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Palletizing Solution - Instruction Manual

3. Installation

The following subsections will guide you through the installation and general setup of your Robotiq Palletizing Solution.

Info

Before installing:

l

Read and understand the safety instructions related to the Palletizing Solution.

l

Verify your package according to the scope of delivery and your order.

l

Make sure to have the required parts, equipment and tools listed in Scope of delivery.

Warning

When installing:

l

Meet the recommended 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 air supply is secured.

Warning

Failure to properly secure and install the equipment can result in material damage and bodily injury. In addition, note that
in situations where the installation is not compliant, the warranty is void.

Warning

When assembling or moving the Solution, make sure there is enough vertical and horizontal clearance all around so you
can avoid material damage and bodily injury.

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Summary of Contents for PALLETIZING SOLUTION 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: ...nd Equipment 24 3 3 Environmental and Operating Conditions 25 3 4 Mounting and Installation 26 3 5 Other Grippers 49 3 6 Installation for Universal Robots 51 3 7 URCap Package 51 3 8 Robot Configurations 57 3 9 License Agreement 60 4 Operation 63 4 1 Starting Up 63 4 2 Light States 64 5 Software 66 5 1 Installation on e Series Universal Robots 66 5 2 Palletizing Script Functions 78 5 3 Vacuum Grip...

Page 3: ...e 99 8 Spare Parts Kits and Accessories 100 9 Troubleshooting 101 9 1 Palletizing Solution except the AirPick Gripper 101 9 2 AirPick Vacuum Gripper 105 10 Warranty 108 11 Harmonized Standards 110 11 1 Applied Standards 110 11 2 EC Declaration of Incorporation 111 12 Appendix 112 12 1 Anchoring Pattern 112 12 2 Safety Connections 113 13 Contact 115 3 ...

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

Page 5: ... scripts Get Pallet State and Set Palletizer State in Software section 2022 03 28 l Added Robot Limits section 2022 02 03 l Added Physical Clearance and Reachable Area of the Robot section l Updated Safety Connections section 2022 01 04 l Added script functions l Updated Installation on Universal Robots e Series section l The palletizer model is now named AX Series 2021 10 07 l Updated Center of m...

Page 6: ...tion section with new cable management instructions l Update of Spare Parts Kits and Accessories section 2021 03 29 l Update of the Software section label orientation option added l Update 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 section 2020 ...

Page 7: ...ther 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 believed to be accurate and reliable However no responsibility is assumed by Robotiq for its use There may be some differences between the manual and the product if the product has been modified after th...

Page 8: ...ady to install It is composed of a base 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 s tool flange The Material Handling Copilot software and accessories e g box sensor anchor kit cable management system etc are also part of the Solution Info Th...

Page 9: ...linear 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 Solution is composed of four 4 sensors to detect pallets presence two per pallet The sensors will allow the Solution to ensure that the pallets are well positioned on each side of the base to optimiz...

Page 10: ...on 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 on how to integrate the Suction Cup System to the AirPick Tip The owner can use a custom bracket or a mounting plate The bracket or mounting plate can be installed directly under the manifold 10 ...

Page 11: ...able 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 Bracket 1 1 9 Box Detection Sensor The Solution includes a box sensor that needs to be installed at the end of the conveyor in a way that it is triggered when a box is ready to be picked up Fig 1 4 B...

Page 12: ...order 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 attached to the AirPick Vacuum Gripper The bracket normally holds two or four suction cups corresponding to the four ports of the manifold l Any unused manifold port should be blocked with a mating plug to...

Page 13: ...rams 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 section for further information about light states 13 ...

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

Page 15: ...perations on the Robotiq Palletizing Solution 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 specifications l ISO 10218 1 2011 Safety Requirements For Industrial Robots Robots l ISO 10218 2 2011 Safety Requirements For Industrial Robots Robots Systems and Integrato...

Page 16: ...in 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 laws regulation and directives automation safety and general machine safety Caution The unit should be used exclusively within the range of its technical data Any other use of the solution is deemed...

Page 17: ...ns 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 that must be assessed during the integration process l Risk of load ejection resulting from loss of vacuum l Risk of load dropping resulting from loss of vacuum l Risk of pinching any moving componen...

Page 18: ...object 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 via the robot controller Warning Loss of vacuum can occur due to power failure or air supply interruption 2 3 1 Expected System Behavior in Normal Operating Conditions l Normal mode The palletizer co...

