Toshiba TS2000 User manual

STE73828-3
INSTRUCTION MANUAL
CONVEYOR SYNCHRONIZATION FUNCTION
Notice
• Make sure that this instruction manual is delivered to the
final user of Toshiba Machine's industrial robot.
• Before operating the industrial robot, read through and
completely understand this manual.
• After reading through this manual, keep it nearby for future
reference.
March, 2004
TOSHIBA MACHINE CO., LTD.
TOKYO, JAPAN

INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
Copyright 2004 by Toshiba Machine Co., Ltd.
All rights reserved.
No part of this document may be reproduced in any form without obtaining prior
written permission from Toshiba Machine Co., Ltd.
The information contained in this manual is subject to change without prior notice to
effect improvements.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
Introduction
This manual describes the outline, specifications and commands of the conveyor
synchronization function used for Toshiba Machine's Industrial Robot Controller
TS2000.
Section 1 General Descriptions
The outline of this function is described.
Section 2 Specifications
The basic specifications of this function are described.
Section 3 Parameters
The parameter setting procedures for using this function are described.
Section 4 Commands
The robot language of this function is described.
Section 5 Interface
The preparations and cautions for using this function are described.
Section 6 Programming and Teaching
The teaching procedures for using this function are described.
Section 7 Operation
The operation for stopping and resetting this function is described.
Section 8 Troubleshooting
The contents of this manual are subject to change without prior notice to effect
improvements.
Various instruction manuals are available, including the Introductory, Startup,
Operation, Robot Language, Interface, Communications, Transportation and
Installation, and Maintenance manuals. Refer to these manuals as necessary.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
Table of Contents
Page
1. General Descriptions........................................................................................6
2. Specifications....................................................................................................9
3. Parameters ......................................................................................................10
3.1 [1] Encoder Rotating Direction...................................................................11
3.2 [2] Encoder Interpolation Sampling Period.................................................12
3.3 [3] Conveyor Stop Judgment Time.............................................................14
3.4 [4] Type of Conveyor Synchronization.......................................................14
3.5 [5] ~ [7] Dummy Data.................................................................................14
3.6 [8] Travel Distance per Pulse of Encoder...................................................15
3.7 [9] [10] Rotation Center Position X, Y of Arc Conveyor (World Coordinate
System)......................................................................................................16
3.8 [11] ~ [15] Dummy Data.............................................................................16
4. Commands.......................................................................................................17
CONV...................................................................................................................18
SYNC ...................................................................................................................21
UNSYNC ..............................................................................................................22
XIN ...................................................................................................................23
CNVSTAT.............................................................................................................25
5. Interface...........................................................................................................28
5.1 High-Speed Signal Input Specifications (Conveyor Synchronization Trigger
Signal Specifications).................................................................................28
5.1.1 Circuit Structure......................................................................................29
5.1.2 Contact/Transistor Specifications...........................................................30
5.1.3 Connection between Conveyor Synchronization Start Trigger Switches 31
5.2 Conveyor Synchronization Specifications..................................................33
5.2.1 Incremental Encoder Specifications .......................................................33
5.2.2 Incremental Encoder Connector Specifications......................................33
5.2.3 Connection between Incremental Encoders...........................................34
5.2.4 Relationship between Encoder Cable Length and Number of Power
Supply Twisted Pairs..............................................................................36
5.3 Fabricating Cable.......................................................................................37
5.4 Assembling Printed Board..........................................................................39
5.5 Setting of terminator...................................................................................42
5.6 Defining Optimal Resolution of Encoder ....................................................44
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
6. Programming and Teaching...........................................................................46
6.1 Cautions on Programming .........................................................................46
6.2 Outline of Programming.............................................................................49
6.3 Setting of CONV Command Parameters A, B, C, D...................................51
6.3.1 Deciding [C: Conveyor Synchronization Delay Distance].......................51
6.3.2 Deciding [D: Conveyor Synch. Acceleration/Deceleration Distance]......52
6.3.3 Teaching [A: Conveyor Synchronization Start Position / B: Conveyor
Synchronization End Position]................................................................53
6.4 Teaching....................................................................................................55
6.4.1 Teaching of Conveyor Waiting Position..................................................56
6.4.2 Teaching of Motion Points during Conveyor Synchronization ................57
6.5 Readjustment and Confirmation of Conveyor Synchronization Parameters
[CONV (A, B, C, D)]...................................................................................58
6.6 Confirming Programmed Operation...........................................................62
6.7 Sample Programs......................................................................................64
6.7.1 Handling Work........................................................................................64
6.7.2 Pick & Place Work..................................................................................66
7. Operation.........................................................................................................68
7.1 Stop Operation...........................................................................................68
7.2 Reset Operation.........................................................................................71
7.3 Conveyor Stop...........................................................................................72
7.4 Conveyor Synchronization Utility (Utility →Conv) .....................................73
7.4.1. Measuring Total Pulses of Conveyor Encoder .......................................74
8. Troubleshooting..............................................................................................76
8.1 Error Message Table .................................................................................76
8.2 Troubleshooting.........................................................................................77
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
1. General Descriptions
This section outlines the conveyor synchronization function.
