Epson IntelliFlex Feeding System User manual

Rev.4

EM208S4495F

EPSON RC+ 7.0 Option

Part Feeding 7.0

Introduction & Hardware (Common) & Software

EPSON RC

+ 7.0 Option Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4 i

EPSON RC+ 7.0 Option

Part Feeding 7.0

Introduction & Hardware (Common) & Software

Rev.4

ii Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

FOREWORD

Thank you for purchasing our robot system.

This manual contains the information necessary for the correct use of the EPSON RC+

PartFeeding option.

Please carefully read this manual and other related manuals before installing the robot

system.

Keep this manual handy for easy access at all times.

WARRANTY

The robot system and its optional parts are shipped to our customers only after being

subjected to the strictest quality controls, tests, and inspections to certify its compliance with

our high performance standards.

Product malfunctions resulting from normal handling or operation will be repaired free of

charge during the normal warranty period. (Please ask your Regional Sales Office for

warranty period information.)

However, customers will be charged for repairs in the following cases (even if they occur

during the warranty period):

1.

Damage or malfunction caused by improper use which is not described in the manual,

or careless use.

2.

Malfunctions caused by

customers’ unauthorized disassembly.

3.

Damage due to improper adjustments or unauthorized repair attempts.

4.

Damage caused by natural disasters such as earthquake, flood, etc.

Warnings, Cautions, Usage:

1.

If the robot system associated

equipment is used outside of the usage conditions and

product specifications described in the manuals, this warranty is void.

2.

If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be

responsible for any malfunction or accident, even

if the result is injury or death.

3.

We cannot foresee all possible dangers and consequences. Therefore, this manual

cannot warn the user of all possible hazards.

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4 iii

TRADEMARKS

Microsoft, Windows, Windows logo, Visual Basic, and Visual C++ are either registered

trademarks or trademarks of Microsoft Corporation in the United States and/or other

countries. Other brand and product names are trademarks or registered trademarks of the

respective holders.

TRADEMARK NOTATION IN THIS MANUAL

Microsoft® Windows® 8 Operating system

Microsoft® Windows® 10 Operating system

Throughout this manual, Windows 8, and Windows 10 refer to above respective operating

systems. In some cases, Windows refers generically to Windows 8, and Windows 10.

NOTICE

No part of this manual may be copied or reproduced without authorization.

The contents of this manual are subject to change without notice.

Please notify us if you should find any errors in this manual or if you have any comments

regarding its contents.

MANUFACTURER

CONTACT INFORMATION

Contact information is described in “SUPPLIERS” in the first pages of the following

manual:

