Omron TM Conveyor Tracking User manual

I853-E-01
TM Conveyor
Tracking
User’s Manual
Original Instruction

TM Conveyor Tracking Software version: TMflow 1.76 2
This Manual contains information of the Techman Robot product series (hereinafter referred to as the TM
Robot). The information contained herein is the property of Techman Robot Inc. (hereinafter referred to as
the Corporation). No part of this publication may be reproduced or copied in any way, shape or form without
prior authorization from the Corporation. No information contained herein shall be considered an offer or
commitment. It may be subject to change without notice. This Manual will be reviewed periodically. The
Corporation will not be liable for any error or omission.
Mark are the registered trademarks of Techman Robot Inc., The Company reserves the ownership and
copyright of this Instruction and its copies.

TM Conveyor Tracking Software version: TMflow 1.76 3
Contents
Revision History ......................................................................................................................................6
1. Introduction....................................................................................................................................... 7
1.1 Scope of Use.............................................................................................................................7
1.2 Limitations of Use......................................................................................................................7
1.3 Warning and Caution Symbols..................................................................................................7
1.4 Safety Precautions ....................................................................................................................8
1.5 Validation and Liability............................................................................................................... 9
1.6 Limitation of Liability..................................................................................................................9
1.7 Functional Note Symbols .......................................................................................................... 9
2. Hardware Requirements ................................................................................................................10
2.1 TM Dongle...............................................................................................................................10
2.2 Applicable EtherCAT Coupler + Encoder Module ................................................................... 10
2.3 Code Wheel ............................................................................................................................ 11
2.4 Camera ................................................................................................................................... 11
2.4.1 Lens..................................................................................................................................... 12
2.5 Reference Guide for Light Source Setup ................................................................................12
2.6 Sensor..................................................................................................................................... 13
2.7 Light box design reference...................................................................................................... 13
2.8 Hardware Connection Diagram...............................................................................................13
3. Operating Guide .............................................................................................................................14
3.1 Sensor Mode........................................................................................................................... 14
3.2 ETH Mode ...............................................................................................................................15
4. Software Functions.........................................................................................................................16
4.1 Conveyor Tracking Setting ......................................................................................................16
4.1.1 Encoder setting....................................................................................................................16
4.1.2 Boundary setting..................................................................................................................17
4.1.3 Advanced setting .................................................................................................................18
4.2 CVSensor1..............................................................................................................................19
4.3 Main Thread Nodes.................................................................................................................20
4.3.1 CVNewObj Node .................................................................................................................20
4.3.2 CVPoint Node......................................................................................................................21
4.3.3 CVCircle Node.....................................................................................................................24
5. Quick Walk-through ........................................................................................................................25
5.1 Sensor Mode........................................................................................................................... 25
5.2 ETH Mode ...............................................................................................................................31

TM Conveyor Tracking Software version: TMflow 1.76 4
Tables
Table 1：EtherCAT Coupler＋Encoder Module (1/2).................................................................... 10
Table 2：EtherCAT Coupler＋Encoder Module (2/2).................................................................... 10
Table 3：Camera .......................................................................................................................... 11
Figures
Figure 1 Code wheel..................................................................................................................... 11
Figure 2 Hardware connection diagram........................................................................................13
Figure 3 Create new project..........................................................................................................14
Figure 4 Sensor Mode diagram .................................................................................................... 14
Figure 5 ETH Mode diagram.........................................................................................................15
Figure 6 Conveyor Tracking Setting.............................................................................................. 16
Figure 7 Encoder setting...............................................................................................................16
Figure 8 Boundary setting.............................................................................................................17
Figure 9 Advanced Setting............................................................................................................18
Figure 10 CVSensor .....................................................................................................................19
Figure 11 Sensor calibration ......................................................................................................... 20
Figure 12 CVNewObj ....................................................................................................................21
Figure 13 CVPoint.........................................................................................................................21
Figure 14 Teach ............................................................................................................................22
Figure 15 Get Point....................................................................................................................... 23
Figure 16 CVCircle........................................................................................................................24
Figure 17 Create new project........................................................................................................25
Figure 18 Start the project ............................................................................................................25
Figure 19 Conveyor Tracking Setting............................................................................................ 25
Figure 20 Select tool .....................................................................................................................26
Figure 21 CVSensor .....................................................................................................................26
Figure 22 Sensor calibration .........................................................................................................26
Figure 23 Two calibration points ................................................................................................... 27
Figure 24 Switch tool ....................................................................................................................27
Figure 25 Point Node ....................................................................................................................27
Figure 26 Select conveyor number ............................................................................................... 28
Figure 27 Set Pass Path ...............................................................................................................28
Figure 28 CVPoint.........................................................................................................................28
Figure 29 Teach ............................................................................................................................29
Figure 30 Get Point....................................................................................................................... 30

