ROBOTIQ PALLETIZING SOLUTION Operation and maintenance manual

Robotiq PalletizingSolution
for Universal Robots
Instruction Manual
ROBOTIQ PALLETIZING SOLUTION
robotiq.com | leanrobotics.org
Original Notice
© 2020Robotiq Inc.

Revisions 4
1. GeneralPresentation 6
1.1. Palletizing SolutionComponents 6
1.2. Object Picking 10
1.3. Palletizing OperationDiagrams 11
2. Safety 13
2.1. Disclaimer 13
2.2. IntendedUse 14
2.3. Warnings, riskassessment and finalapplication 15
3. Installation 19
3.1. Scope of Delivery 20
3.2. RequiredToolsand Equipment 21
3.3. Environmentaland Operating Conditions 22
3.4. Mounting and Installation 23
3.5. OtherGrippers 47
3.6. InstallationforUniversalRobots 49
3.7. URCap Package 49
3.8. License Agreement 55
4. Operation 58
4.1. Starting Up 58
4.2. LightsStates 58
5. Software 61
5.1. InstallationonUniversalRobotse-Series 61
5.2. VacuumGripperbehavior 70
5.3. AirPickVacuum controloverUniversalRobotswithURCaps 70
6. Specifications 71
6.1. Technicaldimensions 71
6.2. Mechanicalspecifications 76
6.3. Electricalspecifications 79
7. Maintenance 82
7.1. LinearAxis 83
7.2. Fasteners 84
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7.3. AirFilterCleaning 84
7.4. AirPickVacuum Gripper 84
7.5. SolutionCleaning 85
7.6. SolutionStorage 85
8. Spare Parts, Kitsand Accessories 86
9. Troubleshooting 87
9.1. Palletizing Solution(except the AirPickGripper) 87
9.2. AirPickVacuum Gripper 88
10. Warranty 91
11. Harmonized Standards 93
11.1. Applied standards 93
12. Appendix 94
12.1. Anchoring pattern 94
12.2. SafetyConnections 95
13. Contact 97
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Revisions
Robotiq maymodifythisproduct without notice,whennecessary,dueto product improvements,modificationsorchangesin
specifications.If such modification ismade,themanual will also berevised,seerevision information.Seethe latest versionof this
manual onlineat:support.robotiq.com.
2020/12/16
lUpdateof thesafetysection
lUpdateof theinstallationsection
lUpdateof thespecificationssection
2020/11/30
Updateof theInstallationsection.
2020/11/25
Initial release
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Copyright
© 2020Robotiq Inc.All rightsreserved.
Thismanual and theproduct it describesareprotected bytheCopyright Act of Canada,bylawsof othercountries,and byinternational
treaties,and therefore may not be reproduced inwhole or inpart, whether for saleornot,without prior writtenconsent from Robotiq.
Undercopyright law,copying includestranslation into anotherlanguage orformat.
Informationprovided byRobotiq inthisdocument isbelieved to be accurateand reliable.However,no responsibilityisassumed by
Robotiq for itsuse.Theremaybe somedifferencesbetween themanual and theproduct if theproduct hasbeenmodified afterthe
editiondate.
Theinformationcontained inthisdocument issubject to change without notice.
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1.General Presentation
The terms '' Palletizing'', ''Palletizing Solution'' and ''Solution'' used in the following manual all refer to the Robotiq Palletizing Solution.
The Robotiq Palletizing Solution is a hardware and software solution already connected and ready to install. It is composed of a base
fully integrated with the linear axis, pallet sensors and status lights. The extra reach gripper bracket is also included in the Solution to
extend the AirPick Gripper of 200 mm from the robot tool flange.The Material Handling Copilot and accessories such as a box sensor,
an anchor kit and acable management system are partsof the Solution.
Info
The following manual usesthemetricsystem.Unlessspecified,alldimensionsare inmillimeters.
1.1.PalletizingSolutionComponents
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Info
Thefollowing sectionpresentsthekeyfeaturesof theRobotiq Palletizing Solutionand must not be considered as
appropriateto theoperationof theSolution.Eachfeatureisdetailed intheappropriate section.