Page 19: ...90 nominal 500 Protective stop 0 Stop Cat 2 Safeguard stop 0 Stop Cat 2 N A Stop Cat 1 and transition to Cat 0 Emergency stop N A Stop Cat 1 and transition to Cat 0 Reduced mode Please refer to the Universal Robots user manual for more details The linear axis exhibits the same behavior in Reduced and Normal modes It is not recommended to use Reduced mode since the linear axis is not safety rated f...

Page 20: ...r Axis Stop 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 please refer to the Universal Robots documentation l For the linear axis o Maximal stopping time for Category 1 500 ms o Maximal stopping time for Category 0 100 ms o Travelled distance when there ...

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

Page 22: ...ery Warning When installing l Meet the recommended 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 air supply is secured Warning Failure to properly secure and install the equipment can result in material damage and bodily injury In addition note that in situa...

Page 23: ...r 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 1500 mm stroke o 1 x Motor o 1 x Linear axis Controller o 4 x Pallet sensors o 2 x Status lights o 1 x Cable management system l 6 x 1 2 13 concrete anchors l 1 x Box detection sensor l 1 x Extra reach br...

Page 24: ... 6 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 screwdriver l 2 Phillips bit l 2 5 mm slotted screwdriver l Utility knife l Ratcheting socket wrench with 10 mm 3 8 in drive or adapter l Torque wrench with 10 mm 3 8 in drive or adapter minimum torque range...

Page 25: ...ance 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 the Robotiq Palletizing Solution is not recommended in presence of chemicals in the environment AirPick Gripper Info The input filter prevents any dust larger than 200 µm from getting inside the gripp...

Page 26: ...can 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 hardware from external elements Since the crate weighs 317 kg 697 lb Robotiq recommends using a pallet truck or forklift truck to move it The operation of such machinery should be done by qualified and aut...

Page 27: ... 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 base out of the crate 5 Unscrew the two 2 bolts that retain the column into the crate 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 27 ...

Page 28: ...tion Instruction Manual 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 28 ...

Page 29: ... 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 have all components in hand before discarding the crate and packaging 29 ...

Page 30: ...an assemble the solution at the place 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 gravity to prevent the equipment from tipping over Make sure to secure and sta bilize the Solution before moving it 2 Using the set of casters provided with the Sol...

Page 31: ...r bolts 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 31 ...

Page 32: ... the robot power cable 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 hole 1 4 Install the cable management system ring on the B sticker present on the cable carrier near the carriage The robot cable must emerge towards the top of the ring so it can ...

Page 33: ...Base Cover Plate 1 Remove the cover plate that will allow the cable management 33 ...

Page 34: ...nstallation 1 Remove the four screws on the top of the linear axis controller 2 Place the UR controller on top of the linear axis controller and secure it with the four screws you previously removed Caution Do NOT plug the UR controller power cable into UR controller 34 ...

Page 35: ... Cables Connections 1 Plug the power cable output of the linear axis controller into the UR controller 2 Plug the robot power cable into the UR controller 3 Connect the Teach Pendant to the UR controller 35 ...

Page 36: ...cable through the hole 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 are inputs only Therefore you can power the control box safely even if they are not yet connected 36 ...

Page 37: ...ure 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 placing the robot wrist at a specific position at the same time as it touches the side of the base 1 Unscrew half a turn the four 4 screws that secure the column onto the base Warning Do not unscrew completely Unscrew only h...

Page 38: ...180 RZ 0 5 Modify the Tool Position X value base reference to 333 35 mm Make sure the TCP is set to 0 the TCP menu can be found in the Installation tab Warning Move the robot slowly and watch the movement to avoid collisions 6 Rotate the column clockwise so that the side of the robot wrist touches the side of the base 7 Tighten the four 4 screws to secure the column onto the base Torque must be 50...

Page 39: ...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 only if necessary Consult the Configurator to find out if it is needed in your case 2 Using four 4 M6 screws and tooth lock washers secure the coupling on the robot tool flange or on the extra reach gripper bracket 3 Mo...

Page 40: ...ulder of the vacuum generator 2 Secure the manifold by inserting screws and tooth lock washers in a cross pattern to properly compress the O ring of the gen erator 3 Insert each suction cup with an O ring into an air node Tighten cups by hands Warning Any unused manifold port should be covered with a provided port plug to avoid air leakage 40 ...

Page 41: ... 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 the cable carrier align the bracket with the sticker shown in the chart below l Using a 5 mm hex key secure the wrist collar assembly smaller collar to the arm Account for the orientation and dis tance from the wrist ...