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Figure 31 Form a loop...................................................................................................................30
Figure 32 Open new project..........................................................................................................31
Figure 33 Sub-thread ....................................................................................................................31
Figure 34 Conveyor Tracking Setting............................................................................................ 31
Figure 35 Vision Job .....................................................................................................................32
Figure 37 Input vision job name....................................................................................................32
Figure 38 Conveyor Tracking camera...........................................................................................32
Figure 39 Automatic calibration steps ........................................................................................... 33
Figure 40 Load workspace............................................................................................................34
Figure 41 Pattern matching...........................................................................................................35
Figure 42 Confirm and exit............................................................................................................35
Figure 43 Confirm “FIND” pattern .................................................................................................35
Figure 44 Save visual task............................................................................................................36
Figure 45 Check visual task on list ...............................................................................................36
Figure 46 Switch tool ....................................................................................................................36
Figure 47 Point Node ....................................................................................................................36
Figure 48 Select conveyor ............................................................................................................37
Figure 49 Set Pass Path ...............................................................................................................37
Figure 50 CVPoint.........................................................................................................................37
Figure 51 Get Point....................................................................................................................... 38
Figure 52 Form a loop...................................................................................................................39

TM Conveyor Tracking Software version: TMflow 1.76 6
Revision History
Revision Date Revised Content
01 April 2020 Original release

TM Conveyor Tracking Software version: TMflow 1.76 7
1. Introduction
TM Conveyor Tracking can obtain the position and direction of the object using vision and/or a sensor.
This software solution allows users to implement high precision application including electronic
assembly, loading and unloading. In addition, TM Conveyor Tracking increases the efficiency of the
assembly line.
When using the TM Conveyor Tracking function during TM Flow, connect the TM license dongle
supplied in the TM Conveyor Tracking product package into any USB port on the control box to activate
the TM ETH Conveyor Tracking function. Sensor mode does not require a license dongle. Be careful
that when editing, running trials or operating, the license dongle must remain connected with the control
box. Otherwise, the project cannot be edited or the robot may stop.
1.1 Scope of Use
1. A single robot can support two conveyors.
2. Conveyor speed < 300 mm/s, average precision±1mm (when the workpiece angle variation
within±15˚).
1.2 Limitations of Use
1. Only supports Sensor + Sensor or ETH + Sensor (ETH +ETH is not supported, and ETH mode
requires use of license dongle)
2. Does not support two robots using one single Encoder + EtherCAT IO
3. Only supports linear conveyor (Does not support circular conveyor).
4. Does not support multiple objects.
NOTE:
The precision specifications in this manual only serves as reference. Upon the actual completion of
automation setting, the precision specifications and calibration accuracy are influenced by
environmental factors, workpiece variation, visual patterns, editing, and conveyor stability. Users still
need to take actual tests.
1.3 Warning and Caution Symbols
The Table below shows the definitions of the warning and caution levels used in our manuals. Pay close
attention to them when reading each paragraph, and observe them to avoid personal injuries or
This manual applies to TMflow Version 1.76.6300. There may be differences between the functions and interfaces of
different software versions. Confirm the software version before using and reading this manual. To confirm the
software version, click at the top right of the screen for the information.

