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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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
3.1 [1] Encoder Rotating Direction
Data format : Integer
Data unit :
Data setting range : 0 or 1
Example of value : 0
When the startup order of phase A and phase B is compared at pulse output of
phase A and phase B as output from the encoder used, the pulse adding direction
is specified based on phase A. The value of this parameter is decided according
to the encoder specifications used and the rotating direction of the encoder set to
the conveyor.
If the "CONV" menu is chosen after pushing the "Utility" key, the following menu
screens will appear.
CONV UT I L I TY <CH1> <CH2>
Conv Form:LINEAR ARC(+)
Conv Veloc :-****.*** -***.****
Conv St a t us : 0 0
Enc Pulse : 32767 32767
Mes Pulse : 632417 0
Mes Trip :-****.*** -***.****
MES1 MES2
Please work a conveyer, and set up a parameter so that the display of
"Pulse" increases among a figure.
( Example )
1). (Encoder rotation direction value=0) & ( "Pulse" increases )
Pleaseset"0".
2). (Encoder rotation direction value=0) & ( "Pulse" decreases )
Please set “1”.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
3.2 [2] Encoder Interpolation Sampling Period
Data format : Integer
Data unit : msec
Data setting range : 3 ~ 30000
Example of value : 3
This parameter specifies the period during which the counter value from the
encoder attached to the conveyor is obtained.
* As the arithmetic operation period of the conveyor synchronization function is
three (3) ms, the actual parameter value is a multiple of this arithmetic
operation period (3 ms) whose fractions are ignored.
[Cautions]
The conveyor synchronization function calculates the synchronization travel
distance at minimum periods of 3 ms (default). It is also possible to specify a
larger value, however. Determine the value, taking note of the following.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
■When the value decreases (minimum value 3 msec):
• The trackability for the conveyor speed improves.
• If this value is too small, however, the synchronization speed changes
even with conveyor pulsation, which may result in vibration of the robot.
■When the value increases:
• The synchronization speed is less affected by conveyor pulsation.
• The conveyor rotating angle arithmetic error can be absorbed.
• The trackability for the conveyor speed deteriorates.
Unless the pulsation is caused, specify the default value (3 msec).
Example:
When the conveyor sampling period is set to 15 msec, the synchronization travel
distance is figured out based on the previous conveyor sampling period average
speed (Vave).
15ms
15ms
15ms
Time (sec)
No. of encoder pulses
Conveyor encoder sampling period
Period for calculating conveyor synchronization
travel distance (predetermined)
Previous This time
15 msec average speed
Vave
Next
3ms
3ms
3ms
3ms
3ms
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
3.3 [3] Conveyor Stop Judgment Time
This parameter specifies the conveyor stop judgment time. Unless the encoder
counter value changes during the time set by this parameter, the system interprets
that the conveyor is stopped and outputs the error of "001–048: Conveyor Stop".
As this is the error of level 1, programmed operation continues.
Data format : Integer
Data unit : msec
Data setting range : 0 ~ 30000
Example of value : 3000
• Normally, the conveyor stop time is specified by the 2nd argument of SYNC
command of the SCOL language. Unless the 2nd argument is specified, the
conveyor stop is judged with this parameter value.
• When the 2nd argument of the SYNC command is not specified and this
parameter value is zero (0), the system will not judge the conveyor stop.
3.4 [4] Type of Conveyor Synchronization
Data format : Integer
Data setting range : 0 ~ 2
Example of value : 0
This parameter specifies the type of the conveyor synchronization function.
Select from the following three (3) types.
0 : Linear conveyor
1 : Arc conveyor (CW)
2 : Arc conveyor (CCW)
As the linear conveyor is used, specify zero (0) for this parameter.
3.5 [5] ~ [7] Dummy Data
Data format : Integer
Areas reserved for the system.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
3.6 [8] Travel Distance per Pulse of Encoder
This parameter specifies the conveyor travel distance (µm) per one (1) pulse of
the encoder set to the conveyor.
Data format : Real number
Data unit : µm
Example of value : 0
If the total number of encoder pulses is ∆P (pulse) when the conveyor moves by
∆L (mm), the conveyor travel distance per one (1) pulse of the encoder α(µm) can
be calculated from the following equation.
α= (∆L / ∆P) * 1000
The total number of encoder pulses (∆P) can be obtained in the following manner.
(1) Press the desired function key (<F1: MES1> or <F2: MES2>) for the channel
(CH) you wish to measure, using the cursor.
CONV UT I L I TY <CH1> <CH2>
Conv Form:LINEAR ARC(+)
Conv Veloc :-****.*** -***.****
Conv St a t us : 0 0
Enc Pulse : 32767 32767
Mes Pulse : 632417 0
Mes Trip :-****.*** -***.****
MES1 MES2
When you wish to count the number of pulses of CH1, press <MES1>.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
(2) To count the number of pulses of CH1 or CH2, select <MES1> or <MES2>,
respectively. After moving the conveyor by ∆L, press the <SET> key.
