Techman Robot TM Palletizing Operator User Manual Download

Page: 1 / 185

Product Version: 1.1

Document Version: 1.2

Release Date: 2022-04-29

TM Palletizing
Operator

User’s Manual

Corresponding models: TM5 Series

Original Instruction

Summary of Contents for TM Palletizing Operator

Page 1: ...Product Version 1 1 Document Version 1 2 Release Date 2022 04 29 TM Palletizing Operator User s Manual Corresponding models TM5 Series Original Instruction Original Instruction ...

Page 2: ...t of this publication may be reproduced or copied in any way shape or form without prior authorization from the Corporation No information contained herein shall be considered an offer or commitment It may be subject to change without notice This Manual will be reviewed periodically The Corporation will not be liable for any error or omission logo is registered trademark of TECHMAN ROBOT INC in Ta...

Page 3: ...rious injury death or significant property damage CAUTION Identifies a potentially hazardous situation which if not avoided might result in minor injury moderate injury or property damage WARNING ELECTROCUTION RISK Identifies a hazardous electrical situation The following symbols require readers users attention regarding some functional details or tips IMPORTANT This symbol represents the relevant...

Page 4: ...perator User s Manual Product Version 1 1 Document Version 1 2 4 Revision History Revision Code Date Description 1 0 2020 12 21 Official release 1 1 2021 10 05 Minor details revised 1 2 2022 04 29 Minor details revised ...

Page 5: ...ripper 27 Vacuum Generator Characteristics 28 Vertical Lifting Force per Suction Cup 29 Vacuum Pressure Sensor 30 Pneumatic Diagram 30 How Can I Get Help 31 Related Documents 31 2 Safety Information 32 Overview 32 Applicable Product Version 32 Safety Precautions 32 Overall Safety Warning 33 Validation and Liability 35 Intended Use 35 Limitations on Liability 36 General Environmental Considerations...

Page 6: ...SF8 Safeguard Pause Output and SF9 Safeguard Human Machine Safety Settings Output 48 SF10 SF16 Defined Safety Functions 49 Payload and Gravity Offset Consideration 51 Safety Distance and Scenario 51 Reset Button Mechanism 56 Operation Mode and Mode Switching 57 Auto Mode 57 Manual Mode 57 Manual Control Mode Manual Reduced Speed 58 Hand Guide Mode 58 Manual Trial Run Mode Manual High Speed 58 Swit...

Page 7: ...stall TM Robot 82 Install the Control Box 85 Install the Rear Housing 90 Install Cable Protection Conduit 92 Connect External Compressed Air Supply 95 Considerations for Connecting External Compressed Air 96 TM Palletizing Operator Transportation 96 Encountering Non Flat Surfaces 99 Relocation and Storage Considerations 101 Connect Disconnect the Teach Pendant 101 Install the Reset Button 107 SYSL...

Page 8: ... Start Setting Pallet 126 Step 1 Pallet Dimension and Boundary Setting 127 Step 2 Box Dimension and Label Direction Setting 128 Step 3 Create Pallet Layers 128 Step 4 Create Palletizing Sequence 132 Copy the Box 133 Palletizing Simulation Parameter Setting 135 Validate 136 Simulation 137 Export 137 Configure Palletizing Software Components in TMflow 138 Import Components and Text Files to TMflow 1...

Page 9: ... 3 Safety System versioning information 32 Table 4 Labels 41 Table 5 Safety Function Definitions 43 Table 6 Stop Category and Action of Fault Detection of SF0 SF1 and SF2 45 Table 7 Stop Category and Action of Fault Detection of SF3 and SF4 47 Table 8 Stop Category and Action of Fault Detection of SF5 47 Table 9 Stop Category and Action of Fault Detection of SF6 48 Table 10 Stop Category and Actio...

Page 10: ...ientation 16 Figure 4 Palletizing Operator Base Dimensions 18 Figure 5 Adjustable Flexible Gripper Overview 27 Figure 6 Dimensions of Adjustable Flexible Gripper 28 Figure 7 Vacuum Generator Characteristics 29 Figure 8 Vertical Lifting Force per Suction Cup 30 Figure 9 Pneumatic Diagram 31 Figure 10 Locations of Safety Warning and Product Labels 41 Figure 11 Safety Device Connection Diagram 44 Fig...

Page 11: ...he Cable Drag Chain 83 Figure 39 Seal and Reinstall Applicable to Pillar Elongation 500 83 Figure 40 Seal and Reinstall Applicable to Pillar Elongation 800 84 Figure 41 Remove EX IO module from control box 85 Figure 42 Secure the Covert Brackets to the Legs of the Control Box 86 Figure 43 Proper Cable Connections 86 Figure 44 Proper connections for robot connector cable 87 Figure 45 All Cable Firm...

Page 12: ...ripper Flange at Centered Position as Delivered 112 Figure 74 Gripper Flange at Shifted Position 113 Figure 75 Remove Two M6x12L Screws and Detach Flange Knob 113 Figure 76 Remove Five M6x6L Screws and Detach Position Converter 114 Figure 77 Fasten the Flange Knob to Shifted Position 115 Figure 78 Flange Position Change Completed 115 Figure 79 Align Gripper and Screws for centered position 116 Fig...

Page 13: ...Calibration 144 Figure 108 Pillar Calibration 144 Figure 109 Bool Value for True 145 Figure 110 Calibration Test 145 Figure 111 Controller 146 Figure 112 Set I O in Controller 147 Figure 113 Project_Main 147 Figure 114 Palletizing Steps 148 Figure 115 Import File Setting 148 Figure 116 Input text file 149 Figure 117 Check Pillar Height 149 Figure 118 Go to Recognizing Box Positions 150 Figure 119 ...

Page 14: ...158 Figure 132 Set Workspace 158 Figure 133 Workspace Calibration 159 Figure 134 Save Result 159 Figure 135 Save Workspace 160 Figure 136 Initiate Visual Recognition 161 Figure 137 Load Workspace 161 Figure 138 Advanced Settings 162 Figure 139 Add a Subflow 165 Figure 140 Add nodes in the subflow 1 2 165 Figure 141 Add nodes in the subflow 2 2 166 ...

Page 15: ...ide a walkthrough of how to configure and initiate the applications of stacking the pallet at each side can go with different objects unstacking the pallet at each side can go with different objects and stack changing the pallet at each side can go with the same objects only Adjustable Flexible Gripper Cable Protection Conduit TM12 Collaborative Robot Pallet Status Sensor L Main Switch Pallet Stat...

Page 16: ...Pillar System Light Connector Air Units Solenoid Valve AC IN socket Pallet Sensor R Reset Button Connector Front Leveling Mount Air Unit I O Connector Figure 2 TM Palletizing Operator Base Overview 2 2 Orientations TM Palletizing Operator system shall be placed as the orientation shown below Figure 3 TM Palletizing Operator Base Orientation ...

Page 17: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 17 Palletizing Operator Base Dimensions Unit Applicable to Elongation 500 Applicable to Elongation 800 ...

Page 18: ...gation 1200 Figure 4 Palletizing Operator Base Dimensions Package Contents Check if all the items listed in this section are included when unpacking the cartons for the first time If any item is missing contact your distributor or dealership immediately In the Palletizing System wooden shipping crate ...

Page 19: ...ing Operator User s Manual Product Version 1 1 Document Version 1 2 19 1 x TM Palletizing Operator Base 1 x Robot Protection Tubing which includes 2 x 6 Wave Tube and 2 x Tube Fittings PLJ6 In the Robot Arm carton ...

Page 20: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 20 Robot Arm TM12 Cable length 300 cm In the Control Box carton Control Box ...