TM Conveyor Tracking Software version: TMflow 1.76 8
equipment damage.
DANGER:
Identifies an imminently hazardous situation which, if not avoided, is likely to result in serious
injury, and might result in death or severe property damage.
WARNING:
Identifies a potentially hazardous situation which, if not avoided, will result in minor or
moderate injury, and might result in serious injury, death, or significant property damage.
CAUTION:
Identifies a potentially hazardous situation which, if not avoided, might result in minor injury,
moderate injury, or property damage.
1.4 Safety Precautions
All personnel who install, operate, teach, program, or maintain the system must read the Hardware
installation Manual, Software Manual, and Safety Manualaccording to the software and hardware
version of this product, and complete a training course for their responsibilities in regard to the
robot.
All personnel who design the robot system must read the Hardware installation Manual, Software
Manual, and Safety Manualaccording to the software and hardware version of this product, and
must comply with all local and national safety regulations for the location in which the robot is
installed.
The TM Robot must be used for its intended use.
Results of the risk assessment may require the use of additional risk reduction measures.
Power to the robot and its power supply must be locked out and tagged out or have means to
control hazardous energy or implement energy isolation before any maintenance is performed.
Dispose of the product in accordance with the relevant rules and regulations of the country or
area where the product is used.
DANGER:
This product can cause serious injury or death, or damage to itself and other equipment, if the
following safety precautions are not observed:
Read Manual Label; Impact Warning Label

TM Conveyor Tracking Software version: TMflow 1.76 9
1.5 Validation and Liability
The information contained herein neither includes how to design, install, and operate a complete robotic
arm system, nor involves the peripherals which may affect the safety of the complete system. The
integrators of the robot should understand the safety laws and regulations in their countries and prevent
hazards from occurring in the complete system.
This includes but is not limited to:
Risk assessment of the whole system
Adding other machines and additional risk reduction measures based on the results of the risk
assessment
Using appropriate software safety features
Ensuring the user will not modify any safety measures
Ensuring all systems are correctly designed and installed
Clearly labeling user instructions
Clearly marked symbols for installation of the robot arm and the integrator contact details
Making accessible relevant documents, including the risk assessment and this Manual
CAUTION:
This product is a
partly complete machine. The design and installation of the complete system
must comply with the safety standards and regulations in the country of use. The user and
integrators of the robot should understand the safety laws and regulations in their countries
and prevent major hazards from occurring in the complete system.
1.6 Limitation of Liability
No safety-related information shall be considered a guarantee by the Corporation that a TM Robot will
not cause personnel injury or property damage.
1.7 Functional Note Symbols
The following table defines the functional note symbols used in this manual. Read the paragraphs
carefully.
IMPORTANT:
This symbol indicates the relevant functional details to assist programming and use.
NOTE:
This symbol indicates the relevant functional use tips to assist programming efficiency.

TM Conveyor Tracking Software version: TMflow 1.76 10
2. Hardware Requirements
2.1 TM Dongle
Use the included TM license dongle to activate ETH Conveyor Tracking function.
2.2 Applicable EtherCAT Coupler + Encoder Module
Equipment
name
EtherCAT Coupler Encoder Module EtherCAT Coupler Encoder Module
Model VIPA: 053-1EC00 VIPA: 050-1BA00 Beckoff: EK1100 Beckoff: EL5151/EL5152
Rated voltage DC24V DC24V DC24V DC24V
Rated current 950mA 75mA 570mA 130mA
Number of
Encoder
N/A 1 N/A 1 or 2
ON voltage N/A 15 – 28.8V N/A 15 – 30V
OFF voltage N/A 0 – 5V N/A 0 – 5V
Table 1：EtherCAT Coupler＋Encoder Module (1/2)
Equipment Name EtherCATCoupler Encoder Module Encoder Module
Model
OMRON:
NX-ECC203
OMRON: NX-EC0112
NPN module (single
encoder)
OMRON: NX-EC0222 PNP
module (dual encoder)
Rated voltage DC24V DC24V DC24V
Rated current 520mA 35mA 39mA
Number of Encoder N/A 1 2
ON voltage N/A 19.6 ~ 28.8V 19.6 ~ 28.8V
OFF voltage N/A 0 ~ 4V 0 ~ 4V
Table 2：EtherCAT Coupler＋Encoder Module (2/2)
NOTE:
Equipment needs to be connected to external power supply for proper use. For detailed
product information, visit the product’s official website.
Suggested Encoder Model: E6C3-CWZ5GH
IMPORTANT:
Techman Robot Inc. is not liable for any imcompatibility issue due to use of equipment not
listed above.

