Columbia/Okura A700 User And Maintenance Manual

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A Series Robot Palletizer

Users and Maintenance Manual

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Summary of Contents for Columbia/Okura A700

Page 1 A Series Robot Palletizer Users and Maintenance Manual...
Page 2 INDEX Safety Section 1 Specifications Section 2 Operation Section 3 Pattern Programming (Teaching) Section 4 Maintenance Section 5 Troubleshooting Section 6 Electrical Wiring and Data Memory Section 7 Installation Section 8 Okura Controller (Oxpa-PLC) Section 9 Technical Training Section 10 Quick Reference Battery Replacements 5-24...
Page 3 Robot Manual Safety Safety...
Page 4 Updating history Version Content Page (Date) 06.01.05 Columbia/Okura Manual Release Safety...
Page 5 WARNING TO ALL PLANT PERSONNEL THIS MACHINE IS AUTOMATICALLY CONTROLLED IT MAY START AT ANY TIME! NEVER WORK ON, CLEAN OR SERVICE THIS MACHINE OR OPEN OR REMOVE ANY PROTECTIVE COVER, GUARD, GRATE, DOOR, OR MAINTENANCE PANEL UNTIL THE POWER HAS BEEN TURNED OFF AND LOCKED OUT.
Page 6 Safety...
Page 7: Table Of Contents
Table of Contents INTRODUCTION ................. 7 Warning____________________________________________________ 7 Safety Summary _____________________________________________ 9 Training Overview ___________________________________________ 10 Risk Assessment ____________________________________________ 11 Training Requirements _______________________________________ 11 Training Program Content _____________________________________ 12 Retraining Requirements _____________________________________ 12 WARNING LABELS ................13 Guarding Types ................14 Fixed Enclosure/Perimeter Fencing/Barrier Guards _________________ 14 Adjustable Barrier/Gate Guard/Access Door ______________________ 15 Belt/Pulleys, Chain/Sprockets, Gear Guards_______________________ 15...
Page 8 Safety...
Page 9: Introduction
INTRODUCTION Warning WARNING TO AVOID SERIOUS BODILY INJURY OR DEATH, LOCKOUT THIS MACHINE BEFORE CONDUCTING ANY MAINTENANCE, OR CLEARING OF PRODUCT. ALWAYS LOCKOUT THIS MACHINE AT THE MAIN CONTROL PANEL, PNEUMATIC POWER INLET AND HYDRAULIC TANK (IF APPLICABLE) BEFORE CONDUCTING MAINTENANCE CLEARING PRODUCT.
Page 10 Safety...
Page 11: Safety Summary
It is the customer’s responsibility to install and use Columbia/Okura products in accordance with provisions of the Occupational Safety and Health Act and/or other local codes or industry standard that are pertinent to the particular end use.
Page 12: Training Overview
Training Overview Each A Series Robotic Palletizer is equipped with a variety of safety features. However, an increased level of safety results when these safety precautions are constantly reviewed and consistently followed by well trained and authorized personnel. Daily maintenance or programming tasks (pallet or sheet placement) may require personnel to be in the robot’s proximity while power is available to it.
Page 13: Risk Assessment
Risk Assessment Each system is operated under unique conditions. It is ultimately the customer’s responsibility to determine if the supplied robot/machinery/equipment is safe to use. The customer must perform their own risk assessment to evaluate the safety issues that impact their operation. A risk assessment shall consider, but is not limited to: 1.
Page 14: Training Program Content
Training Program Content Training appropriate to each assigned task should include, but not be limited 1. A review of applicable industry safety procedures 2. A review of applicable robot vendor safety recommendations 3. An explanation of the purpose of the robot system and its operation 4.
Page 15: Warning Labels
WARNING LABELS The following labels are attached to text throughout this manual and signify importance. Please review their meaning below. Danger A statement preceded by DANGER is information that must be acted upon to prevent the possibility of severe bodily injury or loss of life. Warning A statement preceded by WARNING is information that MUST be acted upon to prevent bodily injury.
Page 16: Guarding Types
GUARDING TYPES Safety guards supplied with the robot/equipment/machinery are designed to provide safe operation and to reduce the possibility of personal injury and/or machine damage. It is absolutely essential to keep all shields, guards and safety devices in place before, during and after machine operation. If a shield, guard or safety device has been removed for any purpose, or is damaged or missing, it must be repaired or replaced BEFORE beginning any robot/equipment/machine operation.
Page 17: Adjustable Barrier/Gate Guard/Access Door
Adjustable Barrier/Gate Guard/Access Door 1. Located at point of operation or where work is being performed. 2. Provided to keep operating/maintenance personnel from areas of potential danger during machine operation. 3. Remains in place through positive connectors. Can be opened without a tool. 4.
Page 18: Safety Precautions
2. Do not attempt to operate any machine until you understand how it functions. If you are not certain after studying the manual, contact Columbia/Okura for additional training. 3. Do not operate the machine when you feel unable to perform your duties due to illness, exhaustion, medication, or distraction.
Page 19 21. Never start a machine until you are certain that all personnel and foreign objects are clear. 22. Do not enter the guarded area when the robot is in operation or in automatic mode. 23. Always use Columbia/Okura recommended spare parts. Special grade bolts must be replaced with equivalent bolts. Safety...
Page 20: Precautions Before Use
(activated). 3. The robot must be activated by power supplied through the switch provided by Columbia/Okura. 4. Verify correct operation of each axis of the robot using manual operation. 5. Verify the doors of the control panel(s) are shut at all times.
Page 21: Precautions When The Main Breaker Is Turned On
Precautions when the Main Breaker is turned Check the following items after turning ON the Main power. The main power lamp on the operation panel is lit. UL type Initializing is completed and displayed. After pressing the abnormal reset button, the display changes to the Automatic Mode Menu.
Page 22: Precautions Before Automatic Operation
2. Become completely familiar with the location and operation of the Emergency Stop Switch(es) to stop the machine immediately if and when the need arises. 3. Columbia/Okura supplies both a Power Disconnect Switch, located on the main panel, and a pneumatic release and lockout device between the machinery and the main source of air supply within your facility.
Page 23: Precautions During Automatic Operation
Precautions During Automatic Operation 1. During Automatic operation, the robot waits to be strobed a program to run. Although, the robot does not appear to be moving while waiting, it is powered and constantly changing its position. The robot can be signaled to run a program at high speed at any time Motor Power is ON.
Page 24: Precautions During Programming
Precautions During Programming 1. Check all safety devices before any teaching is performed. 2. An authorized observer (an observer outside the operation envelope) other than the programmer (personnel programming robot operation) must be present at trial runs and operation times to operate the emergency stop in case of an accident.
Page 25: Precautions During Maintenance
6. After the maintenance operations are completed, automatic operation should be verified a low speed. 7. Always use Columbia/Okura recommended spare parts. Using parts from a third party may result in unsafe operation or equipment damage. 8. When handling any of the integrated circuit boards, use grounding straps to prevent accidental static shock.
Page 26: Precautions For The Infeed Assembly
Precautions for the INFEED ASSEMBLY Columbia/Okura offers a variety on Infeed Assemblies that differ considerably in design due to individual customer specifications, product requirements and other subsequent functions. Therefore, these areas of the machine present unique and potentially hazardous conditions to the operator and assisting personnel.
Page 27: Precautions For The Pallet Dispenser
Precautions for the PALLET DISPENSER To avoid machine damage and possible personal injury, the following precautions must be observed: Danger 1. When performing maintenance, clearing jams or aligning pallets, always ‘Lock Out’ the Power Disconnect Switch, located on the main control panel, with a padlock.
Page 28: Precautions For The Sheet Dispenser
Precautions for the SHEET DISPENSER To avoid machine damage and possible personal injury, the following precautions must be observed: Danger 1. All guards must be properly positioned and securely attached to machinery prior to operation. 2. DO NOT remove any guards unless they are replaced immediately after completing required maintenance.
Page 29: Precautions For Emergency Stop Situations
Precautions for Emergency Stop Situations 1. If a dangerous situation occurs during operation, and the robot or peripheral equipment must be stopped immediately, press the Emergency Stop Button. (red, mushroom, locking type). 2. The Emergency Stop Button locks if it is pressed. To release the lock, turn the button in the direction of the arrow.
Page 30: Brake Release Procedure
BRAKE RELEASE PROCEDURE If the servo control system has trouble, the robot arm can be moved without motor power. Each motor brake can be released independently without motor power using the following procedure. 1. Verify two or more personnel are available to perform this operation. REQUIRED 2.
Page 31: Entering Perimeter Guarding
ENTERING PERIMETER GUARDING If at anytime personnel are required to enter the perimeter guarding the following procedures can be used to minimize the possibility of accidents. Daily Operation using the Trapped Key This procedure is used by personnel required to enter the cell to perform daily operations other than maintenance and cleaning.
Page 32: Maintenance And Cleaning Using Lockout/Tagout
Maintenance and Cleaning using Lockout/Tagout During Maintenance and Cleaning lockout and tagout procedures must be followed. The Main breaker must be padlocked in the OFF position before any machine maintenance or cleaning is begun. Certifications / Qualifications A list of standards that the robot meets and a list of the standards that the robot is third party certified to meet are as below UL1740, ANSI/RIA 15.06, NFPA79, UL508A Safety...
Page 33: Typical Minimum Lockout/Tagout System
TYPICAL MINIMUM LOCKOUT/TAGOUT SYSTEM PROCEDURES GENERAL Lockout is the preferred method of isolating machines or equipment from energy sources. The following procedure is provided for reference in lockout/tagout program. For developing your lockout-tagout program be sure to utilize the OSHA regulations (CFR 1910.147) and ANSI publication Z244.1- 1982, Lockout/Tagout of Energy Sources –...
Page 34: Preparation For Lockout Or Tagout
PREPARATION FOR LOCKOUT OR TAGOUT Make a survey to locate and identify all isolating devices to be certain which switch (es), valve(s) or other energy isolating devices apply to the equipment to be locked or tagged out. More than one energy source (electrical, mechanical, or others) may be involved.
Page 35 RESTORING MACHINES OF EQUIPMENT TO NORMAL PRODUCTION OPERATIONS 1. After the servicing and/or maintenance are complete and equipment is ready for normal production operations, check the area around the machines or equipment to ensure that no one is exposed. 2. After all tolls have been removed from the machine or equipment, guards have been reinstalled and employees are in the clear, remove all lockout or tagout devices.
Page 36: Lockout (Or Tagout) Procedure
LOCKOUT (OR TAGOUT) PROCEDURE Entry No. Description 1. Name of Company 2. Type(s) and Magnitude(s) of energy and hazards 3. Name(s)/Job Title(s) of employees authorized to lockout ot tagout 4. Name(s)/Job Title(s) of affected employees and how to notify 5. Type(s) and Location of energy isolating means 6.
Page 37: Definitions
DEFINITIONS An employee whose job requires him/her to operate or Affected Employees: use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout or whose job requires him/her to work in an area in which such servicing or maintenance is being performed. A person who locks or implements a tagout system Authorized Employee: procedure on machines or equipment.
Page 38 The placement of a lockout device on an energy isolating device, in Lockout: accordance with an established procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed. A device that utilizes a positive means such as a lock, either Lockout Device: key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment.
Page 39: Conclusion
CONCLUSION The preceding text presents comprehensive safety information and procedures for using the robot/equipment/machinery. Operation and maintenance personnel must use extreme caution when installing, inspecting, operating, repairing, and maintaining this equipment. DO NOT attempt these functions without first initiating the safety procedures stated in this text. Keep in mind that as administrators, operators and maintenance personnel, you have direct safety responsibility for your fellow employees.
Page 40 Robot manual Safety <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Columbia/Okura, LLC. 301 Grove St Vancouver, Washington 98661 360.735.1952 Safety...
Page 41 Robot Manual Specifications Specifications...
Page 42 Updating history Version Content Page (Date) 06.01.05 Columbia/Okura Manual Release Specifications...
Page 43 T-axis Details ______________________________________________ 12 Arm Components ____________________________________________ 13 Panel Dimensions (UL type) ___________________________________ 14 Robot Assembly Drawings ________________________________15 A700 Assembly Drawings _____________________________________ 17 A700 Bill of Material _________________________________________ 19 A1600 Assembly Drawings ____________________________________ 20 A1600 Bill of Material ________________________________________ 22 Specifications...
Page 44 GENERAL SPECIFICATIONS Specifications...
Page 45 Model A1600 Specifications Model A1200 III A1600 A1600 -W ○ ○ ○ Model ○ ○ Motion Type Vertical, multi-articulated Load Capacity Max 140 kg Max 300 Kg Inertia of Load Max 10.0 kgm Max 10.0kgm Max 15kgm (Low speed) (Max 30kgm (Max 30kgm (Max 90kgm Degree of...
Page 46 Model A700 Specifications Model A400 III A700 Existence ○ ○ ○ model ○ Motion Type Vertical, multi-articulated Load Capacity Max 140 kg Inertia of Load speed Max 10.0 kgm regulated (Max 30kgm condition) Degree 4 Axes (option 5 Axes: except for UL type)
Page 47 Electrical Specifications Model (A1200III, A1600, (A400III, A700) A1600-W) RC725 RC722 RC720 RC715 RC712 RC710 4-axes simultaneous Number of control axis (option 5 Axes: except for UL type) Path control system PTP (R,T Axes) CP (O,D Axes) Position detection Absolute encoder...
Page 48 A1600 Operation Envelope A-point A-point operation range Specifications...
Page 49 A700 Operation Envelope (Dimensions in () used with A700 envelope optional stopper. Specifications...
Page 50 Capacity Restraints The handling capacity of the palletizer robot is based on 1. Load weight (total weight of hand and handled article) 2. Cell Layout. Among layout factors, the R-axis rotation angle of the robot has the greatest influence on the handling capacity.
Page 51 1000 A1600 Capacity Charts assume motion similar to the diagram above. Rates may be considerably A700 different than indicated if the robot is performing functions other than stacking such as sheet picking or pallet 80 100 120 140 160 180...
Page 52 A1600: Inertia of hand (including product) must be 10.0kgm or less. (Under speed regulated conditions, 30kgm is Maximum.) A700: Inertia of hand (including product) must be 10.0kgm less.(Under speed regulated conditions, 30kgm is Maximum.) Maximum Hand Dimensions: To prevent interference with the arm, the external dimensions of the installed...
Page 53 A1200III, A1600, A1600-W Upper Arm Link Lever Parallel Link(Upper) Link Parallel Link(Lower) T-Axis Flange Lower Arm Lever Rotor Base A400III, A700 Upper Arm Parallel Link (Upper) Link Link Lever Parallel Link (Lower) T-Axis Flange Lever Lower Arm Rotor Base Specifications...
Page 54 Panel Dimensions (UL type) BACK VIEW FRONT VIEW LEFT VIEW RIGHT VIEW Specifications...
Page 55 ROBOT ASSEMBLY DRAWINGS Specifications...
Page 56 Specifications...
Page 57 A700 Assembly Drawings A700 PN 7700 Specifications...
Page 58 A700 PN 7700 Specifications...
Page 59 A700 Bill of Material A700 PN 7700 Specifications...
Page 60 A1600 Assembly Drawings A1600 PN 7600 Specifications...
Page 61 A1600 PN 7600 Specifications...
Page 62 A1600 Bill of Material A1600 PN 7600 Specifications...
Page 63 Robot manual Specifications <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Columbia/Okura, LLC. 301 Grove St Vancouver, Washington 98661 360.735.1952 Specifications...
Page 64 Robot Manual Operation...
