ROBOTIQ PE20 User manual

Robotiq PalletizingSolution- PESeries
for Universal Robots
User Manual
ROBOTIQ PALLETIZING SOLUTION
PE20
robotiq.com | leanrobotics.org
Original instructions(en)
© 2023Robotiq Inc.

Tableof Contents
Revisions 4
1. General Presentation 6
1.1. Palletizing SolutionComponents 6
2. Safety 8
2.1. Disclaimer 8
2.2. RiskAssessment 9
2.3. Use of the Solution 15
3. Installation 20
3.1. Scope of Delivery 21
3.2. Required Toolsand Equipment 23
3.3. Environmental and Operating Conditions 24
3.4. Mounting and Installation 25
3.5. OtherGrippers 58
3.6. URCap Package 60
3.7. Robot Configurations 61
4. Operation 63
4.1. Start Up 63
4.2. Palletizing OperationInstructions 63
4.3. Palletizing OperationDiagrams 65
4.4. StatusLight States 66
4.5. SolutionMobility(WashDownand ProductionLine Shifts) 67
5. URCap Software 73
5.1. License Agreement 73
5.2. Copilot 76
5.3. Command Window 77
5.4. Program Tree 98
5.5. Palletizing Script Functions 107
6. Specifications 111
6.1. Technical Dimensions 111
6.2. Mechanical Specifications 112
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6.3. Electrical Specifications 113
7. PeriodicInspectionand Maintenance 115
7.1. PowerOff and LockOff Procedure 115
7.2. Inspection 116
7.3. FastenersSpecifications 119
7.4. Cleaning 120
7.5. Storage 120
8. Spare Parts, Kitsand Accessories 121
9. Troubleshooting 122
9.1. Palletizing Solution(excluding the PowerPick20 Vacuum Gripper) 122
9.2. PowerPick20 Vacuum Gripper (Optional) 125
9. Warranty 126
10. Harmonized Standards 128
10.1. EC Declarationof Incorporation 128
10.2. Identificationplate 130
11. Appendix 131
11.1. Palletizing Cell Layout 131
11.2. ConveyorPositioning Holes 133
11.3. Overhang Spacers 134
11.4. PneumaticDiagram 135
12. Contact 136
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Revisions
Robotiq may modify thisproduct without notice, when necessary, due to product improvements, modificationsor changesin
specifications. If such modificationsare made, the manual will also be revised. See revision information below. The latest version of
thismanual can be downloaded at support.robotiq.com.
2023/09/05
Initial Release
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Copyright
© 2023 Robotiq Inc. All rightsreserved.
Thismanual and the product it describesare protected by the Copyright Act of Canada, bylawsof 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 includestranslation into another language or format.
Information provided by Robotiq in thisdocument isbelieved to be accurate and reliable. However, Robotiq shall accept no
responsibility for itsuse. There maybe some differencesbetween the manual and the product if the product hasbeen modified
after the editing date.
The information contained in thisdocument issubject to change without notice.
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1.GeneralPresentation
The terms "Palletizer", "Palletizing Solution", "Robotiq Palletizing Solution", "Solution" , PE20 and "PE Series" used in this
manual all refer to the PE Series Robotiq Palletizing Solution for UR20 Universal Robots. The PE Robotiq Palletizing Solution is a
hardware and software solution preconnected and ready to install. It is composed of a base fully integrated with a Robotiq control
box, pallet sensors, a pedestal, and a post with a teach pendant rack and status lights. The standard delivery also contains the
Robotiq PowerPick vacuum gripper and vacuum generator unit. The Material Handling Copilot software and accessories(e.g., box
sensor, anchor kit, cable management system, etc.)are also part of the Solution.
CAUTION
Thissection presentsthe keyfeaturesof the Robotiq Palletizing Solution and must not be
considered assufficient knowledge to operate the Solution. Each feature isdetailed in the
appropriate section.
