ROBOTIQ PALLETIZING SOLUTION User guide

Brand: ROBOTIQ

Model: PALLETIZING SOLUTION

Type: User guide

Robotiq Palletizing Solution - Troubleshooting guide

1. How to consult this troubleshooting guide

We tried to make this guide as convenient and intuitive as possible. Here is an example of how to read this table.

2. Copilot and Polyscope update

The following recommandations take into account that the latest version of the Copilot URcap and the Polyscope operating system are used.

Visit our support page (https://robotiq.com/support) to download the latest URcaps from Robotiq.

3. Air Supply requirements

The air supply must be dried and ﬁltered according to ISO 8573-1 class 3.4.3. Air pressure must be between 3 and 7 bar with an optimal

pressure at 7 bar. (6.5 bar for Airpick serial number ≤ V-01351)

4. Table of contents

1. How to consult this troubleshooting guide 1

2. Copilot and Polyscope update 2

3. Air Supply requirements 2

5. Troubleshooting table 3

APPENDIX A 9

APPENDIX B 10

APPENDIX C 11

5. Troubleshooting table

Problem / issue

Cause(s)

Solution(s)

Collision

Collision with the pallet

sensor on one side, but

not on the other.

[AX series] Linear axis is not aligned with the

base.

[Manual] Execute the centering procedure.

Ch. 3, “Mechanical and Electrical Installation”, “Centering the Solution” section.

[PE series] Pedestal is not aligned with the base.

[Manual] Execute the centering procedure.

Ch. 3, “Mechanical and Electrical Installation”, “Centering the Solution” section.

Collision with a box

already placed on the

pallet.

Collision between the gripped box and the box

on the pallet.

A small Z offset accumulates over many layers.

[Box] Increase the box height parameter (C) to compensate for box variability.

Use the average box height : Measure the height of a full stack of boxes and divide

it by the number of layers.

Box faces are rounded.

[Box] Increase the box width and/or length parameter (A and/or B).

Wrong pallet state.

[Pallet viewer] Restart the program and select the correct pallet state. Enter the

amount of boxes already present on the pallet.

Pallet height is set too low.

[Pallet] Measure the pallet height and set the parameter correctly.

Collision occurred during

palletizing with End Of

Arm Tooling (EOAT) .

TCP conﬁguration is incorrect.

[Software][Installation] Enter correct TCP orientation and position from the manual.

[Info] When using a gripper other than AirPick, refer to the supplier's manual,

measure it yourself or use Polyscope's TCP wizard.

TCP was set without considering the use of an

extension bracket.

Gripper is larger than the box (X and/or Y

dimensions).

[Info] Collision model will consider the gripper

has the same X and Y dimensions as the box.

[Support] Contact Robotiq's Coach team.

[Info] [Manual] Consult Ch. 3, “Other Grippers” section, for more details.

[PE series] Pedestal height does not match the

height conﬁgured in the installation tab.

[Online conﬁgurator][Installation] Adjust the actual pedestal height and/or the

parameter in the installation tab according to the conﬁgurator's results.

(

Installation

URCaps

Copilot

Conﬁguration

)

Problem / issue

Cause(s)

Solution(s)

Error message

"Discontinuous path /

joint solution impossible

detected, please change

your starting position."

Box pick position is too close to the robot’s base.

[Online conﬁgurator] Simulate with your actual installation until it works. Move the

conveyor to move the pick position.

Adjust your real installation correspondingly.

Conveyor position does not allow trajectory.

Robot is not able to generate a vertical trajectory

to avoid the conveyor.

[Info] Conventional conveyor height is between

700 and 900mm.

[Online conﬁgurator] Adjust conveyor position in your simulation until getting

satisfying results.

[Conveyor] Set the conveyor according to the simulation's results.

Joint has reached or is close to its limits.

[Pick position] [Move] Move the tool to the pick position.

Move each joint near the center of their range (°0). Visualize the range using the

Move

tab. Teach the new pick position. [Info] While running the program, the

software will reorient Wrist #3.

Set the robot back to

Home position

(arm straight in the air) and restart the

program.

TCP orientation at pick position is wrong.

[Software][Installation] Enter the correct TCP orientation and position from the

manual.

[Info] When using a gripper other than AirPick, refer to the supplier's manual,

measure it yourself or use Polyscope's TCP wizard.

Speciﬁc point not reachable on the pattern (on

both pallets).

[Online conﬁgurator] Adjust pattern and label orientation until every point is

reachable.