1.1.1.Base andColumn
The Robotiq Palletizing Solutioniscomposed of a base and a columnonwhichall thecomponentsthat are necessaryto thegood
operationof the Solutionareattached.Itsgeometryisdesigned to facilitatethepositioning of theRight and Left palletswithout any
surrounding obstructions.The base hasto beanchored inthefloor.Formoredetails,pleasesee the Installationsection
1.1.2.LinearAxis
To extend thereachof therobot,alinearaxisisinstalled insidethecolumn.It allowstherobot to moveverticallyinorderto build high
pallets.
1.1.3.LinearAxisController
All thecomponentsof theSolution areintegrated and controlled viathelinearaxiscontroller.It allowssimultaneousmotionof theaxis
and therobot during palletizing motion.
1.1.4.Pallet Sensors
TheSolution iscomposed of four(4)sensorsto detect palletspresence(two perpallet).Thesensorswill allowtheSolutionto ensure
that the palletsarewell positioned oneach side of thebase to optimize theapplication process.
1.1.5.StatusLights
Two (2)statuslightsarepositioned onthetop of thebase.Eachstatuslight isassociated to thenearest pallet.Thecolorof thelight
allowsto knowthestatusof the systemorthestate of aspecificpallet.Please referLightsStatessection.
1.1.6.AirPick VacuumGripper
The AirPickisaVacuum Gripper that createsa vacuum via apneumatic vacuum generator.It isequipped with one or multiple suction
cups.Each suction cup canbe adapted to your applicationand grasping needs.TheAirPickGripperiscompatiblewiththeRobotiq
standard coupling interface.
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Palletizing Solution -InstructionManual
Fig.1-1:Robotiq AirPickGripper
1.1.7.SuctionCup System
A Robotiq Suction Cup System can be installed directly under the Vacuum Gripper. Each Robotiq Suction Cup System includes a
bracket,amanifold,airnodes,port plugs,bumpers,tubing and additional suctioncups.
Fig.1-2:Suction cup system
Info
Please referto theInstallationsection formore informationonhowto integratetheSuctionCup Systemto theAirPick.
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Tip
Theownercanuse acustom bracket ora mounting plate.Thebracket ormounting plate canbeinstalled directlyunder the
manifold.
1.1.8.ExtraReachGripperBracket
The extrareach gripperbracket isincluded intheSolution to extend theAirPickGripper of 200mm from therobot tool flange. Thisway,
the Robotiq Palletizing Solution will be able to palletize boxeson large size pallets. Please refer to the Extra ReachBracket section for
moredetailsabout thelimitationsof theextensionbracket
Fig.1-3:AirPickVacuum GripperExtra Reach Bracket
1.1.9.BoxDetectionSensor
TheSolution includesaboxsensorthat needsto beinstalled at theend of theconveyorin awaythat it istriggered whenaboxisready
to bepicked up.
Fig.1-4:BoxSensor
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1.2.Object Picking
TheAirPickGripperallows:
1. Mainunit suction cup
2. Auxiliarysystem with multiple suctioncups
Warning
Object picking causesthecompression of thesuction cup(s),which canresult inpinching pointsbetweenthegripperand the
load.Avoid presenceof bodypartsin thiszoneduring operation.
Warning
Before picking anynewobject or material in autonomousmode,alwayscheck that theresulting vacuum level issufficient to
ensuresafegripping,inorderto prevent dropping orejectionof theload.
1.2.1.MainUnit SuctionCup
lIn orderto use onlyonesuction cup,the single cup canbe mounted right inthe port of thevacuum generator.
1.2.2.AuxiliarySystemwithMultiple SuctionCups
lA standard Suction Cup System can be attached to theAirPickVacuum Gripper.The bracket normallyholds two or foursuctioncups
(corresponding to thefourportsof themanifold).
lAnyunused manifold port should be blocked withamating plug to avoid airleakage.
lOther custom mounting options canalso be used to benefit from a multiple suction cupssolution.
Info
For thecollision avoidance algorithm,therobot control softwareconsidersagenericgrippergeometricenvelope that does
not overlap thebox.
Caution
Custom bracketsand platesmust meet therequired technical specifications(referto theTechnicaldimensionssection.
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1.3.PalletizingOperationDiagrams
The following diagramsexplainthelogical operation of thePalletizing Solution,based ontheoperator'sactionsand all responses
coming out from them such as signals,pallet and boxsensorsbehaviors,etc.