1.1.PalletizingSolutionComponents
Fig. 1-1: PE20 Robotiq Palletizing Solution
1.1.1.Base,PedestalandPost
The Robotiq Palletizing Solution iscomposed of abase, on which apedestal, pallet sensorsand Robotiq control box are mounted,
and apost, on which ateach pendant rack, a push button enclosure, and statuslightsare mounted. The Solution isdesigned to
facilitate the positioning of pallets.
The base hasto be anchored to the floor. For more details, please refer to the Installationsection
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1.1.2.RobotiqControlBox
All the componentsof the Solution are integrated and controlled viathe Robotiq control box.It allowsfor the motion of the robot
during a palletizing process, and the control of the pallet sensorsand statuslights.
1.1.3.Standalone Post
The Solution includesapost to which apush button enclosure, statuslightsand teach pendant rack are attached. The post can
either be mounted to the base or positioned elsewhere,adjacent to the base.
1.1.4.Pallet Sensors
The Solution iscomposed of two (2)sensorsused to detect pallet presence (one for each side of the solution).
1.1.5.StatusLights
Two (2)statuslightsare positioned at the top of the post adjacent to the base. Each statuslight isassociated with the nearest
pallet. The color of the light givesinformation on the statusof the system or the state of a specific pallet. Please refer to the Status
Light Statessection for more information.
1.1.6.PowerPick20 VacuumGripper(Optional)
PowerPick20isa vacuum gripper that usesa venturi system to generate vacuum from a compressed air energy source. The
PowerPick Gripper interfaceswith the robot viainput/output (I/O)cablesconnected directlyto the robot controller.
The kit consistsof a gripper, multiple suction cupsand interchangeable components, along with a dual-channel vacuum
generation unit. The unit also includesa shut-off valve and an integrated filter regulator.
Itsdesign issuitable for the Robotiq Palletizing Solution when used with a UR20 robot (weight, payload, independently
controllable channels).
Fig. 1-2: PowerPick20Gripper and vacuum generation unit
1.1.7.BoxDetectionSensor
The Solution includesabox sensor that needsto be installed at the end of the conveyor, and positioned so that it triggersasignal
when a box isat the picking position.
Fig. 1-3: Box Sensor
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2.Safety
2.1.Disclaimer
The intent of thissection isto provide general guidelinesfor the safe use of the Robotiq Palletizing Solution.
Alwaysfollow local regulations.
The installer isresponsible for the safe installation and commissioning of the Palletizing Solution.
Robotiq acceptsno liability for damage, injury or any legal responsibility incurred directly or indirectly from the use of thisproduct.
The user (installer and operator) shall observe safe and lawful practices including but not limited to those set forth in this
document.
The termsuser,operator and installer, refer to anyone responsible for anyof the following operationson the Robotiq Palletizing
Solution:
lInstallation
lControl
lMaintenance
lInspection
lCalibration
lProgramming
lDecommissioning.
The present section isbased on the following international standardsand technical specifications:
lISO 10218-1:2011 : Safety RequirementsFor Industrial Robots- Robots
lISO 10218-2:2011 : Safety RequirementsFor Industrial Robots- RobotsSystemsand Integrators
lIEC 60204-1 : SafetyOf Machinery - Electrical Equipment Of Machines
lISO/TS15066:2016 : Robotsand robotic devices— Collaborative robots
Thismanual detailsthe componentsof the Robotiq Palletizing Solution, and the general operationsregarding the whole lifecycle
of the product, from installation to operation and decommissioning.
The drawingsand photosin thismanual are representative examples. However, discrepanciesmaybe observed between the
visual supportsand the actual product.
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2.2.RiskAssessment
2.2.1.GeneralRiskAssessment
WARNING
The user must have read and understood all of the instructionsin the following manual before
operating the Robotiq Palletizing Solution. Any use of the Palletizing Solution in non-compliance with
these instructionsisdeemed inappropriate and may cause injury or damage.