Page 42: ...stem 5 Clip the mounting 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 of the mounting bracket Make sure not to crush the tubing or the cable with the cable ties 7 Cut the air tube at the right length 815 mm 32 in past the plastic strain relief 8 Con...

Page 43: ... your local air supply device Caution l The maximum pressure allowed is 7 bar The optimal pressure is 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 provided screws 12 Shut down the robot and power off the linear axis Controller Caution You have to s...

Page 44: ... hole in the hole plug or use a grommet not included Fig 3 1 Linear Axis Controller Cable Summary Safety Signal Connections 1 Take the signal safety cable and pass it through an opening under the UR controller 2 Wire the cable by following the schema and the table available in the Appendix section Caution l Follow the installation guidelines in the UR manual for Emergency stop or Safeguard connect...

Page 45: ...e green and bare wires to the Robotiq RS 485 signal converter as shown in the figure below Also connect the red 24V and black 0V wires to the terminal 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 robot side CBL COM 2065 10 HF the pigtail connection ...

Page 46: ...e Solution Warning The transport lifting and moving of the Palletizing Solution should be done by qualified professionals Failure to do so may result to machine damage bodily injury or death Warning l The Solution must only be installed and anchored by qualified staff If you use the anchors provided with the Solution it should be installed in 28 MPa 4000 psi undamaged concrete minimum l If you cho...

Page 47: ...lasses l Always use proper safety precautions when working with tools that contain sharp edges pinching surfaces or generate heat l Always lift heavy objects with your legs not your back If you can not lift an object alone ask for help or find another method to move it l Use a vacuum cleaner if needed Caution The Solution must be placed on a flat and leveled floor If it is not the case use shims t...

Page 48: ...Solution For more details please refer to the Safety section 3 4 5 Physical Clearance and Reachable Area of the Robot The computed trajectories allow the boxes or the robot to overrun the edges of the pallet when the robot moves the boxes to their final position Mitigation measures can be put in place to prevent a transient or quasi static impact between a box or the robot itself and an operator B...

Page 49: ...ow joint 2 can therefore extend to the side where no pallet is present For a UR10 the possible overrun is represented by a cylinder of 705mm radius aligned with the robot base s Z axis 3 5 Other Grippers It is possible to use a gripper other than the AirPick Vacuum Gripper If another gripper is used it is important to validate that its shape is within the gripper model used for the collision detec...

Page 50: ...tion it is considered 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 mm Same length as TCP offset X Y Same direction as TCP offset X Y 50 ...

Page 51: ...ge 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 PLC firmware might be required A message will show after scanning the linear axis to approve the update 3 7 URCap Package Robotiq provides the user with a Universal Robots URCap package that provides a graphical user int...

Page 52: ...tion URCaps download the zip of URCaps and extract them on the root of a blank USB stick l Insert the USB stick in the UR teach pendant or controller l On the teach pendant tap the triple bar icon in the upper right corner of the screen l Tap Settings l Tap the System button in the navigation pane on the left l Select either the Gripper URCap UCG X X X or the Copilot URCap UCS X X X to install a U...

Page 53: ...he 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 product URCaps down load the zip of URCaps and extract them on the root of a blank USB stick l Select either the Gripper URCap UCG X X X or the Copilot URCap UCS X X X to install a URCap on your Teach Pendant l Repeat the p...

Page 54: ...age l Open the URCaps 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 PolyScope reopens the ActiveDrive toolbar will appear on the screen 54 ...

Page 55: ...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 URCaps box select the URCap to uninstall l Tap the minus button to uninstall the URCap l Restart Polyscope to complete the unin stallation process 55 ...

Page 56: ...nual On CB Series Universal Robots l Go to Setup Robot l Tap URCaps Setup 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 uninstallation process 56 ...

Page 57: ...ive setting Tool speed 1 and tool force 2 can be adjusted as required Please note that adjusting these settings will reduce the Solution s cycle time 3 8 2 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 change the values l The minimum and maximum values for the Elbow will be 167 and 0 l Th...

Page 58: ... minimum and maximum 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 3 Configurable Outputs Some configurable outputs must be set For e Series Universal Robots 1 Tap Installation Safety I O 2 Then unlock the section with the proper password and set the Output Signal config_out 0 config_out 1 at System Emer gency Stopped 58 ...

Page 59: ...For CB Series Universal Robots 1 Tap Installation Safety Safety I O 2 Then unlock the section with the proper password and set the Output Signal config_out 0 config_out 1 at System Emer gency Stopped 59 ...