Page 21: ...calibration plate and one small calibration plate Peel the protective wrap off before using IO cables One 8 pin digital I O cable and one 5 pin analog I O cable Length 100 cm The IO cables are not used in the standard assembly of TM Palletizing Operator but supplied for connection with customized end effector TM Landmark Two TM Landmarks Peel the protective wrap off before using Ground Wire 2 wire...

Page 22: ...ersion 1 1 Document Version 1 2 22 AC power cord of the TM Palletizing Operator Length 500 cm SYSLIGHT Cable 1 x 5 pin analog system indicator light cable Length 500 cm 4 x M10X25L type screws 2 x Control box convert brackets 4 x M6X12L type screws ...

Page 23: ... Version 1 1 Document Version 1 2 23 8 x M4X8L type screws 2 x Software license dongle TMstudio Palletizing Wizard TM Palletizing Operator Software Package 1 x Reset Button w cable at 500cm In the Gripper Set carton 1 x Adjustable Flexible Gripper ...

Page 24: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 24 4 x M6X12L type screws 4 x M6 washers 4 x 4 plugs In the Teach Pendant carton 1 x Teach Pendant Display size 10 1 ...

Page 25: ...nual Product Version 1 1 Document Version 1 2 25 1 x Teach Pendant Holder 1 x Teach Pendant cable with 1 x seal washer and 1 x screw for ground wire Length 300 cm Teach Pendant ESTOP Button Mode Switch Stop PLAY PAUSE Buttons Error Log ...

Page 26: ...ress this button to stop any project Button Adjust project speed single press under Manual Trial Run Mode In Vision Job under TMflow use these buttons to adjust robot positions Error Log Displays error logs Table 1 Teach Pendant Functions DANGER 1 The control box cables power signal cables and Teach Pendant cannot be used when any of them is in contact with liquids This may result in personal inju...

Page 27: ...f sight and reach of personnel working on the robot Adjustable Flexible Gripper Overview TM Palletizing Operator package comes with an Adjustable Flexible Gripper set for box lifting and placement in the palletizing projects The following will describe the parts and characteristics of the gripper Figure 5 Adjustable Flexible Gripper Overview Dimensions of Adjustable Flexible Gripper Unit ...

Page 28: ...rsion 1 2 28 Figure 6 Dimensions of Adjustable Flexible Gripper Vacuum Generator Characteristics The diagram below illustrates the relationships among the input compressed air pressure MPa the final vacuum the air consumption and the suction flow of the vacuum generator ...

Page 29: ...ture and humidity 2 Operating conditions including vacuum pressure workpiece weight and the holding and pressure exerted by the vacuum cup 3 The surface condition of the workpiece The operating conditions may affect the frequency of the replacement of vacuum cups Therefore users may determine the frequency of replacing vacuum cups based on their first time use Vertical Lifting Force per Suction Cu...

Page 30: ...ressure is lower than 40kPa the sensor will determine that the object has been gripped Users may adjust the sensor s default value of vacuum pressure based on the objects to be gripped For details about pressure sensor setting refer to Appendix B It is recommended that the default sensor value of vacuum pressure is no lower than 60kPa If the degree of the vacuum is too high the suction cup may dam...

Page 31: ... documents related to this manual for more or less Documents Descriptions TMflow Software Manual Related to Chapter 6 of this manual TMvision Software Manual Related to Chapter 6 of this manual TM12 TM 14 Hardware Installation Manual Medium Heavy Payload Series Related to the safety and hardware installation of this manual Safety Manual Techman Robot Safety System 3 3 Related to Chapter 2 and Chap...

Page 32: ...duct Version 1 1 TECHMAN ROBOT Safety System 3 3 Table 3 Safety System versioning information Within the scope of product version and TECHMAN ROBOT Safety System combination above the safety system version remains the same as TM Palletizing Operator Safety System 1 1 Users shall confirm whether the software and hardware versions are consistent with the table above Techman Robot Inc assumes no liab...

Page 33: ...rall Safety Warning These safety warnings are relevant for the entire manual DANGER 1 Before transporting installing operating maintaining and repairing this product make sure to read the product specification and operation manual in detail Confirm that all the conditions comply with the requirements of the specification and the Manual to avoid unintended accidents for example improper operation o...

Page 34: ...ore starting the operation of the robot confirm that there are no persons or obstacles that may intrude into the operating area during operation If the operating environment uses human robot cooperative operation be sure to complete the due risk assessment before starting the operation 6 It is forbidden for any unauthorized person to operate this product in order to avoid any possibility of injury...

Page 35: ...e contact information for the integrator Making relevant documents accessible including the risk assessment and this manual Intended Use The TM Palletizing Operator is designed and constructed in accordance with relevant safety standards so that hazards can be reduced to tolerable levels when it is installed as specified and operated under normal and intended use TM Palletizing Operator are intend...

Page 36: ...ility from the work positions Use with inadequate lighting Use with inadequate seating Use with insufficient means for escape or entrapment avoidance Use with inadequate location of manual controls Use with inadequate design of manual controls and their mode of operation Limitations on Liability The safety instructions and information in this manual shall be strictly followed TM Robot is not liabl...

Page 37: ...ystem to reduce possible occurrence of accidents Additional safety related components must be installed in accordance with the manufacturer s specifications for the required risk reduction For operating system safety settings and other safety components usage read and understand this manual the related Software Manual and the Hardware Installation Manual of corresponding versions listed in 1 5 1 P...

Page 38: ...unction to reset safety state when safety devices are triggered Test the Safeguard Output function to test the safeguard output when safety devices are triggered Emergency Stop If any accident or hazardous situation arises during the operation of the robot press the Emergency Stop switch to stop all the movements immediately Once the robot stops all its actions users must ensure that all the risks...

Page 39: ...ternal power Regarding how to operate as well as safety precautions refer and abide by the relevant chapters for safety For details refer to Medium Heavy Payload Series Hardware Installation Manual WARNING Due to gravity additional supports are recommended when manually releasing the brake When manually moving each robot joint the movement angle must be within a range of 45 Labels The following sa...

Page 40: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 40 ...

Page 41: ...Avoid injury to hands when in the vicinity of equipment with closing mechanical parts Electricity hazard Avoid coming into contact with electricity Do not unplug the teach pendant during operation Do not walk or stand here Prohibit walking or standing on a designated area Connect an earth terminal to the ground An earth terminal must be connected Product label Table 4 Labels ...

Page 42: ... Stop Emergency Stop Cat 3 d 4 27E 8 SF1 Pendant Emergency Stop Emergency Stop Cat 3 d 1 01E 7 SF2 External Emergency Stop Emergency Stop Cat 3 d 5 83E 8 SF3 External Safeguard Pause Protective Stop Cat 2 d 7 34E 7 SF4 External Safeguard Human Machine Safety Settings Cat 2 d 7 34E 7 SF5 Pendant Enabling Device Protective Stop Cat 2 d 8 01E 7 SF6 Motion Latching Mechanism Protective Stop Cat 2 d 2 ...

Page 43: ...l safety protective device will be a Cat 2 stop It may be necessary for the user or the system integrator to take these stop times into consideration when implementing risk reduction measures The robot has speed during this time which can transmit energy and present additional risk For details about the stopping time and stopping distance refer to TM12 TM 14 Hardware Installation Manual Medium Hea...

Page 44: ...t robot system actions upon discrepancy refer to 3 3 Explanation of Safety Functions For C1 discrepancy make sure the connection is securely connected and it is highly recommended to re boot the system Another way is to ensure the connection are securely connected and re trigger the input safety device Regarding C2 and C3 discrepancy ensure the connection is securely connected and reboot the syste...

Page 45: ...crepancy Cat 1 Stop C2 Discrepancy Cat 1 Stop Others Cat 0 stop Table 6 Stop Category and Action of Fault Detection of SF0 SF1 and SF2 Users can stop movement by pressing the emergency switch After the movements of the robot system has ceased the user must confirm that no hazardous conditions are present before manually releasing the emergency switch to allow reactivation of the robot system The E...