It isthe user'sresponsibility to ensure that all local safety measuresand regulationsare met.
The entire cell (i.e., the robot, the PowerPickVacuum Gripper or anyother gripper, and anyother equipment used in the final
application)must go through a comprehensive risk assessment processbefore they can be used.
In order to make the palletizing cell collaborative, several aspectsshould be taken into consideration. All cellsbeing different, it is
important to perform a risk assessment and to enforce the required standards. Please note that the resultsof the risk assessment
depend on the usage and application.
The following non-exhaustive list presentsrisksthat must be assessed during the integration process:
lRisk of load ejection resulting from lossof vacuum.
lRisk of load dropping resulting from lossof vacuum.
lRisk of pinching anymoving component of the Robotiq Palletizing Solution or the robot.
lRisk of damage or breaking if using a custom suction cup bracket that doesnot meet the technical requirements.
lRisk of damaged objectsor injuryresulting from a collision between an object and the robot, the gripper or the boxes.
lRisk of injury resulting from a collision between a person and the Solution.
Additional hazardsmay be present, depending on the configuration and what isbeing palletized. For instance, the object handled
by the gripper could be inherentlydangerousto the operator.
To ensure an adequate level of safety, floor markingsmust be applied to delineate safe zonesaround the Solution. It isthe
responsibility of the integrator to establish the proper safe distance from the Solution to protect the user.
DANGER
A collision between a person and the Solution mayresult in material damage, bodily injury and even
death. Make sure anyone working around the Palletizing cell takesall necessaryprecautions:
lBefore starting the machine, make sure there isenough clearance around the Palletizer and make
sure no one isin the work areaof the Solution.
lDuring palletization, it ispossible to accessthe cell from all sides. The customer hasto assessthe
risksaccordingly.
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2.2.2.EmergencyStop
WARNING
There isno emergencystop button directlyon the Robotiq Palletizer. The emergencystop button
used by the Palletizing Solution isthe one found on the robot’steach pendant. Make sure
operatorsknow how to stop the Solution in case of emergency.
Depending on the supply source, when the emergencystop (e-Stop)button ispressed, the following consequencesmayoccur.
The user hasthe responsibility to perform a risk assessment and choose the appropriate option.
Supply
Source Behavior
Robot
control
boxsupply
(any24V
terminal)
The Vacuum Gripper ispowered on.
lAn object isdetected: the vacuum level will continue to be regulated and the object will not be lost.
Note: the PowerPick gripper (optional)connectsto the robot control box supply.
Robot tool
supply(tool
connector)
Power failure to the Vacuum Gripper.
lThe vacuum level will drop to ambient pressure and the object will be lost.
It isnot recommended to connect the Vacuum Gripper to the tool connector.
CAUTION
Lossof vacuum can occur due to power failure or air supplyinterruption.
2.2.3.NoiseLevel
At optimal pressure (see Specificationssection), the noise level at the workstation is75.5dBa. Hearing protection isrecommended
but not required. Make sure that all local safety measuresand regulationsare met.
Noise levelsshould be measured regularlyunder normal operating conditions.
2.2.4.CyberRisk
lThe customer must provide asafe firewall connection to avoid unauthorized remote control of the robot.
lThe customer must set apassword to avoid unauthorized accessto the robot safety configurations.
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2.2.5.ResidualRisk
For the intended use of the robot system, measureshave been taken to prevent personal injuryand property damage.
Nevertheless, residual risk remainsin certain situations.
