Techman Robot TM Palletizing Operator

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TM Palletizing Operator User’s Manual Product Version: 1.0 / Document Version: 1.0 20

(Two TM Landmarks. Peel the protective wrap off

before using.)

(2 wires)

Length: 300 cm

In the bracket and accessory carton:

Length: 500 cm

TM Landmark

Ground Wire

AC power cord of the TM Palletizing Operator

4 x M10X25L type screws

2 x Control box convert brackets

4 x M6X12L type screws

Main Page

Preface3
Product Versioning Information3
Table 1: Safety Definition Symbols3
Table 2: Version Information3
Revision History4
Table of Contents5
Product Introduction15
TM Palletizing Operator Overview15
Figure 1: TM Palletizing Operator Base Overview (1/2)15
Figure 2: TM Palletizing Operator Base Overview (2/2)15
Orientations16
Palletizing Operator Base Dimensions16
Figure 3: TM Palletizing Operator Base Orientation16
Figure 4: Palletizing Operator Base Dimensions16
Package Contents17
Teach Pendant23
Table 3: Teach Pendant Basic Functions24
Adjustable Flexible Gripper Overview25
Dimensions of Adjustable Flexible Gripper25
Figure 5: Adjustable Flexible Gripper Overview25
Vacuum Generator Characteristics26
Figure 6: Dimensions of Adjustable Flexible Gripper26
Figure 7: Vacuum Generator Characteristics26
Vertical Lifting Force Per Suction Cup27
Vacuum Pressure Sensor27
Pneumatic Diagram27
Figure 8: Vertical Lifting Force Per Suction Cup27
How Can I Get Help28
Related Documentations to this Manual28
Table 4: Related Documentations28
Figure 9: Pneumatic Diagram28
Safety Information29
Overview29
Applicable Product Version29
Safety Precautions29
Table 5: Safety System Versioning Information29
Overall Safety Warning30
Validation and Liability31
Intended Use32
Limitations on Liability33
General Environmental Considerations33
Risk Assessment33
Pre-Use Assessment34
Emergency Stop35
3-Position Enabling Device35
Movement Without Drive Power35
Labels35
Figure 10: Locations of Safety Warning and Product Labels36
Table 6: Denotations of Labels37
Safety Function38
General Information38
Safety Function Definitions38
Table 7: Safety Function Definitions38
Stopping Time and Stopping Distance in the Safety System39
Software Safety Setting Permissions39
Safety Device Connection Diagram, Input Discrepancy and Resume Method39
Figure 11: Safety Device Connection Diagram39
Explanation of Safety Functions40
Table 8: Stop Category and Action of Fault Detection of SF0, SF1 and SF240
SF3 External Safeguard-Pause and SF4 External Safeguard-Human-Machine Safety Settings42
Table 9: Stop Category and Action of Fault Detection of SF3 and SF442
SF5 Pendant Enabling Device43
SF6 Motion Latching Mechanism43
SF7 Emergency Stop Output, SF8 Safeguard-Pause Output, and SF9 Safeguard-Human-Machine43
Safety Settings Output43
Table 10: Stop Category and Action of Fault Detection of SF543
Table 11: Stop Category and Action of Fault Detection of SF643
SF10~SF15 Defined Safety Functions44
Table 12: Stop Category and Action of Fault Detection of SF7, SF8 and SF944
Table 13: Safety Function SF10~SF15 Definitions45
Table 14: Stop Category and Action of Fault Detection of SF10~ SF1545
Safety Distance and Scenario47
Figure 12: Relationship between Payload and the Center of Gravity Offset (MM)47
Figure 13: Palletizing Operator Clearance with Sideways Conveyor47
Figure 14: Palletizing Operator Clearance with Straight Conveyor48
Figure 15: Safeguarded Space Setup Scenario with Sideways Conveyor Layouts48
Figure 16: Safeguarded Space with Different Setup Scenario50
Figure 17: Safeguarded Space Setup Scenarios with Multi-Palletizing Operators50