Robot System Safety and Installation Read this manual first

iv Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

Table of Contents

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4 v

Introduction

1. Introduction 3

1.1 Overview of Part Feeding ..................................................................... 3

1.1.1 Background ............................................................................... 3

1.1.2 Merits of the Part Feeding Option ............................................. 4

1.1.3 Functions of the Part Feeding Option ....................................... 5

1.2 Required Basic Knowledge of EPSON RC+ 7.0 .................................. 6

1.3 Related Manuals ................................................................................... 6

1.4 Symbols Used in this Manual ............................................................... 7

2. Safety 8

2.1 Safety Precautions ................................................................................ 8

2.2 Robot Safety ......................................................................................... 8

2.3 Vision System Safety ............................................................................ 8

2.4 Feeder Safety ........................................................................................ 8

2.5 Hopper Safety ....................................................................................... 8

3. Definition of Terms 9

4. System Overview 11

4.1 Overall Configuration .......................................................................... 11

4.2 Feeder ................................................................................................. 12

4.3 Robot ................................................................................................... 12

4.3.1 Manipulator .............................................................................. 12

4.3.2 End Effector ............................................................................. 12

4.4 Vision System ..................................................................................... 12

4.4.1 Vision System.......................................................................... 12

4.4.2 Camera .................................................................................... 13

4.5 Lighting ................................................................................................ 13

4.6 PC ....................................................................................................... 13

4.7 Hopper ................................................................................................. 13

5. Operation Overview 14

5.1 Part Feeding Process ......................................................................... 14

5.2 Supplying Parts to the Feeder ............................................................ 15

5.2.1 Quantities of Supplied Parts ................................................... 15

5.3 Feeder Operation ................................................................................. 17

5.3.1 Flip and Separation ................................................................. 17

5.3.2 Shift ......................................................................................... 17

5.4 Part Pick Positions on Platform .......................................................... 18

5.4.1 Pick From Anywhere ............................................................... 18

5.4.2 Pick From Region .................................................................... 18

5.5 Preventing End Effector and Platform Interference ............................ 18

Table of Contents

vi Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

6. Parts 19

6.1 Conditions for Usable Parts ................................................................. 19

6.1.1 Vision System Compatibility .................................................... 19

6.1.2 Size and Weight ....................................................................... 19

6.1.3 Materials and Characteristics .................................................. 19

6.1.4 Parts Shape and Other ............................................................ 20

6.2 Examples of Parts ................................................................................ 21

6.2.1 Relation of the Quantity of Parts Loaded to the Feeder and the

Quantity Detected by Image Processing ........................................... 22

6.2.2 Relation of Quantity Loaded to Feeder and Average UPM ..... 23

6.2.3 Relation Between Feeder Operation and UPM ....................... 24

6.2.4 Relation Between Quantity of Parts in Feeder and Hopper

Operation............................................................................................ 25

7. Let’s Use the Part Feeding Option 26

7.1 Workflow .............................................................................................. 26

7.2 Requirements ....................................................................................... 27

7.2.1 Device Configuration................................................................ 27

7.2.2 Connection and Adjustment ..................................................... 27

7.2.3 Part ........................................................................................... 27

7.2.4 Settings .................................................................................... 28

7.2.5 Others ...................................................................................... 28

7.3 Enable the Part Feeding Options Key ................................................. 28

7.4 Configure Feeder Communications ..................................................... 29

7.5 Create a Project for Part Feeding ........................................................ 29

7.6 Create a New Part ............................................................................... 30

7.7 Configure the Lighting Settings ........................................................... 31

7.8 Create the Vision Sequences .............................................................. 31

7.8.1 Creating a Vision sequence for Part Detection ....................... 31

7.8.2 Create a Vision Sequence for Feeder Calibration ................... 33

7.9 Configure the Vision Settings .............................................................. 34

7.10 Configure the Pick Settings ............................................................... 35

7.11 Teach Pick Z and Posture ................................................................. 36

7.12 Perform Part Calibration .................................................................... 37

7.12.1 Calibration to Determine the Part Area.................................. 38

7.12.2 Separation Calibration ........................................................... 39

7.12.3 Shift Calibration ...................................................................... 40

7.12.4 Saving the Calibrations .......................................................... 40

7.13 Create the PartFeeding Process Starting Program ........................... 41

7.14 Create the PF_Robot Callback Function ........................................... 42

7.15 Check Robot Operation ..................................................................... 44

Table of Contents

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4 vii

8. Multiple Parts & Multiple Robots 45

8.1 Specifications & Requirements for Multiple Parts & Multiple Robots . 45

8.2 Key Concepts for Multiple Parts and Multiple Robots ........................ 47

8.2.1 PF_ActivePart ......................................................................... 47

8.2.2 PF_Start .................................................................................. 48

8.2.3 Vision and Queue Loading ...................................................... 49

8.2.4 PF_Robot Return Values ........................................................ 49

8.2.5 PF_AccessFeeder / PF_ReleaseFeeder ................................ 51

8.2.6 PF_Stop .................................................................................. 51

8.2.7 PF_InitLog ............................................................................... 51

8.2.8 PF_QtyAdjHopperTime ........................................................... 52

8.3 Tutorials............................................................................................... 52

8.3.1 Tutorial #1: 1 Robot, 1 Feeder, 2 Parts .................................. 52

8.3.2 Tutorial #2: 2 Robots, 1 Feeder, 2 Parts ................................. 57

8.4 Multi-Part / Multi-Robot Summary ....................................................... 62

Hardware (Common)