Page 46: ...izing Operator the suction cup will remain the vacuum to keep the workpiece during an Emergency Stop condition If the system was integrated with user customized power I O enabled end effector the emergency stop condition may cause the workpiece to be dropped For details refer to Safety Manual Techman Robot Safety System 3 3 CAUTION Person should be outside of the robot s operational space areas th...

Page 47: ...ncy detected in the safety functions the system performs a Cat 0 stop When Cat 0 stop occurs reboot the robot system to recover from Cat 0 stop status Safety Function Number Name Stop Category Action of Fault Detection SF3 External Safeguard Pause Cat 2 stop C1 Discrepancy Cat 2 Stop C2 Discrepancy Cat 1 Stop Others Cat 0 stop SF4 External Safeguard Human Machine Safety Settings C1 Discrepancy Tri...

Page 48: ...ne Safety Settings Output Refer to the table below regarding details of the output signal triggering status action of output upon Cat 1 Stop and fault detection actions Safety Function Number Name Output Signal in Regular Status Definition of Triggered Status Output signal of Triggered Status Action of Output when System Cat 1 Stop Occurs Action of Fault Detection SF7 Emergency Stop Output HIGH ES...

Page 49: ...mit The additional force that TCP received after compensating the weight of tool in TCP setting and weight of workpiece in payload setting in the programming The force limit of the tool center point can be set When the robot exceeds its set value it will trigger a protective stop The force of the tool center point is the external force at the tool center point estimated through the model by the ro...

Page 50: ... risk and users should apply risk assessment for the detection of SF14 TCP force near the singularity case SF14 TCP force should not be solely applied as the only safety protection measure in human robot collision case It s always recommended to include SF10 Joint Torque Monitoring in the human robot collision safety protection measure WARNING Cartesian Limit A is designed when robot s monitored p...

Page 51: ...elow the maximum payload weight decreases as the distance of gravity offset increases For instance TM12 robot arm can safely pick up or put down a heavy workpiece up to 12 within 100 of gravity offset distance If the distance is extended to 600 it is safer that TM12 robot arm picks up or puts down a workpiece at approximately 4 Figure 12 Relationship between Payload and the Center of Gravity Offse...

Page 52: ...ssary to reserve a distance of 500 from the outer boundary of the picking item and around the pallet as shown below The box location in this figure indicates the position where the robot will grip the box Figure 14 Palletizing operator clearance with straight conveyor Conveyor 500 500 500 500 Conveyor 500 500 500 500 Box location where the robot grips box ...

Page 53: ...he Palletizing Operator 2 Safeguard device SF3 SF4 and software limits SF15 Cartesian limit have to be set before the machine is taken into operation Instruction for sideways conveyor layouts had shown as below Operating Space Restricted Space Safeguarded Space Safeguard Pause Safeguard Human Machine Safety Settings Figure 15 Safeguarded space setup scenario with sideways conveyor layouts Conveyor...

Page 54: ...cted safeguard device sensing area is defined as the safeguarded space The safeguarded space can be set up into Full Pause Space Full Human Machine Safety or Pause Human Machine Safety Space scenario shown as below Safety Area Scanner DANGER Perimeter safeguarding measures shall be implemented using safeguard device or safety sensitive protective equipment Users have to consider the safety distanc...

Page 55: ...pace and restricted space The safeguarded space is still defined by the perimeter of user connected safeguard device sensing area and the safeguarded space should cover all of the TM Palletizing Operator in the space The safeguarded space with multi palletizing operator set up scenario is shown as below T each Pendant Conveyor T each Pendant Light Curtain d Multi Palletizing Operators Operating Sp...

Page 56: ...ardware methods However the reset method for the robot and the system shall be configured separately Regarding the software reset method of SF3 External Safeguard Pause and SF4 External Safeguard Human Machine Safety Settings For details see 5 1 3 Unpack the Palletizing Operator Regarding the hardware reset of SF3 External Safeguard Pause and SF4 External Safeguard Human Machine Safety Settings of...

Page 57: ...y functioning and the wires are securely connected Operation Mode and Mode Switching TM Palletizing Operator supports two main operation modes Manual Mode reduced speed and high speed and Auto Mode The modes are visually distinguishable by the color of the Indication Light Ring on the robot s end module The robot is in Auto Mode upon system boot up Auto Mode In Auto Mode the Indication Light Ring ...

Page 58: ...ow project editing page and pressing the Play Pause button on the pendant The initial project speed will reduce to 5 during each trial run forcing the path motion of the robot lower than 250 s The buttons on the Teach Pendant are for the adjustment of the project run speed Each button press increases or decreases project run speed by 5 WARNING The person should be outside of the safeguarded space ...

Page 59: ...r s Manual Product Version 1 1 Document Version 1 2 59 DANGER Users have to properly set the safety parameters and instruct the safety devices according to users risk assessment before start running the robot or the task program ...

Page 60: ...ion design and installation of the TM Palletizing Operator should comply with the following safety DANGER 1 Ensure all pieces of the equipment are kept dry If water enters the equipment disconnect the power and contact your supplier 2 Only use the original cables included with the robot If you need longer cables contact your supplier 3 Ensure that the robot is properly grounded If the grounding is...

Page 61: ...e electrical switchboard inside the Distribution Box Figure 20 Electric switchboard diagram By default most of the I Os on the switchboard are pre occupied and connected to devices upon shipment The table below gives a brief description for each component on the board Palletizing I O 24V 0V GND External I O CP1W 20EDT Safety controller G9SP N20S Safety controller SF C21 AC Power L N PE Power suppl...

Page 62: ...n once precaution steps have been taken Safety controller SF C21 Safety I O for external devices Input I O IN1 IN2 IN7 IN8 can be used to connect external safety devices Output I O SF0_2 SF0_3 output low when external safeguard device are triggered Breaker The No Fuse Breaker unit AC Power L N PE AC Power Supply Power Supply 2 Power supply component 120W 24V is the power supplying unit for the ele...

Page 63: ...I0_2 SI1_1 SI1_2 SI2_1 SI2_2 SI3_1 SI3_2 SI4_1 SI4_2 SO0_2 SO1_2 SO2_2 SO3_2 SO4_2 O_COM O_COM O_COM O_COM O_COM O_COM O_COM DI_00 DI_02 DI_04 DI_06 DI_08 DI_10 DI_12 DI_14 DO_00 DO_02 DO_04 DO_06 DO_08 DO_10 DO_12 DO_14 AOUT_V AIN_0P AIN_1P REMO SAFE SAFE SAFE SAFE SAFE SAFE SAFE SAFE SAFE SAFE SO0_1 SO1_1 SO2_1 SO3_1 SO4_1 Table 15 I O signals for DIO Analog I O and Safety I O Digital Input Digi...

Page 64: ..._13 DI_15 DI_01 DI_03 DI_05 DI_07 DI_09 DI_11 DI_13 DI_15 DI_00 DI_02 DI_04 DI_06 DI_08 DI_10 DI_12 DI_14 Reserved I O Available I O Set to sink input type When a device such as a transistor output sensor is connected NPN open collector transistor output can be used Set to source input type When a device such as a transistor output sensor is connected PNP open collector transistor output can be us...

Page 65: ...de Figure 22 NPN example Digital Output Digital Outputs can be set to either sink output or source output by selection The maximum drive current is 300mA per channel If the load exceeds 300mA a relay should be used to drive it The I O highlighted in red are reserved for the control box upon shipment while the I O highlighted in blue come in both reserved and available I O ...