Page 60: ...he 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 products developed by UR in the course of the UR s Business 7 Licensor s Authorized Representatives means and includes the Licensor and Licensor s authorized vendors resellers distributors and licensors 8 Purchase Agreement means an agreement bet...

Page 61: ...and without warranty of any kind THE LICENSOR AND THE LICENSOR S AUTHORIZED REPRESEN TATIVES DO NOT WARRANT THAT Software WILL BE FREE OF ERRORS AND YOU ACKNOWLEDGE THAT THE EXISTENCE OF ANY SUCH ERRORS DOES NOT CONSTITUTE A BREACH OF THIS AGREEMENT TO THE EXTENT PERMITTED BY LAW LICENSOR AND LICENSOR S AUTHORIZED REPRESEN TATIVES EXPRESSLY DISCLAIM ALL WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT ...

Page 62: ...ensor and the End User for any purpose concerning this Agreement or the parties obligations hereunder shall be brought exclusively in a court of competent jurisdiction sitting in the judicial district of Trois Rivières Quebec 3 The Licensor s failure to insist upon or enforce strict performance of any provision of this Agreement shall not be con strued as a waiver of any provision or right Neither...

Page 63: ... is always displayed tap Installation URCaps Vacuum and tick the Show Vacuum Toolbar checkbox 4 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 signal changes 5 Test the Vacuum Gripper Tap Installation URCaps Vacuum Scan Then test the grip and release functions of the Vacuum in the Gripper Toolbar 6 Activate and test the l...

Page 64: ...p the system again RED Slow blink Communication between the robot and the linear axis controller PLC is established 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 Installation URCaps Copilot Linear Axis Then check the error message and act accordingly...

Page 65: ... new pallet BLUE Fast blink l The pallet is complete and the 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 the robot controller l A program is running without a Palletizer node N A GREEN Solid A program with a Palletizer node is running but the pa...

Page 66: ...n 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 transition when resuming from a Safeguard stop option This is required when another URCap or a Polyscope option for example ProfiNET or Ethernet IP needs to control the speed slider c If required sel...

Page 67: ...imit 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 ActiveDrive toolbar click on Extra Axis thenScan and make sure your linear axis is ready 67 ...

Page 68: ...q Palletizing Solution is set this way 2 On the Teach Pendant tap the Program button 3 Select URCaps in the navigation pane on the left 4 Tap the Palletizer button Info To use the palletizer node in its depalletizing mode see figure in step 13 Info You will have to configure four 4 parameters to program your Palletizing Solution 68 ...

Page 69: ...s parameter 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 side on which the label will appear on your box by clicking on the button 69 ...

Page 70: ...r 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 of their motion range b Make sure to align the TCP with the center of the box c Once you are done click on Ok l You can also move the linear axis and to do so click on Active Drive Extra Axis 8 The BO...

Page 71: ...er 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 PATTERN to continue the configuration 71 ...

Page 72: ...rn A and the Pattern 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 position the boxes on the pallet as desired o If you have ticked the Set label orientation checkbox in the box parameters the side of the box with the label will be identified 72 ...

Page 73: ...l Enter the number of layers needed l Your current layer sequence is represented Click on Edit Layer Sequence to modify it 73 ...

Page 74: ...The checkbox Validate pallet state at program startup is checked by default If you unselect it l The first time the program is run the system will consider that the pallets are 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 be saved with it and the ...

Page 75: ...perform rotations of 90 or 180 around the Z axis for trajectory optimization It can be unticked if it is not possible for the gripper to pick the box at 90 or 180 relative to the gripping position originally taught 6 To configure a collision avoidance with a conveyor select the Avoid collision with conveyor checkbox Choose the applicable configuration perpendicular parallel or custom and fill in t...

Page 76: ...t s option When ticked this feature adds virtual planes when the tra jectories are computed in order to prevent the boxes and the robot from extending too far beyond the edges of the pallet dur ing approach To ensure a proper operation of the Solution a minimum distance of 50 mm is recommended 76 ...

Page 77: ... be used to move the linear axis 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 position The entered value can be positive or negative 3 Variable position the position is dictated by a variable global or local 77 ...

Page 78: ... Manual 5 2 Palletizing 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 functions list 78 ...

Page 79: ...he event is recorded in the UR Log 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 whether successful or failed is recorded in the UR Log tab 5 2 3 Start Linear Axis Description This function is the equivalent of the Start button The linear axis brake is released Use this function before a palletizer o...