TM Conveyor Tracking Software version: TMflow 1.76 11
2.3 Code Wheel
Reference specifications:
Perimeter: circumference
300 mm
If a different sized wheel
is used, go to Encoder
Setting (Section 5.1.1) to
adjust the parameters for
perimeters.
Make sure that the code
wheel is flat against the
conveyor to ensure its
accuracy.
Figure 1 Code wheel
2.4 Camera
Equipment name Camera
Model Basler acA2440-20gc Basler acA2500-20gc Basler acA2500-14gc
Shutter Global Rolling
Sensor Color 2/3 inch Color 1 inch Color 1/2.5 inch
Connection
interface
GigE interface
Remark
When conveyor speed <
300
mm/s, the average
tolerance is ±1 mm.
When conveyor speed < 300
mm/s, the average tolerance is ±
1 mm.
Rolling shutter camera is
recommended to be used at
low speed (conveyor speed
< 100 mm/s) and when
precision requirement is
lower.
For detailed product information, please visit the product’s official website.
Table 3：Camera
IMPORTANT:
Techman Robot Inc. is not liable for any incompatibility issue due to use of equipment not
listed above.

TM Conveyor Tracking Software version: TMflow 1.76 12
2.4.1 Lens
It is strongly recommended to use an industrial-grade C/CS Mount lens. The lens focal distance
should be set based on the real-world applications.
Lens selection example (object is 500 mm away from the camera)
Reference for calculation:
When using a 12 mm lens, the field is 232 x 174 mm2; pixel resolution is 232/2590 ~ 0.09
mm/pixel.
When using an 8 mm lens, the field is 351 x 263 mm2; pixel resolution is 351/2590 ~ 0.14
mm/pixel.
2.5 Reference Guide for Light Source Setup
To obtain decent image quality and rapid imaging time, it is strongly recommended that the light source
intensity of the image range can reach to 2500 Lux, with uniformity higher than 90% to avoid light
reflection.
At light levels below 2500 LUX, it may be necessary to increase the camera exposure time and
decrease the conveyor belt speed.
For example (when the camera is 500 mm from the focus object):
When the light intensity is 2500 Lux, exposure time setting should be set as 0.5 msec, and the conveyor
speed shall be set to 300 mm/sec;
Calculation of Uniformity：
Divide the camera field into a 3 x 3 grid as in the following figure. Measure the brightness in
the center of each cell and obtain the maximum and minimum value,
Substitution：
Uniformity =�1−( −)
( +)�× 100%

TM Conveyor Tracking Software version: TMflow 1.76 13
2.6 Sensor
Choose the most appropriate sensor based on the object material that needs to be detected.
When using Sensor Mode, it is strongly recommended using the official TM Robot Calibration Set for
positioning. When setting CVPoint is required, switch back to the specific tool for your application.
NOTE:
To purchase TM Calibration Set, contact your local distributor or dealership.
2.7 Light box design reference
For relevant details about reference design of light box, contact your local distributor or dealership.
2.8 Hardware Connection Diagram
The diagram below shows the recommended hardware connection.
For details about the supply voltage of the power socket, refer to the robot in use.
Camera
Sensor
Code wheel Encoder
EtherCAT Coupler
Power supply
Encoder Module
Light source
TM Robot
Power Socket
TM Control Box
EtherCAT
24V(DC)
IO in
Network cable
Conveyor
Figure 2 Hardware connection diagram

TM Conveyor Tracking Software version: TMflow 1.76 14
3. Operating Guide
Once user has inserted the TM license dongle, click
“New” on the top-left corner of TMflow and then
“Conveyor Tracking” to create a new conveyor
tracking project. Remember to enter a project name.
Select “Conveyor_0” or “Conveyor_1”
Conveyor_0: application requires only one
conveyor
Conveyor_1: application requires two conveyors
TM Conveyor Tracking supports two operating modes:
Sensor Mode: detect the objects passing
through the sensor beam (default mode)
ETH Mode: obtain object position through
camera imaging (requires use of a license
dongle)
Figure 3 Create new project
3.1 Sensor Mode
Sensor Mode consists of a robot and external
sensors. The sensor will detect objects passing
through the sensor beam. Schematic of Sensor
Mode presented in Figure 6.
Figure 4 Sensor Mode diagram

TM Conveyor Tracking Software version: TMflow 1.76 15
3.2 ETH Mode
ETH Mode is composed of a robot, an external
camera, and light sourcing devices. Schematic of
ETH Mode shown in Figure 7.
Figure 5 ETH Mode diagram
*Currently, TM Conveyor Tracking only supports Sensor Mode by default. For purchase of ETH Mode
license, consult with your local representatives.