Encoder
TS2000 Controller
C D DConstant-speed interval DD
Total travel distance for conveyor synchronization
Synchronization start
trigger sensor
Workpiece A: Conveyor synchronization start position B: Conveyor synchronization end position
P0: Robot waiting position
Conveyor
Conveyor
present position Trigger
detection
Conveyor synchronization
processing unit
0123456789
T: Conveyor
move time
0123456789
Robot
synchronous
speed
T: Conveyor move time
Fig. 1.1 Outline of synchronized operation (*)
The conveyor synchronization processing unit reads the conveyor present position
(speed) from the encoder attached to the conveyor, then starts processing the
conveyor synchronization tracking based on the encoder counter at the same time
that the trigger sensor has detected a workpiece flowing on the conveyor.
Additionally, points A and B in Fig. 1.1 are taught in parallel with the conveyor to
specify the synchronization direction and synchronization travel distance of the
conveyor. Thus, the robot moves synchronously along a straight line connecting
point A and point B in the conveyor distance of (B – A).
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
If the robot waiting position for conveyor synchronization is required as shown in
the above figure, [P0: Robot waiting position] should be provided at a position
aligned with point A. (Point A: Synchronization start point, Point B:
Synchronization end point, P0: Robot waiting position)
[1] Conveyor move time T (0 ~ 1): Delay interval
The robot stops at the waiting position during the time from the trigger signal
detection by the controller to the conveyor movement by [C: Conveyor
synchronization delay distance].
[2] Conveyor move time T (1 ~ 3): Acceleration interval
If the robot momentarily starts (or stops) movement at the conveyor speed,
an excessive impact may be imposed on the robot or workpiece, or the
robot will vibrate. To avoid this, [D: Acceleration/deceleration distance for
conveyor synchronization] should be specified to assure smooth start and
stop of the robot. When T = 1, the robot starts accelerating from point A,
and catches up with the conveyor speed when T = 3. In other words, while
the conveyor moves by "2D", the robot accelerates to the conveyor speed in
the distance of "D", starting from point A.
[3] Conveyor move time T (3 ~ 7): Constant-speed interval
During conveyor synchronization (i.e., while the robot is moving by tracking
the conveyor), the robot moves in parallel with the conveyor at the same
speed as the conveyor. During this time, the workpiece is chucked.
(Teaching of the synchronized operation program and work positions is
performed in this interval.)
[4] Conveyor move time T (7 ~ 9): Deceleration interval
When T = 7, the robot starts decelerating. When T = 9, the robot stops
completely at point B. That is, while the conveyor moves by "2D", the robot
slows down and stops in the distance of "D".
(*) Both C and D are the independent variables. In the above explanation, C
= D to simplify the operation. It is also possible to specify another different
values for C and D.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
!CAUTION
1. Even if the program stopped during conveyor synchronization, continuous
operation is possible by using the restart function just after the program stop.
In principle, however, after the stop operation, be sure to reset the operation,
move the robot to the safe place by manual guidance, reset the program, then
resume the operation. (For details, see Para. 7.2.)
