ROBOTIQ PALLETIZING SOLUTION AX Series User manual

Robotiq Palletizing Solution - AX Series
for Universal Robots
Instruction Manual
ROBOTIQ PALLETIZING SOLUTION
AX Series
robotiq.com | leanrobotics.org
Original Notice
© 2022 Robotiq Inc.

Palletizing Solution - Instruction Manual
Table of Contents
Revisions 5
1. General Presentation 8
1.1. Palletizing Solution Components 8
1.2. Object Picking 12
1.3. Palletizing Operation Diagrams 13
2. Safety 15
2.1. Disclaimer 15
2.2. Intended Use 16
2.3. Warnings, Risk Assessment and Final Application 17
3. Installation 22
3.1. Scope of Delivery 23
3.2. Required Tools and Equipment 24
3.3. Environmental and Operating Conditions 25
3.4. Mounting and Installation 26
3.5. Other Grippers 49
3.6. Installation for Universal Robots 51
3.7. URCap Package 51
3.8. Robot Configurations 57
3.9. License Agreement 60
4. Operation 63
4.1. Starting Up 63
4.2. Light States 64
5. Software 66
5.1. Installation on e-Series Universal Robots 66
5.2. Palletizing Script Functions 78
5.3. Vacuum Gripper Behavior 82
5.4. AirPick Vacuum Control over Universal Robots with URCaps 82
6. Specifications 83
6.1. Technical Dimensions 83
6.2. Mechanical Specifications 88
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6.3. Electrical Specifications 92
7. Maintenance 95
7.1. Linear Axis 96
7.2. Fasteners 97
7.3. AirPick Vacuum Gripper 98
7.4. Cleaning 99
7.5. Solution Storage 99
8. Spare Parts, Kits and Accessories 100
9. Troubleshooting 101
9.1. Palletizing Solution (except the AirPick Gripper) 101
9.2. AirPick Vacuum Gripper 105
10. Warranty 108
11. Harmonized Standards 110
11.1. Applied Standards 110
11.2. EC Declaration of Incorporation 111
12. Appendix 112
12.1. Anchoring Pattern 112
12.2. Safety Connections 113
13. Contact 115
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Palletizing Solution - Instruction Manual
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Palletizing Solution - Instruction Manual
Revisions
Robotiq may modify this product without notice, when necessary, due to product improvements, modifications or changes in
specifications. If such modification is made, the manual will also be revised, see revision information. See the latest version of this
manual online at: support.robotiq.com.
2022/04/25
lAdded warning note for Moving and Positioning the Solution (Installation section).
lAdded Add virtual planes around pallet(s) option (Installation and Software sections).
lAdded an Avoid collision with conveyor option in the Palletizer node and the different configurations (Software section).
lAdded scripts Get Pallet State and Set Palletizer State in Software section.
2022/03/28
lAdded Robot Limits section
2022/02/03
lAdded Physical Clearance and Reachable Area of the Robot section
lUpdated Safety Connections section
2022/01/04
lAdded script functions
lUpdated Installation on Universal Robots e-Series section
lThe palletizer model is now named AX Series
2021/10/07
lUpdated Center of mass, tool center point (TCP) table
2021/09/22
lUpdated Safety Connections Appendix
lPink wire is now orange
lUpdated Safety section to add information regarding Reduced mode
lUpdated Software section with more details for the pick position
2021/08/03
lUpdate of the Software section
lAdded Depalletizing mode to Palletizer node
lUpdated info on the Limit height for Palletizer program node
lAdded section 5.2 (Palletizing script functions)
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2021/07/14
lUpdate of the Specifications section (Center of mass, tool center point table)
lUpdate of the Appendix section (Safety Connections)
lUpdate of the Software section
lUpdate of the Troubleshoot section
lUpdate of the Warranty section
lUpdate of the Installation section with new cable management instructions
lUpdate of Spare Parts, Kits and Accessories section
2021/03/29
lUpdate of the Software section: label orientation option added.
lUpdate of the Specifications section
lUpdate of the Installation section (Robot configurations)
2020/12/16
lUpdate of the safety section
lUpdate of the installation section
lUpdate of the specifications section
2020/11/30
Update of the Installation section.