Page 65 Updating history Version Content Page (Date) 06.01.05 Columbia/Okura Manual Release Operation...
Page 66 Table of Contents Daily Operation Procedures ............... 5 Main Power ON ______________________________________________ 6 Program Selection ____________________________________________ 6 Motor Power ON _____________________________________________ 7 Start Operation ______________________________________________ 7 Stop Operation ______________________________________________ 8 Partial Discharge and Shut Down ________________________________ 8 Change Layer or Work Count____________________________________ 9 Manual Operation ___________________________________________ 10 Conveyor Operation (Manual Operation)__________________________ 12 Reset Conveyors ____________________________________________ 14...
Page 67 Operation...
Page 68 DAILY OPERATION PROCEDURES This section gives an easy to understand explanation of the daily operation procedures for an A series robot palletizer. Maintenance procedures are not covered in this section, however; daily operation procedures will be used by maintenance personnel. Operation...
Page 69 Main Power ON Turn the Main breaker switch located on the front of the robot control panel, to "ON". The robot will begin to initialize its processor and when it is complete a screen will appear. Press the abnormal reset button, which will reset the safety circuit and go to the Automatic Mode Screen shown below.
Page 70 Motor Power ON Important! Before turning on the "motor power" switch, verify the area around the robot is clear of all personnel and that there are no obstacles on the conveyor or pallet. Turn the "Motor Power" switch "ON". The Motor power indicator lamp will turn on.
Page 71 Stop Operation This procedure is used when daily procedures such as pallet hopper filling are to be performed. Press the station switch. The indicator will turn to "OFF". Products will not be loaded onto the station conveyor and robot stops at the standby position. Press the Stop button.
Page 72 Change Layer or Work Count Important Counter changes can only be made with operation "OFF". Press the appropriate Pallet No. button to select which load to change the count on. The screen will display a counter change and numerical ten-key pad. Select the counter value desired for the next pick.
Page 73 Manual Operation The Operator can move each axis of the robot independently using the keypad from Main Control Panel. This operation is referred to as "Manual Operation". Manual operation is used to move the robot to a specific point in space for troubleshooting, maintenance, and programming.
Page 74 Motion Type When the robot is operating in Manual operation, the operator can alternate between, Continuous Path (CP), Point to Point (PTP), and Palm Mode (PM) motion types. Each of these motions is useful in particular steps or processes. Motion of each axis Motion Type Moves in Moves in...
Page 75 Conveyor Operation (Manual Operation) The Peripheral Equipment can be manually operated from the Robot Control Panel. operator interface is customized for application to allow for different equipment and customer needs. Each Robot has two screens to access manual functions: From the Manual Mode screen. From the Automatic Operation Mode screen.
Page 76 From the Automatic Mode screen: Using the Automatic Mode screen, some pieces or optional functions that are pre programmed can be operated. The equipment or optional functions can be changed with a combination of PLC and Operator Interface programming additions. The Robot can be operating during many of the optional functions, but it is best if Motor Power and Automatic operation are OFF.
Page 77 Reset Conveyors Resetting conveyors clears latched data in the PLC for ALL of the peripheral equipment for ALL of the lines. In most applications, conveyors should be reset if pallets or products have been lifted up and replaced or removed all together. Note: •...
Page 78 Reset Line Resetting a line clears latched data in the PLC for a single line of the peripheral equipment. In most applications, lines should be reset if pallets or products have been lifted up and replaced or removed all together. Line resets are useful on applications with multi-pick logic because product only needs to be cleared from the affected line rather than all lines.
Page 79 Sequence Reset Resetting the sequence forces the robot to perform program zero and then the current program being strobed to it. In practical terms, a sequence reset makes the robot start its sequence over. In most applications, sequence reset is only used during maintenance or troubleshooting to stop a robot from completing the remaining lines of it's sequence that may prevent damage or the loss of time.
Page 80 OPERATOR INTERFACE The operator interface at the Main Control Panel includes two main components: The Pushbutton Section which includes hard wired switches and lamps relating to robot operation and stopping. The Touch Panel Display Section which includes soft buttons and selectors relating to robot operation and programming.
Page 81 Switches and lamps relating to abnormalities and emergency stopping: Emergency stop push-button (Red). This turns off motor power and turns ON the motor brake. Note: This button switch locks off. Twist the button to release . Abnormality reset button (CE:Blue, JIS,UL:Yellow). This resets the abnormality state when an abnormality occurs.
Page 82 Touch Panel Display The user interface is a full color, 7.7 inch LCD, interactive, touch screen. The operator selects from numerous functions, menus, and displays to operate different elements of the robot. The top level, operator interface display screen is the Main Menu.
Page 83 Data Input There are four methods of inputting data from the touch screen: Using numerical input buttons. By direct selection of an item. Using character input buttons. By Parameter selection and input using function buttons Numerical Input Buttons Enter program numbers, counter values, and other numerical variables using a numeric keypad.
Page 84 Parameter Selection Edit individual parameters by alternating through possible values using the function buttons. Press the parameter directly or use the arrow buttons to move the cursor to the field to be entered. Press the change or edit button. The value should alternate between choices.
Page 85 Semi-automatic Operation Using the Semi-automatic function, an operator can automatically move the robot to an entered position or a particular step of a program. Move to a position in space Select "Manu" on the Manual-Automatic Mode Selector. The Manual operation screen will be displayed. Press the Half-Auto button in the robot manual operation screen.
Page 86 Move to a program step Select Manu on the Manual-Automatic Mode Selector. The Manual operation screen will be displayed. Press the Half-Auto button in the robot manual operation screen. The Half-Auto screen will be displayed. Press the PROGRAM No. button and enter the value. Press the STEP No.
Page 87 Robot manual Operation <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Columbia/Okura, LLC. 301 Grove St Vancouver, Washington 98661 360.735.1952 Operation...
Page 88 Robot Manual Pattern Programming Pattern Programming...
Page 89 Updating history Version Content Page (Date) 06.01.05 Columbia/Okura Manual Release Pattern Programming...
Page 90 Computer, the disk is necessary for documentation and program back up. In addition, a CD containing the DiySPII software was also supplied. The DiySPII software is specifically used with a Columbia/Okura robot for the purpose of palletizing. The software runs under the Windows platform, which enables relatively simple pattern programming compared to the more traditional method of “move and store”...
Page 91 Pattern Programming...
Page 92 By default the program files will be placed in the C:\Program Files\Okura\OxpaQm2 folder. Install Patterns When the Columbia/Okura robot was installed the technician left a disk or CD containing the patterns that have been programmed for your system. It is important to install these patterns onto your PC immediately after you have installed the DIYSPII program.
Page 93 INDEX Install DIYSPII Software (From CD) ______________________________ 5 Install Patterns ______________________________________________ 5 Save Patterns to Back Up ______________________________________ 5 Index _____________________________________________ 6 “How to” Index _____________________________________ 8 What is DiyspII? ___________________________________ 10 DiySPII Specifications: _______________________________________ 10 Main Screen________________________________________________ 11 Starting out ________________________________________________ 12 New Robot File and Program Creation Flowchart ___________________ 12 Standard Movement Patterns _________________________ 15 What is a Standard Movement Pattern? __________________________ 16...
Page 94 DIYSPII COMMAND DEFINITIONS ______________________ 74 Commands on the “Job Selection” Menu _________________ 74 Job selection _______________________________________________ 74 Robot Registration __________________________________________ 74 Commands on the "Registration" menu__________________ 76 Robot Type ________________________________________________ 77 System Parameters __________________________________________ 77 End effector and station ______________________________________ 84 Conveyor name ____________________________________________ 101 Pallet Parameter ___________________________________________ 102 Registration default value ____________________________________ 104...
Page 95 “HOW TO” INDEX Job Selection ........74 Accuracy dialog box ......80 Manual pattern creation ....129 Memory Switches (Changing)....83 Move Area Dialog Box ......79 Multi-Pick more then one product: ..125 Communication ( robot to OXPA host CPU) ............ 82 Communication (robot and PLC ...
Page 96 Station conveyor postion (Description) ..96 Station Conveyors (Changing type)..94 Step commands .........51 Step, Adding Parameter ......49 Same layer........67 Step, Deleting a Parameter....49 Same Layer (Cancel) ......67 Step, Selecting Parameter ....49 Save Patterns to Back Up ..... 5 Sequence (Add Line in Panel) ....28 Sequence (Change in Panel) ....
Page 97 DiySPII is short for DIY Soft Pack and is also referred to as Oxpa-QmII. DiySPII is a programming support software specifically designed to be used with a Columbia/Okura robot for purpose of palletizing. The software runs under the Windows platform which enables relatively simple pattern programming compared to the more traditional method of “move...
Page 98 Main Screen When DIYSPII is first opened the screen is blank with the following pull down menus "Job selection" "Registration" "Teaching" "Utilities" "Peripheral control" "Help" "Quit" Frequently used commands can also be selected with buttons on the tool bar. Pattern Programming...
Page 99 Starting out During the process of learning how to use the DIYSPII software you will gather an abundance of knowledge. The conclusion of the learning will be the ability to program a new pattern using the software. During the process, helpful tips will be highlighted by: Step by Step on “How to”...
Page 100 How to Create a New Pattern The main components of DIYSPII are the OXPA (1/2) and OXPA (2/2) screens that are used to input data specifically about the product, placement locations, pattern shape, and positioning detail. The following flow chart takes you step by step through the OXPA (1/2) and the OXPA (2/2) screens.
Page 101 How to Connect your Laptop It is suggested that your PC should be shut down when attaching or detaching cables from the PC to the Control Panel. Back of Laptop 1) Ground yourself to the panel by holding onto a metal component Serial Port of the panel.
Page 102 STANDARD MOVEMENT PATTERNS Okura A series robot palletizers take advantage of standard movement patterns that are stored in the controller. This section describes the standard movement pattern concept, and discusses the program for each standard movement pattern. Using standard movements simplifies pattern programming by requiring very few steps, including: Product details such as length, width, height, and weight.
Page 103 What is a Standard Movement Pattern? Palletizing and depalletizing work is a simple, round-trip movement between the pick-up and the put-down positions. Each time this repetitive motion is used to move a product from the pick up (Station Conveyor) to the put down (Pallet) it is defined as taking 1 round-trip or 1 cycle.
Page 104 Steps 1-9 are standardized, regardless of the layer and work being stacked, and in a palletizing program these are called steps or MOVes. As the robot performs each line of its "Sequence", additional relays are turned on an off to actuate hand functions or communicate information to the PLC.
Page 105 Program Composition (Memory Explanation) As discussed above, Pattern Programs consist of multiple elements. The program is very simple to produce using standards and afterwards can be edited to fine tune speeds and position. Each standard is automatically generated from additional information (data) that is customized for each application.
Page 106 (MOV 1), the position command is "FIX", which means the position never changes, regardless of what layer or work is being stacked. There is only one position stored (1st layer and 1st work) which is used every time the sequence gets to MOV 1. In a step which stores the stacking position on the pallet (MOV 7), the position command is "ALT", which means the position varies depending on the layer and work being stacked.
Page 107 Coordinate Systems The A-Series robot has four axes: R,D,O, and T. One position of the robot is determined by each of the axes having a data value. The data values can be expressed in different coordinate systems to identify the robot's position, including: 1.
Page 108 Arm coordinates Arm coordinates are similar to cylindrical coordinates. The X-axis and Z-axis express the position of the point A at the tip of the robot arm, in terms of the distance from point O, running parallel to the X-axis and Z-axis respectively. If CP Mode is in use during operation, the robot uses these coordinates to display it's location.
Page 109 Pallet coordinates These coordinates are on the pallet where stacking occurs. The origin of pallet coordinates are set for each program. (As a rule, the other 4 types of coordinate systems are not editable). Pallet coordinates are the same as hand coordinates (See above), with point O shifted to the pallet itself.
Page 110 PROGRAM EDITING This section explains how to edit programs. When creating pattern programs, it is usually easier for customers to copy existing programs that they are familiar with and edit them rather than creating new ones. The following section provides enough information to edit all levels of a program.
Page 111 Copy and Delete (Control Panel) Use the following procedures for copying and deleting programs stored in the Main Control Panel. Copy a program (Panel) At the teaching menu screen, move the cursor to the program No. to be copied (this is the copy source) Note To display a program which does not appear on the screen, use the...
Page 112 Program parameter editing (Control Panel) Program Parameters: Using the Main Control Panel Touch Panel, select the following items: Teaching menu ↓ Editing ↓ Program parameter Program parameters includes multiple screens of data that can be changed. The items on each screen are shown below: Program parameters editing (1/5) Editable parameters include: -Product name...
Page 113 4. Program parameter editing (4/5): a. All parameters can be changed. (See Inching Distance for expanations) 5. Program parameter editing (5/5): a. Editable parameters and explanations include: (A)This sets the planar position for step 6 (AND) to one of the following: 7:LOD 5:APR 7: LOD...
Page 114 (F) This parameter sets the T-axis motion during movement from step 5 to step 6 to: Parallel with LOD: Attempts to keep paddle of the hand parallel to the load in order to maximize speed. T-axis fixed: Allows the hand to rotate the shortest possible amount to reach it's target.
Page 115 Sequence program Using the Main Control Panel Touch Panel, select the following items: Teach menu ↓ Editing ↓ Sequence program editing (1) How to Change Move the cursor to required line to change Press CHANGE key The Command input screen is displayed. Perform change -Move the cursor by the keys...
Page 116 2. Move the cursor to the beginning line No. of the range to copy on reference program. 3. Press the From key. 4. Move the cursor to the last line No. of the range to copy on reference program. 5. Press the To key. 6.
Page 117 Sequence Command List: Command Format Description Name AMSPS AMSPS n Wait until the arm reaches to a height of current (n: ascent value.) one plus n mm. g. :Turning on a signal of “entry allowed” the arm move 200mm up above the station. MOV 4 AMSPS 200 M6002 = 1...