Reset Button Mechanism51
Figure 18: Teach Pendant Outside Safeguarded Space51
Operation Mode and Mode Switching52
Auto Mode52
Manual Mode52
Manual Control Mode (Manual Reduced Speed)53
Hand Guide Mode53
Manual Trial Run Mode (Manual High Speed)53
Switching between Modes53
Safety Setting in Tmflow Software53
Electrical Interface54
General Electrical Specifications54
Electrical Warnings and Cautions54
A Glance Inside TM Palletizing Operator Base54
Table 15: AC Input Specifications of TM Palletizing Operator54
Figure 19: Inside the Distribution Box (the Image Serves as Reference Only)54
Electric Switchboard Inside the Distribution Box55
Figure 20: Electric Switchboard Diagram55
Palletizing I/O Configuration56
Table 16: Default Pallet Templates by Drop-Down Menu56
Figure 21: Palletizing I/O56
Palletizing I/O Pin Definitions57
Digital Inputs57
Table 17: Pin Signals for DIO, Analog I/O, Safety I/O and COM57
Considerations for Sensor Connections58
Digital Outputs59
Figure 22: Set to Sink/Source Input Type59
Considerations for Terminal60
Figure 23: Set to Sink/Source Output Type60
Analog Input/Output61
Analog Input62
Analog Output62
Figure 24: Analog Input Application62
Figure 25: Analog_Out Application62
Safety Input/Output63
Table 18: Definitions of Safety I/O Connectors63
Safety Input64
Safety Output65
Safety Controller (G9SP-N20S) I/O Configuration66
Figure 26: Safety Controller (G9SP)66
Table 19: Safety Controller (G9SP) Pin Definition67
Figure 27: Connecting Safety Devices67
Safety Controller (SF-C21) I/O Configuration68
Figure 28: Safety Controller SF-C2168
Power Terminal69
Table 20: Safety Controller (SF-C21) I/O I/O69
Figure 29: Power Terminal (+24V/+0V)69
External I/O (CP1W-20EDT) and Reset Button Setting70
Figure 30: Switch to Auto Mode for Reset Button70
Light Indications71
Table 21: System Light Indicator71
Figure 31: Pallet Light Indications71
Figure 32: System Light Indications71
Unpacking, Installation and Transportation72
Unpacking Procedures72
Unpacking the Control Box72
Unpacking the Robot72
Unpacking the Palletizing Operator72
Figure 33: Palletizing Operator Base in Wooden Crate72
Assembling TM Palletizing Operator73
Removing the Rear Housing73
Figure 34: Unlatch the Side Cover Hinge73
Figure 35: Remove the 6 Screws74
Figure 36: Unfasten the 4 Screws74
Installing TM Robot75
Figure 37: Secure the Robot Arm Onto a Base Plate75
Figure 38: Open the Covers of the Cable Drag Chain75
Figure 39: Seal and Reinstall76
Installing the Control Box77
Figure 40: Remove EX-IO Module from Control Box77
Figure 41: Secure the Covert Brackets to the Legs of the Control Box77
Figure 42: Proper Cable Connections78
Figure 43: Proper Connections for Robot Connector Cable79
Figure 44: All Cables Are Firmly Plugged80
Figure 45: Secure the Bracket Plates of the Control Box81
Installing the Rear Housing82
Figure 46: Place the Rear Housing82
Figure 47: Wire the Robot Cable through Notch83
Figure 48: Reinstallation of the Side Cover83
Installing Adjustable Flexible Gripper84
Figure 49: Gripper Flange at Centered Position as Delivered84
Figure 50: Gripper Flange at Shifted Position84
Changing Gripper Flange Position85
Figure 51: Remove Two M6X12L Screws and Detach Flange Knob85
Figure 52: Remove Five M6X6L Screws and Detach Position Converter85
Figure 53: Fasten the Flange Knob to Shifted Position86
Figure 54: Flange Position Change Completed86
Installing the Gripper Onto the Robot (for Centered Position)87
Figure 55: Align Gripper and Apply Screws (for Centered Position)87
Figure 56: Connect 8-Pin Gripper Cable to I/O Connector on Robot (for Centered Position)87
