Techman Robot TM Palletizing Operator User manual

Product Version: 1.0
Document Version: 1.0
Release Date: 2020-04-27
TM Palletizing
Operator
User’s Manual
Corresponding models: TM5 Series
Original Instruction
Original Instruction

TM Palletizing Operator User’s Manual Product Version: 1.0 / Document Version: 1.0 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.
logo is registered trademark of TECHMAN ROBOT INC. in Taiwan and other countries and the company
reserves the ownership of this manual and its copy and its copyrights.

TM Palletizing Operator User’s Manual Product Version: 1.0 / Document Version: 1.0 3
Preface
Techman Robot Inc. assumes no responsibility for any damage or injury arising from the improper use of the palletizing
operator and the robot. The following symbols indicate the definitions of the warning and caution levels used in this
manual. Pay close attention to these symbols when reading the manual and using the system to avoid personal injuries
or 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.
WARNING: ELECTROCUTION RISK
Identifies a hazardous electrical situation.
Table 1: Safety definition symbols
The following symbols require readers’/users’attention regarding some functional details or tips.
IMPORTANT:
This symbol represents the relevant functional details to assist the programming and
use.
NOTE:
This symbol represents the relevant functional use tips to assist programming efficiency
Product Versioning Information
TM Palletizing Operator Product Version 1.0
TM Robot Software Version
1.76
TM Robot Hardware Version
3.2
TMstudio Software Version
1.0
TM Palletizing Operator Software Package
V001
TM Palletizing Operator Safety System
1.0
*Within the scope of hardware and software combination above, the product
version remains the same as TM Palletizing Operator Product Version 1.0.
Table 2: Version information

TM Palletizing Operator User’s Manual Product Version: 1.0 / Document Version: 1.0 4
Revision History
Revision
Date
Revised Content
1.0
2020-04-22
Official release

TM Palletizing Operator User’s Manual Product Version: 1.0 / Document Version: 1.0 5
Contents
Preface..............................................................................................................................................................................3
Product Versioning Information.........................................................................................................................................3
Revision History ................................................................................................................................................................4
1Product Introduction.................................................................................................................................................15
1.1 TM Palletizing Operator Overview ..............................................................................................................15
1.1.1 Orientations.........................................................................................................................................16
1.1.2 Palletizing Operator Base Dimensions................................................................................................16
1.2 Package Contents.......................................................................................................................................17
1.3 Teach Pendant ............................................................................................................................................23
1.4 Adjustable Flexible Gripper Overview.........................................................................................................25
1.4.1 Dimensions of Adjustable Flexible Gripper .........................................................................................25
1.4.2 Vacuum Generator Characteristics .....................................................................................................26
1.4.3 Vertical Lifting Force per Suction cup..................................................................................................27
1.4.4 Vacuum pressure sensor.....................................................................................................................27
1.4.5 Pneumatic Diagram.............................................................................................................................27
1.5 How Can I Get Help ....................................................................................................................................28
1.5.1 Related Documentations to this Manual .............................................................................................28
2Safety Information....................................................................................................................................................29
2.1 Overview .....................................................................................................................................................29
2.2 Applicable Product Version .........................................................................................................................29
2.3 Safety Precautions ......................................................................................................................................29
2.4 Overall Safety Warning ...............................................................................................................................30
2.5 Validation and Liability.................................................................................................................................31
2.6 Intended Use...............................................................................................................................................32
2.7 Limitations on Liability.................................................................................................................................33
2.8 General Environmental Considerations ......................................................................................................33
2.9 Risk Assessment.........................................................................................................................................33
2.10 Pre-Use Assessment...................................................................................................................................34
2.11 Emergency Stop..........................................................................................................................................35
2.12 3-Position Enabling Device .........................................................................................................................35
2.13 Movement without Drive Power ..................................................................................................................35
2.14 Labels..........................................................................................................................................................35
3Safety Function........................................................................................................................................................38
3.1 General Information.....................................................................................................................................38
3.1.1 Safety Function Definitions .................................................................................................................38