Page 66: ...DO_03 DO_05 DO_07 DO_09 DO_11 DO_13 DO_15 DO_01 DO_03 DO_05 DO_07 DO_09 DO_11 DO_13 DO_15 DO_00 DO_02 DO_04 DO_06 DO_08 DO_10 DO_12 DO_14 Reserved I O Available I O Set to sink output type Connect DO_COM terminal to the minus side of the power supply Set to source output type Connect DO_COM terminal to the plus side of the power supply ...

Page 67: ...e relay or PLC input Analog Input Output Below are Analog Input Output pin assignments The I O highlighted in red are reserved for the control box upon shipment while the I O highlighted in blue come in both reserved and available I O AOUT_V AIN_0P AIN_1P REMO AOUT_G AIN_0G AIN_1G REMO AOUT_G AIN_0G AIN_1G REMO AOUT_V AIN_0P AIN_1P REMO Reserved I O Available I O ...

Page 68: ...og Output 10 00V 10 00V 11bit 0 07 1 ms Analog Input Analog Input only supports a certain voltage mode and the detectable range is between 10 00V and 10 00V Red device is connected to AIN_1P Purple device is connected to 24V Black device is connected to AIN_1G Gray device is connected to 0V GND Figure 23 Analog Input Application Analog Output Analog Output only supports a certain voltage mode and ...

Page 69: ...nt Version 1 2 69 Figure 24 Analog Output Application Safety Input Output Below are Safety I O pin assignments The I O highlighted in red are internally wired for robot control box by default while the I O highlighted in blue come in both reserved and available I O ...

Page 70: ...or Human Machine Safety Settings SI3 1 SI3 2 Internally wired to Enabling Device Input SO3 1 SO3 2 Internally wired for Robot Internal Protective Stop Output SI4 1 SI4 2 Internally wired to ESTOP Input without Robot ESTOP Output SO4 1 SO4 2 Internally wired for Robot Encoder Standstill Output Table 16 Definitions of Safety I O connectors Safety Input Below are Safety Input pin assignments Be noted...

Page 71: ...highlighted in blue come in both reserved and available I O SO0_1 SO1_1 SO2_1 SO3_1 SO4_1 SO0_2 SO1_2 SO2_2 SO3_2 SO4_2 Reserved I O Available I O Safety Controller G9SP N20S I O Configuration The Safety Controller G9SP N20S provides I O configurations for 1 set of Emergency Stop and 4 sets for PAUSE function for customers to connect with safety device SO0_2 SO1_2 SO2_2 SO3_2 SO4_2 SO0_1 SO1_1 SO2...

Page 72: ...uard devices Trigger SF3 External Safeguard Pause If external safeguard devices are connected SI4 SI5 SI6 SI7 SI8 SI9 SI10 SI11 Connected to Safety Controller SF C21 SI12 SI13 Connected to Teach Pendant Emergency Stop SI14 SI15 Connected to SF_13 of the robot SI16 SI17 Connected to SF_14 of the robot SI18 SI19 Connected to Test Signal of the pillar Safety Output Pin Description Function SO0 SO1 Co...

Page 73: ...e to prevent short circuit and the emergent stop of the machine Connecting Safety Devices with Mechanical Contacts Connecting Safety Devices with Semiconductor Outputs Figure 26 Connecting Safety Devices Safety Controller SF C21 I O Configuration The Safety Controller SF C21 inputs are pull high 24V cables by default but can be used to connect external safety units for robot collaborative function...

Page 74: ... default Users may connect it to external safeguard device IN7 IN8 Connected to 24V by default Users may connect it to external safeguard device Safety Output Pin Description Function SF0_0 SF0_1 Connected to SI10 SI11 of Safety Controller G9SP Trigger SF4 External Safeguard Human Machine Safety Settings SF0_2 SF0_3 Available for customer use Output low when external safeguard device triggered Tab...

Page 75: ... total output of 24V 5A These terminals are used for external and internal device Figure 28 Power Terminal 24V 0V External I O CP1W 20EDT and Reset Button Setting By default the external Reset Button is in Manual Reset If users wish to set it in Auto Reset connect the IN_03 pin of External I O CP1W 20EDT to GND terminal as shown in the figure below IMPORTANT Make sure the reset button module is al...

Page 76: ...te To resume Manual Reset simply disconnect the wiring to Ground Light Indications Refer below for the details about pallet light indicators LED Status Description Pallet Light Red No pallet detected Pallet Light Orange Pallet is empty or stacked fully with boxes Pallet Light Green Normal operation Figure 30 Pallet light indications ...

Page 77: ...als lie in the External I O component CP1W 20EDT as depicted in the diagram below Signal Color Indication Status Output0 Green System normal Output1 Orange System pause Output2 Red System emergency stop Table 19 System Light Indicator Pin Signal 1 F_24V 2 EXO1_00 3 EXO1_01 4 EXO1_02 5 PE Figure 31 System Light Indication I O ...

Page 78: ...g slip or are damaged do not sign the receipt and contact your distributor dealership support as soon as possible If the items received do not match your order contact your corporation support immediately Inspect each item for external damage as it is removed from its container If any damage is evident contact your corporation support Unpack the Control Box Refer to TM12 TM14 Hardware Installation...

Page 79: ...ck Assemble TM Palletizing Operator Remove the Rear Housing Before installing TM Palletizing Operator it is necessary to remove the rear housing first 1 Unlatch the side cover hinge of the rear housing then remove the cover required both left and right Figure 33 Unlatch the Side Cover Hinge 2 Remove the 6 screws marked in the diagram and disassemble the rear housing Remember to keep the screws in ...

Page 80: ...ion 1 2 80 Figure 34 Remove the 6 screws 3 Unfasten the 4 screws shown in the diagram to detach the pneumatic quick connector and then disassemble the drag chain Remember to keep the screws in a safe place Figure 35 Unfasten the 4 Screws Applicable to Pillar Elongation 500 ...

Page 81: ... User s Manual Product Version 1 1 Document Version 1 2 81 Figure 36 Unfasten the 4 Screws Applicable to Pillar Elongation 800 1200 4 Refer the followings for each pillar drag chain bracket installation Pillar Elongation 500 ...

Page 82: ... Manual Product Version 1 1 Document Version 1 2 82 Pillar Elongation 800 Pillar Elongation 1200 Install TM Robot Once the rear housing is removed the robot can be installed 1 Secure TM Robot on the fixed plate with 4 of M10 screws ...

Page 83: ...rewdriver to open the covers of the cable drag chain Figure 38 Open the Covers of the Cable Drag Chain 3 Place the robot cable in the cable drag chain and seal the cover of the cable drag chain 4 Use the unfastened screws to reinstall the cable drag chain and pneumatic quick connector Figure 39 Seal and Reinstall Applicable to Pillar Elongation 500 ...

Page 84: ...he 4 screws completely tightened One person should continuously support the robot arm while the other person goes to get required parts Otherwise the robot arm may tip result in equipment damage or personal injury WARNING Do not attempt to move any robot links until the robot has been secured in position Failure to comply could result in the robot falling and causing either personnel injury or equ...

Page 85: ...10 x L30 at least 8 8 strength Install the Control Box 1 Remove the EX IO module from the control box by unplugging the 44pin 40pin ribbon cable located at the rear of the module Figure 41 Remove EX IO module from control box 2 Secure the control box covert brackets to the legs of the control box Use 4 x M4 screws for each of the bracket ...

Page 86: ...igure 42 Secure the Covert Brackets to the Legs of the Control Box 3 Lay the control box down horizontally Place AC power 40pin 44pin HDMI and USB cables through the space between the legs and the brackets to plug into their corresponding connectors Figure 43 Proper Cable Connections ...

Page 87: ...off Do not install while the robot is on to avoid abnormal shutdown 4 Note that the robot connector cable does not go through the space between the legs and the brackets Simply plug this cable as the shown in the diagram Figure 44 Proper connections for robot connector cable 5 Make sure all the cables are firmly plugged Also ensure the cables align the notch of the connectors ...