1. Check Included Items 65

2. System Configuration 66

2.1 Configuration Example ........................................................................ 66

2.2 Considerations for Configuration Selection ........................................ 67

2.3 Select a Camera Lens ........................................................................ 67

3. Installation and Adjustment 68

3.1 Manipulator and Controller .................................................................. 68

3.2 Camera and Lens................................................................................ 68

3.3 Feeder and Hopper ............................................................................. 69

4. Electric Wiring 71

4.1 Cautions for Power Supply ................................................................. 71

4.2 Power wiring for the feeder ................................................................. 72

4.3 Power wiring for the Hopper ............................................................... 72

4.4 Robot Wiring ...................................................................................... 72

4.5 Camera Wiring .................................................................................... 72

5. Option Part List 73

Table of Contents

viii Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

Software

1. Introduction 77

1.1 Part Feeding Software Configuration .................................................. 77

1.1.1 Part Feeding Window............................................................... 77

1.1.2 Part Feeding SPEL+ Commands ............................................ 78

1.1.3 Part Feeding Process .............................................................. 79

1.1.4 Part Feeding Callback Functions ............................................. 80

1.2 Part Feeding Projects .......................................................................... 81

1.2.1 Applying the Part Feeding Option to a Project ........................ 81

1.2.2 Creating a Project .................................................................... 82

1.2.3 Configuration Files ................................................................... 82

1.2.4 Importing Files ......................................................................... 83

1.2.5 Backing up/Restoring the Controller ........................................ 83

1.3 SPEL Programming ............................................................................. 84

1.3.1 Programming Overview ........................................................... 84

1.3.2 Starting the Part Feeding Process ........................................... 87

1.3.3 Pick and Place Processing ...................................................... 88

1.3.4 Processing Errors .................................................................... 90

1.3.5 End Processing ........................................................................ 93

1.3.6 Other ........................................................................................ 93

2. Part Feeding GUI 94

2.1 System Configuration .......................................................................... 94

2.1.1 Part Feeding Page ................................................................... 94

2.1.2 Security Page ........................................................................... 96

2.2 Part Wizard .......................................................................................... 97

2.2.1 Add a new part ......................................................................... 97

2.2.2 General .................................................................................... 97

2.2.3 Lighting ..................................................................................... 98

2.2.4 Flip............................................................................................ 99

2.2.5 Vision ....................................................................................... 99

2.2.6 Vision Calibration Sequence .................................................. 100

2.2.7 Vision Find Part Sequence .................................................... 101

2.2.8 Feeder Orientation and Pick Region ..................................... 102

2.2.9 Avoid Hand Interference ........................................................ 102

2.2.10 Purge .................................................................................... 103

2.2.11 Calibration ............................................................................ 103

2.2.12 Finish .................................................................................... 104

2.3 Part Feeding Dialog ........................................................................... 105

2.3.1 General .................................................................................. 105

2.3.2 Lighting ................................................................................... 107

2.3.3 Vision ..................................................................................... 108

2.3.4 Part Supply............................................................................. 109

Table of Contents

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4 ix

2.3.5 Pick ........................................................................................ 111

2.3.6 Teach Window....................................................................... 112

2.3.7 Purge ..................................................................................... 113

2.3.8 Calibration ............................................................................. 114

2.4 Feeder Calibration Wizard ................................................................ 117

2.4.1 Basic Operation ..................................................................... 118

2.4.2 Preparation ............................................................................ 119

2.4.3 Starting the Wizard ................................................................ 119

2.4.4 Part Area Calibration ............................................................. 120

2.4.5 Flip & Separate Calibration ................................................... 121

2.4.6 Shift Calibration ..................................................................... 123

2.4.7 Purge Calibration .................................................................. 124

2.4.8 Finish ..................................................................................... 125

2.4.9 Recalibrating the Feeder ....................................................... 125

2.5 Testing Feeder Calibration Results .................................................. 126

2.6. [File] Menu ....................................................................................... 127

2.6.1 [Import] (File Menu) ............................................................... 127