Page 80: ... function inside a Grip or Release folder The palletizer will process the current box and go directly to the Add after pallet folder The Add between layer folder will not be executed Declaration rq_set_pallet_completed Return value There is no return value with this function 5 2 6 Get Pallet State Description This function can be used anywhere in the program It returns the state of a pallet Declar...

Page 81: ...ocessed_boxes Number of boxes palletized or depalletized on the current pallet l next_step Next step on the current pallet l BOX The robot will place a box on next step l BEFORE_PALLET The robot will execute the Add before pallet on next step l BETWEEN_LAYERS The robot will execute the Add between layer on next step l AFTER_PALLET The robot will execute the Add after pallet on next step l NEXT_PAL...

Page 82: ... simple some behaviors deserve a better explanation The Vacuum Gripper can work in two different mode the Automatic and Advanced modes For more details please refer to the AirPick Vacuum Gripper instructions manual 5 4 AirPick Vacuum Control over Universal Robots with URCaps Info Please refer to the AirPick Vacuum Gripper instructions manual to have all the information about the URCap 82 ...

Page 83: ...ion This manual uses the metric system unless specified all dimensions are in millimeters The following subsections provide data on the various specifications for the Robotiq Palletizing Solution 6 1 Technical Dimensions 6 1 1 Linear Axis Base with Controller 83 ...

Page 84: ...6 1 2 AirPick Vacuum Gripper Fig 6 1 AirPick general dimensions 84 ...

Page 85: ...Palletizing Solution Instruction Manual 6 1 3 Extra Reach Bracket 85 ...

Page 86: ...6 1 4 Bracket for Two 2 Suction Cups Fig 6 2 Two air nodes bracket s dimensions 86 ...

Page 87: ...Palletizing Solution Instruction Manual 6 1 5 Bracket for Four 4 Suctions Cups Fig 6 3 Four air nodes bracket s dimensions 87 ...

Page 88: ...mm Up to 108 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 conditions 2 g Maximum box throughput Up to 13 boxes min4 Maximum number of box patterns 2 Energy source Electricity 1 Maximum box weight depends on the robot model and gripper used 2The minimum box dimensions depend on pallet dimensi...

Page 89: ...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 are possible 1The sum of the pallet and box heights plus the TCP offset in Z direction 2Boxes imprint is square If your box is not the figure can be used using the smaller dimension l Please refer to C...

Page 90: ...ipper 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 Maximum Feed pressure 7 bar 101 5 PSI Optimal feed pressure 1 6 5 bar 7 bar 95 PSI 101 5 PSI Air consumption at optimal pressure 1 135 9 SLPM 106 7 SLPM 35 9 gpm 28 2 gpm Maximum torque permissible by...

Page 91: ... 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 suction cups 0 2 4 2 46 7 0 0 0 0 127 7 1180 AirPick without suction cup extra reach bracket 145 8 4 1 27 9 200 0 0 0 72 2 1192 AirPick with 1 suction cup extra reach bracket 147 3 4 0 29 6 200 0 0 0 104 ...

Page 92: ...cifications 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 modification will void the certification The following diagram illustrates the basic connections of the linear axis Controller For more information download the electrical package on the Robotiq supp...

Page 93: ...Palletizing Solution Instruction Manual Info The complete electrical diagram is available on our the Robotiq support website 93 ...

Page 94: ...out AirPick Vacuum Gripper specifications please consult its instruction manual available on the Robotiq support website 6 3 3 Universal Robots Controller Please refer to the Installation section for more details about all connections in the UR controller 94 ...

Page 95: ...s l Presence of physical objects debris 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 before performing any maintenance operation on it For more details about the depressurization please refer to Depressurizing the Supply Line section Caution The...

Page 96: ...s 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 lubricating move the carriage all over the axis stroke to distribute the lubricant uniformly Cover Strip and Guide Rail Lubrication Lubrication have to be done if it is needed or when the component doesn...

Page 97: ...able 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 anchors 54 2 40 0 M8 Hoist ring 9 5 7 0 M8 Robot carriage link 20 0 14 8 M8 Lifting bracket Linear axis link 9 5 7 0 Motor Coupling Coupling collar 8 0 5 9 Table 7 1 Torque Settings Palletizing Solu...