Page 88: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 88 Figure 45 All Cable Firmly Plugged 6 Insert the supplied USB dongle into an available USB port ...

Page 89: ...oduct Version 1 1 Document Version 1 2 89 7 Secure the bracket plates of the control box onto the base Apply 4 x M6 screws to tighten the plates so that the control box is securely fixed Figure 46 Secure the Bracket Plates of the Control Box ...

Page 90: ... Housing 1 Place the rear housing properly and apply 3 x M8 screws at each side as shown in the diagram Figure 47 Place the Rear Housing DANGER Screws must be properly tightened when using this product Improper tightening may cause the tool or part to fall out or even cause personal injury and death ...

Page 91: ...onnection cable through the notch of the housing as shown Figure 48 Wire the Robot Cable through Notch 3 Apply strain reliefs to fix the cables in place 4 Then reinstall the side covers of the rear housing Figure 49 Reinstall the Side Cover 5 Place the robot stick on the top cover or inner side of the side cover ...

Page 92: ...t the stick is immediately stored out of sight and reach of personnel working on the robot Install Cable Protection Conduit 1 Install the cable protection conduit along the specified segments to fasten it with Velcro on the robot The length of each segment on the conduit S1 330 S3 600 S5 160 S2 250 S4 270 Figure 50 Segments Using with Velcro The distance of each segment between the joints and the ...

Page 93: ...alletizing Operator User s Manual Product Version 1 1 Document Version 1 2 93 Figure 51 Distance of Each Segment 2 Penetrate the air tubes through the space between the camera module and the flange as shown ...

Page 94: ...ument Version 1 2 94 Figure 52 Penetrate the Air Tubes through example by centered gripper position 3 Connect the air tube plug to the gripper plug Make sure the cable is connected to the corresponding A B plug Figure 53 Connect Air Tube Plug to the Gripper Plug ...

Page 95: ... B plug Figure 54 Connection Completed Connect External Compressed Air Supply Before connecting external compressed air supply make sure the ON OFF valve is switched OFF 2 3 position The external compressed air supply is connected to the air unit of TM Palletizing Operator Base through an 8 compressed air tube ON OFF Valve at OFF 2 3 position Connect 8 tube Figure 55 Air Unit for External Compress...

Page 96: ...essure Too Low appears refer to Num 17 in 6 5 1 Advanced1_General_Parameters The default value of external compressed air pressure is 0 5MPa 5 bar Users may adjust the pressure detect value based on the relation between the supplied compressed air and the object to be gripped The output air pressure is adjustable through filter regulator The output air pressure is shown on the pressure gauge The o...

Page 97: ...sion 1 1 Document Version 1 2 97 Figure 57 TM Palletizing Operator Transportation 1 4 Figure 58 TM Palletizing Operator Transportation 2 4 For jack lifts narrower than 550 typically 540 wide insert the jack lift into the rear slot to lift the operator ...

Page 98: ...tation 3 4 Note When transporting TM Palletizing Operator with the robot on top of the Palletizing Operator Base it is necessary to tie and surround the robot with durable packing materials to protect it from potential damage For wider jack lifts typically 685 wide insert the jack lift into the side slot to lift the operator ...

Page 99: ...ed to the equipment before transporting it 4 Remove all of the connections to external devices external storage devices through any interface Encountering Non Flat Surfaces When encountering non flat surfaces apply a wrench to adjust the leveling mounts in order to avoid wobbling 1 Rotate upper hex nut clockwise to loosen the leveling mounts 2 Rotate lower hex nut clockwise to lower the leveling m...

Page 100: ...2 100 Figure 61 Using a wrench to Loosen Tighten Leveling Mounts If the operator is not relocated frequently it can be fixed to the floor using anchor points The following diagram provides a dimensional reference for anchor points Figure 62 TM Palletizing Operator Anchor Points ...

Page 101: ...instructions in 5 4 TM Palletizing Operator Transportation WARNING This product must be shipped and stored in a temperature controlled environment within the range 20 C to 60 C 4 F to 140 F The recommended humidity is up to 75 percent non condensing It should be shipped and stored in the supplied package which is designed to prevent damage from normal shock and vibration You should protect the pac...

Page 102: ...crew from the product package 3 Remove the screw circled in red in the image below and prepare the seal washer and screw shown in the last step to connect the Ground Wire 4 Assemble the Ground Wire connection in this sequence screw Ground Wire O ring seal washer Then align the screw to the screw hole and tighten it ...

Page 103: ...gn the notch of the plug with the latch of the receptacle and insert the cable 6 Rotate the first green ring on the plug clockwise until it is totally tightened 7 Push the second green ring toward the palletizing operator base User may need to repeat step 5 and 6 until the cable plug is firmly tightened to the palletizing operator base ...

Page 104: ... 104 Figure 65 Rotate and tighten the cable rings IMPORTANT DO NOT twist the black ring to tighten the connection NOTE After the connection is secured there should be three threads visible generally 8 Teach Pendant cable connection to the palletizing operator base is now complete ...

Page 105: ...t motion When using a teach pendant user is responsible for ensuring that the stick is immediately stored out of sight and reach of personnel working on the robot Disconnect the Teach Pendant For proper disconnection of the Teach Pendant disconnect the Teach Pendant connector first and then the ground wire 1 Rotate the first green ring on the plug counterclockwise to disconnect the cable from the ...

Page 106: ...Version 1 2 106 Figure 67 Disconnect the Teach Pendant Cable IMPORTANT DO NOT twist the black ring to disconnect the cable 3 Remove the seal washer screw and Ground Wire O ring and place the original screw back into the palletizing operator base Then tighten the screw ...

Page 107: ...y to install the Reset Button before activating the palletizing operator to ensure safety For installation connect the Reset Button cable to the Reset input of the palletizing operator Figure 68 Install Reset Button SYSLIGHT Connection Users may choose a M8 5 pin cable based on IEC 61076 2 104 standard to establish SYSLIGHT connection Make sure to match the pin definition below ...

Page 108: ...er to the table below regarding the AC input specifications of the TM Palletizing Operator Parameter Min Typical Max Unit Input voltage 100 240 VAC External AC fuse 100V 120V 16 A External AC fuse 220V 240V 11 A Input frequency 43 63 Hz Table 20 AC Input Specifications of TM Palletizing Operator IMPORTANT 1 The robot will automatically limit the total output if an AC 100V 199V power input is used ...

Page 109: ...tizing operator is OFF as well 4 As depicted in the figure below connect the power cable through the housing of the distribution box to the AC Power L N PE and connect another end of the power cable to the AC IN of the palletizing operator Keep in mind that the palletizing machine must adopt single phase AC 100 240V power supply Figure 70 Power Connection Reference IMPORTANT The power supply shoul...

Page 110: ...t current of the palletizing operator is protected by the Residual Current Device RCD and appropriate fuses 3 Ensure that all cables are correctly connected before powering on the machine Always use genuine power cables correctly Activate Deactivate TM Palletizing Operator Activate the system 1 Power on the operator machine Turn the main switch clockwise to the right Figure 72 Turn the Main Switch...

Page 111: ...nitialized 6 Press the Reset Button again when the Reset Button light is on CAUTION Before booting up the robot system make sure that all of the parts with electrics like teach pendant or safeguard devices have been correctly connected and securely fastened Deactivate the system 1 Power off the robot through TMflow or press and hold the Power Button on the Teach Pendant 2 Once the robot is complet...

Page 112: ...x directly 3 Loosen the power of robot body directly Install Adjustable Flexible Gripper TM Adjustable Flexible Gripper can be installed in 2 positions centered or 10 cm shifted By default the gripper is delivered in centered position Figure 73 Gripper Flange at Centered Position as Delivered If users wish to change the gripper flange to 10 cm shifted position follow the steps in the following sub...