[Software] [Pattern] Apply the changes required to have the simulation running.

[Info] When possible, allow the gripper to pick the box at 90° and/or 180°

(

Palletize

r node ->

Settings

Speciﬁc point not reachable on the pattern (on

only one side)

[Software] [Pattern] Center your pattern on the pallet in the

Palletizer

node.

Create a

Palletizer

node for each side, allowing to bring the pattern closer to the

base for the left and right sides.

[PE series] Incorrect pedestal height for a speciﬁc

box and pattern.

[Online conﬁgurator] Simulate your use case online, note the pedestal height

selected in the KPI window.

[Software][Installation] Set the pedestal height according to the online conﬁgurator

results.

(

Installation

URCaps

Copilot

Conﬁguration

)

[Installation] Set the actual pedestal height accordingly.

None of the above has worked.

[Support] Contact Robotiq's Coach team.

[AX series] "Please use

the Safeguard reset

before starting the linear

axis"

System has been restarted or a new installation

ﬁle has been loaded.

Press the safeguard reset button.

Cables were installed or removed in the

controller while the unit was powered on.

Power-off then power-on (power cycle) the linear axis controller.

Linear axis security relay latched. Dual channel

security signal mismatched for more than 0.5s.

Wires from the linear axis are not properly

connected into the UR controller.

[Manual] [I/O] Connect the wires according to the "Safety connections" section.

"Safety conﬁguration" and/or "System

Emergency Stopped" are not properly

conﬁgured.

[Installation] [I/O] Verify that "Safeguard reset" and "System Emergency Stopped"

functions are properly conﬁgured.

(

Installation

Safety

I/O

)

Safeguard function is not used and not bypassed.

[I/O] If the safeguard function is not used, bypass this function by adding a jumper

between pin 1-2 and 3-4 of the provided connector.

[Manual] See "Safety connections" section.

An OSSD safeguard device is used directly.

A safety relay to convert the signal from OSSD to standard signal is required.

[Info] OSSD signals are not compatible with the AX series controller.

[Info] We recommend the PSR-MS60-2NO-24DC-SC by Phoenix Contact.

Emergency output from the UR controller is set to

"OSSD signal".

(e-Series only)

Verify that the OSSD checkbox for the "System Emergency Stopped" output is

unchecked. (Installation -> Safety -> I\O)

[Info] OSSD signals are not compatible with the AX series controller.

[AX series] "Unable to

ﬁnd the linear axis. Make

sure it is connected and

try again."

Ethernet connection between the UR controller

and linear axis controller is faulty.

Verify connection and power cycle (power-off then power-on) both controllers.

USB to Ethernet adapter is not used.

[Manual] Refer to the installation steps.

Problem / issue

Cause(s)

Solution(s)

"Collision detected"

during program

execution

Pallet viewer state does not match reality.

Box number parameter was set higher than what

is really on the pallet.

[Pallet viewer] Restart the program and select the right step using the “

” and “

”

buttons.

No feasible trajectory was found, the program

cannot avoid a collision.

[Online conﬁgurator] Use the simulation to conﬁrm the pattern is possible with the

actual installation. Consider changing the following elements :

- TCP offset (length of the extension bracket);

- Label orientation;

- Pattern.

[Installation] Apply the changes to the actual installation, if required.

[Software] When possible, allow the gripper to pick the box at 90° and/or 180°.

(

Palletize

r node ->

Settings

)

[Pick position] When possible, change the gripper orientation when teaching the

pick position.

(

Palletizer

node ->

Box

)

Virtual collision between the box and the virtual

planes around the pallet.

Increase the distance from these planes to the pallet (

Palletize

r node ->

Settings

[Info] A minimal distance of 50 mm is recommended.

"RTDE interface cannot

initialize. Make sure that

Ethernet/IP adapter and

Proﬁnet are disabled, and

that no other URCaps use

the RTDE interface."

[Software] Upgrade to the latest version of Copilot and Polyscope.

[Support] Contact Robotiq’s technical support if the problem persists.

Installation issues

[AX series] Unable to

scan the Robotiq

controller.

Ethernet connection between the UR controller

and the linear axis controller is faulty.

Connect the Ethernet adapter.

Shut down and restart both controllers.

[Support] Contact Robotiq’s technical support if the problem persists.

Unable to touch the base

with the robot’s wrist

when performing the

centering procedure.

The robot’s ﬁrst joint, also known as the base

joint, is near its limit (close to +/- 360 degrees).

Center the base joint (close to 0°) using the

Move

tab.