Page 118 Command Format Description Name COUNT COUNT Resetting a value of palletizing and de-palletizing movement. To reset values of layer counter (D0) and work counter (D1) of inner data memory of current- operating program. When “palletizing” is selected in function type, increase a number in the work counter.
Page 119 Command Format Description Name (Note) This shall not be used when a movement exceed the moving range (AX is too short), because checking of moving range is to be performed the start and end points only ELSE ELSE If the previous IF or ELSIF condition has been reached, then an operation to the next ENDIF will not be performed.
Page 120 Command Format Description Name simultaneously execute the next COUNT command g. : Check if one pallet operation is finished before step 9 is started. If finished, set the relay M6006 ON. MOV 9 ENCHK M6006 COUNT WTARM The following chart lists the change of memory and relay status at the time of completion of one pallet operation (an example for 5 products and 4 layers)
Page 121 Command Format Description Name ENDIF ENDP ENDP Finish of program ENDLP ENDLP End of LOOP sentence HMOV HMOV n Move the hand axis to the designated step (n: hand step no.) position. HMOVD HMOVD Dn Move the hand axis to the designated step (n : data memory no.) position designated by a value in data memory Dn : Target position [0.1mm]...
Page 122 Command Format Description Name memories. Turn on a relay M601D for the 1 work of 1 layer. IF D1 = = 0 & D1 = = 0 M601D = 1 ENDIF Important! perform logical statement such IF D2 & D6 == D2 in the A1600, it must now be replaced with two lines: D4 = D2 &...
Page 123 JTOP JTOP Return to the beginning of a program. Example: Repeat a program MOV 1 WTARM - - - JTOP ENDP LBL n (n: label no..) Designation of label for commands of CALL, JMPL and SUBP. Example: Move to step 1 after program change, but skip step 1 from then on.
Page 124 MOV n (n: step no.) Move the arm to the designated step position Each MOV command must be paired with a WTARM or WTAOC command. Example: move to step 1 MOV 1 WTARM MOVDM MOVDM Dn Move to the position designated by a value in data (n: data memory no..) memory.
Page 125 MOVDZ MOVDZ Dn Move the arm to the height designated by data (n: data memory no.) memory. It is necessary to set a data before executing this command. : Standard step no for a movement Dn+1 : Moving height data (unit is 0.1 mm) Dn+4 : Moving flat position (0 : current position, 1 : step position of Dn) Dn+5 : Moving mode (0 : MOV, 1 : DMOV)
Page 126 Dn+5 : AR(HX) [unit AR : 0.01゜ HX : 0.1 mm PX : 0.1 Dn+6 : AX(HY) [unit AX : 0.1mm HY : 0.1 mm PY : 0.1 Dn+7 : AT(HT) [unit AT : 0.01゜ Ha : 0.01゜ Pb : 0.01゜] Dn+8 : AZ(HZ) [unit AZ : 0.1mm HZ : 0.1 mm PZ : 0.1 mm] No operation...
Page 127 coordinates) into four registers (one for each axis) of data memory. Example : Write the robot’s position data into data memory D1000 when a sensor (X0) turns MOV 1 WTCON X0 RDCP D1000 WTARM Result D1000 = HX (x 0.1 mm) D1001 = HY (x 0.1 mm ) D1002 = HT (x 0.01mm) D1003 = HZ (x 0.1 mm)
Page 128 Dn+1 : Layer number -1 Dn+2 : Work number -1 Dn+3 : Coordinates system [ 0 : Arm, 1 : Hand, 2 : Palett.] Dn+4 : Do not use Data is written into: Dn+5 : AR(HX) [unit AR : 0.01゜ HX : 0.1 mm PX : 0.1 mm] Dn+6 : AX(HY) [unit AX : 0.1mm HY : 0.1 mm PY : 0.1 Dn+7 : AT(HT)
Page 129 Dn+1 : internal speed (0-10) Dn+2 : external speed (1-10) Dn+3 : SPD set value (1-10: It is 10 usually. ) Actual operation speed is shown by internal speed × external speed × SPD set value. When speed is set by ASPD, Dn+1 : ASPD set value (1-100) Dn+2 : Fixed to 1 Dn+3 : Fixed to 10...
Page 130 WTARM SPD 10 The setting condition shall revert to SPD 10 automatically when power on the robot sequence reset is executed program is changed STATM STATM Dn Commencing a handling of which a value of data (n: data memory no.) memory is to + 1 at every 10 mS.
Page 131 STPTM D1000 D1001 = D1000 PGSEL RESTM D1000 STATM D1000 SUBP SUBP n Runs an additional program simultaneously with (n : label no.) the main program. SUBP differs from the CALL command because it does not wait for the processing completion of the subroutine is not waited for.
Page 132 ENDP TRQC TRQC n Change the maximum torque of the T axis to (n: limit data %) protect the Hand and the product. n : 0-308% n=0 : Default data Example : grip a product HMOV 1 WTHAND TRQC 70 Example : release a product HMOV 2 WTHAND...
Page 133 WTARM is paired, with following commands: MOV, SMOV, DMOV, MOVDZ, MVDWN MOVDM. Example : After completion of moving to step 1, turn on a relay M0. MOV 1 WTARM M0 = 1 WTCON WTCON (condition 1)* Wait until the condition has been matured g.
Page 134 adjust timers. Example: MOV 7 WTARM WTMSP 10 Y1D = 0 Wait for expiring a setting time (n x 10msec) WTTMR WTTMR n (n: wait time) Example : After completion of movement to step 7, and after waiting 300ms, turn the relay Y1D to OFF.
Page 135 [Operation] Addition between data memory and constant Subtraction between data memory and constant Multiplication between data memory and constant Division between data memory and constant Remainder of division between data memory and constant Logical AND between relays & Logical AND between data memory and constant Logical OR between relays Logical OR between data memory and constant Exclusive OR between data memory and constant...
Page 136 Step parameter editing To edit the step parameters select: Teach menu (Select the program No. to edit) ↓ Editing ↓ Step parameter Add (Define) a Step: -When a step is added, the smallest step number not currently stored will be used (Except 10 and 11).
Page 137 [Step parameters] The following 8 step parameters can be edited at the step parameter editing screen 1. Step command 1 2 3 4 5 6 7 8 2. Position command 3. Speed 4. Acceleration coefficient 5. Deceleration coefficient 6. Overlap 7.
Page 138 Step Commands The position coordinates of different steps are determined by a step command. A step command is a name for position calculation. For example HWT(RZ) = STA(RZ)+ D1 is stating that the height of step command named HWT is equal to the height of step command STA + the inching distance D1.
Page 139 Step Calculation formula Position coordinate Concept Z shift command -Position ADN(PZ)=LOD(PZ)+D3 above Ο (Approach ADN(PX,PY,Pβ)=LOD(PX,PY,Pβ) down) LOD (Load) Stored data Ο CLW(PZ)=LOD(PZ)+D4 -Position CLW(PX,PY,Pβ)=LOD(PX,PY,Pβ) above Ο (Clear work) LOD step HRD(RZ)=(1)STA(RZ)+D1 -Position =(2)LOD(RZ)+D4 above STA ① or ② whichever is larger (at inclined movement always step -Height ①)
Page 140 Step Calculation formula Position coordinate Concept Z shift command PUP(PX,PY,Pß)=LOD(PX,PY,Pß) 1: There is a Z shift if the position command is ZSF, ALL or ALT. Note Step commands other than NON can only be used once in the same program. Note What is a Z shift? If there are multiple direct placement pallets, the height data is shifted...
Page 141 2 Stations to 1 Pallet (1 Program) In cases where the product is being palletized simultaneously from 2 stations to 1 pallet by one pattern program the following step commands can be used. standard station additional station HWT2 STA2 HLD2 SUP2 HRT2 The step commands above are not added automatically to a stacking program.
Page 142 Position command The Position command determines if the position data in a step changes for the layer and/or product count as it is stacked. If the position data changes depending on the layer or product count, the command indicates by how much. Each time the robot must move to a different position value it must have a data memory register, although it is only 1 step.
Page 143 Multiple positions. One.(1) planar position (x and y) for every product (limited-see below) , but with only one "Z" Height is fixed. height. Position changes When "Column" stacking, the planar positions for each depending on layer product are stored for the first layer , but used for all and product, but is layers.
Page 144 Changes depending Column stacking: amount for 1 layer on layer and work Interlocking stacking: amount for 2 layer (Height has also the number of works stacked) Note When performing direct placement with multiple pallets, the height data for each ALT, ALL of ZSK step automatically varies during arm movement, in accordance with the number of pallets.
Page 145 Step Auxiliary Data Editing The procedure for moving to the step auxiliary data editing screen is as follows: Teach menu (Select the program No. to be edited) ↓ Editing ↓ Step auxiliary data The step auxiliary data allows additional parameters to be set for each work and layer. The parameters include: 12 3 4 5 6 7 Dropping from above...
Page 146 Grip quantity The grip quantity is the amount of products picked by the hand. This is used to increment or decrement the stacking counter. If the grip quantity is 0, no auxiliary data except turn can be input. Also the step will have no position data.
Page 147 Step Position Coordinate Editing To move to the step position coordinate editing screen, follow the next procedure: Teaching menu (Select the program NO. for editing) ↓ Editing ↓ Step editing menu ↓ Step position data To change the position of a step, the following methods may used: 1.
Page 148 [Procedure] 1) Designate a step No. for edit program. 2) Designate a step No. for reference program. 3) Press the Copy key. 4) The selection mark of the line for the copy of edit and reference program is reversed from the gray to red. copy executed with...
Page 149 Pallet coordinate origin shift This moves and rotates pallet coordinate axes. The procedure for moving to the pallet coordinate origin shift screen is as follows Teaching menu (Select the program No. for editing) ↓ Editing ↓ Pallet coordinate origin shift [Procedure] -Input the shift value for each axis -Press EXECUTE key to execute.
Page 150 Copy Pallet Coordinate] 1. Move the cursor to the program No. which pallet origin data is to be copied. 2. Press COPY key. Pattern Programming...
Page 151 Auto calculation for height This shall be used for canceling the auto-composition of height direction after 2nd layer in the designated step. An effective step for this editing is any one whose position command is ZSF, ALT, ALL, SPL or AZA. Change "...
Page 152 Specialized Movement Types) This section explains practical teaching methods using standard movement pattern, and teaching methods which do not use standard movement pattern. This section also explains how to create programs using layout patterns with multiple pallets and stations. Pattern Programming...
Page 153 Special Stacking Special stacking is used when the pattern is not a column or interlocking stack pattern. Special stacking can only be selected when first creating a new program. Special Stacking is selected on the program new creation (2/7) screen. If special stacking is selected, the order of each product's set down must be determined manually.
Page 154 Same layer Setting When at the program new creation(3/7) screen: (If special stacking is selected, the work number is automatically set to 6. For layers where same layer setting is not performed, input the correct stacking work number.) Move the cursor to the layer for same layer setting.
Page 155 Variable Pick-Up In some applications such as case stacking using paddles or bag stacking with labels out, the set down position will possibly interfere with product already stacked. This is caused because it is simplest to pick up product at a single fixed position ("Fixed" Pick Up). In these applications, Variable pick up is selected.
Page 156 Variable pick-up can be used in situations other than facing labels outside when it is desirable to change to grasping direction. Variable pick-up is only selectable when starting a new pattern. To Select Variable Pick Up: ① Select variable at the pick-up item on the program new creation (2/7)screen ②...
Page 157 Multi-Stacking The term "multi-stacking" refers to a layout pattern like that in the diagram below, with multi pallets and station. ← 1 station, 2 pallets Example 1: While a new pallet is provided in one side, articles are stacked on the other pallet.
Page 158 RP Mode When stacking in a pyramid shape for bagged product such as rice, the program can be created using "RP" mode. When a program is created with this mode, the planar position (X and Y) for each layer is automatically adjusted so that the stacking pattern forms a pyramid.
Page 159 Grip quantity Set 2 at the grip quantity during origin storage. planar data needed special layers program creation(7/7) Screen Note -Layers which are not symetrical are also displayed, but you are not required to enter data for these. -Same layer sets are all handled the same as special layers after program creation, even in layers which are created with the same layer setting, changing the planar position of one workpiece will never result in an automatic change in planar positions in other layers.
Page 160 Non-Palletizing Movement Types When creating a special program which is not for palletizing or depalletizing, teaching is performed without using a standard movement pattern. The following explains the operation procedure for new program creation when using a Non-standard movement pattern. 1.
Page 161 Pattern files x.prg Robot Registration When initially setting up a Columbia/Okura robot for the first time to do palletizing, it is necessary to register the robot. Registration is only performed once at the beginning of setting up a new robot system.
Page 162 To Register a New Job (Cont.): Click on " Job selection " from the main menu Input the name of the robot in the "New job" box. Click the "New job" button. Click “Ok” The “Robot type” dialog box is displayed Click on the robot model being used.
Page 163 COMMANDS ON THE "REGISTRATION" MENU Robot Type System Parameter Move Area Accuracy Communication Memory Switch Endeffector and Station End Effector Station conveyor Position Conveyor Name Pallet Parameter Default Value Pattern Programming...
Page 164 Robot Type Robot type determines the operating envelope and system parameters for DIYSPII to work within. An A1500 and A1600 has a larger operating envelope than other models which allows additional patterns to be selected from. How to Change Robot Type Click on Click on Enter at...
Page 165 (Z-pulse) and the position where the robot found the limit switch determining origin. This is used on models A330, A630, A730. It is not used on models A700, A1500, A1600. Teaching area: The teaching limit determines the area where robot teaching is possible. The teaching area confines the standard pattern size to points within the range.
Page 166 Decl time: The Decl time is used to determine the deceleration time for standard robot movement. (Units:msec). When 0 is input as an decelleration coefficient in step parameters this time is used to help generate robot motion. Endef wght: Endef wght (End Effector Weight) is the weight of the tool mounted onto the robot. When the acceleration and deceleration values in the step parameters are set to zero, the end effector weight value(in kilograms) is used as a variable in programming calculations.
Page 167 The robot coordinate offset value is the rotational offset in degrees from where the robot axes equal zero This offset is not set directly. This parameter is not shown on robots with absolute encoders such as the A700 or A1600 because those models maintain position when main power is off. The A330,...
Page 168 Smov Parameter: “Smooth move”. These values are coeficients used to allow the robot to begin rotation of the “R” axis before “D, O, and T” axes. This movement creates a smooth effect and increases speed. Smov parameter 1: For the move selected in the sequence program, this is the amount relative to normal deceleration that the robot iniates the “R”...
Page 169 Communication These communication parameters determine the method of high level communication between the robot controller and the PLC OR Laptop. Communication between robot and host CPU: These settings give communication specifications between the robot controller and the personal computer. When connecting DIYSPII and the robot controller, set the following communication specifications with DIYSPII for serial communication.
Page 170 The switches are set at the factory and are crucial to the robot performing well. The meanings of these switches can change with CPU Board RC201 versions. Do not change switches unless instructed to by a Columbia/Okura robot representitive. The "Reset" button sets memory switches to the settings used at initial manufacture of the robot (not the palletizing system).
Page 171 End effector and station End effector End effector parameters are standardized measurements used by the DIYSPII software in calculations. The calculations determine the necessary pick up and set down positions of the pattern program. Some parameters are also used in preventing mis- programming of positions that would produce crashing or invalid positioning.