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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 safeand lawful practicesincluding but not limited to thoseset forthinthisdocument.
Info
Theterms“operator”,''installer'',''commissioning'' or ''installation'' referto anyoneresponsible foranyof thefollowing
operationsontheRobotiq Palletizing Solution:
lInstallation
lControl
lMaintenance
lInspection
lCalibration
lProgramming
lDecommissioning
The present sectionisbased onthefollowing international standardsand technical specifications:
lISO 10218-1:2011:SafetyRequirementsFor Industrial Robots- Robots
lISO 10218-2:2011:SafetyRequirementsFor Industrial Robots- RobotsSystemsand Integrators
lIEC 60204-1 :SafetyOf Machinery-Electrical Equipment Of Machines
lISO/TS15066:2016 :Robotsand roboticdevices— Collaborativerobots
Thismanual explainsvariouscomponentsof theRobotiq Palletizing Solution and thegeneral operationsregarding thewhole life-cycle
of the product,from installation to operation and decommissioning.
The drawingsand photosinthismanual are representative examples.However,discrepanciesmaybeobserved betweenthevisual
supportsand theactual product.
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2.2.Intended Use
TheRobotiq Palletizing Solution isspecificallydesigned forpalletization.
Warning
Onlyusetheapplication initsoriginal condition without unauthorised modifications.
Warning
Onlyusetheapplication if it isinperfect technical condition.
Warning
The emergencystop function isintended foruse inemergencyconditionsand not fornormal conditionstop.
Info
The Solution isintended to be used with a UR10or UR10e from Universal Robots.
Info
Alwayscomplywithlocal,state,provinceand/orfederallaws,regulationand directivesautomationsafetyand general
machine safety.
Caution
Theunit should be used exclusivelywithintherangeof itstechnicaldata.Anyotheruse of thesolutionisdeemed improper
and unintended. Robotiq will not be liable for anydamagesresulting from anyimproperor unintended uses.
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Palletizing Solution -InstructionManual
2.3.Warnings, riskassessment and final application
Warning
The operatormust have read and understood all of theinstructionsinthefollowing manual before operating theRobotiq
Palletizing Solution.
Caution
Anyuseof thePalletizing Solutionin non-compliance withthese warningsisdeemed inappropriateand maycauseinjuryor
damage.
The robot, the AirPickVacuum Gripper or anyothergripper used,the linear axisand anyother equipment used in the final application
must go througha comprehensiveriskassessment processbefore theycanbeused.Special caremust betakenduring thisstep if
custom mounting optionsare used forthe suction cups.
Caution
It istheinstaller/operator'sresponsibilityto ensurethat all local safetymeasuresand regulationsare met.
Thefollowing non-exhaustive list presentsrisksthat must beassessed during theintegration process:
lRiskof load ejectionresulting from lossof vacuum;
lRiskof load dropping resulting from lossof vacuum;
lRiskof pinching anymoving component of the Robotiq Palletizing Solutionortherobot;
lRiskof damage or breaking if using a custom suction cup bracket that doesnot meet the technical requirements;
Depending on theapplication,theremaybe hazardsthat requireadditional protectionand/orsafetymeasures.Forinstance,the
workpiece handled bythegrippercould beinherentlydangerousto theoperator.
Warning
The linear axisisNOT powerand force limited.Pinching or crushing risk must be considered seriously.
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Warning
Whentherobot isnot moving,thecollaborative collisiondetectionisdisabled.If thelinearaxismoves,it canhurt peoplewith
therobot.
Warning
Depending onthesupplysources,whenanemergencystop (e-Stop)buttonispressed,thefollowing consequencesmay
occur.Therobot ownerhastheresponsibilityto do a riskassessment and choosetheappropriate option.
Supplysources e-Stop consequences
Robot tool supply
(tool connector)
Powerfailureto theVacuumGripper.Thevacuum level will drop to ambient pressureand
theobject will belost.
Caution
ForthePalletizing Solution,it isnot recommended to connect theGripperto
thetool connector.
Robot controllersupply*
(Any24Vpin)
Vacuum Gripperpowered ON.
lIf anobject isdetected:thevacuum levelwill continueto beregulated and theobject will
not belost.
lIf no object isdetected:theVacuum Gripperwill go into a standby state 2secondsafter
thee-Stop button ispressed.