2020/11/25
Initial release
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Palletizing Solution - Instruction Manual
Copyright
© 2020-2022 Robotiq Inc. All rights reserved.
This manual and the product it describes are protected by the Copyright Act of Canada, by laws of other countries, and by
international treaties, and therefore may not be reproduced in whole or in part, whether for sale or not, without prior written consent
from Robotiq. Under copyright law, copying includes translation into another language or format.
Information provided by Robotiq in this document is believed to be accurate and reliable. However, no responsibility is assumed by
Robotiq for its use. There may be some differences between the manual and the product if the product has been modified after the
edition date.
The information contained in this document is subject to change without notice.
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Palletizing Solution - Instruction Manual
1. General Presentation
The terms "Palletizer", "Palletizing Solution", "Robotiq Palletizing Solution", "Solution" and "AX Series" used in this manual all refer
to the AX Series Robotiq Palletizing Solution. The AX Robotiq Palletizing Solution is a hardware and software solution already
connected and ready to install. It is composed of a base fully integrated with a linear axis, pallet sensors, and status lights. An extra
reach gripper bracket is also included in the Solution to extend the reach of an end-of-arm tool of 200 mm from the robot's tool
flange. The Material Handling Copilot software and accessories (e.g., box sensor, anchor kit, cable management system, etc.) are
also part of the Solution.
Info
The following manual uses the metric system. Unless specified, all dimensions are in millimeters.
1.1. Palletizing Solution Components
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Info
The following section presents the key features of the Robotiq Palletizing Solution and must not be considered as
appropriate to the operation of the Solution. Each feature is detailed in the appropriate section.
1.1.1. Base and Column
The Robotiq Palletizing Solution is composed of a base and a column on which all the components that are necessary to the good
operation of the Solution are attached. The Solution is designed to facilitate the positioning of pallets. The base has to be anchored
to the floor. For more details, please refer to the Installation section
1.1.2. Linear Axis
To extend the reach of the robot, a linear axis is installed inside the column. It allows the robot to move vertically in order to build
high pallets.
1.1.3. Linear Axis Controller
All the components of the Solution are integrated and controlled via the linear axis Controller. It allows for the simultaneous motion
of both the axis and the robot during a palletizing action, and the control of the pallet sensors and status lights.
1.1.4. Pallet Sensors
The Solution is composed of four (4) sensors to detect pallets presence (two per pallet). The sensors will allow the Solution to
ensure that the pallets are well positioned on each side of the base to optimize the application process.
1.1.5. Status Lights
Two (2) status lights are positioned at the top of the base. Each status light is associated to the nearest pallet. The color of the light
gives information on the status of the system or the state of a specific pallet. Please refer to the Light States section for more
information.
1.1.6. AirPick Vacuum Gripper
The AirPick is a Vacuum Gripper that creates a vacuum via a pneumatic vacuum generator. It is equipped with one or multiple
suction cups. Each suction cup can be adapted to your application and grasping needs. The AirPick Gripper is compatible with the
Robotiq standard coupling interface.
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Palletizing Solution - Instruction Manual
Fig. 1-1: Robotiq AirPick Gripper
1.1.7. Suction Cup System
A Robotiq Suction Cup System can be installed directly under the Vacuum Gripper. Each Robotiq Suction Cup System includes a
bracket, a manifold, air nodes, port plugs, bumpers, tubing and additional suction cups.
Fig. 1-2: Suction cup system
Info
Please refer to the Installation section for more information on how to integrate the Suction Cup System to the AirPick.
Tip
The owner can use a custom bracket or a mounting plate. The bracket or mounting plate can be installed directly under
the manifold.
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1.1.8. Extra Reach Gripper Bracket
The extra reach gripper bracket is included in the Solution to extend the AirPick Gripper of 200 mm from the robot tool flange. This
way, the Robotiq Palletizing Solution will be able to palletize boxes on large size pallets. Please refer to the Extra Reach Bracket
section for more details about the limitations of the extension bracket
Fig. 1-3: AirPick Vacuum Gripper Extra Reach Bracket
1.1.9. Box Detection Sensor
The Solution includes a box sensor that needs to be installed at the end of the conveyor in a way that it is triggered when a box is
ready to be picked up.