Page 172 How to Change End Effector Parameters Click Select Select Click Enter Endeffector Select Registration Endeffector Endeffector at password dialog box Product Gap and station dialog box appears Select Select Select Select Select Type Select Colliding Colliding Synchronized Finger Endeffector Check Check Palm Weight...
Page 173 Type Type designates the end effector type that is being used. Each type of end effector, case, bag, or vacuum require distinct information so that the calculations for the pick and set down are correct. Different end effectors are used for different stacking situations and the position of the products differ on how they actually positioned relative to the robot.
Page 174 STA-HLD The auxiliary palm is aligned with one side of the station conveyor during pick up. With fixed pick up, the auxiliary palm will be aligned with the side of the station as selected in this field. The right side of the station is referenced as if the the programmer were sitting on the product as it contacted the product stop.
Page 175 For finger style (bag and fork) end effectors set length to the finger mounting frame length. Fra m e Dep th T-Axis Mo unting Fla ng e Auxilia ry Pa lm Heig ht (F) Fing er Pa lm / C V top First Closed Wid th g a p...
Page 176 For multi pick multi place zoned end effectors: Frame Depth (G) T-Axis Mounting Flange T offset C=CW/2-X Example 600/2-15 = 285 Auxiliary Palm Height (F) Right Palm Palm gap should be set to 10mm Palm/CVtop(H)>finger thickness First Finger(E)=17 Closed Width=Any small value First Open Width (B)=(CW) = 17mm...
Page 177 For vacuum end effectors set length to the distance from the tip of the first front cup outside diameter to the tip of the last rear cup outside diameter. Fra m e Dep th Cup s (G) Heig ht (F) Cup s Set to the sa m e a s (F) Colla p sed T-Axis Mo unting Fla ng e...
Page 178 End effector Offsets: In some applications, an end effector is designed or built to accommodate the product being picked up offset of the center of the “T” axis flange. To account for this variable in calculations, the following offsets are included. The values can be negative or positive depending on the position relative the center and right side of the end effector.
Page 179 First finger: To calculate the position of the fingers, DIYSPII needs a position of the fingers relative to the length of the paddle. The first finger distance is measured from the end of the paddle or finger mount (front of the end effector) to the center of the first finger. Due to limitaitons of DIYSPII enter 17mm into the first finger field and adjust the paddle length as follows.
Page 180 Frame depth: For case and bag end effectors the frame depth is used in calculations to prevent the end effector from interfering with the product when it is straddling it during pick up. The distance is measured from the end effector mounting flange surface to the bottom of cylinders or brackets which would interfere with the paddles or fingers from closing on the product.
Page 181 Station conveyor parameters The Station conveyor parameters include standardized information about the pick up location (station) used by the DIYSPII software in calculations, but does not include its position. The station conveyor that is desired must be selected by the programmer. Station 1,2,3, or 4 are available for selection.
Page 182 Roller pitch: This is used when the station conveyor type is roller. This is the distance between the rollers. The distance is assumed to be typical along all of the rollers. Palm direction above conveyor: By default the end effector is required to have a standard position above the pick up position.
Page 183 Position The position parameters include standardized position information about the station conveyor position (product pick up location) and pallet conveyor position (load building pallet location). Refer to the the following diagram for reference to the position coordinate screen. Dimension each of the Points marked HX=? Teach Pallet...
Page 184 How to Change Position Parameters Click on Select Select Click Enter Select Select Registration Endeffector Position at password Conveyor Guide and station dialog box Select Apply Select Pallet Select Select Rear Select Front Select Width and Click Width Teach Position Position Orientation Position...
Page 185 Station conveyor position (Station Origin): DIYSPII uses a single point on the station conveyor to help calculate step 2 which is key value in determining the remaining steps. This point gives us the station origin. Simply put, the position set for each station is the point on the conveyor where the top of roller plane intersects the point at the bottom, center of the fixed stop.
Page 186 Pallet conveyor position (Pallet Origin): The pallet conveyor position is made up of two points on the pallet which help determine the stacking location for the products being palletized. These two points determine the pallet origin and give us the pallet coordinates used during programming.
Page 187 Pallet width orientation: When pallet parameters (pallet size) are defined, one side is registered as the width (PW). PW is always referenced to the front of the pallet. In the “Pallet width orientation” (Formerly “Approach for fork lift”) field, the pattern selection will depend upon which side of the pallet is contacting the pallet stop (i.e.
Page 188 Conveyor name Up to 15 individual pieces of peripheral equipment can be operated from the robot panel if programmed by PLC (programmable logic controller) to do so. The PLC recognizes operation of these outputs from the robot panel, but the robot panel controls the identifying description (name).
Page 189 Pallet Parameter Pallet parameters define the size, product overhang limits, and forklift direction. The pallet orientation to the robot is referenced by the forklift direction. PW (pallet width) is always the side which is received by the pallet. Up to a 10 different pallet arrangements can be stored in DIYSPII.
Page 190 Pallet type Default Input the number type to be used as the default pallet. to be normally used at the "Default pallet type" box. Click the "OK" button at the "Pallet list" dialog box, and click the "OK" button at the "Pallet parameter" dialog box. Pallet delete To delete a previously stored pallet, input the pallet type at the "Pallet type"...
Page 191 Registration default value The default screen allows the programmer to set certain global programming paramaters which affect pattern stacking options. These default values are used during initial pattern creation. How to Change Default Value “Values” Select Click Select Select Select Select Base Manual Registration...
Page 192 Stopper direction: The "Stopper direction" list box is changed by the programmer when they need to program at the robot and would like to view the patterns relative to the way their laptop screen is positioned relative to the robot. When the programmer is standing at the laptop screen, the pallet conveyor pallet stop can be referenced their left, right, up (front), or down (rear).
Page 193 Distance for fall: When palletizing directly on a pallet that is supported by a powered lift, the pallet will be lowered after stacking a specific amount of layers. The “distance for fall” is the amount the lift will lower. When not using a lift, set the “distance for fall” value to zero (0).
Page 194 APR (Special) (mm): These values can be set to change the approach for the top layer differently than the other layers. This will prevent the robot from going out of range at the top of the envelope. If set to “0” the top layer will have approaches equal to the other layers. “Manual stacking seq”...
Page 195 COMMANDS ON THE "TEACHING" MENU Create/Delete program Edit program Program selection Program parameter Sequence program Step parameter Auxiliary data Position data Pattern Programming -108...
Page 196 Create/Delete program OXPA (1/2) The main components of DIYSPII are the OXPA (1/2) and OXPA (2/2) screens which are used to input data specifically about the product, placement locations, pattern shape, and positioning detail. How to Change Pattern Shape on an Existing Pattern “Values” Select Select OXPA (1/2)
Page 197 How to Create a New Pattern “Values” Pattern does Select Select OXPA (1/2) Click Next Select not exist, which Teaching Create/delete dialog box Page Pattern was registered Program… appears by user is displayed Continue to Alternatives OXPA (2/2) Click Click Click OK select patterns to the...
Page 198 How to Create a New Pattern “Values” (Cont.) Double “click” on the pattern choice. Double “click” on the pattern alternative displayed. Change pattern sequence if required. The display after selecting the pattern and modifying the pattern the OXPA (2/2) screen will be displayed. Click on “Transfer”...
Page 199 Program Number Assignments Certain program number ranges are dedicated to specific items: No. 0: Robot standby position program No. 650-699: Internal pattern reference programs. (obsolete) No. 700: Former position reference programs (obsolete) No. 701-732: Sequence reference programs No. 749: Peripheral equipment control program Program 0 is used to protect the robot after certain operations.
Page 200 Station: The “station” is the point where the product is picked up from. Sometimes the station is also referred to as the station conveyor. In this field choose a station conveyor no. between 1-4. Ordinarily the station no. is 1 if there is only one station. Pattern Programming -113...
Page 201 Pallet: The “pallet” is the point where the product is palletized at. Sometimes the “pallet” is also referred to as the pallet station or pallet conveyor. In this field choose a “pallet station” no. between 1-4. Ordinarily the “pallet station” no. is 1 if there is only one pallet to stack on.
Page 202 Distance: Each program created uses specific “inching distances” to create step positions. New programs use the data from a reference program as a template. The default inching distance for the new program is also the reference program’s inching distance. When the "Distance"...
Page 203 How to Change Inching Distance: Select Select Editing Edit screen Double click Select Prog Select Next Teaching Program… appears on desired Parameters Page program Highlight the Select Next Select Next Select OK Parameters Select Exit have changed desired inching Page Page is displayed distance...
Page 204 Distance Setting Menu Inching rise distance above station (D1): During operation the robot moves from Step 2 (MOV2) to Step 4 (MOV4). During the move the robot moves vertically by a fixed distance referred to as “D1”. After moving vertically the robot will move laterally to the next position. If D1 is not high enough, the robot will interfere with peripheral equipment.
Page 205 Next Page: “OXPA (2/2)” If the "Next page..." button is clicked at the "OXPA (1/2) " dialog box, the "OXPA (2/2)" dialog box will open. Enter the following items. mum No. of layer: This field displays the maximum quantity of layers which can be stacked. The value is automatically calculated, but can be reduced if preferred.
Page 206 Actual Height (Height Decrement): In situations where the stacking height varies for each layer due to the product, the “actual height” field is used to compensate. The height a completed load is measured and this value is entered. DIYSPII calculates the required height decrement using the actual height of the load and the single product height entered.
Page 207 Extra E/O layer (Cont.): If the "Extra E/O layer" created is registered by the user, it is treated as an alternate stacking type. Extra top layer: The "Extra top layer" option allows the programmer to select a completely different pattern for the top layer. This option is available when the stacking type is column or alternate.
Page 208 Prev page Selects the previous page of available pattern configurations stored in OXPA. Refrain: When refrain is selected the patterns created for the existing layers are duplicated for the remaining layers. I.e. if layers 1,2,3 had been selected, layer 4 was to be selected, and the refrain button was selected, then remaining layers 4,5,6 would be the same pattern as 1,2,3 respectively.
Page 209 How to change the pattern on an existing special stacking pattern Pattern does not exist, which Select Select OXPA (1/2) Click Next Select was registered Teaching Create/delete dialog box Page Pattern by user is Program… appears displayed OXPA Continue selecting Alternatives Click Click...
Page 210 How to Change a Pattern Configuration: Select “Teaching” Select “Create/delete program…” The " OXPA (1/2)"dialog box will open Enter the appropriate program number and press tab “Click” on the “Next Page” button “Click” on the “Ptn.sel” button Message "Pattern is not exist, which was registered by user" is displayed Click on "Ok"...
Page 211 Stacking sequence modification A great benefit of the DIYSPII software is the ability to adjust the sequence of a pallet stack with minimal programming effort. The "Stacking sequence modification" dialog box allows the programmer to adjust stacking approach direction, orientation (product direction), multi-pick, and dropping from above (for bags).
Page 212 During sequence modification the graphic representation of the products change color: Light blue: Indicates the selected product for modification. Left “Click” ONE TIME. Red: The product has been sequenced. (Is not dropped from above) Left “Click” TWO TIMES. Dark Blue: The product has been sequenced. (The BAG is dropped from above) Left “Click”...
Page 213 Turn The "Turn" function turns the product in DIYSPII 90° relative to the default direction. This assumes that the product will be physically turned before entering the station conveyor. The default product direction enters the station conveyor “Width” way leading. Product that is turned is “Length” way leading. Approach The "Approach"...
Page 214 How to perform a Stacking Sequence Modification: Make sure Select Select OXPA (1/2) Click Next OXPA (2/2) the Max of Teaching Create/delete dialog box Page dialog box multi-pick is Program… appears appears set for more than one Alternatives Pattern does not Select Select Click Ok...
Page 215 Conditions where pick-up of the product is impossible When the product is smaller than the closed width of the endeffector. When the product is larger than the opened width of the endeffector. When multi-picking and the length of the palm is too short to pick all of the products. If L is the palm length, L is the product length, and Q is the quantity of cases...
Page 216 "Manual" (Manual Pattern Creation) This allows the programmer to create a fully custom pattern. When the “Manual” button is “clicked” the “Manual created stacking pattern” dialog box is displayed. Manually created patterns take more memory than standard patterns. How to make a manually created pattern: Make sure Select Select...
Page 217 How to make a manually created pattern (Cont.): To rotate the product: “Click” the center of the product. To place product on pallet: “Click” the position. The product is positioned at the green dot in the corner of the product. The first product must be in the upper left corner of the pallet.
Page 218 Pitch: The pitch designates the amount a product is moved for each “click” of the mouse. The pitch can be selected and adjusted as required. Pattern centering: After the pattern has been constructed using the “Add”, “Move”, Rotate, and “Delete” functions, the entire pattern can be centered on the pallet by “clicking”...
Page 219 Editing program…(Program Editing) When editing programs the following elements can be changed after a program has been initially created and are available on the pull down menu from the main screen in DIYSPII. Program selection Program parameter Sequence program Step parameter Auxiliary data Position data Convert to SPZ...
Page 220 Program selection Select the program to be edited. How to select the program to be edited: Select Select Enter the Highlight the Enter the Teaching Editing appropriate Reference appropriate Program program. program field. program if desired. Click Exit Change Pos Change Aux Change Step Change...
Page 221 Pattern Programming -134...
Page 222 COMMANDS ON THE "UTILITIES" MENU View/delete program Transfer program Print out Global Remake Back up Program copy Error content Password registration Communication method Pattern Programming -135...
Page 223 View/delete program Enables the programmer to view (view only) and delete existing program numbers and comments stored in the personal computer or robot control panel. How to view existing pattern program numbers and comments Select “Utilities” “Click” on “View/delete program” “Click”...
Page 224 Programs may also be deleted using a file explorer or through the OXPA (1/2) screen. How to delete existing pattern programs Do not delete program 0, or system parameters files from the robot or personal computer. Pattern Programming -137...
Page 225 Transfer program (From the main pull down screen) This function is used to transfer a program stored in the personal computer to the control panel or vice versa. Transfer program (PC to Robot Control Panel) How to transfer a program from the personal computer to the robot control panel.