Installing the Gripper Onto the Robot (for Shifted Position)88
Figure 57: Align Gripper and Apply Screws (for Shifted Position)88
Figure 58: Connect 8-Pin Gripper Cable to I/O Connector on Robot (for Shifted Position)88
Installing Cable Protection Conduit89
Figure 59: Segments for Velcro Use89
Figure 60: Distance Intervals of each Segment90
Figure 61: Penetrate the Air Tubes and Connectors (Example by Centered Gripper Position)91
Figure 62: Connect Air Tube Plug to the Gripper Plug91
Figure 63: Connection Completed92
Figure 64: Air Unit for External Compressed Air Supply92
Considerations for Connecting External Compressed Air93
Figure 65: Filter Regulator and Pressure Gauge Location93
Installing the Reset Button94
TM Palletizing Operator Transportation94
Figure 66: Installing Reset Button94
Figure 67: TM Palletizing Operator Transportation (1/4)94
Figure 68: TM Palletizing Operator Transportation (2/4)95
Figure 69: TM Palletizing Operator Transportation (3/4)95
Encountering Non-Flat Surfaces96
Figure 70: TM Palletizing Operator Transportation (4/4)96
Figure 71: Using Wrench to Loosen/Tighten Leveling Mounts97
Figure 72: TM Palletizing Operator Anchor Points97
Relocation and Storage Considerations98
Installing Teach Pendant98
Figure 73: Connect the Cable to the Pendant98
Adjusting Pallet Sensor99
Figure 74: Connect the Cable to the Palletizing Operator99
Figure 75: Adjust Pallet Sensor Horizontally99
Connecting Power Supply to TM Palletizing Operator100
Table 22: AC Input Specifications of TM Palletizing Operator100
Figure 76: Default Sensor Position100
Figure 77: Maximum Sensor Position100
Figure 78: Power Connection Reference101
Activating/Deactivating TM Palletizing Operator102
Figure 79: Ground Connection102
Figure 80: Turn the Main Switch in a Clockwise Direction to Power on102
Required Software Installation and Safety Configuration104
Downloading Tmflow and Tmstudio Software104
Entering Tmflow Software104
Setting Teach Pendant in Tmflow104
Figure 81: Log-In104
Figure 82: I/O Setup for Pendant105
Figure 83: Setting in User Defined I/O105
Figure 84: Go to "Safety" Setting106
Figure 85: Enable Device Setting106
Figure 86: Set Pendant as Display Device107
Figure 87: Select "Pendant107
Reset Button Setting in Tmflow108
TCP Setting for the Adjustable Flexible Gripper108
Figure 88: Set Manual Reset108
Figure 89: Go to TCP Setting109
Figure 90: Select "Manual Input Parameters of TCP109
Figure 91: Import the Pallet Tool110
Figure 92: TCP Values for Non-Shifted Gripper110
Figure 93: Example of Non-Shifted Gripper111
Figure 94: TCP Values for Shifted Gripper111
Figure 95: Example of Shifted Gripper111
Application Software Setup112
TM Palletizing Operator Software Overview112
TM Palletizing Operator Software Configuration Workflow112
Table 23: TM Palletizing Operator Software Configuration Workflow112
Downloading TM Palletizing Operator Software Package113
Setting Palletizing Application under Palletizing Wizard113
Figure 96: Launch Palletizing Wizard113
Step 1 - Setting Box Size and Label Direction114
Figure 97: Palletizing Wizard_Step 1114
Step 2 - Choose/Set Pallet115
Table 24: Default Pallet Templates by Drop-Down Menu115
Figure 98: Choose/Set Pallet115
Step 3 - Create Pallet Layers116
Figure 99: Create Pallet Layers116
Table 25: Functional Icons for Pallet Layers117
Figure 100: Interval Value Displayed117
Figure 101: Shift Box118
Step 4 - Create Palletizing Sequence119
Table 26: Shift Box Configurations119
Figure 102: Create Palletizing Sequence119
Table 27: Functional Icons for Palletizing Sequence120
Step 5 - Palletizing Simulation121