Fig. 1-4: Box Sensor
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Palletizing Solution - Instruction Manual
1.2. Object Picking
The AirPick Gripper allows:
1. Main unit suction cup
2. Auxiliary system with multiple suction cups
Warning
Object picking causes the compression of the suction cup(s) , which can result in pinching points between the gripper and
the load. Avoid presence of body parts in this zone during operation.
Warning
Before picking any new object or material in autonomous mode, always check that the resulting vacuum level is sufficient
to ensure safe gripping, in order to prevent dropping or ejection of the load.
1.2.1. Main Unit Suction Cup
lIn order to use only one suction cup, the single cup can be mounted right in the port of the vacuum generator.
1.2.2. Auxiliary System with Multiple Suction Cups
lA standard Suction Cup System can be attached to the AirPick Vacuum Gripper. The bracket normally holds two or four suction
cups (corresponding to the four ports of the manifold).
lAny unused manifold port should be blocked with a mating plug to avoid air leakage.
lOther custom mounting options can also be used to benefit from a multiple suction cups solution.
Info
For the collision avoidance algorithm, the robot control software considers a generic gripper geometric envelope that
does not overlap the box.
Caution
Custom brackets and plates must meet the required technical specifications (refer to the Technical Dimensions section.
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1.3. Palletizing Operation Diagrams
The following diagrams explain the logical operation of the Palletizing Solution based on the operator's actions, as well as
responses such as signals, pallet and box sensor behaviors, etc.
Please refer to the Status Lights section for further information about light states.
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Palletizing Solution - Instruction Manual
2. Safety
2.1. Disclaimer
The intent of this section is to provide general guidelines for safe use of the Robotiq Palletizing Solution, always follow local
regulations. The installer is responsible for the safe installation and commissioning of the Palletizing Solution. Robotiq accepts no
liability for damage, injury or any legal responsibility incurred directly or indirectly from the use of this product. The user (installer
and operator) shall observe safe and lawful practices including but not limited to those set forth in this document.
Info
The terms “operator”, ''installer'', ''commissioning'' or ''installation'' refer to anyone responsible for any of the following
operations on the Robotiq Palletizing Solution:
lInstallation
lControl
lMaintenance
lInspection
lCalibration
lProgramming
lDecommissioning
The present section is based on the following international standards and technical specifications:
lISO 10218-1:2011 : Safety Requirements For Industrial Robots - Robots
lISO 10218-2:2011 : Safety Requirements For Industrial Robots - Robots Systems and Integrators
lIEC 60204-1 : Safety Of Machinery - Electrical Equipment Of Machines
lISO/TS 15066:2016 : Robots and robotic devices — Collaborative robots
This manual explains various components of the Robotiq Palletizing Solution and the general operations regarding the whole life-
cycle of the product, from installation to operation and decommissioning.
The drawings and photos in this manual are representative examples. However, discrepancies may be observed between the
visual supports and the actual product.
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2.2. Intended Use
The Robotiq Palletizing Solution is specifically designed for palletization.
Warning
Only use the application in its original condition without unauthorised modifications.
Warning
Only use the application if it is in perfect technical condition.
Warning
The emergency stop function is intended for use in emergency conditions and not for normal condition stop.
Info
The Solution is intended to be used with a UR10 or UR10e from Universal Robots.
Info
Always comply with local, state, province and/or federal laws, regulation and directives automation safety and general
machine safety.
Caution
The unit should be used exclusively within the range of its technical data. Any other use of the solution is deemed
improper and unintended. Robotiq will not be liable for any damages resulting from any improper or unintended uses.
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Palletizing Solution - Instruction Manual
2.3. Warnings, Risk Assessment and Final Application
Warning
The operator must have read and understood all of the instructions in the following manual before operating the Robotiq
Palletizing Solution.
Caution
Any use of the Palletizing Solution in non-compliance with these warnings is deemed inappropriate and may cause injury
or damage.
The entire cell (i.e., the robot, the AirPick Vacuum Gripper or any other gripper used, the linear axis, and any other equipment used
in the final application) must go through a comprehensive risk assessment process before they can be used. Special care must be
taken during this step if custom mounting options are used for the suction cups.
Caution
It is the installer/operator's responsibility to ensure that all local safety measures and regulations are met.