Page 226 Transfer program (From the OXPA (2/2) screen) method of transferring a pattern program from the personal computer to the control panel is by “clicking” on the “Transfer” button on the OXPA (2/2) screen. Transfer program (Icon) method of transferring a pattern program from the personal computer to the control panel is by “clicking”...
Page 227 Print out To assist in programming and training, the pattern parameters can be printed using this function. How to print out pattern information: Set Print Parameters: Select Click Print Click once on Select the Line/Page to 60 Utilities the program number(s) to Line Height to 70 number(s) to...
Page 228 Program copy Used to copy programs from one program number to another program. How to copy a program: Highlight and change Click Copy Select Select Click once on the the Target No. to the Utilities Program program number you destination program Copy would like copied.
Page 229 Error content This programmer to upload the error history log from the robot control panel to the personal computer. How to upload error history from the robot Select Click Error Click Exit Utilities Content Select “Utilities” “Click” on “Error content..” Click on "Exit"...
Page 230 DIYSPII Password Registration Password protection is available to allow only authorized personnel to access the robot parameters via DIYSPII. When the password has been set, the programmer will be required to input the password at the "Refer to password" dialog box, and click the "Enter" button. Initially after robot registration, the password is not set.
Page 231 To set Password: Select “Utilities” “Click” on “Password registration..” Select the appropriate level. The “Password registration..”dialog box will be displayed. Highlight and enter the “Current password” Highlight and enter the “New password” Highlight and enter the “Password confirmation” with the same value as entered above in “new password”.
Page 232 Communication method For the personal computer to communicate with the robot control panel the communication port must be selected. How to set communication port Select Click Communication Highlight the Click OK Utilities Communication dialog box Communication thru Method appears RS232-C (COM1) Select “Utilities”...
Page 233 COMMANDS ON THE "PERIPHERAL CONTROL" MENU Program selection Sequence editing Program selection (peripheral equipment) In some applications, the peripheral equimpment such as conveyors and pallet dispensers is controlled by a program written within the OKURA programming language (similar to BASIC). This program is usually stored as program number 749. This function allows the programmer to select the peripheral program that will be edited.
Page 234 COMMANDS ON THE "HELP" MENU Index How to use Version Index This is the help index for DIYSPII. The available online help topics are displaye. See How to Use for usage of the help menus. How to use This explains how to use general help functions. Version This displays the DIYSPII version in use.
Page 235 COMMANDS ON THE "EXIT" MENU Exit T he following are the four methods of quitting DIYSPII. 1. Selecting "Exit" from the menu bar. 2. Double clicking on the control menu box. 3. Clicking on the control menu box, and selecting "Close". 4.
Page 236 DRY RUN-PROGRAM CHECK PROCEDURE Unloaded Operation The purpose here is to check the actual number of stacking layer of the created program, and to check for interference with peripheral equipment. Low speed unloaded operation Use the following procedure to perform automatic operation at low speed, without product. From the Main Menu Press Maintenance Menu Enter the password if required.
Page 237 What is the PGS type? -To prevent the robot from switching program numbers at the wrong time, the PGS type can be changed. The PGS type can be set to one of the following: PGS Type Descriptions Conditions for switch-possible Single Pallet station...
Page 238 Danger -The following procedure starts robot operation, so check that there are no people inside the guard rail, and that there are no obstructions on the conveyor or pallet. -During operation, always keep your hand on the emergency stop button so you can stop operation immediately if a problem occurs.
Page 239 are no obstructions on the conveyor or pallet. - During operation, always keep your hand on the emergency stop button so you can stop operation immediately if a problem occurs. Press - and + to set the robot speed to 10. Press the start button Perform checking just as in low speed unloaded operation.
Page 240 Low speed actual operation Use the following procedure to perform automatic operation at low speed, while moving the actual product. Continuing from above, press Automatic Mode from the Main Menu. Change counters. Set the Layer to 1 and the Work to 1 Press - and + to set the robot speed to 2.
Page 241 High speed actual operation Now perform automatic operation at high speed, with product. Press - and + to set the robot speed to 10. Important -The following procedure starts robot operation, so check that there are no people inside the guard rail, and that there are no obstructions on the conveyor or pallet.
Page 242 Bag Palletizing This section explains the procedure for creating and inputting a program when bag palletizing pattern is selected. The basic concept is the same as case palletizing except for the following: At screen (4/7), STEP 3 （HLD）and STEP 6 (ADN) are unnecessary. Bag Palletizing steps include 1, 2, 4, 5, 7, 8 and 9 as shown in the diagram at right.
Page 243 Bag Hand verses Case Hand The differences between bag and case hands are shown below. [hand for cases] [hand for bags] The standard bag hand has fingers which open to both sides as shown in the diagram below, which allows bags to be placed next to previously placed product. Hand closed Hand opened Pattern Programming...
Page 244 GLOSSARY The Accl time is used to determine the acceleration time for Acceleration Time standard robot movement (msec). The accuracy dialog box contains accuracy parameters and Accuracy coordinate system offset parameters. In situations where the stacking height varies for each layer due Actual Height to the product, the actual height field is used to compensate.
Page 245 By clicking on centering the pattern created on the pallet, will Centering center itself on the pallet. This allows the programmer to begin the stacking sequence Clear modification from the first case. This dimension is used to verify that a product is not too small Closed Width during pattern creation.
Page 246 When palletizing directly on a pallet that is supported by a Distance for Fall powered lift, the pallet will be lowered after stacking a specific amount of layers. The “distance for lift” is the amount the lift will lower. When not using a lift, set the “distance for lift” values to zero (0).
Page 247 This point is used to define the pallet coordinate origin. The Front Position pallet has a front, back, left, and right. In most applications, a conveyor positions the pallet. The conveyor moves the pallet until it is registered and stopped by a fixed or pop up stop. The pallet edge that contacts the stop is routinely the front.
Page 248 Not used at this time Min Gap This section of the OXPA 2/2 screen is used to modify the Modify pattern and/or the sequence of placing products. Used to move previously placed product on the pallet. Move This option is used if an end effector has the ability to pick Multi Place multiple cases and place them on the pallet separately.
Page 249 view what other type of pallets are available and enter the number between 1 and 10 of your choice. Pallet width orientation references the direction of the width of Pallet Width the pallet. The same pallet can be oriented in two different Orientation directions for flexibility, but the robot requires the orientation to stack correctly.
Page 250 Refer to the Manual for the A Series Robot Palletizer, Chapter 8, Program Parameter page 3. This is for setting the range for notifying other control R Area equipment about the current angle of the robot's R-axis. The rear position of the pallet. This point is used to define the Rear Position pallet coordinate origin.
Page 251 The point where the product is picked up from. Choose a Station number between 1and 4. Ordinarily the station number is 1 if there is only one station. Refer to the manual for the A Series Robot Palletizer, Chapter 8, Step Parameters page 15.
Page 252 Select if the product will be turned clockwise or counter- Turn Direction clockwise. Type designates the end effector type that is being used. Each Type type of end effector, case, bag, or vacuum require distinct information so that the calculations for the pick and set down are correct.
Page 253 Sequence Program Examples Sequence programs and step parameters are given below for standard movement. Palletizing bag When station NO. 1 and pallet No. 1 are selected [Sequence program] WTTMR 2 Wait 200ms Command Explanation MOV 4 Move to step 4 WTARM Wait movement...
Page 254 ENDIF Y1E=1 Wait for hand 2 close WTARM Wait movement completion JMPL 1 Jump to label 1 JTOP Return to beginning of program ENDP Program finish [Step parameter] Select Speed Acl Dcl Overlap coordi nates Positi *1 All with special stacking Pattern Programming -167...
Page 255 Palletizing case When station NO. 1 and pallet No. 1 are selected [Sequence programming] completion M6002=1 Conveying into station Command Explanation allowed ON MOV 1 Move to step 1 WTCON M5008 Wait for OFF of “on pallet Y1D=0 Hand 1 close off discharge “...
Page 256 COUNT Resetting count value IF M6006 Execute next line stacking completed WTCON M500F Wait for answer from ENDIF Y1C=1 Hand 1 open ON WTARM Wait movement completion JMPL 1 Jump to label 1 JTOP Return beginning program ENDP Program finish Pattern Programming -169...
Page 257 [Step parameter] Select Speed Acl Dcl Overlap coordi nates Positi *1 TZF with variable pick-up *2 ALT with variable pick-up with special stacking Pattern Programming -170...
Page 258 Pattern Programming <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Columbia/Okura, LLC. 301 Grove St Vancouver, Washington 98661 360.735.1952 Pattern Programming...
Page 259 Robot Manual Maintenance Maintenance...
Page 260 Updating history Version Content Page (Date) 06.01.05 Columbia/Okura Manual Release Maintenance...
Page 261: Battery Replacements
Table of Contents Preventative Maintenance _________________________________5 Inspection Types _____________________________________________ 5 Inspection Schedule __________________________________________ 6 Inspection Items_____________________________________________ 7 Lubricant List ______________________________________________ 12 Bolt Fastening Torque ________________________________________ 13 Hand Inspection ____________________________________________ 14 Cable Harness Inspection (Cables and air hoses) ___________________ 15 Robot Bearing lubrication _____________________________________ 15 Over-Travel Limit Switch Inspection _____________________________ 16 Emergency Stop Switch Inspection ______________________________ 16 Discharge Exit Switch Inspection _______________________________ 16...
Page 262 System Storage menu ________________________________________ 42 Soft Limit Screen ____________________________________________ 43 Communication Setting _______________________________________ 44 External PLC Communication Setup _____________________________ 45 Memory Switch _____________________________________________ 46 Axis Accuracy ______________________________________________ 48 Servo Parameters ___________________________________________ 49 Spare Parts ___________________________________________50 Electrical Spare Parts ________________________________________ 50 Maintenance...
Page 263 PREVENTATIVE MAINTENANCE This section gives the periodic maintenance and inspection schedule for a typical palletizing cell which may include the robot arm, control panel, end effector, conveyor, pallet dispenser, sheet dispenser, and guarding. Many robot palletizing cells include other types of equipment or specialized assemblies not recognized in this manual.
Page 264 Inspection Schedule Using the inspection schedule below, apply your operation schedule to determine the appropriate inspection type and interval. Operation time per day, and Hours of Routine number of years operation inspection inspection inspection inspection 8hours 16hours 24hours 1000 Ο 2000 Ο...
Page 265: Battery Replacements
Equipment CPM Description Type Routine ROBOT A700/A1600 Inspect cable harness for Cable Harness chafing, binding, or interference along robot arm and inside panel.
Page 266 Equipment CPM Description Type Routine End Effectors Bag Style (Fingers) Inspect fingers for tightening Fingers Varies. or replacement. Replace if sharp. Check whether hand Daily Level orientation is horizontal. Inspect shaft assembly for Arm pivots bushing replacement. Replace if noticeable play. Inspect timing cable for Timing cable correctly centering arms.
Page 267 Sealed for life. Inspect for Wheels <1 normal operation. Inspect for normal operation Cylinder <1 and leakage. Check with Columbia/Okura for seal kit. Replace fluid. Initially after Hydraulic System <1 ISO 32 500 hours or 6 months whichever comes first grade Hydraulic fluid.
Page 268 Equipment CPM Description Type Routine 702C See Specific Equipment <1 manual Provided by Columbia Machine Inc. Change lubricant. Initially Electragear Reducers <1 after 500 hours or 6 months whichever comes first Electragea r service manual. Lubricate bearing. Remove Headshaft bearings <1 No.
Page 269 Equipment CPM Description Type Routine Stacking Bin SB-2 Change lubricant. Sumitomo Gear <1 No. 2 NLGI Reducers Grease Lubricate bearings. Remove Headshaft bearings <1 No. 2 NLGI excess grease. Grease Chain should be lightly oiled. Pallet and Stripper <1 30 wt Oil Only lubricate if appearance is dry.
Page 270 Gear Reducers For Each Axis Brand shown Moly-white table right only. (Kyodo Yushi) below *Replace grease at Inspection C. Amount of grease needed for each reduction gear Axis Model A1600 1920 1850 1850 A700 1200 1000 1000 Units: cc Maintenance...
Page 271 Bolt Fastening Torque The following table lists the prescribed tightening torque for each diameter of fastener. This table shows values for fasteners used on the robot arm that have a grade of 12.9. Table values should not be used unless fastener grade is known. Always tighten fasteners in gradual increments.
Page 272 Hand Inspection Applies to standard hands for bags and cases . Hand rattle 1. Check the fingers are oriented correctly and securely fastened. 2. Check the actuators (air cylinder etc.) are 5, 6 securely fastened and have no abnormal wear. 3.
Page 273 The bolts are replaced and there is nothing else to do. The T and R axes require dismantling and should only be performed after consulting Columbia/Okura Service. Maintenance...
Page 274 Over-Travel Limit Switch Inspection Turn the motor power ON. Press the R-axis over travel switch on the robot. Check that motor power will turn OFF and an error message is displayed on the touch panel screen. Reset the over travel switch by pulling the blue reset button on the switch.
Page 275 Trapped key Lock Inspection Turn the motor power ON. Twist and remove the Trapped Key from the control panel. Check that motor power will turn OFF. Verify the Trapped Key door lock is in place and that the door will not open without the Trapped key removed from the panel.
Page 276 Control Board Inspection Check that boards inside the controller are undamaged and clear of dust. Clean with dry, clean, low pressure air or contact cleaner as necessary. Verify the cable connectors to each board are connected firmly in their sockets. Fan Operation Inspection After filter cleaning, check that the controller fans (side and back) work normally when the main breaker is turned ON.
Page 277 MAINTENANCE MENU DISPLAY The Maintenance Menu is displayed by choosing "Maintenance mode" from the main menu. The Maintenance Mode can be reached when the robot is stopped or under operation. Menu structure Auto Operation Automatic operation mode Menu (Running) Teaching mode Main Menu System storage mode Maintenance mode...
Page 278 Maintenance Menu (During Operation) Most maintenance menu items are selectable only when the robot is stopped. To move to the maintenance menu under operation, press the hidden key located below on the auto mode screen. Auto mode screen (under Main menu operation) Maintenance Auto mode...
Page 279 Software Software Applications: Multiple software applications are used to control the robots behavior including: DiySPII Pattern Programming Software OXPA Plc Conveyor Control Software RC101FROMWriter Flash Rom Management UG00S-CW Operator Interface Software Software Files Required: RC101.bin Operating System RC101 (Hitachi RISC Processor SH) SrvMain1.bin Servo...