3. Part Feeding SPEL+ Command Reference 128

PF_Abort .................................................................................................. 129

PF_AccessFeeder .................................................................................... 130

PF_ActivePart .......................................................................................... 132

PF_Backlight ............................................................................................ 133

PF_BacklightBrightness ........................................................................... 134

PF_Info Function ...................................................................................... 135

PF_InitLog ................................................................................................ 136

PF_IsStopRequested Function ................................................................ 137

PF_Name$ Function ................................................................................ 138

PF_Number Function ............................................................................... 139

PF_OutputOnOff ...................................................................................... 140

PF_Purge Function .................................................................................. 141

PF_QtyAdjHopperTime Function ............................................................. 142

PF_QueAdd.............................................................................................. 144

PF_QueAutoRemove ............................................................................... 145

PF_QueAutoRemove Function ................................................................ 146

PF_QueGet Function ............................................................................... 147

PF_QueLen Function ............................................................................... 148

PF_QueList .............................................................................................. 149

PF_QuePartOrient ................................................................................... 150

PF_QuePartOrient Function .................................................................... 151

PF_QueRemove ...................................................................................... 152

PF_QueSort ............................................................................................. 153

PF_QueSort Function .............................................................................. 154

PF_QueUserData ..................................................................................... 155

Table of Contents

x Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

PF_QueUserData Function ...................................................................... 156

PF_ReleaseFeeder ................................................................................... 157

PF_Start .................................................................................................... 159

PF_Stop .................................................................................................... 161

4. Part Feeding Callback Functions 162

4.1 Common Items................................................................................... 162

PF_Robot ......................................................................................... 163

PF_Control ....................................................................................... 166

PF_Status ........................................................................................ 168

PF_MobileCam ................................................................................ 171

PF_Vision ......................................................................................... 172

PF_CycleStop .................................................................................. 174

5. Part Feeding Log File 175

5.1 Summary ............................................................................................ 175

5.2 Enabling the Log Function ................................................................. 175

5.3 Log File Format .................................................................................. 175

5.3.1 Common Items ....................................................................... 175

5.3.2 Vision Sequence Log ............................................................. 176

5.3.3 System Vision Sequence Log ................................................ 176

5.3.4 Feeder Log ............................................................................. 176

5.3.5 PF_Robot Callback Function Log .......................................... 177

5.3.6 PF_MobileCam Callback Function Log ................................. 177

5.3.7 PF_Control Callback Function Log ........................................ 177

5.3.8 PF_Status Callback Function Log ......................................... 178

5.3.9 PF_Vision Callback Function Log .......................................... 178

5.4. Log Sample ....................................................................................... 179

6. Vision Sequences Used With the Part Feeding Option 180

6.1 Vision Calibration ............................................................................... 180

6.2 Feeder Calibration Vision Sequence ................................................. 180

6.2.1 Vision Sequence .................................................................... 181

6.2.2 Vision Objects ........................................................................ 181

6.3 Parts Detection Vision Sequence ...................................................... 182

6.3.1 Simple Parts ........................................................................... 182

6.3.2 Parts With Sides .................................................................... 184

6.3.3 Parts that Require Gripper Clearance ................................... 186

6.3.4 Special Vision Configurations ................................................ 189

6.3.5 Example of not picking up when contacting with the next parts

.......................................................................................................... 189