The following non-exhaustive list presents risks that must be assessed during the integration process:
lRisk of load ejection resulting from loss of vacuum;
lRisk of load dropping resulting from loss of vacuum;
lRisk of pinching any moving component of the Robotiq Palletizing Solution or the robot;
lRisk of damage or breaking if using a custom suction cup bracket that does not meet the technical requirements;
Depending on the application, there may be hazards that require additional protection and/or safety measures. For instance, the
workpiece handled by the gripper could be inherently dangerous to the operator.
Warning
The linear axis is NOT power and force limited. Pinching or crushing risk must be considered seriously.
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Warning
When the robot is not moving, the collaborative collision detection is disabled. If the linear axis moves, it can hurt people
with the robot.
Warning
Depending on the supply sources, when an emergency stop (e-Stop) button is pressed, the following consequences may
occur. The robot owner has the responsibility to do a risk assessment and choose the appropriate option.
Supply sources e-Stop consequences
Robot tool supply
(tool connector)
Power failure to the Vacuum Gripper. The vacuum level will drop to ambient pressure
and the object will be lost.
Caution
For the Palletizing Solution, it is not recommended to connect the Gripper to
the tool connector.
Robot controller supply*
(Any 24V pin)
Vacuum Gripper powered ON.
lIf an object is detected: the vacuum level will continue to be regulated and the object
will not be lost.
lIf no object is detected: the Vacuum Gripper will go into a standby state 2 seconds
after the e-Stop button is pressed.
*The AirPick Vacuum Gripper that comes with the Robotiq Palletizing Solution is connected via the robot controller.
Warning
Loss of vacuum can occur due to power failure or air supply interruption.
2.3.1. Expected System Behavior in Normal Operating Conditions:
lNormal mode: The palletizer continuously fills pallets when no human operator is within the vicinity of the palletizing cell.
lSafeguarded mode: The system stops when a human operator enters the vicinity of the palletizing cell to manipulate a filled pal-
let, place pallets in an empty pallet slot, or troubleshoot the system or any other operations requiring human intervention. In such a
state the robot will maintain a Category 2 stop and the linear axis will undergo a Category 1 stop transitioning to a Category 0*
stop. When the safeguards are removed, the system will resume operation in normal mode.
Info
See IEC 60204-1 for definitions of stop categories.
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Palletizing Solution - Instruction Manual
Emergency stop mode when the emergency stop button is pressed. All components of the system will undergo stop category 1
transitioning to stop category 0.
Operation mode
Robot Linear Axis
Force (N) Power (W) Speed
(mm/s) Force (N) Power (W) Speed (mm/s)
Normal mode
(Up to safety limits)
up to 250 up to 1000 up to 5000 2400*
690
(nominal)
500
Protective stop
0
(Stop Cat 2)
Safeguard stop
0
(Stop Cat 2)
N/A
(Stop Cat 1 and transition to Cat 0)
Emergency stop
N/A
(Stop Cat 1 and transition to Cat 0)
Reduced mode Please refer to the Universal Robots user manual
for more details.
The linear axis exhibits the same behavior in
Reduced and Normal modes. It is not
recommended to use Reduced mode since the
linear axis is not safety rated for collaborative
applications.
*Calculated using the following assumptions: static force at peak current with a 90% efficient ball screw and no friction.
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Fig. 2-1: Safety Logical Schema
Warning
In the event of a collision or after an emergency stop, an inspection of the solution must be performed before resuming the
use of the machine. Special attention must be given to the carriage assembly, the linear axis, the cable management
system, and the gripper components. Please contact Robotiq Support if any sign of damage is detected.
2.3.2. Linear Axis Stop Category 0 and 1
When a stop is required, the robot and the linear axis start the process at the same time, even if they are independent, so the
stopping time can differ.
lFor robot information, please refer to the Universal Robots documentation.
lFor the linear axis:
oMaximal stopping time for Category 1: 500 ms;
oMaximal stopping time for Category 0: 100 ms*;
oTravelled distance when there is a stopping time: 33 mm (1-5/16 in)*
*For cases where the robot is immobile, with a payload of 8 kg and the initial speed of the linear axis is 500 mm/s, which is the
maximum allowed speed.
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