Page 98: ...up and release or use time hours Warning Unless specified any repairs done on the Vacuum Gripper will be done by Robotiq Operation Daily Monthly 1 M cycles or 1000 hours Gripper Cleaning Dirty conditions Normal conditions Periodic Inspection X Info For more details about the AirPick Vacuum Gripper maintenance please consult its instruction manual available at robotiq com support 98 ...

Page 99: ... 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 For more information about the AirPick Gripper filter cleaning please refer to the maintenance section of its instruction manual 7 5 Solution Storage Ensure short storage times Choose cool dry wellsha...

Page 100: ...Light for the Robotiq Palletizing Solu tion PAL 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 Right pallet side sensor PAL SENS A Type B Pallet Sensor Palletizing Solution Type B Pallet Sensor Kit for the Robotiq Palletizing Solution l 1 x Type B Pall...

Page 101: ...irm that the TCP is located above the box at 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 the gripped box and a box on the palllet A minor palletizing error carried over from previous layers l Increase the box height value to compensate for box siz...

Page 102: ...llision with an object that is not actually present l Restart the program and select the right box step l Verify the TCP position and orientation values Error Message Discontinuous path joint solution impossible detected please change your starting point A singularity was reached on a planned trajectory l Go to PolyScope s Move tab and verify if the joints are at the center of their range 0 when t...

Page 103: ...ount for the bracket used Configure the TCP correctly 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 of the face of the box that is being gripped Please refer to the Other Grippers section for more details The robot waits indefinitely over the picking position The box presence sensor is misused or ...

Page 104: ... connected to a 24V terminal block in the UR controller bypass Please refer to the Safety Connections section for more information A safeguarding OSSD is connected directly to the robot OSSD signals are not compatible with the Linear Axis even if the e Series UR controller can be compatible A special relay is required to convert OSSD signals to standard signals The emergency output from the UR con...

Page 105: ...rting 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 Troubleshooting from the Gripper LED 1 LED is not lit Gripper not powered a Check Gripper power supply and electrical setup 2 LED is solid blue and red Gripper is in fault a Disconnect the communication and powe...

Page 106: ... Setup menu inside the URCaps tab 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 version c Gripper toolbar should appear if installed properly 2 URCap is installed but Gripper cannot be controlled a If Gripper LED is not blue follow the steps in the first section above b If Gripper...

Page 107: ...l From the UR teach 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 Driver is installed but Gripper cannot be controlled a If Gripper LED is not blue follow the steps in the first section above b If Gripper LED is blue driver is installed with the latest available versio...

Page 108: ...nty is not applicable anymore l Usage respects 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 Robotiq will repair or replace any defective component of the Palletizing Solution as well as verify and adjust the component free of charge if the equipment sh...

Page 109: ...es 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 Solution is connected or the operation of any system of which the Palletizing Solution may be a part Exclusions This warranty excludes failure resulting from improper use or installation normal wear...

Page 110: ...ation compliance with safety measures and normal usage A risk assessment specific to the user s final application must also be carried out The following standards have been applied ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction ISO 9409 1 2004 Manipulating industrial robots Mechanical interfaces Part 1 Plates ISO 4414 2010 Pneumatic fluid power ...

Page 111: ...wnload Robotiq Palletizing Solution Universal Robots Documents Standards Declarations and Certificates 11 2 2 AirPick Vacuum Gripper Info For all information about the EC Declaration of Incorporation for the AirPick Vacuum Gripper please refer to the instruction manual of the device available on the Robotiq support website The declarations are available for download Vacuum Grippers Universal Robot...

Page 112: ...Palletizing Solution Instruction Manual 12 Appendix 12 1 Anchoring Pattern Fig 12 1 Palletizing Work Zones Schema for UR10 ...

Page 113: ...12 2 Safety Connections Fig 12 2 Universal Robots Controller Safety Connections Schema ...

Page 114: ... triggered 2 Brown 0V 0V link between both electrical enclosures 3 Green UR E Stop Status 1 E Stop status signal when an emergency signal is applied to EI0 4 Yellow UR E Stop Status 2 E Stop status signal when an emergency signal is applied to EI1 5 Grey UR Safeguard input 1 UR does not support safeguard statuses in configurable outputs Connect this pin to the regular safeguard input SI0 for statu...

Page 115: ...3 Contact www robotiq com Contact Us Phone 1 888 ROBOTIQ 762 6847 01 418 380 2788 Outside US and Canada Technical support and engineering option 3 Sales option 2 Head office Robotiq 966 chemin Olivier Suite 500 St Nicolas Québec G7A 2N1 Canada ...

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