2. Unless an error is caused, DO NOT effect the servo OFF or emergency stop
during conveyor synchronization. Otherwise, the robot hand will collide with a
workpiece on the synchronized conveyor.
3. To avoid the above accident, construct the system, taking notice of the
following matters.
[1] If the conveyor or other external equipment enters an emergency stop
state, the robot should also enter an emergency stop state.
[2] If the robot enters an emergency stop state, the conveyor or other
external equipment should also enter an emergency stop state.
[3] If the robot program stops due to some reason (error stop/stop operation
by operator), the conveyor should be stopped also.
4. Before teaching operation, be sure to stop the conveyor. If the conveyor is
moving, the synchronization start trigger sensor may operate under some
teaching condition, resulting in an unexpected movement or collision. (The
robot at the robot waiting position is only kept stationary until the trigger sensor
turns on, and it can start moving at any time.)
5. The robot retract position should be the completely safe position where it will
not collide with a workpiece running on the conveyor even if the robot
operation is stopped. (Desirably, the robot waiting position should serve as
the robot retract position.)
6. The trigger sensor should be adjusted so that it can always be turned on at a
predetermined position without causing shift of the workpiece detecting
position. If the sensor is turned on due to mixture of different workpieces or
at a position other than the adjusted position, the robot tracking shift or
collision may be caused.
7. While the test operation mode is selected, DO NOT execute the step of the
program (between SYNC command to UNSYNC command), machine lock (dry
mode operation) or [MODE: Motion]. If the conveyor is running, an expected
collision may be caused.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
2. Specifications
This section describes the specifications of the conveyor synchronization function.
Table 2.1 Basic specifications of conveyor synchronization
Item Specification Remarks
1. No. of axes
(*1) A maximum of two (2) conveyor axes can be used. This function can be used at a conveyor speed of 75 ~ 250
mm/sec. The conveyor speed of
under 75 mm/sec can be used
under some conditions.
2. Synchronous
accuracy
(*2)
Accuracy: ±10 mm (at 200 mm/sec
conveyor speed)
• Position interpolation sampling
speed: 3 ms
• Minimum interpolation unit (X, Y,
Z): 0.001 mm
• Trigger signal sampling period: 500
µs
The accuracy is the value when
the conveyor speed fluctuation is
within ±7.5 %.
3. Teaching method Teaching during conveyor stop.
4. Robot language CONV, SYNC, UNSYNC, XIN,
CONVSTAT For details, see Section 4.
5. Conveyor encoder
interface
(*3)
Power supply: +5 V (supplied from
internal source)
Method: A, B 90° phase difference
Specification: RS422 differential input
(line driver method)
Counter: 15-bit absolute counter
(0 ~ 32767)
Port: Two (2) numbers
Resolution: 10 ~ 100 pulses per 3
msec
6. Trigger signal
interface Power supply: +24 V (supplied from external source)
Specification: Photocoupler input
Port: Two (2) numbers
*1: When the conveyor speed is 75 mm/sec or less, an encoder with high
resolution is required.
*2: The speed interpolation sampling period can be set by parameter.
*3: The encoder resolution and conveyor stop judgment time can be set by
parameters.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
3. Parameters
The parameters for the conveyor synchronization function are set in "[U20]
Conveyor Parameter" of user parameter file [USER.PAR]. The parameter format
is as shown below.
[U20] Conveyor Parameter
{Conveyor Parameter1(CH1,CH2)}
= 0 0 [1] Encoder rotating direction
= 3 3 [2] Encoder sampling period (ms)
= 0 0 [3] Conveyor stop judgment time (ms)
= 0 0 [4] Type of conveyor synchronization
= 0 0 [5] Dummy data
= 0 0 [6] Dummy data
= 0 0 [7] Dummy data
USER.PAR
{Conveyor Parameter2(CH1,CH2)}
= 0 0 [8] Travel value per pulse of encoder (µm/pulse)
= 0 0 [9] Rotation center position X of arc conveyor (mm)
= 0 0 [10] Rotation center position Y of arc conveyor (mm)
= 0 0 [11] Dummy data
= 0 0 [12] Dummy data
= 0 0 [13] Dummy data
= 0 0 [14] Dummy data
= 0 0 [15] Dummy data
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