*The AirPick Vacuum Gripper that comes with the Robotiq Palletizing Solution is connected via the robot controller.
Warning
Loss of vacuum canoccurdueto powerfailureor air supplyinterruption.
2.3.1.Expectedsystem behaviorinnormaloperations:
lNormalmode:whenno human operatorispresent withinthepalletizing cell.
lSafeguard mode: when a human operator is present within the palletizing cell in order to manipulate a filled pallet, 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 be
maintained in a stop category 2 and the linear axis will undergo stop category 1 transitioning to stop category 0*. When the safe-
guards are removed,thesystem will resume normal operation.
Info
SeeIEC60204-1for definitionsof stop categories.
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Palletizing Solution -InstructionManual
Emergency stop mode when the emergency stop button is pressed. All components of the system will undergo stop category 1
transitioning to stop category0.
Operationmode
Robot LinearAxis
Force(N) Power(W) Speed
(mm/s) Force (N) Power(W) Speed (mm/s)
Normalmode
(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 1and transition to Cat 0)
Emergencystop
N/A
(Stop Cat 1and transition to Cat 0)
*Calculated using thefollowing assumptions:staticforceat peakcurrent witha 90%efficient ball screwand no friction.
Fig.2-1:SafetyLogical Schema
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2.3.2.LinearAxisStopCategory 0 and1
Whenastop isrequired,therobot and thelinearaxisstart theprocessat the sametime,evenif theyareindependent,so the stopping
timecandiffer.
lFor robot information,pleasereferto theUniversal Robotsdocumentation.
lForthelinearaxis:
oMaximal stopping timefor Category1:500ms;
oMaximal stopping timefor Category0:100ms*;
oTravelled distance when there isa stopping time:33 mm (1-5/16in)*
*Forcaseswheretherobot isimmobile,witha payload of 8 kg and theinitial speed of thelinearaxisis500mm/s,which isthe
maximum allowed speed.
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3.Installation
The following subsectionswill guide youthroughtheinstallation and general setup of yourRobotiq Palletizing Solution.
Info
Before installing:
lRead and understand thesafetyinstructionsrelated to thePalletizing Solution.
lVerifyyour package according to the scope of deliveryand yourorder.
lMakesure to have therequired parts,equipment and toolslisted inScopeof delivery.
Warning
Wheninstalling:
lMeet therecommended environmental conditions.
lDo not operate thePalletizing Solution,oreventurn on thepowersupply,before the deviceisfirmlyanchored and the
machine area iscleared.Make surethat theairsupplyissecured.
Warning
Failureto properlysecureand installtheequipment canresult inmaterial damage and seriousinjury.In addition,note that in
situationswheretheinstallation isnot compliant,thewarrantyisvoid.
Warning
Whenmounting sectionsof thelinearaxisbase,and when moving it,make sureto let enough of safespace around,so you
canavoid material damagesand seriousinjuries.
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Warning
lMake sure to followall thesafetyrulesand regulationsof yourworkplace whileusing theRobotiq Palletizing Solution.
lAlwayswearall recommended personal protectiveequipment inaccordancewithyourworkplace'ssafetystandards,
including:
oSafetyglasses;
oHearing protection;
oHard hats;
oSteel-toeboots
lAlwaysusepropersafetyprecautionswhen working withtoolsthat containsharp edges,pinching surfaces,orgenerate
heat.
lAlwayslift heavyobjectswith your legs,not your back.If you cannot lift anobject alone,askforhelp orfind anothermethod
to moveit.
3.1.Scope of Delivery
l1xrobot baseincluding:
o1 xLinear axis(1500mm stroke)
o1xMotor
o1xLinearaxiscontroller
o4xPallet sensors
o2xStatuslights
o1xCablemanagement system
l6xconcrete anchors(1/2-13)
l1xBoxdetectionsensor
l1xExtrareachbracket
l1 xVacuum Gripperkit (Airpick, suctionscups,bracketsfor 2or 4cups)
l1 xAir tube8mm (already mounted on the column)
l1xGrippercoupling kit
l1xMaterial Handling Copilot software dongle license
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