[Manual] Perform the centering procedure.

Ch. 3, “Mechanical and Electrical Installation”, “Centering the Solution” section.

Protective stop

Protective stop occurs

after a couple of layers.

Collision between the gripped box and the box

on the pallet.

A small Z offset accumulates over many layers.

[Software][Box] Increase the box height parameter (C) to compensate for box

variability.

Use the average box height : Measure the height of a full stack of boxes and divide

it by the number of layers.

Protective stop occurs

when placing a box on

the ﬁrst layer.

Box height is set too low.

[Software][Box] Adjust the box height parameter (C) to compensate for box

variability.

Use the average box height : Measure the height of a full stack of boxes and divide

it by the number of layers.

Pallet height is set too low.

[Software][Pallet] Measure your pallet and set the pallet height in the

Palletizer

node.

Wrong TCP.

[Software][Installation] Change your TCP Z value to match your gripper.

[Manual] Refer yourself to the documentation (Ch. 6, “Center of Mass, Tool Center

Point (TCP)” section),

or use Polyscope’s TCP wizard.

Protective stop occurs

while palletizing.

Cable management system hinders the robot’s

movements.

Install the cable management system according to the procedure.

[See appendix B]

[Manual] Additional info in Ch. 3, “Mechanical and Electrical Installation” section.

Problem / issue

Cause(s)

Solution(s)

Unexpected behavior

Palletizer releases boxes

from too high.

A small Z offset accumulates over many layers.

[Box] Decrease the box height parameter (C).

Use the average box height : Measure the height of a full stack of boxes and divide

it by the number of layers.

Wrong TCP.

[Software][Installation] Validate the TCP is located over the box at the pick position.

Pallet height is set too low.

[Pallet] Measure the pallet height and set the parameter correctly.

[PE series] The pedestal height does not match

the height conﬁgured in the installation tab.

[Installation] Adjust either the actual pedestal height or the parameter in the

installation tab accordingly.

(

Installation

tab ->

URCaps

Copilot

Conﬁguration

)

Boxes are not always

placed straight on the

pallet.

Box pick position is not stable.

[Conveyor] [Pick position] Adjust the conveyor stop rig to generate a precise and

repeatable box pick position.

A stable box position ensures a reliable box positioning on the pallet.

Box pick position is incorrect.

[Box][Pick position] While teaching the pick position, make sure that the vacuum

gripper is squared and centered with the box.

TCP is not deﬁned correctly.

[Installation] Adjust the orientation of the TCP to match the orientation of the

gripper.

[AX series] Linear axis is not aligned with the

base.

[Manual] Perform the centering procedure.

Ch. 3, “Mechanical and Electrical Installation”, “Centering the Solution” section.

[PE series] Pedestal is not aligned with the base.

[Manual] Perform the centering procedure.

Ch. 3, “Mechanical and Electrical Installation”, “Centering the Solution” section.

Robot is waiting over the

pick box position

indeﬁnitely.

Box presence input is not properly conﬁgured.

[Box sensor] When using a custom box sensor, the sensor should be set to "active

high" = Normally Open.

Box presence input is not well deﬁned.

[Software] [Box sensor] [I/O] Set the Box presence input to the one the box sensor

is connected to.

(

Palletizer

node ->

Settings

)

Palletizer stays idle after

the pallet has been

changed.

[PE series] "Pallet conﬁrmed" safety option is

enabled.

Press the "Pallet conﬁrmed" button once the pallet has been changed.

[AX series] Active drive

axis position is wrong.

Active Drive menu shows a negative “Actual

position” for the linear axis.

[Support] Contact Robotiq’s technical support.

A program will be provided to ﬁx the issue.

APPENDIX A

Air Supply setup recommendations

The air supply must be dried and ﬁltered according to ISO 8573-1 class 3.4.3.

Air supply pressure must be between 3 and 7 bar with an optimal pressure at 7 bar. (6.5 bar for Airpick serial number ≤ V-01351)

APPENDIX B

Cable management system (valid for AX and PE series)

Notes :

-Cut the air tube at the right length (815 mm / 32 in) past the plastic strain relief.

-For more details about the cable management system, consult the AX or PE series manual (Ch. 3, “Mechanical and Electrical

Installation” section).

APPENDIX C

Safety connections

ROBOTIQ PALLETIZING SOLUTION User guide

Brand: ROBOTIQ

Model: PALLETIZING SOLUTION

Type: User guide

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ROBOTIQ PALLETIZING SOLUTION User guide

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