Page 280 Using a torque wrench, slightly tighten each bolt in an alternating fashion until the torques below are reached. Do not over tighten. 14.8 N-m (150kgf-cm) (A700 III) 23.5 N-m (240kgf-cm) (A1600) Raise the torque levels to 37.0 N-m (380kgf-cm) (A700) 40.2 N-m (410kgf-cm)
Page 281 Hand lubrication (LM -linear bearing) Open the paddles on the hand. Pump grease into the nipples located on the bearings as necessary. Open and close the hand paddles 3-5 times and then lubricate again. Remove excess grease from the bearing housing and rail. Maintenance...
Page 282 Memory Backup Battery The Memory Backup Battery maintains Program Data, Servo Settings Data, and System Data in memory when AC power fails or is turned OFF. The battery must be replaced at the B inspection, or when the error message “70. Battery voltage drop” appears.
Page 283 “Encoder battery voltage drop” appears. Use the procedure below. Battery Type: ER6K-#17-A (Hitachi Maxell) A1600 (Columbia Okura Part Number 1865) ER6K-#17-3 (Hitachi Maxell) A700 (Columbia Okura Part Number 7344) Battery Mounting Position Inside robot base (See diagram at right) Replacement Procedure Turn ON the main breaker.
Page 284 Battery Replacement Date After exchanging batteries, following operation is necessary in "Hour Meter Revision" screen of the touch panel. To set the date of replacement: From the Main Menu Press System Menu Enter the password. Press Hour Meter Revision Press the appropriate Replace key for the battery replaced.
Page 285 Assembly, seal the thermal compound between the heat sink and the IPM module. This minimizes the heat resistance between them and keeps the components cooler. Back of IPM Apply 0.5 g of Thermal compound as shown. Columbia/Okura part number 8001 (Qty 1 tube, 5 grams). Maintenance...
Page 286 Reset Robot Memory This describes how to reset the robot controller. After performing the following, the robot will boot up operating on factory settings. The robot type, servo files, OXPA PLC file, and pattern data will all need to be downloaded from DiySPII to restore previous operations.
Page 287 Mechanical Stop Replacement-A1600 On the A1600, the R, D, and O-axes have mechanical metal stops that absorb the robot energy by deformation. If the robot collides with one of these stops, it needs to be replaced immediately. The stoppers are bolted in place. The part numbers are listed below.
Page 288 Inspection C component list Parts name Parts code location When to replace Robot From robot Inspect possible internal base robot replacement of wiring inside wiring hand robot base. Higher rotation will shorten life of cables. Inspect possible replacement wiring between T-axis and Hand. Higher rotation will shorten life of cables.
Page 289 MAINTENANCE PROCEDURES (SOFTWARE ON PANEL) Password Setting Passwords can be set for each of the main menus: Automatic, Teaching, System Storage, and Maintenance. The System Storage screen must have a password set. The standard password if all data is lost and the robot is restarted is F1, F2, F3. Press System Storage from the Main Menu.
Page 290 The R, D and O axes each have a match mark to align the robot position to. Columbia/Okura provides straightedges suited to this function, however a small straight edge will work.
Page 291 The positions for storing the origins are shown below: Axis Origin Position Procedure The robot arm is positioned 180 degrees Move the R-axis, and align the opposite of the cables exiting the back of match marks on the base and the robot base.
Page 292 Setting T-Axis Origin -Attaching the Hand End Effectors (Hands) vary greatly. The following procedure is applicable to initial installation only and shown for a standard case end effector. Assemble the T-axis cable cover to the hand if used (designs vary greatly and are only used on the A1600).
Page 293 Rotate the hand to 220 degrees (Clockwise). Wind T-axis cable approximately 2-1/2 times (Clockwise). Connect the hand connectors and an Air hose. Make sure the cable is not tight. If the cable is too tight, rotate hand counterclockwise satisfactory point. If the cable is too tight at 220 degrees, then set the T- axis soft limit to the satisfactory angle.
Page 294 Encoder setup Encoder setup is required the following cases. When an encoder cable or motor connector is disconnected. When the [encoder backup alarm] has occurred. To perform an encoder setup Move robot manually to the standard position. Perform a standard position storage (0-90-0) Cycle main power supply and start up again.
Page 295 Peripheral Equipment Name Input Conveyors or other peripheral equipment operated through the "Conveyor Manual" screen can be named in the following screen. In addition, the number of stations and pallets are set in this screen along with the quantity of words to transfer to the POD.
Page 296 Hand Manual Operation Name Input Hand functions operated through the "Robot Manual" screen can be named in the following screen. Press System Storage from the Main Menu. Enter the Password. The System storage menu is displayed. Press Hand manual operation name. The screen is displayed.
Page 297 Counter Revision The counter initialization sets the counter to layer 1, product 1 for a particular pallet number or all of the pallets. The program being changed is displayed while selecting the pallet No. to initialize. From the Main Menu Press Maintenance Menu Enter the password if required.
Page 298 Setting of Timer value From the Main Menu Press Maintenance Menu Enter the password if required. Press Stacked Counter Revision For RP, stop position, centering position, and press height can be set up for every station. ● To set up the value, select the location value of value with cursor key.
Page 299 Conveyor information The OXPA PLC can be disabled by performing the following: From the Main Menu Press Maintenance Menu Enter the password if required. Press Conveyor Information Press the appropriate Change key to toggle the operation of the corresponding PLC. Enter the Password if required.
Page 300 ROBOT SETUP System Storage menu This section explains the various system parameters. During normal operation, there is no need to change the system parameters; however, these parameters must be reset after performing servo motor replacement or other data has been lost for some other reason.
Page 301 This screen displays the Soft Limits, Teaching Area, Origin Offset, and R-Area. All of the values have the possibility of allowing the robot to damage itself during operation. Do not experiment with values. Please contact Columbia/Okura for instructions on use. To set the values: Press System Storage from the Main Menu.
Page 302 Communication Setting Serial communication from the robot to external sources (OXPA PLC, DiySPII) except for the touch panel, are determined in the following screen. Press System Storage from the Main Menu. Enter the Password. The System storage menu is displayed. Press Communication setting.
Page 303 Centronics communication can be selected in this menu. As a standard, Columbia/Okura does not use this method and all options should be set NO. Press System Storage from the Main Menu. Enter the Password. The System storage menu is displayed.
Page 304 Many of the switches have the possibility of allowing the robot to damage itself during operation. Do not experiment with values. Please contact Columbia/Okura for instructions on use. Press System Storage from the Main Menu. Enter the Password. The System storage menu is displayed.
Page 305 Standard Name Type setting T-axis motion T-axis turns to designated position without T-axis turns, taking short cut direction. Used for 72 hour testi. short cut direction EX: Target position is -179 degree, when current position is 179 degree. The robot Move to 181 (Approx.
Page 306 Axis Accuracy The Axis Accuracy screens allows the programmer to set the accuracy of the robot, the robot type, the job number, and the SMOV parameters. Press System Storage from the Main Menu. Enter the Password. The System storage menu is displayed. Press Axis accuracy.
Page 307 Press System Storage from the Main Menu. Enter the Password. The System storage menu is displayed. Press Servo parameter. The screen is displayed. As previously stated, do not proceed with changes unless directed by an authorized Columbia/Okura technician. Maintenance...
Page 308 Servo Motor SGMGH55 Robot (R,D,O) Servo Motor SGMPH04 Robot (T) Battery ER6K-#17 Controller (CPU board) Robot (Base) Touch Panel UG330H-SS4 Controller (TP) A700 Name Model Qty. Area used Switching ZWQ80-5225 Controller (AVR1) regulator Switching regulator ZWS100AF-24/J Controller (AVR2) Servo Amp...
Page 309 Robot manual Maintenance <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Columbia/Okura, LLC. 301 Grove St Vancouver, Washington 98661 360.735.1952 Maintenance...
Page 310 Robot Manual Troubleshooting Troubleshooting...
Page 311 Updating history Version Content Page (Date) 06.01.05 Columbia/Okura Manual Release Troubleshooting...
Page 312 Table of Contents Diagnostic Menus________________________________________4 Error content display __________________________________________ 4 Data memory content _________________________________________ 5 Deviation trace ______________________________________________ 6 Acceleration and deceleration time _______________________________ 6 Operation Ready Condition _____________________________________ 6 I/O monitor (Relay Actuation X,Y,M) _____________________________ 7 Executed sequence command ___________________________________ 8 Overlap trace________________________________________________ 8 RISC output data _____________________________________________ 9 Operation Trace_____________________________________________ 10...
Page 313 DIAGNOSTIC MENUS The Diagnostic Menus provide a technician with valuable information when the robot has an error does not move correctly. Error content display The most recent one hundred robot error messages can be displayed using the Error Content Display screen. The screen is only available during operation. Each error includes a message number, date, time, and sub codes if applicable.
Page 314 Data memory content Internal data memory (data held for each program) and external data memory (data available by all programs) can be checked and modified using this screen. The list below is a summary. Please check the appendix for a detailed list of data memory locations and descriptions.
Page 315 Deviation trace Deviation of each axis is displayed. (Max value and current value) Press [Max val clear] key to clear Max value. (Max value is memorized even if the power is OFF.) Acceleration and deceleration time Displays the Last 12 steps trace data. Includes: position, acceleration time, and deceleration time.
Page 316 I/O monitor (Relay Actuation X,Y,M) Internal inputs and outputs (relays for each program) and external inputs and outputs (relays available to all programs) can be checked and modified on this screen. X = INPUTS Y = OUTPUTS M = BITS without external terminations. To access the I/O monitor Display screen: Press Maintenance Menu on the Main Menu.
Page 317 External data memory (One location): Press to display Inputs, Outputs, or Internal bits. Press Display Start No. to display a ten-key pad. Select the desired relay register number to view and press enter. The relay register number will be displayed along with the current state.
Page 318 RISC output data The position data of each axis can be displayed as an instruction value to servo motor control board (RC103). * Last about 20 seconds data can be shown. but, in case a motor power is OFF, data is not automatically updated.
Page 319 Operation Trace Last 112 histories of operation by touch- panel can be shown. Display content Date : DD HH:MM Scrn : Base screen No. : Overlap screen No. : Operation content Result : Operation content (Detailed code) PLC & Tie-in Trace Last 90 special commands (stcnt/sthgt/wtrspd etc.) of the palletize system executed from Built-in PLC are...
Page 320 Task Counter The executed situation of every task of a program is monitored. ● Press [Measure Start]. The number of executed times of each task is counted until the“move”task (the highest priority task) adds up 1000 times. * As a result of measurement, in the case of few executed time of a lower ranked task by CPU load, trouble is caused to processing operation of the corresponded task.
Page 321 Press [Re-indicate] key, the present current value is displayed as an offset value. ● Press [Enter] key, a current offset value on display is reflected to apparatus. A power re-injection is not necessary. ● Press [Saving the File] key, the offset value on display is saved to file. * [Enter] and [Saving the File] key cannot be pressed under robot operation.
Page 322 TROUBLESHOOTING Problems with an Error Message If there is an error message on display screen, refer to the cause and remedy message displayed on the screen or refer to the chart below. Problems with No Error Message For problems that are not accompanied by an error message, first check the list near the end of this section.
Page 323 Problems with Error Messages When an error message is displayed, an abnormal condition has forced the robot to stop. Error messages are displayed in red as shown in the diagram at right. An error message is composed of an error no. and an error message. To stop the buzzer from sounding, press Silence Alarm.
Page 324 Error Error message Cause Remedy 1-15 Unused While pressing the abnormal reset switch, C-axis out of Robot moved to out of 1. Turn on motor power 2. Move the robot into the move-area by operation range operation range manual operation Unused R- axis out of operation range...
Page 325 DSP Tele- Data communication If error occurs only once, do reset. communication error abnormality If occurs frequently replace CPU board S - I/O Initialize S-I/O port initialization If error occurs only once, do reset. error abnormality If occurs frequently replace CPU board Touch Panel Check the communication cable or Communication abnormality...
Page 326 Program selection Any other PGS type than the When work is on the pallet Discharge the mistake current one was selected before pallet by conveyor manual mode completion of current stacking Using automatic mode menu, set PGS type selection to every work, and start Then restore the original PGS selection PGS Type Descriptions...
Page 327 The content of the pertinent Program check sum program has been destroyed at Check the stacking program error program selection The pertinent program is not in No program stored Creation of the stacking program memory at program selection At program execution, the No program ENDP Insert ENDP on the pertinent program program contains no ENDP...
Page 328 Initial pulse The pulse when power was last See the explanation about this item in the mismatch turned off differs greatly from manual What has clear causes, such as the initial pulse when turning power OFF under arm-operation, is reset in on power manual mode.
Page 329 Change the Memory Backup Battery on the CPU board (RC101) within one week of the Warning that the CPU Board error. The error can be reset and (RC101) memory backup operation can continue, however Memory's battery low battery needs to be changed operation is continued, the voltage (warning) (determined by the exchange...
Page 330 Break in position Data calculation for arm IF the error occurs only once, it can be data movement at the main CPU is corrected by resetting not completed in time Make speed quick when automatic operation speed is not 10 If 10, shorten acc-dec time of a generating step Note...
Page 331 RAMDISK is crashed Auto repaired because Initialize the RAMDISK Auto repair RAMDISK area is unreadable Execute RAMDISK Memory was initialized. initialization Initialization is to be executed by turning on the power after setting a dip switch 8 in RC-101 PC board to ON RAMDISK Failure in initialization Replace the RC101...
Page 332 Check mechanical operation. Change program so that robot operates with smooth movement. Note Deviation limits are as follows Model A1600 III / A1200 III A700 III / A400 III 47 degree 33 degree 47 degree 33 degree 47 degree 33 degree Overload Robot was operated for a while Check for wiring, contact.
Page 333 Robot type not The version of a DSP program The newest DSP program is used. register is old. 212- Unused Break in position Data calculation at the main Makes speed quick when automatic data from SH CPU is not completed operation speed in time.
Page 334 Encoder battery When the following value is Replace battery within a week. Do not turn voltage drop displayed on sub No, off the main power supply until the battery it's drop in voltage of battery. is replaced. 4-axis type = No.15 5-axis type = No.31 *Other causes can be considered when sub 2-axis type = No.3...
Page 335 Emergency Stop Emergency Stop Enabled Reset the emergency stop button (twist to release). Press the abnormal reset button to clear the error. Over Load Tripped Motor overload has tripped. Inspect the motor condition. Reset the overload. Press the abnormal reset button to clear the error.