Page 113: ...e 74 Gripper Flange at Shifted Position Change Gripper Flange Position To change the gripper flange position simply perform the steps below 1 Remove the two M6x12L screws with Allen wrench and detach the flange knob from the gripper Figure 75 Remove Two M6x12L Screws and Detach Flange Knob ...

Page 114: ...nt Version 1 2 114 2 Remove five M6x6L screws with an Allen wrench and detach the position converter from the gripper Figure 76 Remove Five M6x6L Screws and Detach Position Converter 3 Fasten flange knob to 10cm shifted position and secure it with two M6x12L screws ...

Page 115: ...Shifted Position 4 The figure below shows that the flange position change is completed Figure 78 Flange Position Change Completed Install the Gripper on the Robot for centered position 1 Turn the Main Switch to power on the Robot see 5 9 for details 2 Hand guide the robotic arm to the appropriate or pre defined posture ...

Page 116: ...r and the robot 4 Align the gripper flange to the robot flange and fasten the gripper with four M6x12L screws Figure 79 Align Gripper and Screws for centered position 5 Connect the 8 pin gripper cable to the I O connector on the robot Figure 80 Connect 8 pin Gripper Cable to I O Connector on Robot for centered position ...

Page 117: ...n the Robot see 5 9 for details 2 Hand guide the robotic arm to the appropriate or pre defined posture 3 Shut down the palletizing operator and the robot 4 Align the gripper flange to the robot flange and fasten the gripper with four M6x12L screws Figure 81 Align Gripper and Screws for shifted position 5 Connect the 8 pin gripper cable to the I O connector on the robot ...

Page 118: ...r on Robot for shifted position Adjust Pallet Sensor 1 Unfasten two M4 screws 2 Adjust the sensor module position horizontally 3 Fasten the two M4 screws back Figure 83 Adjust Pallet Sensor Horizontally Be noted that the default sensor position is 22 as defined to detect standard EPAL pallet corner with a range of 17 4 2 or smaller size ...

Page 119: ...up which is the next chapter users particularly those using TM Palletizing Operator for the first time have to download TMstudio software and TM Palletizing Operator Software Package from Techman Robot official website and launch TMflow software TMstudio a PC based offline graphical simulation software program for robotic applications Users will use Palletizing Wizard in TMstudio to create and con...

Page 120: ... a USB drive The USB drive must be labelled TMROBOT for the robot system to detect the device The file location TM_Export TMPLTZOP TextFiles will be used to store palletizing layout text file generated in TMstudio For details about TM Palletizing Operator Software package refer to 6 1 TM Palletizing Operator Software Package Overview Set Teach Pendant and TCP Settings in TMflow NOTE It is required...

Page 121: ...External Safeguard Pause and SF4 External Safeguard Human Machine Safety Settings it is recommended to set in Manual Reset 5 Click System Input Display Devices 6 Click Input Devices check Pendant and read messages in Caution 7 Test the functions of the Teach Pendant such as pressing the Error Log button on the pendant to display the log history on the screen TCP Setting for the Adjustable Flexible...

Page 122: ...1 2 122 RX deg 0 RY deg 0 RZ deg 0 Figure 86 Non Shifted Gripper Schematic TCP values for the Shifted Gripper X 0 Y 100 Z 100 RX deg 0 RY deg 0 RZ deg 0 Mass 1 977 lxx 28732 lyy 16540 lzz 37245 X 8 97 Y 7 29 Z 3 88 RX deg 0 RY deg 0 RZ deg 0 Figure 87 Shifted Gripper Schematic ...

Page 123: ...in a USB drive labelled TMROBOT 3 Set palletizing applications in TMstudio and generate text file which has the data about the relation between boxes and pallets 4 Export the generated layout text file to the destined path in USB details in next section 5 Plug the USB labelled TMROBOT into an available USB port of the Teach Pendant 6 Import palletizing components and text file into TMflow 7 Set I ...

Page 124: ...tudio and select the TM Palletizing Operator Template file with the pillar length 500 800 or 1200 in the TM Palletizing Operator Software Package folder Import the files Scene CAD TCP and Palletizing in the TM Palletizing Operator Template to use in TMstudio Figure 88 Import Open a Scene Switch to Palletizing Wizard and click Wizard Click OK to open the default scene Figure 89 Open a Scene 1 2 ...

Page 125: ...Figure 90 Open a Scene 2 2 Gripper Change To use the different gripper click Change Tool to select the applicable gripper Figure 91 Gripper Change Select Application Type Palletizing Wizard supports Pallet Depallet and Change Pallet for respective application types by the users needs ...

Page 126: ...ing Operator User s Manual Product Version 1 1 Document Version 1 2 126 Figure 92 Select Application Type Start Setting Pallet After selected the pallet to edit click Edit to begin editing Figure 93 Pallet Setting ...

Page 127: ...boundary setting to define the maximum area to put the boxes by referring to the figure below The figure below showing a custom pallet setting Length 1000 Width 800 Height 144 Figure 94 Pallet Dimension and Boundary Setting Note Users can save the pallet parameters as a new one or delete the custom pallet parameters Template Dimension Customize N A EPAL 6 PALLET 800 x 600 x 144 EPAL 3 PALLET 1200 ...

Page 128: ...om box setting Length 200 Width 370 Height 250 dx 10 dy 10 Figure 95 Box Dimension and Label Direction Setting Note Users can save the pallet parameters as a new one or delete the custom pallet parameters Note Check Enabling Z Direction Clearances allows users to set tasks between layers such as inserting partitions Once checked users can insert intervals between layers in Step 3 Step 3 Create Pal...

Page 129: ...in previous steps Figure 96 Create Pallet Layers Users can use the question mark icon to view the respective icon description Refer the table for details of icon functions Icon Function Icon Function Add Box Layer Add Box Add Z Direction Clearance Rotate Box Before Placing Copy Box Layer Change Box Label Side Paste Box Layer Auto Layout Clear Box Layer Shift Box Delete Box Layer Delete Box Table 2...

Page 130: ...ersion 1 2 130 Users can use the auto layout icon to set auto layout types on demand Note When selected for both Odd layer and Even layer users can check INVERT to set their placements in reverse Users can click or tap the box to select and shift the box by preferences ...

Page 131: ...ined shift step Shift the box es to the arrow direction as close to the boundary by dx dy setting in Step 1 or previously placed box as possible If a single box is selected clicking tapping on this Arrow will only shift the selected box only If no boxes are selected clicking tapping on this Arrow will shift all the boxes Table 24 Shift Box Configurations Snap can align the borders or boxes to comp...

Page 132: ...n Step 4 users can set the palletizing sequence based by the pallet information in Step 3 The following gives an example of how to configure the palletizing sequence for the first time with Auto Sequence Auto Sequence has the system set the palletizing sequence automatically The number denotes the order to stack the box ...

Page 133: ...respective icon description Refer the table for details of icon functions Icon Function Icon Function Copy Sequence Auto Sequence Paste Sequence Add Sequence Undo Table 26 Palletizing Sequence Icons Copy the Box After setting the pallet the system will return to the previous page and users can plan another pallet setting in sequence ...

Page 134: ...n 1 2 134 Or users can use Copy and Paste to complete the setting for both sides of pallets Click Next to go to the next step Note Once the box of Pallet_0 is copied to Pallet_1 if proceeding to rotate other than the box placement the placement vector will be rotated as well ...

Page 135: ...ize of the boundary gets copied There will be no box exceeding the bounds after copying and pasting Palletizing Simulation Parameter Setting Click Parameters Setting to set parameters for palletizing as shown below Users can input parameters for the simulation Refer below the descriptions of each parameter Click Apply when done ...