Table of Contents

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4 xi

7. How to Adjust the Hopper 191

7.1 How to Adjust ..................................................................................... 191

7.2 How to Adjust the IF-80 Hopper ....................................................... 192

8 Errors that Occur While Using EPSON RC+ 194

9. Application Programming Examples 195

9.1 One Robot Per Feeder & One Part Per Feeder ............................... 195

9.1.1 Program Example 1.1 ........................................................... 195

9.1.2 Program Example 1.2 ........................................................... 197

9.1.3 Program Example 1.3 ........................................................... 199

9.1.4 Program Example 1.4 ........................................................... 201

9.1.5 Program Example 1.5 ........................................................... 203

9.1.6 Program Example 1.6 ........................................................... 206

9.1.7 Program Example 1.7 ........................................................... 209

9.1.9 Program Example 1.9 ........................................................... 210

9.1.9 Program Example 1.9 ........................................................... 212

9.1.10 Program Example 1.10 ....................................................... 214

9.1.11 Program Example 1.11 ....................................................... 216

9.2 One Robot – Multiple Parts ............................................................... 219

9.2.1 Program Example 2.1 ........................................................... 219

9.3 Two Robots – One Part .................................................................... 221

9.3.1 Program Example 3.1 ........................................................... 221

9.3.2 Program Example 3.2 ........................................................... 223

9.3.3 Program Example 3.3 ........................................................... 226

9.4 Two Robots – Multiple Parts ............................................................. 229

9.4.1 Program Example 4.1 ........................................................... 229

9.4.2 Program Example 4.2 ........................................................... 231

9.4.3 Program Example 4.3 ........................................................... 234

Troubleshooting 239

Don’t know the IP address of the feeder. ................................................. 239

Feeder does not vibrate or vibration is weak ........................................... 239

Parts in the feeder do not move smoothly or are separated unevenly .... 239

Hopper does not vibrate ........................................................................... 240

Parts completely fill up the platform ......................................................... 240

Parts on the platform run out ................................................................... 240

TP3 cannot build the project including PartFeeding Option .................... 240

Cannot save the feeder name more than 17 characters in length .......... 240

Table of Contents

xii Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

Introduction

Introduction 1. Introduction

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

3

1. Introduction

1.1 Overview of Part Feeding

The Part Feeding option for EPSON RC+ 7.0 (“Part Feeding option” hereinafter) can be

used for easily developing a system in which parts are separated by a part feeder and a

robot picks up the parts from the feeder.

1.1.1 Background

Types of manufacturing are becoming more diversified in response to the growing trends

of shorter product life and multi-product diversification, “Just-in-time” manufacturing

(small lots with short turnarounds), and similar factors. In contrast, factors such as

continuously increasing wages, persons moving away from production site areas, and the

aging of the worker population make it increasingly difficult to perform manufacturing,

resulting in the issue of how to achieve the flexibility necessary to respond to

diversification.

Let’s look at part feeding as one element in creating automated production lines.

Part feeding is actually a key element for production equipment because you cannot

increase productivity beyond the part feeding capacity. Currently, the main method used

for part feeding is the comparatively inexpensive vibrating bowl feeder which provides

great diversity of use.

However, it is necessary to create bowls corresponding to the fed parts and, moreover, to

manually replace bowls for each part type, which requires the coordination of specialized

technical personnel for such purposes. These requirements make it difficult to respond to

diversification and short turnaround times due to the necessity for advanced engineering

capabilities and experience.

One device that resolves some of the shortcomings of a bowl feeder is the “intelligent

parts feeder” (“feeder” hereinafter) that was first put in use a few years ago. This device

allows you to easily handle various types of fed parts just by changing the feeder settings.

There are also products that combine this feeder with image processing that is capable of

identifying parts and a robot that handles the recognized parts.

However, these types of products require users to specify settings for themselves for

feeder adjustment and operation, image processing, and robot parts handling because

individual operations of the feeder can only be performed from the robot system. Time

and experience are necessary for comprehensively studying and designing part feeding.

For example, the cycle time greatly varies depending on the number of parts fed and the

position where the robot picks up parts. Failure to provide a proper design will prevent the

feeder from operating at full functionality and a high-performance level even if, for

example, a high-performance/high-functioning feeder is used, and thereby prevent any

improvement to the cycle time. These current feeder products cannot just be used right

away by any person.

Introduction 1. Introduction

4

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

1.1.2 Merits of the Part Feeding Option

The Part Feeding option is a product that brings innovation to these current part feeders.

Introducing this option provides the following merits.

- Complete Integration of Feeder, Vision System, and Robot

All the necessary elements for part feeding are provided in a single package. The

complete integration of the feeder, robot, and vision system requires less labor time at

introduction in comparison with having to prepare and evaluate each of these separately.