Page 336 Pusher Jam Pusher has taken too long to Remove the product if jammed. If not, cycle. check the alignment of the photocells and switches on the pusher. Press the abnormal reset button to clear the error. Mixing different job Detected another stacking Please check the stacking pattern is pattern product.
Page 337 Re-level end-effector and torque bolts to Detected occurred. End-effector is out of (A1600 40.2N-m {29ft-lb}) level. (A700 16.7N-m {12ft-lb}) Verify the robot count is correct. Press the abnormal reset button to clear the error. Grid turn up-down Turning device (90°-270° turn)
Page 338 Low Vacuum Level Vacuum level is too low. Check the vacuum level with what is required. Verify the vacuum level switch is working properly. Clear product as required and reset product count. Press the abnormal reset button to clear the error.
Page 339 Lift Exit Error Product detected at the exit Move or remove the product blocking the from the lifter. exit from the lift. Verify the sensors are aligned properly. Press the abnormal reset button to clear the error. Lift Height Error Product is too high on the lift.
Page 340 Pallet Count Error Empty pallet quantity is set too Too many empty pallets are present. The high. pallet count has been set too low. The pallet count must be reset to the correct value. Verify the photocell checking for pallet quantity is properly aligned (if used). Press the abnormal reset button to clear the error.
Page 341 Layered pallet arrival Photocell sensor for rear side of Fix the empty pallet stacking figure. Or error pallet magazine turns ON. check the photocell sensor. Then check the photocell sensor works. Press the abnormal reset button to clear the error. Layered pallet figure- Detector for empty pallet Fix the empty pallet stacking frame.
Page 342 Full Pallet Error The full pallet appears to be Verify condition of pallet. Reset counters empty. as required. Press the abnormal reset button to clear the error. Out of Pallets Occurs when the pallet Load Pallet Dispenser with pallets. Press dispenser is out of pallets.
Page 343 Low Sheets Occurs when sheet table or Load Sheet table or dispenser with sheets. dispenser is low on sheets. Press the abnormal reset button to clear the error. High Sheets Occurs when sheet table or Remove the necessary amount of sheets dispenser is loaded to high of from pallet dispenser to clear high level sheets.
Page 344 Pallet Hopper Jam Pallets in pallet hopper are not Remove pallets and re-level stack or clear level or jammed. jammed pallet. Press the abnormal reset button to clear the error. Spare Error Spare Error Spare Error Spare Error Spare Error Spare Error Spare Error Spare Error...
Page 345 Problems with No Error Message In many cases, no error message will be displayed. The problems listed below are more common items that may be readily repaired. Problem Cause Remedy Main power lamp Burn out of main power supply lamp. Replace lamp.
Page 346 movement Check the speed parameter (in step Basically input 10 slow parameter) Stacking position When creating program in OXPA, check Input the correct value shifted system parameters (pallet station, hand ) Check the T-axis 0 degree position. Set the end effector parallel to the robot arm in T-axis origin setting.
Page 347 Robot manual Troubleshooting <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Columbia/Okura, LLC. 301 Grove St Vancouver, Washington 98661 360.735.1952 Troubleshooting...
Page 348 Robot Manual Electrical Electrical...
Page 349 Updating history Version Content Page (Date) 06.01.05 Columbia/Okura Manual Release Electrical...
Page 350 Electrical Drawings _____________________________________55 A700 Internal (Inside Panel) Cable Drawings______________________ 57 A1600 Internal (Inside Panel) Cable Drawings_____________________ 59 A700 External (On Robot Arm and outside Panel) Cable Drawings ______ 61 A1600 External (On Robot Arm and outside Panel) Cable Drawings _____ 63 Electrical...
Page 351 Electrical...
Page 352: Controller
CONTROLLER A1600 Panel Layout The diagram here shows the arrangement of parts inside the robot controller. Please correlate these with the table on the following page. FRONT VIEW BACK VIEW RIGHT VIEW LEFT VIEW Electrical...
Page 353: A1600 Controller Parts
A1600 Controller Parts Parts No. Name Model NFB0 Circuit breaker NF-SFW 3P 70AT NFB1 Circuit breaker SA53RCUL/30 3P 50AT NFB2 Circuit breaker EA32AC 2P 3AT NFB3 Circuit breaker PKZM0-4-T 3P 2.5AT R･A･V-801BXZ-4 Surge protector Noise filter MBS-1340-33 Noise filter MBW-1203-22 CP1,2 Circuit protector CP31TM/2...
Page 354: A700 Panel Layout
A700 Panel Layout The diagram here shows the arrangement of parts inside the robot controller. Please correlate these with the table on the following page. BACK VIEW FRONT VIEW RIGHT VIEW LEFT VIEW Electrical...
Page 355: A700 Controller Parts
A700 Controller Parts Parts No. Name Model NFB0 Circuit breaker NF-SFW 3P 50AT SA53RCUL/15 NFB1 Circuit breaker 15AT NFB2 Circuit breaker EA32AC 2P 3AT NFB3 Circuit breaker PKZM0-4-T 3P 2.5AT Surge protector R･A･V-801BXZ-4 Noise filter MBS-1320-33 Noise filter MBW-1203-22 CP1,2...
Page 356: Cables
CABLES NOTE: The cable layout drawings are shown below for quick reference. Please refer to the appendix for a complete package of electrical schematics and cable drawings. Electrical...
Page 357 Electrical...
Page 358: A1600 External Cable Diagram
A1600 External Cable Diagram The following shows the cables wiring the robot arm from the Hand to the Control Panel. Please refer to the Electrical Appendix for a complete set of drawings. Location of CN1-CN5 on Robot POWER POWER CONTROL POWER CONTROL OPTION...
Page 359: A700 External Cable Diagram
A700 External Cable Diagram The following shows the cables wiring the robot arm from the Hand to the Control Panel. Please refer to the Electrical Appendix for a complete set of drawings. Location of CN1-CN4 on Robot Base Air Pressure...
Page 360: Pc Boards
Safety Relay Board RC103 RC102 Servo CPU Board I/O Board RC107/(RC104)* Servo Amplifier RC105 R axis Servo Power Supply Motor Board RC107/(RC104)* Servo Amplifier D axis Motor RC107/(RC104)* * A700 Servo Amplifier O axis Motor RC108/(RC110)* T axis Servo Amplifier Motor Electrical...
Page 361: Rc 101 Switch Explanations And Led Descriptions
RC 101 Switch Explanations And LED Descriptions LED Table Switch Table Explanation Color Explanation Lights up when 5 V is supplied Green CPU Reset Switch Go on and off when CPU is executing Green Lights up when battery voltage drop Green 7- Segment Display DIP Switch (DSW 1)
Page 362: Rc 102 Lower I/O Board Arrangement Of Led's And Jumpers
RC 102 Lower I/O Board Arrangement of LED’S and Jumpers Input Relay-LED Explanation Table Output Relay-LED Explanation Table Jumper Table Explanation Relay # Terminal # Relay # Terminal # Relay # Terminal # Relay # Terminal # Short TB1-3 TB1-27 TB2-3 TB3-23 Open...
Page 363: Rc 102 Upper I/O Board Arrangement Of Led's And Jumpers
RC 102 Upper I/O Board Arrangement of LED’S and Jumpers Jumper Table Input Relay-LED Explanation Table Output Relay-LED Explanation Table Explanation Relay # Terminal # Relay # Terminal # Relay # Terminal # Relay # Terminal # Open TB1-3 TB1-27 TB2-3 TB3-23 TB1-4...
Page 364: Rc102 I/O Board-Integrated Circuits
RC102 I/O Board-Integrated Circuits Connections to RC102 are made at terminal blocks that run through Integrated Circuit Chips (ICC).The Input and Output integrated circuit connections to RC102 are shown below. Note: the output circuit limitation of 100mA per connection. Input current 4V 100mA 7.2K Output On max.
Page 365: Rc 103 Switch Explanations And Led Descriptions
RC 103 Switch Explanations And LED Descriptions DIP Switch (U3) LED Table Explanation Normal Setting Not used Explanation Color Not used Lights up during sub DSP operation (D & O axis) 7 Seg Not used Lights up during sub DSP operation (R & T axis) 7 Seg Not used Lights up during sub DSP operation (C axis)
Page 366: Rc 105 Switch Explanations And Led Descriptions
RC 105 Switch Explanations And LED Descriptions Electrical...
Page 367: Rc 106 Jumper Settings And Descriptions
RC 106 Jumper Settings and Descriptions Jumper # Standard Position Description Open If shorted, would by-pass teach pendant e-stop (Channel-1) Open If shorted, would by-pass teach pendant e-stop (Channel-2) Open If shorted, would by-pass guard door switch in motor power enable circuit for MC-1 Open If shorted, would by-pass discharge safety pc’s in motor power enable circuit for MC-1 Open...
Page 368: A1600 Servo Amplifier Board Box
A1600 Servo Amplifier Board Box Electrical...
Page 369: A700 Servo Amplifier Board Box
A700 Servo Amplifier Board Box Electrical...
Page 370: Servo-Amplifier
Servo-Amplifier The Servo Amplifier is a combination of the current board and the Individual Power Module (IPM) for each drive motor. The part numbers are listed below for reference. A1200II A400II, A700 A1600,A1600-W Servo-Amplifier Board IPM Form Board IPM Form...
Page 371 Electrical...
Page 372: Peripheral Equipment Control
PERIPHERAL EQUIPMENT CONTROL Columbia/Okura uses a control system that allows for the robot's motion control and the peripheral equipment control surrounding the robot ( inputs and outputs used on the station conveyor, pallet conveyor, guarding, pallet dispenser, etc.) The inputs and outputs are activated through the RC102 I/O Board.
Page 373: Functional Details (Okura Control Of Conveyor)
When Memory Switch 1-5 is set to ON the Okura controller is used to control the peripheral equipment (Conveyor, dispensers, checkers, etc.). Columbia/Okura has standardized on using these internal capabilities of the Okura controller. This information is helpful during training to obtain a general overview of the controller.
Page 374 5.3. The OKURA CONTROLLER should turn OFF the pallet program allocation relay one second after turning it ON. In addition, the OKURA CONTROLLER should issue an error if this does not happen within a set amount of time. If the Counters are changed or initialized on the controller: 6.1.
Page 375: Memory And Bit Ranges --X, Y, M, D
Memory and Bit Ranges --X, Y, M, D The following table lists the symbols that are used to classify whether variables are inputs, outputs, bits, or data words. Start Symbol Classification Type Indication Points Power ON number number Input (*1) Output (*1) "...
Page 376: I/O Connections To The Internal Okura Controller
I/O Connections to the Internal OKURA CONTROLLER The external I/O wires are connected to the RC102 I/O board via terminal blocks TB1,TB2,and,TB3. A drawing and termination points are described the under the heading of RC102 I/O Board. The additional I/O signals to the Hand are connected through CN1 to the RC102 I/O Board.
Page 377 Electrical...
Page 378: Standard I/O
Standard I/O D WORDS D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 lower X= Input Reference or upper Y= Output. D1000 D1001 CYCLE TIME LINE1 D1002 CYCLE TIME LINE2 D1003 CYCLE TIME LINE3 D1004 CYCLE TIME LINE4 D1005 WTCON TIME OUT D1006 D1007...
Page 379 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 lower X= Input Reference or upper Y= Output. D1040 TOTAL TIME D1041 CYCLE TIMER D1042 RESET TIMER D1043 PRODUCT COUNT L1 D1044 PRODUCT/MIN D1045 D1046 D1047 D1048 D1049 D1050 D1051 D1052 D1053 D1054...
Page 380 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 lower X= Input Reference or upper Y= Output. D1088 D1089 D1090 D1091 D1092 D1093 D1094 D1095 D1096 D1097 D1098 D1099 D1100 CURRNT SHT HT T1 D1101 HT,TBL 1,BOT D1102 HT,TBL 1,TOP D1103 DIST,TBL1,SAFE D1104...
Page 381 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 lower X= Input Reference or upper Y= Output. D1136 Position AX(HY) D1137 Position AT(HT) D1138 D1139 D1140 Ref Step No. D1141 Layer No. - 1 D1142 Product No. - 1 D1143 Ref Coordinates D1144...
Page 382 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 lower X= Input Reference or upper Y= Output. D1504 Line 4 Fault D1505 Universal Fault D1506 L1 Height Data D1507 L2 Height Data D1540 Start Timer Value D1700 Current Speed D1701 New Speed D1702...
Page 383 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 lower X= Input Reference or upper Y= Output. D6003 Date (Year,Month) <BCD>U8bit- Year(L2digit) L8bit- Month D6004 Date, Time (Day,Hour) <BCD>U8bit-Day L8bit-Time D6005 Time (Min,Sec) <BCD>U8bit-Min L8bit-Sec D6006 Normal OKURA CONTROLLER status 0:stop 1:run 2:error D6007 Normal OKURA CONTROLLER 1sec counter...
Page 384 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 lower X= Input Reference or upper Y= Output. D6042 Pallet 4 current lay No D6043 Pallet 4 current work No D6044 Pallet 4 work size (L) [mm] D6045 Pallet 4 work size (W) [mm] D6046 Pallet 4 work size (H)
Page 385 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 lower X= Input Reference or upper Y= Output. D6086 Number of stacking pieces 3 D6087 Number of stacking pieces 4 D6088 Number of stacking pieces 5 D6089 Number of stacking pieces 6 D6090 Stack pattern pallet 1 1:BAR,2:INTRK,3:SPC...
Page 386: M Bits
M BITS D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 X= Input Reference lower or upper Y= Output. M0000 CN resetCmd M0001 Zero ResCmd1 M0002 Zero ResCmd2 M0003 Zero ResCmd3 M0004 Zero ResCmd4 M0005 Zero ResCmd5 M0006 Zero ResCmd6 M0007 Disch Pal1 Cmd...
Page 387 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 X= Input Reference lower or upper Y= Output. M0031 M0032 M0033 M0034 M0035 No Use M0036 No Use M0037 No Use M0038 No Use M0039 No Use M003A No Use M003B No Use M003C...
Page 388 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 X= Input Reference lower or upper Y= Output. M0206 CV Manu7 M0207 CV Manu8 M0208 CV Manu9 M0209 CV Manu10 M020A CV Manu11 M020B CV Manu12 M020C CV Manu13 M020D CV Manu14 M020E CV Manu15...
Page 389 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 X= Input Reference lower or upper Y= Output. M0411 Sheet required M0412- M041F M0420 Sht pgrm 122 M0421- M042E M0430 Sht pgrm 123 M0431- M043F M0440 Prgm 0 M0441 Prgm 0-90-0 M0442 Prgm Park M0443- M044F...
Page 390 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 X= Input Reference lower or upper Y= Output. M723 Sheet Not Detected R2026 M724 "Missed Sheet" Acknowledgement R1032 M726 Sheet Placed Line 2 R2066 M727 Sheet Ready Table 1 R1035 M728 Sheet Ready Table 2 M0729- M0730...
Page 391 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 X= Input Reference lower or upper Y= Output. M0798 Send sling stck M0799 Bag in chute M079A PLS end stack1 M079B PLS Bag @ BS CV M079C Lift up enable M079D Retainrs open EN M079E...
Page 392 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 X= Input Reference lower or upper Y= Output. M5028 Hand 4 M5029 Hand 5 M502A Hand 6 M502B Hand 7 M502C Hand 8 M502D Hand 9 M502E Pallet 1 counter setting M502F Pallet 2 counter setting M5030...
Page 393 D= Word Termination Detail M= Bit A1600 I Description Terminal,Block,RC102 X= Input Reference lower or upper Y= Output. M601C Spare M601D First article 1 M601E First article 2 M601F First article 3 M6020 First article 4 M6021 First article 5 M6022 First article 6 M6023...
Page 394: Inputs
X INPUTS RC102 LOWER BOARD INPUTS +24 VDC (Both Boards) TB1, 1,11,21 TB2, 1,11 TB3, 1,11,17,27,33 TB1, 2,12,22 -24 VDC TB2, 2,12 TB3, 2,12,18,28,34 TB1, 3, Lower PC-101 LINE1 READY FOR PICK PC-102,LINE 1 PRODUCT,@ BELT TB1, 4, Lower PC-131,LINE 1 PALLET IN,STACKING TB1, 5, Lower POSIITON PC-132,LINE 1 PRODUCT,ON PALLET...
Page 395 PC-103,LINE 1 UPSTREAM CONVEYOR # 1 TB3, 13, Lower PC-104, LINE 1 UPSTREAM CONVEYOR # 2 TB3, 14, Lower PC-105,LINE 1 BAG SHAPING CONVEYOR TB3, 15, Lower PC-105A, LINE 1 BAG IN CHUTE TB3, 16, Lower HRS1 - HAND REED SWITCH, FINGERS OPEN R1045 CN1, 4, Lower HRS2 - HAND REED SWITCH, PALMS OPEN...
Page 396 TB3, 10 ,Upper TB3, 13 ,Upper DISCHARGE SAFETY TB3, 14 ,Upper TRAPPED KEY STATUS TB3, 15 ,Upper CLS HAND SPARE TB3, 16 ,Upper S6 HAND SPARE CN1, 4 ,Upper S7 HAND SPARE CN1, 5 ,Upper S8 HAND SPARE CN1, 6 ,Upper S9 HAND T-AXIS OUT OF LEVEL CN1, 7 ,Upper Electrical...
Page 397: Y Outputs
Y OUTPUTS RC102 LOWER BOARD OUTPUTS MS-101 STATION CONVEYOR (RUN) TB2, 3, Lower MS-101 STATION CONVEYOR (SPD1) TB2, 4, Lower TB2, 5, Lower MS-102 BELT CONVEYOR TB2, 6, Lower TB2, 7, Lower TB2, 8, Lower MS-201 STATION CONVEYOR (RUN) TB2, 9, Lower MS-201 STATION CONVEYOR (SPD1) TB2, 10, Lower MS-202 LINE 2 BELT INFEED CONVEYOR...
Page 398 MS-105 LINE 1 BAG SHAPING CONVEYOR TB2, 5, Upper MS-106 LINE 1 UPSTREAM CONVEYOR # 3 TB2, 6, Upper MS-107 LINE 1 UPSTREAM CONVEYOR # 4 TB2, 7, Upper MS-108 LINE 1 UPSTREAM CONVEYOR # 5 TB2, 8, Upper MS-203 LINE 2 UPSTREAM CONVEYOR # 1 TB2, 9, Upper MS-204 LINE 2 UPSTREAM CONVEYOR # 2 TB2, 10, Upper...
Page 399: I/O For Hand
I/O for Hand I/O signals for hand will be connected to CN 33 and CN36 in T-axis connector box. The standard wiring diagram below is only a representative. Please refer to your electrical prints for up to date wiring. CN33 CN36 Electrical...
Page 400: Emergency Stop Connections