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3.1.2 Stopping Time and Stopping Distance in the Safety System..............................................................39
3.1.3 Software Safety Setting Permissions..................................................................................................39
3.2 Safety Device Connection Diagram, Input Discrepancy and Resume Method...........................................39
3.3 Explanation of Safety Functions..................................................................................................................40
3.3.1 SF0 Robot Stick Emergency Stop, SF1 Pendant Emergency Stop and SF2 External Emergency Stop
40
3.3.2 SF3 External Safeguard-Pause and SF4 External Safeguard-Human-Machine Safety Settings.......42
3.3.3 SF5 Pendant Enabling Device ............................................................................................................43
3.3.4 SF6 Motion Latching Mechanism........................................................................................................43
3.3.5 SF7 Emergency Stop Output, SF8 Safeguard-Pause Output, and SF9 Safeguard-Human-Machine
Safety Settings Output .........................................................................................................................................43
3.3.6 SF10~SF15 Defined Safety Functions................................................................................................44
3.5 Safety Distance and Scenario.....................................................................................................................47
3.6 Reset Button Mechanism............................................................................................................................51
3.7 Operation Mode and Mode Switching.........................................................................................................52
3.7.1 Auto Mode...........................................................................................................................................52
3.7.2 Manual Mode.......................................................................................................................................52
3.7.2.1 Manual Control Mode (Manual Reduced Speed)............................................................................53
3.7.2.2 Hand Guide Mode...........................................................................................................................53
3.7.2.3 Manual Trial Run Mode (Manual High Speed)................................................................................53
3.7.2.4 Switching Between Modes..............................................................................................................53
3.8 Safety Setting in TMflow Software ..............................................................................................................53
4Electrical Interface ...................................................................................................................................................54
4.1 General Electrical Specifications.................................................................................................................54
4.2 Electrical Warnings and Cautions ...............................................................................................................54
4.3 A Glance inside TM Palletizing Operator Base ...........................................................................................54
4.4 Electric Switchboard inside the Distribution Box.........................................................................................55
4.5 Palletizing I/O Configuration........................................................................................................................56
4.5.1 Palletizing I/O Pin Definitions..............................................................................................................57
4.5.2 Digital Inputs........................................................................................................................................57
4.5.2.1 Considerations for Sensor Connections .........................................................................................58
4.5.3 Digital Outputs.....................................................................................................................................59
4.5.3.1 Considerations for Terminal ............................................................................................................60
4.5.4 Analog Input/Output ............................................................................................................................61
4.5.4.1 Analog Input....................................................................................................................................62
4.5.4.2 Analog Output .................................................................................................................................62

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4.6 Safety Input/Output .....................................................................................................................................63
4.6.1 Safety Input .........................................................................................................................................64
4.6.2 Safety Output ......................................................................................................................................65
4.7 Safety Controller (G9SP-N20S) I/O Configuration......................................................................................66
4.8 Safety Controller (SF-C21) I/O Configuration .............................................................................................68
4.9 Power Terminal............................................................................................................................................69
4.10 External I/O (CP1W-20EDT) and Reset Button Setting..............................................................................70
4.11 Light Indications ..........................................................................................................................................71
5Unpacking, Installation and Transportation..............................................................................................................72
5.1 Unpacking Procedures................................................................................................................................72
5.1.1 Unpacking the Control Box .................................................................................................................72
5.1.2 Unpacking the Robot...........................................................................................................................72
5.1.3 Unpacking the Palletizing Operator.....................................................................................................72
5.2 Assembling TM Palletizing Operator...........................................................................................................73
5.2.1 Removing the Rear Housing...............................................................................................................73
5.2.2 Installing TM Robot .............................................................................................................................75
5.2.3 Installing the Control Box ....................................................................................................................77
5.2.4 Installing the Rear Housing.................................................................................................................82
5.2.5 Installing Adjustable Flexible Gripper..................................................................................................84
5.2.5.1 Changing Gripper Flange Position..................................................................................................85
5.2.5.2 Installing the Gripper onto the Robot (for centered position)..........................................................87
5.2.5.3 Installing the Gripper onto the Robot (for shifted position) .............................................................88
5.2.6 Installing Cable Protection Conduit.....................................................................................................89
5.3.1 Considerations for Connecting External Compressed Air...................................................................93
5.4 Installing the Reset Button ..........................................................................................................................94
5.5 TM Palletizing Operator Transportation ......................................................................................................94
5.5.1 Encountering Non-Flat Surfaces.........................................................................................................96
5.5.2 Relocation and Storage Considerations..............................................................................................98
5.6 Installing Teach Pendant.............................................................................................................................98
5.7 Adjusting Pallet Sensor...............................................................................................................................99
5.8 Connecting Power Supply to TM Palletizing Operator..............................................................................100
5.9 Activating/Deactivating TM Palletizing Operator.......................................................................................102
5.10 Required Software Installation and Safety Configuration .........................................................................104
5.10.1 Downloading TMflow and TMstudio Software...................................................................................104
5.10.2 Entering TMflow Software .................................................................................................................104
5.10.3 Setting Teach Pendant in TMflow......................................................................................................104