Figure 103: Palletizing Simulation121
Figure 104: Change Gripper122
Figure 105: Parameter Setting123
Table 28: Parameter Descriptions124
Figure 106: Palletizing Parameter Illustration124
Figure 107: Export the File124
Step 6 - Export File125
Configuring Palletizing Software Components in Tmflow125
Importing Components and Text File into Tmflow125
Figure 108: Export File125
Figure 109: Import/Export126
Figure 110: Import File126
Figure 111: Robot List127
Figure 112: Import Selected Components127
Figure 113: Import Completed128
Figure 114: Import Text File129
Figure 115: Select "Component" in Setting129
Setting I/O While Project Stop/Error130
Table 29: Component Descriptions130
Figure 116: Enable the Imported Components130
Figure 117: Set I/O While Project Error131
Figure 118: Set I/O While Project Stop131
Setting Tmoperator_Tmrobot_Tmpltzop_V001_Pillar132
Figure 119: Start Using Pillar Calibration132
Figure 120: Pillar Calibration132
Figure 121: "Bool" Value Must be True133
Figure 122: Calibration Test133
Lowering the Pillar Height134
Figure 123: Go to "Controller134
Setting Tmoperator_Tmrobot_Tmpltzop_V001_Main135
Figure 124: Set IO in Controller135
Figure 125: Project_Main135
Step 1 - Import File136
Figure 126: Palletizing Steps136
Figure 127: Setting for Import File136
Step 2 - Recognizing Box Position137
Figure 128: Input the File137
Figure 129: Go to Step 2137
Figure 130: Vision Job138
Figure 131: Select "Step 2138
Figure 132: Guide Robot to Initial Position139
Figure 133: Recognizing TM Landmark139
Step 3 - Teach Gripping Point140
Figure 134: Move the Robot to Grip the Box141
Figure 135: Go to "Step 3141
Step 4 - Visual Recognition142
Figure 136: Set Point Manager142
Figure 137: Enable Overwrite142
Figure 138: Step4_Visual Recognition143
Figure 139: Step4_Visual Recognition143
Figure 140: Click "+" for Step4_Visual Recognition144
Figure 141: Job Name Input144
Figure 142: Calibration145
Figure 143: Calibration by Automatic Option145
Figure 144: Configurations to Set Workspace146
Figure 145: Tilt Correction147
Figure 146: Tilt Correction_Yes/No147
Figure 147: Set Workspace148
Figure 148: Workspace Calibration149
Figure 149: Save Result149
Figure 150: Save Workspace150
Figure 151: Initial the Visual Recognition Process151
Figure 152: Load Workspace151
Sensor Input Considerations152
Setting Tmoperator_Tmrobot_Tmpltzop _Vxxx_Grip and Tmoperator_Tmrobot_Tmpltzop152
Vxxx_Release152
Advanced Palletizing Setting152
Advanced1_General_Parameters152
Figure 153: Advanced Setting152
Advanced2-8155
Table 30: Advanced Setting for General Parameters155
Figure 154: Add a Subflow155
Figure 155: Add Nodes in the Subflow156
Figure 156: Add Nodes in the Subflow156
Table 31: Definitions of Advanced2-8157
Table 32: Relevant Parameters158
Product Specifications159
Maintenance and Repair161
Table 33: Summary of the Preventive Maintenance Procedures and Guidelines162
Warranty Statement163
Product Warranty163
Disclaimer163
Appendix - A: Troubleshooting and Error Messages164
Troubleshooting164
Adjusting Pillar Height164
Recovering from Emergency Stop165
Resume from Safeguard Stop Status165
Error Messages165
Appendix - B: Vacuum Pressure Sensor Setting167
Pressure Sensor Setup Steps167
Pressure Setting (Single-Point Setting Mode)168
Pressure Sensor Setup for Vacuum Suction Cup168
Pressure Setting (Single-Point Setting Mode)169
Appendix - C: Declaration of Incorporation171
Appendix - D: Certificate of Compliance172
Appendix - E: Verification of EMC Compliance175

Techman Robot TM Palletizing Operator - Page 20

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