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IntelliFlex Feeding System

Epson IntelliFlex Feeding System User manual

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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
Copyright 2019-2020 SEIKO EPSON CORPORATION. All rights reserved.
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.
/