MaintenanceandRepair
WARNING
During maintenance and repair work, make sure that the Palletizing Solution isturned off, de-
energized and cannot be accidentally turned on again.
lMaintenance and repair work should only be carried by qualified and authorized service personnel.
lAfter maintenance and repair work,make sure to remove all toolsand equipment to prevent ejected or falling parts, material
damage or bodily injury.
lAll pneumatic toolsand devicesmust be emptied of compressed air before maintenance and repair work.
lAll electric toolsand devicesmust be safely isolated before maintenance and repair work.
lAlwaysinform the operator before performing maintenance or repair work. Notify asupervisor and lock out/tag out the machine
to prevent usersfrom turning on and using the system. Enforce local safety regulations.
lIf necessary, secure the maintenance and repair areawith temporary barriers.
lBefore performing repair work, clean the affected parts, especially the connectionsand fittings.
lInstall the Solution in asafe position. Depending on the maintenance and repair work to carryout, partsmaycome loose and
cause injury.
WARNING
lMaintenance and repair work on electrical equipment must be carried out by qualified and
authorized personnel.
lDo not bring electrical componentsinto contact with cleaning agents. Electrical components
should only be cleaned when the Palletizing Solution isturned off and de-energized.
lAfter having performed maintenance and repair work,verify screw torque and adjust accordingly if required.
lIf the dismantling of safety equipment isnecessarybefore performing maintenance or repair work,the equipment must be
reinstalled and assessed immediately after completion of said work.
lUse original spare partsexclusively.
lPerform preventive maintenance and cleaning work at regular intervalsaccording to the PeriodicInspectionand Maintenance
section.
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Riskof Accident
WARNING
During maintenance, there isan increased risk of accident due to the parts, toolsand equipment
used in and around the Palletizing Solution area.
lSlip, trip and fall hazardscan be avoided bymaintaining order and cleanlinessin the workplace.
lFor work in elevated positions(500 mm and more), fall protection equipment must be installed and used.
lWhen dismantling or replacing machine partsin elevated positions(500 mm and more), suitable lifting devicesshould be used.
Hot Surfaces
The proper use of the Palletizing Solution doesnot create hot surfaces. If surfacesget hot, investigate to see where the heat is
coming from.
Radiation
The proper use of the Palletizing Solution doesnot create non-ionizing radiation.
PneumaticLimitations
lThe maximum permissible pressure for all pneumatic componentsmust never be exceeded.
lPneumatic tubing must be checked at regular intervalsand replaced if necessary.
lLeaky connectionsmust be sealed to avoid breakage, unnecessaryor excessive noise, lossof energy, etc.
Protective Devices
Manipulating or circumventing protective devicesduring the operation of the Solution isgenerally not permitted and should be
considered negligent.
WARNING
In the event of incorrectlyinstalled, defective or even missing protective devices, operation of the
machine isnot permitted.
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ElectromagneticCompatibility(EMC)
lUnauthorized changesto electrical componentscan lead to increased sensitivity to interference,and increased interference
emission. Asa result, safety componentsmay be impaired.
lWork on electrical equipment must only be carried out by qualified and authorized personnel.
lBe aware of the possible residual energy after turning off an electrical device with large capacitive components
ElectricalEnergy
lWork on electrical equipment must only be carried out by qualified and authorized personnel.
lBe aware of the possible residual energy after turning off an electrical device with large capacitive components. Wait the
appropriate amount of time before working on the device.
lSecure the work area with temporary barriersand a warning note. Secure the main switch with a padlockto prevent unauthorized
switching on.
lUse only isolated toolsin the corresponding voltage level.
lUse only fuseswith specified cut-off current and appropriate dielectric strength.
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Robot Risks
WARNING
lAll personnel working with and around the robot must be informed of the inherent risksand safety
instructions.
lTo avoid being pinched or crushed when the robot movestoward a stationary object, alwayskeep
aminimum distance of 500mm.
lTo avoid being pinched or crushed when the robot movestoward the floor, alwayskeep a
minimum distance of 300 mm.
lTo avoid being pinched or crushed between the robot (or gripper)and wallsor peripherals,
alwayskeep a minimum distance of 500mm.
lThose valuesaforementioned are taken from standard EN 13854:2019(Minimum gapsto avoid
crushing of partsof the human body). The installation must maintain the minimum distances
specified in thisstandard.