TM Conveyor Tracking Software version: TMflow 1.76 16
4. Software Functions
4.1 Conveyor Tracking Setting
After opening the Conveyor Tracking project, selecting the Start Node sets encoder parameters,
working boundary, camera and advanced conveyor parameters like vectors. Further description will be
discussed in the following:
Figure 6 Conveyor Tracking Setting
4.1.1 Encoder setting
Encoder setting allows users to set resolution and encoder wheel perimeters.
Resolution: Encoder resolution.
Perimeter: encoder wheel circumference
(mm).
Reverse: (Reverse rotation): when the
conveyor is operating, the speed indicator
should be in positive values. If shown in
negative values, select “Reverse”. .
The officially designated encoder model is
the Omron E6C3- CWZ5GH 2000P/R 2M.
However, settings shall be based on the
actual encoder hardware used by users.
Figure 7 Encoder setting

TM Conveyor Tracking Software version: TMflow 1.76 17
4.1.2 Boundary setting
Set the working area boundary for the robot.
B Start: Work start point
B End: Work end point
Range: Robot working range
Recommended maximum ranges:
650 mm (TM5-700 model)
850 mm (TM5-900 model)
1150 (TM12)
1350 (TM14)
(Regarding the actual movement range, please refer to the 6DOF Workspace for the
respective user manual of each robot model.)
New object range: the range robot selects new object (this range is executed in CVNewObj
node)
Working Area: Actual work range, based on the intersecting boundaries of B Start and B End.
If there is no intersecting point, in the case that B Start is set to be small while B End is set to be
very large, the system will use the distance of range to determine the working area.
Robot Base: Robot placement position.
Figure 8 Boundary setting

TM Conveyor Tracking Software version: TMflow 1.76 18
4.1.3 Advanced setting
Advanced Setting is used for setting conveyor object compensation. Description is as follows:
Conveyor Vector Compensate
(Calibration Point 2
）
X offset (mm): when adjusting calibration,
the calibration plate x direction error.
Y offset (mm): when adjusting calibration,
the calibration plate y direction error.
Z offset: when adjusting calibration, the
calibration plate Z direction error.
(Based on Robot Base coordinates,
correct the X/Y/Z offset of Calibration
Point 2 coordinates)
Maximum object moving distance in a
frame (ETH Mode only): this function
prevents a single object from being
detected as multiple objects.
•If a single object is detected as
multiple objects, increase the value.
•If multiple objects are detected as a
single object, decrease the value.
Figure 9 Advanced Setting
NOTE:
When executing Conveyor Tracking project, click “View Page” from the drop-down
menu on the top-left corner of TMflow and click “Conveyor Data” to adjust Advanced
Setting.
Advanced Setting does not support Warp Node project switching. If your project
would use Warp Node, remember to set Advanced Setting first and then use Warp.

TM Conveyor Tracking Software version: TMflow 1.76 19
4.2 CVSensor1
Click the pencil icon of CVSensor1 to set the sensor calibration.
Conveyor NO.: current conveyor in use
I/O Number: Digital Input channel of the
control box connected to the sensor
Enable Time: sets the minimum trigger
time of the sensor. If the sensor trigger
time is lower than Enable Time, this
signal will not be considered as an
object moving pass the sensor.
Rising Edge Detect: the default is
checked, indicating the signal is active
High when an object is detected by the
sensor.
•When no object passes through
the sensor beam, the signal is Low.
•When an object passes through
the sensor beam, the signal is
High.
Then, click “Next” to start calibration.
Figure 10 CVSensor
Follow the instruction on the screen to
perform calibration. Users have to
calibrate two Calibration Points.

TM Conveyor Tracking Software version: TMflow 1.76 20
Figure 11 Sensor calibration
4.3 Main Thread Nodes
4.3.1 CVNewObj Node
Return to Conveyor main thread to select CVNewObj node.
This node indicates that the robot is waiting for valid objects that have been detected
by the sensor and will move to the robot’s New Object Range within the Working Area
(refer to Section 4.1.2 for details about range and area).
Conveyor NO: Selected conveyor
Time Out: Set the waiting time for a valid
object, which is detected within New
Object Range.
•When Time Out = 0, it indicates no
time out is set.
When a valid object enters the robot
operating range, the thread will go to the
next node.