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5.10.4 Reset Button Setting in TMflow.........................................................................................................108
5.10.5 TCP Setting for the Adjustable Flexible Gripper ...............................................................................108
6Application Software Setup....................................................................................................................................112
6.1 TM Palletizing Operator Software Overview.............................................................................................112
6.2 TM Palletizing Operator Software Configuration Workflow.......................................................................112
6.3 Downloading TM Palletizing Operator Software Package ........................................................................113
6.4 Setting Palletizing Application under Palletizing Wizard ...........................................................................113
6.4.1 Step 1 - Setting Box Size and Label Direction..................................................................................114
6.4.2 Step 2 –Choose/Set Pallet...............................................................................................................115
6.4.3 Step 3 –Create Pallet Layers ...........................................................................................................116
6.4.4 Step 4 –Create Palletizing Sequence ..............................................................................................119
6.4.5 Step 5 –Palletizing Simulation..........................................................................................................121
6.4.6 Step 6 –Export File...........................................................................................................................125
6.5 Configuring Palletizing Software Components in TMflow .........................................................................125
6.5.1Importing Components and Text File into TMflow.............................................................................125
6.5.2 Setting I/O While Project Stop/Error..................................................................................................130
6.5.3 Setting TMOperator_TMROBOT_TMPLTZOP_V001_Pillar.............................................................132
6.5.3.1 Lowering the Pillar Height .............................................................................................................134
6.5.4 Setting TMOperator_TMROBOT_TMPLTZOP_V001_Main .............................................................135
6.5.4.1 Step 1 –Import File.......................................................................................................................136
6.5.4.2 Step 2 –Recognizing Box Position...............................................................................................137
6.5.4.3 Step 3 –Teach Gripping Point ......................................................................................................140
6.5.4.4 Step 4 –Visual Recognition..........................................................................................................142
6.5.4.5 Sensor Input Considerations.........................................................................................................152
6.5.5 Setting TMOperator_TMROBOT_TMPLTZOP _Vxxx_Grip and TMOperator_TMROBOT_TMPLTZOP
_Vxxx_Release ..................................................................................................................................................152
6.6 Advanced Palletizing Setting.....................................................................................................................152
6.6.1 Advanced1_General_Parameters.....................................................................................................152
6.6.2 Advanced2-8 .....................................................................................................................................155
7Product Specifications ...........................................................................................................................................159
8Maintenance and Repair........................................................................................................................................161
9Warranty Statement...............................................................................................................................................163
9.1 Product Warranty.......................................................................................................................................163
9.2 Disclaimer..................................................................................................................................................163
Appendix –A: Troubleshooting and Error Messages....................................................................................................164
Troubleshooting .....................................................................................................................................................164

