 2200 mm 87 in Shipping crate dimensions 2380 950 1250 mm L W H 93 7 8 37 3 8 49 1 16 in L W H Gross shipping weight 317 kg 697 lb Maximal acceleration in operating condition...

Page 87: ...u have a pallet of 1165 x 1165 mm yellow line and a total height1 of 300 mm all boxes with a length width 250 will work l The pallet 800 mm x 1200mm is not represented in the figure as all box sizes a...

Page 88: ...per Specifications AirPick Vacuum Gripper Metric Units Imperial Units Energy source Electricity and compressed air Gripper mass including coupling 545 g 1 20 lb Minimum Feed pressure 3 bar 43 5 PSI Ma...

Page 89: ...X Y Z AirPick without suction cup 0 5 9 0 21 0 0 0 0 0 44 7 545 AirPick with 1 suction cup 0 5 8 5 23 4 0 0 0 0 76 7 580 AirPick with 2 suction cups 0 3 5 1 40 3 0 0 0 0 127 7 955 AirPick with 4 sucti...

Page 90: ...fications of the Robotiq Controller excluding the robot The overall voltage consumption will vary depending on the robot used Warning The linear axis controller is CE marked and cCSAus certified Any m...

Page 91: ...Palletizing Solution Instruction Manual Info The complete electrical diagram is available on our the Robotiq support website 91...

Page 92: ...out AirPick Vacuum Gripper specifications please consult its instruction manual available on the Robotiq support website 6 3 3 Universal RobotsController Please refer to the Installation section for m...

Page 93: ...scraps dust grease etc l Interaction with operated parts sharp or rough l Dynamics of the operation accelerations Caution Always turn off the Palletizing Solution and depressurize the air supply tube...

Page 94: ...before the lubrication Info Recommended lubricant LUB KC1 Ball Screw and Bearing Guide Lubrication Lubrication of the axis should be done every 2 years considering a typical use of 80h week When lubri...

Page 95: ...ble below Designation Location Tightening Torque Nm ft lb M6 Column Axis interface 10 5 7 7 M6 Linear axis carriage interface 9 9 7 3 M8 Pallet sensors 15 0 11 1 M10 Base Column 50 0 36 9 1 2 13 Wedge...

Page 96: ...up and release or use time hours Warning Unless specified any repairsdone on the Vacuum Gripper will be done by Robotiq Operation Daily Monthly 1 M cyclesor 1000 hours Gripper Cleaning Dirty condition...

Page 97: ...cloth as required Cleaning agents include all non abrasive media Caution Do not use compressed air to clean the Vacuum Gripper Doing so can result in a damage to the check valve or the release valve F...

Page 98: ...AL STAT LIGHT Type A Pallet sensor Palletizing Solution Type A Pallet Sensor Kit for the Robotiq Palletizing Solution l 1 x Type A Pallet Sensor l 1 x screw kit Used for o Left pallet back sensor o Ri...

Page 99: ...the picking position The pallet height value entered is too low Increase the pallet height value The robot entered in collision with a box already placed on the pallet A collision occurred between th...

Page 100: ...sion with an object that is not actually present l Restart the program and select the right box step l Verify the TCPposition and orientation values Error Message Discontinuous path joint solution imp...

Page 101: ...unt for the bracket used Configure the TCPcorrectly The gripper is bigger than the box The size of the surface covered by the gripper or suction device should always be equal or smaller than the size...

Page 102: ...onnected to a 24V terminal block in the URcontroller bypass Please refer to the Safety Connections section for more information A safeguarding OSSD is connected directly to the robot OSSD signals are...

Page 103: ...ing the program l Update to the latest version of the Copilot software 9 2 AirPick Vacuum Gripper 9 2 1 Communication When using AirPick Vacuum gripper with USB to RS485 serial converter Troubleshooti...

Page 104: ...tup menu inside the URCapstab a URCaps installation instructions are in the Installation section b Inside the URCaps tab if you select the appropriate URCap file you can see the current software versi...

Page 105: ...l From the URteach pendant screen click the Gripper button i Driver version will be shown ii If Gripper button is not displayed driver package is not properly installed see instruction from the 2 Driv...

Page 106: ...spects maintenance specified in the Maintenance section l Usage respects recommended payload force acceleration and speed specified in the Mechanical specifications section During the warranty period...

Page 107: ...Robotiq shall not be liable for damages resulting from the use of the Palletizing Solution nor shall Robotiq be responsible for any failure in the performance of other items to which the Palletizing S...

Page 108: ...stallation safety measure and normal usage must be respected The following standards have been applied ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reducti...

Page 109: ...Palletizing Solution Instruction Manual 1 2 Appendix 1 2 1 Anchoring Pattern Fig 12 1 Palletizing Work Zones Schema for UR10...

Page 110: ...1 2 2 Safety Connections Fig 12 2 Universal Robots Controller Safety Connections Schema 110...

Page 111: ...of the protected area 2 Brown 0V 0V link between both electrical enclosures 3 Green URE Stop Status 1 E Stop status signal when a emergency signal is applied to EI0 4 Yellow URE Stop Status 2 E Stop s...

Page 112: ...ne 1 888 ROBOTIQ 762 6847 01 418 380 2788 Outside USand Canada Technical support and engineering option 3 Sales option 2 Head office Robotiq 966 chemin Olivier Suite 500 St Nicolas Qu bec G7A 2N1 Cana...

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