For more information, refer to the robot'sinstruction manual.
lRobotsmove quicklyand exert high force. A program interruption or stop can be followed by rapid and dangerousmovements.
lEven a programmed robot can be affected by external signalsand make unexpected movements. Therefore, when entering the
work area, all safety instructionsmust be observed.
lRobot teaching, robot programming and software modification may only be performed by competent and authorized personnel.
lChangesto the robot'ssafety settingsmay only be made by competent and authorized personnel. The changesmust be verified
and documented.
lReducing the speed and acceleration of the robot reducesthe risksasit:
oGivesthe operator more time to react appropriately.
oReducesthe robot'sbraking time.
WARNING
Reducing the robot'sspeed doesnot reduce the risk of pinching or crushing. Even at itsslowest
speed, the robot movementscan cause material damage and bodily injury.
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Movement Without PowerSupply
DANGER
If aperson hasbeen trapped bythe robot arm, make sure that attempting to free the person does
not aggravate an injury or further increase the risk of injury.
In the case of an undesired event (malfunction, emergency, blockage, etc.), power lossor unwanted power surge, you can:
lUse forced back-driving. To perform forced back-driving, push or pull the robot arm hard enough to move the joint. Each joint
brake hasa friction clutch that enablesmovement during high forced torque.
Performing forced back-driving requireshigh force and cannot be performed by one person alone. In clamping situations, two or
more people are required to do the forced back-driving. In some situations, two or more people are required to disassemble the
robot arm if necessary.
WARNING
Moving the robot arm manually isintended for urgent/emergencyproceduresand service
purposesonly.
Do not move the joint more than necessary, not more than 160 degrees, to ensure the robot can
find itsoriginal physical position.
CAUTION
Attempting to release a joint brake manually maycause material damage and bodily injury.
For more information, refer to the robot'sinstruction manual.
2.3.Useof theSolution
2.3.1.IntendedUse
CAUTION
The emergencystop function isintended for use in emergencyconditionsand not for stopsin
normal conditions.
The Robotiq Palletizing Solution isspecifically designed for palletization.
Only use the Solution in itsoriginal condition without making unauthorized modifications.
Only use the Solution if it isin perfect technical condition.
The Solution isintended to be used with a UR20robot from Universal Robots.
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Alwayscomply with local, state, province and federal laws, regulationsand directives, and alwaysoperate the Solution in
compliance with automation safetyand general machine safety guidelines.
Do not use the Solution to handle boxescontaining hazardoussubstances. Should hazardoussubstancesbe handled by the
Solution, perform a risk assessment that accountsfor such substances.
CAUTION
Since there are numerousdifferent materialsused in the packaging industry, and since each
material hasitsown characteristics, propertiesand behavior with vacuum pressure, a thorough risk
assessment isin order, regardlessof the box/packaging material.
2.3.2.Misuse
WARNING
The unit should be used exclusively within the range of itstechnical data. Any other use of the
Solution isdeemed improper and unintended. Robotiq will not be liable for anydamagesresulting
from anyimproper or unintended use of the Solution.
Any use of the Solution other than that described in thismanual isconsidered a misuse and should be avoided.
Misuse of the Solution includesbut isnot limited to the following situations.
Integration misuse:
lUse of the Solution with a robot other than aUR20.
lUse of a payload higher than the robot’smaximum payload.
lUse of the Solution outside of the environmental and operating conditions.
Operational misuse:
lStanding on the pallet.
lOperation of the Solution byinexperienced or untrained staff members.
lManual placing or adjustment of a box on the pallet while the Solution isin operation.
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2.3.3.FinalApplication
ExpectedSystemBehaviorinNormalOperatingConditions
NOTICE
Varioustypesof external safety devicescan interface with the Robotiq Palletizing Solution to ensure
asafe operation.