CONV UT I L I TY <CH1> <CH2>
Conv Form:LINEAR ARC(+)
Conv Veloc :-****.*** -***.****
Conv St a t us : 0 0
Enc Pulse : 32767 32767
Mes Pulse : 632417 0
Mes Trip :-****.*** -***.****
SET
This value is ∆P.
(3) When you press the <SET> key, the present total number of pulses (Mes
Pulse) is shown on the display. Then figure out the travel distance per one
(1) pulse (αµm) by substituting this value for "∆P" in the above equation.
(To measure the value again, press the <MES1> or <MES2> key.)
3.7 [9] [10] Rotation Center Position X, Y of Arc Conveyor (World Coordinate
System)
These parameters are used for the arc conveyor synchronization function.
3.8 [11] ~ [15] Dummy Data
Data format : Real number
Areas reserved for the system.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
4. Commands
This section deals with the commands used for the conveyor synchronization
function.
The following five (5) commands are newly added to the SCOL language
(Symbolic Code Language for Robot) for the conveyor synchronization function.
Command Function
CONV Defines the conveyor synchronization parameters.
SYNC Starts the conveyor synchronization.
UNSYNC Finishes the conveyor synchronization.
XIN Monitors the encoder cable breakage.
CNVSTAT Accesses the information on conveyor synchronization status.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
CONV
Function
: Defines the conveyor synchronization parameters.
Format : CONV (<Number>, <Position 1>, <Position 2>,
<Relative distance 1>, <Relative distance 2>,
<Real number 3>)
Example
: CONV (N, A, B, C, D, E)
Explanation
& caution : Defines the parameters required for conveyor synchronization.
Synchronization
start trigger signal Robot waiting
position
CDD
Constant-speed interval
D D
Robot motion
finish position
Total travel distance for conveyor synchronization
B
A
0123456789
Direction of conveyor synchronization
T: Conveyor
move time
Robot speed
0123456789
<Number; N> Logical conveyor number
Specify the logical number of the conveyor to be synchronized.
Either 1 or 2 can be designated.
(A constant or variable of scalar type data can be used.)
<Position 1; A> Conveyor synchronization start position (position type data)
Specify the position for starting the conveyor and robot
synchronization. The robot starts synchronization with the conveyor
from this position. (Only position type data of vector type data can be
specified.)
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
<Position 2; B> Conveyor synchronization end position (position type data)
Specify the position for ending the conveyor and robot synchronization.
The robot finishes synchronization with the conveyor at this position.
(Only position type data of vector type data can be specified.)
When A = (XA, YA, ZA) and B = (XB, YB, ZB), the travel distance for
conveyor synchronization can be figured out from the following
equation.
AB = (XB–XA)2+ (YB– YA)2+ (ZB– ZA)2
<Relative distance 1; C> Conveyor synchronization delay distance (mm)
Specify the relative distance between the synchronization start trigger
signal ON point and the robot waiting point, considering a delay in the
servo response, etc.
This parameter should be specified to compensate for the physical
synchronization delay. If this value is too large, however, an error will
occur. To avoid this, this value should be used for fine adjustment
and the system should be configured so as to minimize this distance,
where possible.
<Relative distance 2; D> Conveyor synchronization acceleration/deceleration distance
(mm)
Specify the acceleration/deceleration distance (unit: mm) required for
conveyor synchronization.
Unless the condition of D ≤AB
2is satisfied, the error saying
"002–033: Conveyor Parameter Error" generates and the robot stops.
When the conveyor has moved by the distance of A–B after the start
of synchronization, the conveyor synchronization finishes.
<Real number 3; E> Travel distance per pulse of encoder (µm)
This parameter is the same as user parameter "[U20] Conveyor Parameter
(Travel value per pulse of encoder)". For how to figure out the value, see
Para. 3.2.6.
This parameter can be omitted.
• When it is omitted (or E = 0), the user parameter value is used instead.
• When the value of the user parameter is zero (0), the value of "CONV
(....E) is used.
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INSTRUCTION MANUAL CONVEYOR SYNCHRONIZATION FUNCTION
(Caution)
When the value of the user parameter is 0.0 with the E parameter
omitted (or E = 0), the error saying "002–033 Conveyor Parameter
Error" occurs at the time of program execution and the robot stops.
Cautions
• Once defined, the conveyor synchronization parameter data are stored in the internal
memory until the controller power is turned off. To change the conveyor
synchronization parameter value, be sure to describe the new CONV command and
perform the reset operation.
• Zero (0) can be specified for each of parameters C and D. When D
(acceleration/deceleration distance) = 0, however, the synchronization speed of the
robot is sharply increased to the conveyor speed, as shown below, which results in an
excessively large load exerted on the robot.
Trigger
signal
position
Robot
waiting
position
DD
Constant-speed interval
DD
Robot motion
finish position
Total travel distance for conveyor synchronization
B
A
012345678
Direction of conveyor synchronization
T: Conveyor
move time
Synchronization
speed of robot
012345678
Robot waiting position
&
Trigger signal position Constant-speed interval
Robot motion
finish position
Total travel distance for conveyor synchronization
B
A
01234
Direction of conveyor synchronization
Synchronization
speed of robot
T: Conveyor
move time
01234
When C = 0 When C = D = 0
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