Emergency Stop Connections Input signals for emergency safety stops are connected to 3 terminals in the controller. The OKURA CONTROLLER signals an emergency stop to the robot, when sensor is turned on on condition that memory switch 2-4 is OFF. -After sensor is turned on, it can return by abnormal release button.
Page 401 Electrical...
Page 402: Electrical Drawings
ELECTRICAL DRAWINGS Electrical...
Page 403 Electrical...
Page 404: A700 Internal (Inside Panel) Cable Drawings
A700 Internal (Inside Panel) Cable Drawings Electrical...
Page 437 Electrical...
Page 438: A1600 Internal (Inside Panel) Cable Drawings
A1600 Internal (Inside Panel) Cable Drawings Electrical...
Page 472 Electrical...
Page 473: A700 External (On Robot Arm And Outside Panel) Cable Drawings
A700 External (On Robot Arm and outside Panel) Cable Drawings Electrical...
Page 499 Electrical...
Page 500: A1600 External (On Robot Arm And Outside Panel) Cable Drawings
A1600 External (On Robot Arm and outside Panel) Cable Drawings Electrical...
Page 527 Electrical...
Page 528 Robot manual Electrical <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Columbia/Okura, LLC. 301 Grove St Vancouver, Washington 98661 360.735.1952 Electrical...
Page 529 Robot Manual Installation Installation...
Page 530 Transport Method-A1600 ______________________________________ 7 Foundation Requirements ______________________________________ 9 Protection against lightning strikes _____________________________ 11 Grounding Equipment ________________________________________ 12 Factory Set Procedures __________________________________13 Limiting Devices- R,D, & O ____________________________________ 14 R-axis mechanical stop Adjustment _____________________________ 16 A700 Optional Range_________________________________________ 18 Installation...
Page 531: System Installation
SYSTEM INSTALLATION Installation...
Page 532: System Installation Checklist
System Installation Checklist Please have the following items available during the scheduled installation time: • 4000lb capacity fork lift • Hammer drill • 3/4” masonry drill bit • Power drill • 15/16” deep socket with extension • Portable welder for welding washers to base extension •...
Page 533 • Drill holes ¾” dia. X 5 1/8” deep in concrete for each hole in the base plate. Typically there are 12 holes for an A1600 and 8 holes for an A700. • Clean holes thoroughly using a vacuum cleaner to remove any concrete powder.
Page 534: Robot Base Dimensions
Robot Base Dimensions [All types] 8-∅22 10° 10° ∅850 4-M20 □ 750 Installation...
Page 535: Transport Method-A1600
There are a total of (3) hoisting bolts, (2) on the left side and (1) on the right. They are each rated for 625kg(1377lb). The robot should be set to the following coordinates before it is lifted: D-axis: 0° A700 O-axis:140° Important! Remove the hoist bolts after installation and before robot operation begins.
Page 536 Strapping Eyebolts are not used to lift robot: Eyebolts can be found at both sides of rotor which are bolted in one of the following 3 patterns as shown below. There are extra eyebolts shown in the photos for descriptive purposes only. Use the eyebolts circled in green to lift the robot.
Page 537: Foundation Requirements
Foundation Requirements Strength and Rigidity During operation the robot repeatedly applies loads to the robot base and base foundation. The following standard values for bending moment (M) and torsional stress (T) are shown in the diagram below. A1600 [Strength] The stand must withstand the following repetitive load.
Page 538 A700 [Strength] The stand must withstand the following repetitive load. M =±7500 Nm (5532 Ft.-lb) T =±6000 Nm (4425 Ft.-lb) [Rigidity] Sufficient rigidity is required to avoid vibration during robot motion. Recommended values are 3.9x10 Nm/rad (2.9x10 Ft.-lb/rad.) 3.9x10 Nm/rad (2.9x10 Ft.-lb/rad.)
Page 539: Protection Against Lightning Strikes
Protection against lightning strikes There is no protection against lightning strikes inside of controller. Most applications will use a transformer for power isolation, however, adequate protection against lightning shall be the customers sole responsibility when connecting the main power supply. Installation...
Page 540: Grounding Equipment
Grounding Equipment Grounding the robot panel and arm are mandatory to prevent Electromagnetic Field issues. Verify the ground wire connection between the robot body and the conductor shielding inside controller. Wire: UL standard Wire size : #4 or larger Color : green/yellow Measure the resistance between each motor frame and the shielding inside the controller.
Page 541: Factory Set Procedures
The following procedures are included only as reference. They are used in very few applications and are preset by Columbia/Okura as part of a palletizer's assembly process. These procedures are not to be installed by customers unless instructed by authorized Columbia/Okura personnel.
Page 542: Limiting Devices- R,D, & O
D,O-axis fixed adjustable (*)Only a limit switch is used when rotation is more than 250°. The mechanical stoppers are not used. A1600/A700 R-Axis Stop R-axis: Inside the base Mechanical stoppers Limit switch Part Number 8069 (Includes 2) Installation...
Page 543 A1600 D & O Stops O-axis: Inside the rotor D-axis: Inside the rotor Part Number Part Number 8075 (Includes 2) 8050 (Includes 2) A700 D & O Stops O-axis: Inside the rotor and D-axis: Inside the rotor on the lower arm. Installation...
Page 544: R-Axis Mechanical Stop Adjustment
R-axis mechanical stop Adjustment Each mechanical stopper requires (2) M10x40L shoulder bolts. The bolts are not required to clamp the stopper firmly in position but are there only to prevent the stopper from rubbing on the A,B,C,D,E,F,G,H internal casting. The bolt installation positions are shown in the table below.
Page 545 Bolts Installation Position Bolts Installation Position +100 -100 +105 -105 +110 -110 +115 -115 +120 -120 +125 -125 +130 -130 D, O-axis The limit switch is mounted to a slotted bracket which allows the contact position to be adjusted. Installation...
Page 546: A700 Optional Range
A700 Optional Range This optional stopper allows the A700 operational envelope to be changed to a reduced range. With optional Without optional stopper 2300mm 1900mm Stopper 1318mm 1750mm Figure 1: A700 operation range Eye-bolt Remove the Eye-bolt. Installation...
Page 547 Using the existing eye bolt mounting hole, place optional stopper shown. Tighten screws and verify operation. Optional stopper Installation...
Page 548 Robot manual Installation <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Columbia/Okura, LLC. 301 Grove St Vancouver, Washington 98661 360.735.1952 Installation...
Page 595 Robot Training Manual, Rev. 5 10-1 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 596 Columbia/Okura LLC is jointly owned by two industry leading material handling companies, Columbia Machine of Vancouver, WA, and Okura Yusoki or Kakogawa, Japan. Columbia/Okura LLC puts over 20 years of robotic palletizing expertise and over 100 years of combined materials handling experience into each and every machine we produce.
Page 597 The following table decribes the training currently available with Columbia/Okura. The hours below are for dedicated training without interruption. A robot must be available full time for training. Instruction taking place on site at Columbia/Okura uses a demonstration robot, end effector, and conveyor.
Page 598 Thorough explanation of pattern program sequence • Thorough explanation of pattern program step parameters, accelerations, and speeds. Robot Training Manual, Rev. 5 10-4 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 599 -----------------------------ELECTRICAL LAYOUT--------------------------------- --------------------------------------ROBOT OPERATION------------------------------------ Technical Training Manual FORKLIFT OPERATOR ------------------------------------------SYSTEM OPERATION----------------------------------------- -----------------------------------------------PHYSICAL LAYOUT------------------------------------------------ BY STANDER ---------------------------------------------------------SAFETY---------------------------------------------------------------- Robot Training Manual, Rev. 5 10-5 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 600 HOW TO MOVE THE CONVEYORS IF THERE IS PROBLEM • MOVING A PALLET OUT OF THE DISCHARGE PHOTOEYES • Basic Basic Operation Operation Robot Training Manual, Rev. 5 10-6 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 601 • TURN STATIONS ON AND OFF • EJECT PARTIAL PALLETS • CLEAR JAMS AND ADJUST COUNTERS Basic Basic Operation Operation Robot Training Manual, Rev. 5 10-7 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 602 PREVENTITIVE MAINTENANCE LUBRICATION POINTS MAINTENANCE PROBLEMS WITH END EFFECTOR WHICH THINGS LOOSEN UP Basic Basic Maintenance Maintenance Robot Training Manual, Rev. 5 10-8 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 603 Relay identification • Brake Power Circuit • Terminal connections. • Start / Stop Circuit Extended Extended Robot Training Manual, Rev. 5 10-9 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 604 PATTERN PROGRAMMING USING THE MANUAL • Operation Cards • A700 /A1600 Manual “Pattern Programming” Technical Training Manual • ROBOT PROGRAMMING BASICS Service Support CD (PARAMETERS,SEQUENCE,STEPS) DIY CD • ROBOT COORDINATE SITEMAPS (PULSES, ARM, HAND, PALLET) • THE DIFFERENCE BETWEEN CP AND PTP MOVEMENT PATTERN PROGRAMMING USING DIY •...
Page 605 HIGH LEVEL COMMUNICATION FROM THE PLC TO THE ROBOT IS PRIMARILY ERROR MESSAGES • Strobing programs and discrete handshaking • Fault logic • Conveyor logic • Conveyor reset Robot Training Manual, Rev. 5 10-11 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 606 Reference Material: – RIA/ANSI 15.06 – Columbia/Okura Safety Manual Discussion Topics: – Carry the “Trap Key” Feedback: – Name the major restrictive controls of the robot – Name who has control over the major restrictive controls of the robot – Demonstrate that all emergency stop inputs work Robot Training Manual, Rev.
Page 607 AIR LOCKOUT/TAGOUT DISCHARGE EXIT PROTECTION DOOR SWITCH and/or TRAP KEY MOTOR POWER KEYSWITCH and/or TRAP KEY Robot Training Manual, Rev. 5 10-13 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 608 – Name the major components of a Robotic Palletizer – Name the location and quantity used in your system Robot Training Manual, Rev. 5 10-14 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 609 END EFFECTOR PERIMETER (GRIPPER OR HAND OR HEAD OR CLAW) GUARDING DISCHARGE CONVEYOR (FULL LOAD PICKUP) Robot Training Manual, Rev. 5 10-15 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 610 OR PRESS BACK 1. CHANGING PROGRAMS 2. CHANGING COUNT 3. PALLET DISCHARGE ERROR SCREEN WARNING SCREEN Robot Training Manual, Rev. 5 10-16 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 611 THE PLC IS NOT IN RUN OR REM MODE. PATTERN DATA IS LOST AND HAS NOT BEEN BACKED UP BY CUSTOMER. Robot Training Manual, Rev. 5 10-17 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 612 Motor Position and Speed RC103 Servo Motor DIY SOFT PAK ON PC Servo Motor Servo Motor Servo Motor Robot Training Manual, Rev. 5 10-18 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 613 EMERGENCY STOP CIRCUIT SERVO ENABLE LIMIT SHORT (ARM OUT OF RANGE LIMIT SWITCHES) PENDANT IS PLUGGED IN Robot Training Manual, Rev. 5 10-19 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 614 (Cartesian-Hx, Hy, Hz in mm. Ht in degrees) 5. Pallet β (Cartesian-Px, Py, Pz in mm. P in degrees) Robot Training Manual, Rev. 5 10-20 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 615 +Py=? -Py=? +Px=? AZ, HZ is measured from the bottom of the robot base casting upwards. Robot Training Manual, Rev. 5 10-21 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 616 - Up (+) and Down (-) Reverse Forward - In (-) and Out (+) - Twist CCW+ Robot Training Manual, Rev. 5 10-22 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 617 Parameters (Speed, Acl, Dcl, Cp/Ptp) Auxillary Data (Drop from above, data 1,2) Position (Position of product at any step) Robot Training Manual, Rev. 5 10-23 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 618 GO TO 200mm IN PY DIRECTION MOVE AT SPEED 5 AND ACCEL AT 4 ON STEP 4 Robot Training Manual, Rev. 5 10-24 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 619 3. Step 6 can be aligned below Step 5 or above Step 7. This is optionally selected from the Program Parameters Menu. Robot Training Manual, Rev. 5 10-25 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 620 Pallet Coordinates. D2y and D2x are spaced away from Step 7 in relation to the approach direction. Robot Training Manual, Rev. 5 10-26 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 621 Front Front Robot Envelope Robot Cables Robot Training Manual, Rev. 5 10-27 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 622 Right Left HY=? Right Left Rear Front Pallet Stops, front and left Product Stop Robot Cables Robot Training Manual, Rev. 5 10-28 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 623 Robot Envelope +180 Fixed Stop on Station Conveyor (Shown in 4 different locations) +135 Robot Cables Robot Training Manual, Rev. 5 10-29 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 624 Fixed Stop on Station Conveyor (Shown in 4 different locations) Station Conveyor +180 Angle Reference Robot Envelope Robot Cables Robot Training Manual, Rev. 5 10-30 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 625 This is an example only and may be different than your application. Robot Training Manual, Rev. 5 10-31 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 626 The hand coordinate origin is the same for every pattern and Robot Cables pallet location on every robot. Robot Training Manual, Rev. 5 10-32 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 627 A700/A1600 Manual “Pattern Programming” section Example-Moving a case position to one side Example-Moving the drop height of a case. Trainee should perform examples to re-enforce learning retention. Robot Training Manual, Rev. 5 10-33 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 ©...
Page 628 “T” axis pivot. -500 PZ= +2300 PZ= +1800 -500 Robot Training Manual, Rev. 5 10-34 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 629 PX=+600 origin at a different New position location, but this is the most common. Robot Training Manual, Rev. 5 10-35 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 630 Big Product overhang overhang value used value used Big-Small Limit OHL Value Overhang Ratio (1/X) * Product Width Robot Training Manual, Rev. 5 10-36 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 631 Acl Time Acl Time Min. Setting Min. Setting Spd = 10 Spd = 10 Auto Auto Robot Training Manual, Rev. 5 10-37 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 632 Palm Height (F) Palm/Pallet gap (I) Palm/CV top Length Closed Width Open Width (B) Station Pallet Robot Training Manual, Rev. 5 10-38 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 633 (I) Palm/CV top First Closed Width Finger(A) = 17mm Open Width (B) Station (A)-34mm Pallet Length Robot Training Manual, Rev. 5 10-39 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 634 Cup Length Set to 0 Length Palm/Pallet gap (I) Set to 0 Open Width Station Pallet Robot Training Manual, Rev. 5 10-40 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 635 End Effector Offsets Robot Training Manual, Rev. 5 10-41 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 636 (Pallet Width) Pallet width (PW) is always determined by the forklift direction into the pallet Robot Training Manual, Rev. 5 10-42 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 637 Stopper Direction Pallet 3-Left Pallet 2-Right Pallet 1-Bottom Pallet 1-Top Laptop Robot Training Manual, Rev. 5 10-43 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 638 D1001 Clearance =150mm Clearance =150mm D1010 D1010 Sheet Stack Pallet Set height of clearance if needed. Robot Training Manual, Rev. 5 10-44 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 © 2005, Columbia/Okura, LLC.
Page 639 Repeat Training Class The A700/A1600 Manual Custom Integration Manual Which Includes: – Description of Operation – Layouts Electrical Wiring Diagrams PLC program printout Columbia/Okura, LLC. Service 360-735-1952 www.columbiaokura.com Robot Training Manual, Rev. 5 10-45 Your Highest Valued Supplier of Robotic Material Handling Solutions PRINTED ON 8/22/2005, Version 4 ©...

This manual is also suitable for:

A400iii A series A1200iii A1600-w A1600

Columbia/Okura A700 User And Maintenance Manual

Table of Contents

Introduction

Warning Labels

Guarding Types

Safety Precautions

Brake Release Procedure

Entering Perimeter Guarding

Typical Minimum Lockout/Tagout System

Conclusion

Table of Contents

Controller

Cables

PC Boards

Peripheral Equipment Control

Electrical Drawings

Robot Manual

Quick Links

Chapters

Summary of Contents for Columbia/Okura A700

This manual is also suitable for:

Table of Contents