NOTICE
lCategory 0 Stop: Stopsthe Solution by immediate removal of power.
lCategory 1Stop: A controlled stop of the Solution. Power isremoved when the stop isachieved.
lCategory 2Stop: A controlled stop of the Solution. Power isstill available once the stop is
achieved.
Please refer to IEC 60204-1for additional information on stop categories.
lNormal mode: The palletizer continuously fillspalletswhen no human operator isin the vicinity of the palletizing cell.
lSafeguarded operation
oReduced mode: The palletizer continuously fills pallets, even when an operator enters the palletizing cell. The operator can
safely remove a filled pallet or place a pallet in an empty slot. The system will not start to palletize on an empty pallet unless
the operator has pressed the “Confirm pallet(s) ready” button. To obtain this behavior, the “Confirm pallet(s) ready”
checkbox in the Installation tab must be ticked. Also, to allow cell access to the operator, a complete risk assessment must
be performed, and additional parametersmust be set (which include, but are not limited to: robot speed, robot force, safety
planes, guardrails).
oSeparation monitoring mode: The system stops when a human operator enters the vicinity of the palletizing cell to
manipulate a filled pallet, place a pallet in an empty pallet slot, troubleshoot the system or any other operation requiring
human intervention. In such a state the robot will maintain a Category 2 stop. When the safeguardsare removed, the system
resumesoperation in Normal mode.
The system entersemergencystop mode when the emergencystop button ispressed.
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The following table indicateswhich stop category based on the operation mode.
Operationmode
Robot
Force (N) Power(W) Speed (mm/s)
Normal mode
(Up to safetylimits) Up to 250 Up to 1,000 Up to 10,000
Protective stop Category 2Stop
Safeguard stop Category 2Stop
Emergencystop Category1 Stop
Reduced mode Please refer to the Universal Robotsuser manual for more details.
Fig. 2-1: Safety Logic Diagram
WARNING
After a collision or 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 pedestal, the cable
management system, and the gripper components. Please contact [e-mail] if any
sign of damage isdetected.
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StoppingTimesof theSafetySystem
The stopping time related to the Solution’ssafety system correspondsto the stopping time of the robot.
Please refer to the UR20 user manual on the Universal Robotswebsite to calculate the stopping time based on the application.
If safety devicesand safety relaysare part of the palletizing cell, the stopping timesof such devicesmust be accounted for (i.e.,
added to robot’sstopping time).
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3.Installation
Thissection will guide you through the installation and general setup of the Robotiq Palletizing Solution.
Before installing:
lRead and understand the safety instructionsrelated to the Palletizing Solution. Refer to the Safetysection.
lVerifythe package according to the scope of deliveryand the order.
lMake sure to have the required parts, equipment and toolslisted in the scope of delivery.
lMake sure to meet the recommended environmental conditions.
NOTICE
Robotiq usesthe metric system. Unlessotherwise specified, all dimensionsin thismanual are in
millimeters.
WARNING
lDo not turn on or operate the Palletizing Solution before making sure the device isfirmly
anchored and the machine areaiscleared.
lWhen assembling or moving the Solution, make sure there isenough vertical and horizontal
clearance in order to avoid material damage and bodilyinjury.
lMake sure that the air supplysource issecured.
lFailure to properlysecure and install the equipment can result in material damage and bodily
injury.
lIf the installation isnot performed in compliance with the manufacturer'sinstructions, the warranty
will be void.
lMake sure to follow all workplace safety rulesand regulationswhen operating the Robotiq Palletizing Solution.
lAlwayswear all recommended personal protective equipment in accordance with the safety standardsof the workplace,
including but not limited to:
oSafety glasses
oHearing protection
oHard hats
oSteel-toe boots
lAlwaysuse proper safety measureswhen working with toolsthat have sharp edges, pinching surfaces, or heat sources.
lAlwayslift heavy objectswith the legs, not the back. Ask for help or find alternative solutionsif a heavyobject cannot be lifted by
asingle person.
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