Page 136: ... box Elevated Height B The elevated height along Z axis after the robot grips the box Via Point Offset C Position relative to the Gripping Up point Placement Vector Box Approaching Vector X Y Z D Placement Vector Elevated Height Before Placing E Pillar Left Right Pillar Layer Z direction height is considered as a layer Pillar Floor Distance Compensation Safety Distance When the distance between th...

Page 137: ...letizing simulation cycle time does not include I O wait time and gripper suction time The box gripping in palletizing simulation is based on the matching coordinates between TCP and the center points of boxes Motion simulated on TMstudio Palletizing Wizard is a combination of LINE motion e g picking placing and PTP motion e g moving to via Point with 100 of the Project speed precise positioning b...

Page 138: ... TMflow After downloading the software package from the official website put TM_Export of TM Palletizing Operator Software Package V1 1 to an USB driver labelled TMROBOT Insert the USB drive to the control box and launch TMflow and proceed with the steps below 1 In TMflow click at top left and click System Import Export Figure 97 Import Export 2 Click Import at top left ...

Page 139: ... Figure 98 Import Files 3 Select the robot name TMPLTZOP as in this example in the Robot List as prompted and click OK Figure 99 Robot List 4 Click Component and check all the avalalbie components in the list After checking all the components the components will be in Selected Files ...

Page 140: ...sion 1 1 Document Version 1 2 140 Figure 100 Import Selected Components Figure 101 Import Completed 5 Import the text file generated by Palletizing Wizard to set the palletizing project Click Text File check Layout txt and click Import at bottom right ...

Page 141: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 141 Figure 102 Import Text File 6 Click and click Setting Component Figure 103 Select Component in Setting ...

Page 142: ... Palletizing TMOperator_TMROBOT_TMPLTZOP_V002_Grip Box Gripping TMOperator_TMROBOT_TMPLTZOP_V002_Release Gripper Release Table 28 Component Descriptions Set I O While Project Stop Error Before using the imported components it is necessary to set digital I O first to ensure that the pillar is paused when palletizing project is stopped or encounters error Please follow the steps below for setting 1 ...

Page 143: ...ick Set I O While Project Stop Customized 5 In circles below Control Box set DO0 and DO1 to L Figure 106 Set I O While Project Stop Set TMOperator_TMROBOT_TMPLTZOP_V002_Pillar Before starting the palletizing project please calibrate pillar first and connect the USB dongle to the control box Note The component will be unavailable if the USB dongle is not connected ...

Page 144: ... setting 1 In the node menu at left of TMflow drag the TMOperator_TMROBOT_TMPLTZOP_V002_Pillar node to flow editing area 2 Click the pencil icon on the node Figure 107 Start Pillar Calibration 3 Click Pillar Calibration to go to Expression Editor Setting Make sure the bool value is true Figure 108 Pillar Calibration ...

Page 145: ...lues as the maximum and the minimum 4 Calibration test Press PLAY PAUSE button on the teach pendant to start the test If successful the screen will prompt a Calibration OK message with related voltage information Press Stop button if wish to exit Figure 110 Calibration Test Danger During pillar calibration make sure the pillar is free of disturbance or collision from external forces Please use the...

Page 146: ...146 Lower the Pillar Height When proceeding vision base editings it is necessary to lower the pillar to its minimum height at first The steps are as below 1 Press the reset button when the button light is on 2 In TMflow click Setting Controller Figure 111 Controller 3 Click IO tab ...

Page 147: ...vide a walkthrough of the setting options for the component TMOperator_TMROBOT_TMPLTZOP_V002_Main This is the component to set main palletizing parameters to execute palletizing applications Please make sure the USB dongle is connected to the control box Note The component will be unavailable if the USB dongle is not connected Please follow the steps below for setting 1 In the node menu at left of...

Page 148: ... 3 Recognizing Box Position Step 4 Teach Gripping Point Step 5 Visual Recognitions Figure 114 Palletizing Steps Step 1 Import File 1 Clic Step1_Import File and click Variables Figure 115 Import File Setting 2 After Expression Editor Setting shows click the filename Layout txt by default of the text file imported in 6 4 1 and click OK ...

Page 149: ... identical settings the following steps depict box1 merely Step 2 Check Pillar Height 1 Check Advanced 2 Click Advance1_General_Parameters and click Variables 3 Navigate to g_TMOperator_TMROBOT_TMPLTZOP_Pillar_Elongation 4 Modify the variable value by the pillar length such as writing 500 to the variable for the pillar height is 500 Figure 117 Check Pillar Height Step 3 Recognizing Box Position 1 ...

Page 150: ...Recognizing Box Positions Figure 118 Go to Recognizing Box Positions 3 Click Vision Job TMOperator_TMROBOT_TMPLTZOP_V002_Main_Step2_Recognizing Box Positions Figure 119 Vision Job 4 In the Vision Job list click the pencil icon of TMOperator_TMROBOT_TMPLTZOP_V002_Main_Step2_Recognizing Box Positions ...

Page 151: ...his position is suitable to take as the initial point in the meantime when picking up the box B If using for the first time without the initial position being taught and guided beforehand click Cancel and proceed to teach and guide to the initial position i Put the box properly and place TM Landmark on the lower left corner of the box ii Hand guide the robot to the initial position for picking up ...

Page 152: ...ck the save icon at top left Figure 122 Identify TM Landmark NOTE If the robot is unable to detect TM Landmark due to obscurity right click Initiate Edit to adjust Camera Parameters IMPORTANT Do NOT move or touch the box during this step otherwise the recognition may fail Step 4 Teach Gripping Point 1 Lower the pillar to the rock bottom Refer to 6 4 3 1 Lower the Pillar Height for ...

Page 153: ...per to the gripping point DANGER When using the FREE button to release brakes without motor power the robot may sag due to gravity Be prepared to support the robot system If it is found that it is not possible to support the robot system release the FREE button immediately which will lock the robot joint brakes IMPORTANT Do NOT move or touch the box during this step otherwise the recognition may f...

Page 154: ... 1 1 Document Version 1 2 154 Figure 123 Move the Robot to Grip the Box 3 Click Step3_Teach Gripping Point Point Manager Overwrite new pose to this point to set and record the gripping point Figure 124 Step 3 Teach Gripping Point Step 5 Visual Recognition ...

Page 155: ... to grip or teaching the work space again as required please proceed to the steps below 1 Lower the pillar to the rock bottom Refer to 6 4 3 1 Lower the Pillar Height for instructions 2 Click Step4_Visual Recognitions Figure 125 Step4_Visual Recognition 3 Click Vision Job TMOperator_TMROBOT_TMPLTZOP_V002_Main_Step4_Visual_Recognitio ns and click the icon at top right 4 Input the name in the field ...

Page 156: ...127 Calibration 6 Click Automatic recommended to reduce the process Figure 128 Automatic Calibration 7 Click the camera setting icon at top left Set the best shutter time white balance and focus by the factors in surroundings or application requirements Users can also choose Auto once to have the robot camera detect and adjust the parameters to shorten the setting process ...

Page 157: ...ext Figure 130 Tilt Correction 1 2 When prompted click Yes to skip automatic tilt correction and go to the next directly When prompted click No to start automatic tilt correction Select this option to make sure all the following steps can be executed as recommended Users will be requested to tap PLAY PAUSE on the teach pendant and the robot will navigate visually and calibrate automatically ...

Page 158: ... Stage 2 Set Workspace the robot will set the workspace automatically Make sure TM Landmark remains still Click OK after the message Success prompts Figure 132 Set Workspace 10 In Stage 3 Workspace Calibration tap PLAY PAUSE on the teach pendant to start visual navigation The robot will start to celibate the workspace ...

Page 159: ... Document Version 1 2 159 Figure 133 Workspace Calibration 11 In Stage 4 Save Result click Save after calibration completes Figure 134 Save Result 12 When the Save Workspace window prompts input the name in field next to Name for this workspace and click Save ...