- Reduced Labor Time for Device Development/Startup

Feeder and vision system operations are performed automatically so that the user does

not have to perform any programming. The robot operation needs to be described by the

user, but this can be simply done by writing in a template code. The feeder, vision

system, and robot operations are subject to automatic simultaneous control so that device

development can be performed with minimal programming. It is simple to integrate into

whatever environment the user is currently using.

Feeder, robot, and vision system settings can be easily specified by using the GUI.

- Reduced Downtime and Running Costs

The Part Feeding option supports a great variety of parts. There is no need to change

equipment each time you change parts, thereby reducing production downtime.

There is also no need for newly producing equipment to reduce long-term running costs.

Introduction 1. Introduction

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

5

1.1.3 Functions of the Part Feeding Option

Use of the following representative functions allows you to readily achieve full feeder

functionality and performance to create a highly efficient part feeding system.

Feeder and Communication I/F

Communication programs for specifying feeder settings and performing control are

incorporated into this system.

You do not have to perform any programming for communication.

Automatic Feeder Adjustment Function

This system includes a function that automatically adjusts feeder parameters (such as

vibration amplitude and time) according to the parts fed. Feeder adjustment can be

performed easily even by persons with no knowledge of feeders just by performing a few

simple procedures.

Feeder Control Algorithms

Algorithms for controlling the feeder are included in the system. These algorithms take

into account reducing as much as possible the time required by the robot to pick parts in

order to provide efficient operation with no effort on the part of the user.

Cycle Time Log Output Function for Ascertaining Robot and Feeder Operating

Status

This system includes a function to output the robot, feeder, and vision system operating

times to a file. This can be used for more efficient operation by changing the parameter

settings, and then obtaining the log to analyze operation. The Controller must be

connected to a PC with the EPSON RC+ installed in order to use this function.

Multi-feeder operation

Up to 4 feeders can be connected to and controlled by a single controller. For T series,

up to 2 feeders can be controlled. When you want to link multiple feeder operations, you

can control them with a single controller, so it makes programming easier.

Multi-part operation

Up to four different parts can be processed in a single feeder at the same time. The

number of feeders can be reduced, which results in lower costs and space savings. In

multi-part operation, up to two robots can be used per feeder.

Purge operation

This system includes a built-in purge operation for parts on the feeder. When you want to

automatically eject a part from the feeder by switching parts, or when you want to use it

for damaged parts or overfeeding.

The IF-80 includes a platform for the purge operation and a container for storing the

ejected parts. (Optional)

The IF-240, IF-380 and IF-530, the ejection mechanism is provided by the customer.

This includes a door that opens and closes when the part is ejected, a mechanism to open

and close the door, a container to store the ejected part etc.

Introduction 1. Introduction

6

Part Feeding 7.0 Introduction & Hardware (Common) & Software Rev.4

1.2 Required Basic Knowledge of EPSON RC+ 7.0

The Part Feeding option operates within the EPSON RC+ 7.0 environment.

Knowledge of the EPSON RC+ 7.0 development environment, Epson’s robots, and

EPSON RC+ 7.0 Option Vision Guide 7.0 is required for using the Part Feeding option.

The information in this manual is for persons with knowledge of the following items.

General knowledge of the EPSON RC+ 7.0 project management and procedures for use

Procedures for creating and editing SPEL+ programs using the EPSON RC+ 7.0

Procedures for executing SPEL+ programs from the Run window

Basic language structure, functions, and procedures for use of SPEL+

Vision Guide 7.0 functions and procedures for use

1.3 Related Manuals

Refer to the following related manuals along with the Part Feeding option manuals for

using the Part Feeding option.

EPSON RC+7.0 User's Guide

This manual contains information on using the EPSON RC+ Robot Control System.

SPEL

+

Language Reference Manual

This manual contains a complete description of all commands for the SPEL

+

language.

Each Robot Manual

Each robot manual contains information on our robots.

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Epson IntelliFlex Feeding System User manual

Epson IntelliFlex Feeding System User manual

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