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Adjusting pillar height .........................................................................................................................................164
Recovering from Emergency Stop .....................................................................................................................165
Resume from Safeguard Stop Status ................................................................................................................165
Error Messages......................................................................................................................................................165
Appendix –B: Vacuum Pressure Sensor Setting..........................................................................................................167
Pressure sensor setup steps .................................................................................................................................167
Pressure setting (single-point setting mode)......................................................................................................168
Pressure sensor setup for vacuum suction cup.....................................................................................................168
Pressure setting (single-point setting mode)......................................................................................................169
Appendix –C: Declaration of Incorporation..................................................................................................................171
Appendix –D: Certificate of Compliance ......................................................................................................................172
Appendix –E: Verification of EMC Compliance............................................................................................................175
Tables
Table 1: Safety definition symbols......................................................................................................................3
Table 2: Version information ...............................................................................................................................3
Table 3: Teach Pendant Basic Functions..........................................................................................................24
Table 4: Related documentations .....................................................................................................................28
Table 5: Safety System versioning information ................................................................................................29
Table 6: Denotations of labels ..........................................................................................................................37
Table 7: Safety Function Definitions .................................................................................................................38
Table 8: Stop Category and Action of Fault Detection of SF0, SF1 and SF2...................................................40
Table 9: Stop Category and Action of Fault Detection of SF3 and SF4 ...........................................................42
Table 10: Stop Category and Action of Fault Detection of SF5........................................................................43
Table 11: Stop Category and Action of Fault Detection of SF6 ........................................................................43
Table 12: Stop Category and Action of Fault Detection of SF7, SF8 and SF9.................................................44
Table 13: Safety Function SF10~SF15 Definitions...........................................................................................45
Table 14: Stop Category and Action of Fault Detection of SF10~ SF15 ..........................................................45
Table 15: AC Input Specifications of TM Palletizing Operator..........................................................................54
Table 16: Default Pallet Templates by drop-down menu..................................................................................56
Table 17: Pin signals for DIO, Analog I/O, Safety I/O and COM.......................................................................57
Table 18: Definitions of Safety I/O connectors..................................................................................................63
Table 19: Safety controller (G9SP) pin definition..............................................................................................67
Table 20: Safety controller (SF-C21) I/O I/O.....................................................................................................69
Table 21: System Light Indicator ......................................................................................................................71
Table 22: AC Input Specifications of TM Palletizing Operator........................................................................100

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Table 23: TM Palletizing Operator software configuration workflow...............................................................112
Table 24: Default Pallet Templates by drop-down menu................................................................................115
Table 25: Functional icons for pallet layers.....................................................................................................117
Table 26: Shift Box configurations ..................................................................................................................119
Table 27: Functional icons for palletizing sequence.......................................................................................120
Table 28: Parameter descriptions...................................................................................................................124
Table 29: Component Descriptions.................................................................................................................130
Table 30: Advanced setting for general parameters.......................................................................................155
Table 31: Definitions of Advanced2-8 .............................................................................................................157
Table 32: Relevant parameters.......................................................................................................................158
Table 33: Summary of the Preventive Maintenance Procedures and Guidelines ..........................................162
Figures
Figure 1: TM Palletizing Operator Base Overview (1/2)...................................................................................15
Figure 2: TM Palletizing Operator Base Overview (2/2)...................................................................................15
Figure 3: TM Palletizing Operator Base Orientation.........................................................................................16
Figure 4: Palletizing Operator Base dimensions ..............................................................................................16
Figure 5: Adjustable Flexible Gripper Overview ...............................................................................................25
Figure 6: Dimensions of Adjustable Flexible Gripper .......................................................................................26
Figure 7: Vacuum Generator Characteristics ...................................................................................................26
Figure 8: Vertical Lifting Force per Suction Cup...............................................................................................27
Figure 9: Pneumatic Diagram...........................................................................................................................28
Figure 10: Locations of safety warning and product labels ..............................................................................36
Figure 11: Safety Device Connection diagram .................................................................................................39
Figure 12: Relationship between Payload and the Center of Gravity Offset (mm) ..........................................47
Figure 13: Palletizing operator clearance with sideways conveyor..................................................................47
Figure 14: Palletizing operator clearance with straight conveyor.....................................................................48
Figure 15: Safeguarded space setup scenario with sideways conveyor layouts .............................................48
Figure 16: Safeguarded space with different setup scenario ...........................................................................50
Figure 17: Safeguarded space setup scenarios with multi-palletizing operators.............................................50
Figure 18: Teach Pendant outside Safeguarded space ...................................................................................51
Figure 19: Inside the Distribution Box (the image serves as reference only)...................................................54
Figure 20: Electric switchboard diagram ..........................................................................................................55
Figure 21: Palletizing I/O ..................................................................................................................................56
Figure 22: Set to Sink/Source Input Type.........................................................................................................59
Figure 23: Set to Sink/Source Output Type......................................................................................................60