Page 160: ...r User s Manual Product Version 1 1 Document Version 1 2 160 Figure 135 Save Workspace 13 Back to the Vision Job list click the pencil icon of TMOperator_TMROBOT_TMPLTZOP_V002_Main_ Step4_Visual Recognition and click Imitate ...

Page 161: ...gripping position in case triggering DI14 as High Set TMOperator_TMROBOT_TMPLTZOP _Vxxx_Grip and TMOperator_TMROBOT_TMPLTZOP _Vxxx_Release Both of the components function as gripping and releasing of the Adjustable Flexible Gripper If you need to apply the gripper to any self defined project in Advanced 2 8 both of the components are applicable Advanced Palletizing Setting TM Palletizing Operator ...

Page 162: ...ection Int 1 1 Start palletizing from the right pallet 2 Start palletizing from the left pallet 5 Pallet1_Start_LayerIndex Int 1 1 Pallet1_Start_LayerIndex M N Start palletizing run from right pallet with Box N in Layer M M the number of layers starting from the right pallet N the corresponding index towards the number of layers 6 Pallet2_Start_LayerIndex Int 1 1 Pallet2_Start_LayerIndex M N Start...

Page 163: ... ignore parameters X Y Z M 0 use TMflow input values X Y Z X Y Z The offset in X Y Z directions related to Elevated_Height 14 Pallet1_Approach_XY_Z Float 1 30 300 Pallet1_Approach_XY_Z M X Y Z M 1 use TMstudio settings ignore parameters X Y Z M 0 use TMflow input values X Y Z X Y Z The approach vector X Y Z upon box placement 15 Pallet2_Approach_XY_Z Float 1 30 300 Pallet2_Approach_XY_Z M X Y Z M ...

Page 164: ...ce Pressure if air gripper is not used please set the variable to False 26 Movement_Protection Bool FALSE TRUE detect if the boxes on the other side of pallet are higher than the base False does not detect if the boxes on the other side of pallet are higher than the base 27 Movement_Protection_Layer Int 4 If Movement_Protection True the detection will be triggered when the current pallet is being ...

Page 165: ... on gripper cause PAUSE message For details please see Appendix A 3 If visual recognition fails due to light distraction from the environment the palletizing system will pause and the robot will not be able to grab the box The system will show Grab fail cause pause Resume after checking For details please see Appendix A Advanced2 8 Advanced2 8 settings are programmed with editable subflows offerin...

Page 166: ...Layers This subflow allows users to add interval between layers of boxes such as insertion of slip sheet Users may refer to TMOperator_TMROBOT_TMPLTZOP_V002_Main1_pillar_robot_base for XYZ coordinates which will record the relative direction between the point position and the pillar height Advanced6_Via_Point This subflow allows users to replace Via Point nodes Advanced7_Box_Placement This subflow...

Page 167: ...ing Vector X Y Z Relevant Parameters Parameter Description TMOperator_TMROBOT_TMPLTZOP_V002_Main1_var_now_layer_inder Current layers including Z axis intervals TMOperator_TMROBOT_TMPLTZOP_V002_Main1_var_box_info 2 Box height var_Box_Height TMOperator_TMROBOT_TMPLTZOP_V002_Main1_var_pillar_now Current pillar height TMOperator_TMROBOT_TMPLTZOP_V002_Main1_var_now_right_left Current palletizing direct...

Page 168: ... 1219 L x1016 W Maximum Pallet Speed Up to 7 boxes object per minute Dimension footprint 1400x854 Weight 245 9 not including Teach Pendant Power Supply 100 240VAC Power consumption Typical 400 Watts Temperature Operating 0 50 C Temperature Storage Transportation 20 C 60 C Humidity Operating Less than 85 Humidity Storage Transportation Less than 75 Certification CE Machine Directive 2006 42 EC ISO ...

Page 169: ...x dual channel outputs Compressed Air Requirements Dry filtered air according to ISO 8573 1 2010 7 4 4 Supplied compressed air pressure 2 0 to 8 0 bar 0 2 to 0 8MPa Operating Pressure of vacuum generator 2 0 to 6 0 bar 0 2 to 0 6MPa Software Offline programming Simulation TMstudio Palletizing Wizard Setting and Running TM Palletizing Operator Software Packages Eye in Hand Camera Built in 1 2M 5M p...

Page 170: ...lowing When this function is enabled in Manual Mode all manual control operations are enabled only when users press the three position enabling device in the middle position If the Enabling Device is released or fully pressed the robot system performs a protective stop When starting a manual trial run of the project pressing the PLAY button the Enabling Device should be pressed in the middle posit...

Page 171: ...ures and Guidelines Only the legal distributor or authorized service center can repair the TM Robot Users should not repair it by themselves DANGER Before performing maintenance or service record the details of each setting for the robot for normal operation Make sure that each setting satisfies the original conditions before resuming normal operation including but not limited to Safety Software S...

Page 172: ...ned items are the property of the Corporation This warranty does not cover other requests directly or indirectly related to equipment No conditions of this warranty shall attempt to limit or exclude customer s statutory rights or manufacturer s responsibility for personal injury or death due to negligence The warranty cannot be extended even if it is the initial warranty The Corporation reserves t...

Page 173: ...0 seconds to enter the Safe Start Up Mode The Indication Light Ring will turn light blue The joints of the robot are still in the state without driving power 4 Press the FREE button continuously to release the joint axis brake and move the robot 5 After the issue is resolved press the Stop button on the robot stick or the teach pendant for about three seconds The robot will perform the calibration...

Page 174: ...n The project paused to prevent the robot from crashing into the opposite working pallet boxes Reset Procedure Clear the full state of the pallet and press Start to continue 3 No box detected on gripper cause PAUSE Situation The robot detects abnormal air pressure on the tool when grapping the box Reset Procedure Check the state of the box dropping and stop the project Then restart the project whe...

Page 175: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 175 Place the box in the picking position Press Start to start the project again ...

Page 176: ...erating mode use up and down arrow buttons to select oPS mode single point setting 3 Press the set button to enter OUT1 mode Use up and down arrow buttons to select no normal open mode 4 Press the set button to enter OUT2 mode Use up and down arrow buttons to select oFF mode 5 Press the set button to switch response time sequence 2 5ms SoG Backlight Control 6 Press the set button to enter unit set...

Page 177: ... mode press and hold the button the blue button for about 3 seconds to enter OUT1 operating mode 2 In OUT1 operating mode use up and down arrow buttons to select oPS mode single point setting 3 Press the set button to enter OUT1 mode Use up and down arrow buttons to select nC normal close mode 4 Press the set button to enter OUT2 setting Use up and down arrow buttons to select oFF mode 5 Press the...

Page 178: ...essure value at 40 Kpa default value 2 Press the set button to return to measurement mode 3 When it detects the pressure value lower than 40Kpa it indicates the gripper has already gripped the workpiece 4 Users may adjust the pressure value to detect based on the workpiece to grip 5 Avoid setting the pressure value lower than 60Kpa If the vacuum pressure is too high the suction cup may damage the ...

Page 179: ...hes the pallet size The combinations at the right of each line are the available ranges of the box sizes For example the box with a height of 150 and a length width of 450 or more can apply to 1165 x 1165 the green line 3 Please ensure that if the offset of the exact TCP end fits the existing configuration 4 The calculation includes the sum of the heights of the pallet and the box plus the TCP off...

Page 180: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 180 Appendix D Declaration of Incorporation ...

Page 181: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 181 Appendix E Certificate of Compliance ...

Page 182: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 182 ...

Page 183: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 183 ...

Page 184: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 184 Appendix F Verification of EMC Compliance ...

Page 185: ...TM Palletizing Operator User s Manual Product Version 1 1 Document Version 1 2 185 ...

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