Opex Perfect Pick HD User Manual
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Opex Perfect Pick HD User Manual

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April 27, 2018
Perfect Pick HD User Manual
Document Revision 18-01
Original Language Instructions
®
© 2017, 2018 OPEX
Corporation
All rights reserved. This document is provided by OPEX for use by their customers, partners and dealers. No portion
of these materials may be reproduced, published, or stored in a database or retrieval system, other than for its in-
tended use without the express, written consent of OPEX Corporation.

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Summary of Contents for Opex Perfect Pick HD

  • Page 1 Corporation All rights reserved. This document is provided by OPEX for use by their customers, partners and dealers. No portion of these materials may be reproduced, published, or stored in a database or retrieval system, other than for its in-...
  • Page 2 Draft Release, Rev 2 18-01 April 27, 2017 Initial Release If you find errors, inaccuracies, or any other issues or concerns with this document, please contact the OPEX Technical Writers via email at: GroupTechwriters@opex.com Perfect Pick HD User Manual - OPEX Corporation...

  • Page 3: Table Of Contents

    Chapter 3 Operation Overview ....................... 34 Starting up the system .................. 34 Navigating the Host software ..............36 Continuous mode ..................40 Replenish mode .................... 49 Zeros ......................53 Table of Contents Perfect Pick HD User Manual - OPEX Corporation...
  • Page 4 Specifications: ................. 62 Wireless Transceiver ..................64 FCC information / informations FCC ............64 Industry Canada information / Industrie Canada l'information ....65 Contacting OPEX Service ................66 Table of Contents Perfect Pick HD User Manual - OPEX Corporation...
  • Page 5 Ergonomics ........23 Perfect Pick HD User Manual...

  • Page 6: Safety

    About this manual The information provided in this chapter is intended to educate you on various safety issues regarding the operation and maintenance of the OPEX equipment described in this manual. This chapter provides an explanation of the safety conventions used throughout this manual, as well as safety guidelines to be observed when working with this equipment.

  • Page 7: Safety Guidelines

    Gardez les objets lâches à l'écart des parties exposées et mobiles de la machine - Les parties mobiles du Perfect Pick HD, telles que le convoyeur, peuvent être bloquées et / ou endommagées par des objets étrangers. Gardez les mains, les cheveux, les vêtements lâches et les bijoux loin des pièces mobiles.
  • Page 8 - This equipment is not suitable for use in locations where children are likely to be present. Tenir à l'écart des enfants - Cet équipement ne convient pas aux endroits où les enfants sont susceptibles d'être présents. Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 9: Safety Labels

    Safety labels CAUTION: Follow the safety precautions on all labels to avoid injury when operating the Perfect Pick HD. Failure to follow these CAUTION precautions may result in severe personal injury or damage to the machine. Machine Entry Only approved OPEX technicians and qualified personnel can enter the machine.
  • Page 10 The “WARNING Arc Flash and Shock Hazard” label is found on the front of the Main Power Enclosure Figure 2: Main Power Enclosure - Warning label Safety Perfect Pick HD User Manual - OPEX Corporation...
  • Page 11 Climbing the structure Do not climb on any part of the Perfect Pick HD (see Figure 3). CAUTION DO NOT CLIMB STRUCTURE The “DO NOT CLIMB STRUCTURE” label is found on the exposed ends of every other ladder, above CUIDADO where the exterior cover ends.
  • Page 12 Do not operate or ride in either of these machines unless you have taken the corresponding training course. Only approved OPEX technicians and qualified personnel are authorized to use the scissor lifts and iBOT recovery tools. Figure 4: Scissor Lift...
  • Page 13 Keep hands and loose objects away from any exposed, moving parts of the machine (see label in Figure 5). The moving parts of the Perfect Pick HD can become jammed and/or damaged by foreign objects. Also, keep hair, loose clothing or jewelry away from the moving parts.
  • Page 14 Figure 6: Charging Rails iBOT safety The iBOT (Figure 7) was designed to carry loads of up to 80 pounds. In order to function properly, the iBOT incorporates automated Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 15: Other Cautions

    CAUTION: The ultra-capacitors that power the iBOTs contain acetoni- trile. In the event that an ultra-capacitor should leak, avoid contact with CAUTION or breathing the acetonitrile. For information on ultra-capacitor safety, refer to “Ultra-capacitor Product Information” on page Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 16: Ultra-Capacitor Product Information

    3KRQH     )D[       6KDQJKDL  35 &KLQD )D[     3KRQH     LQIR#PD[ZHOOFRP ± ZZZPD[ZHOOFRP )D[     Document #1004596.4 Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 17: Emergency Stop (E-Stop) Buttons

    WARNING: Emergency stop switches do not remove power from all electrical devices within the Perfect Pick HD. Power to main enclosure components, UPS, computers and other devices remains energized after the E-Stop switch is pushed.
  • Page 18 • To restart the machine, clear the machine (if needed), pull the E-Stop knob out, and press the green Start button. Start button E-Stop Switch Figure 9: Main power enclosure E-stop Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 19: Safety Interlocks

    Entering the machine while it is running can pose a safety hazard due to the rapidly-moving iBOTs. For your safety, interlocks have been installed on the front and rear break-away panels (Figure 10) of the Perfect Pick HD machine. The interlocks will stop the machine whenever a break-away panel is opened.

  • Page 20: Light Curtain

    The light curtain is a sensor used to stop just the iBOTs in the pick station area, should you have your hands in the iBOT travel areas when the iBOTs are in motion (Figure 11). Light Curtain sensor Figure 11: Light curtain sensor Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 21: Clear-To-Pick Indicators

    When illuminated, the light indicates when it is safe for the user to pick an item from the presented tote (Figure 12). Clear-to-Pick light Figure 12: Pick station Clear-to-Pick indicator light Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 22: Light Tower

    Once the technician determines that the machine is operating properly, he/she will turn off the flashing blue light by exiting out of Maintenance mode, leaving only the solid green light. Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 23: Ergonomics

    • Maintain an upright body posture. • Occasionally change the angle of your posture for greater comfort. • Avoid operating the machine for longer than a single 10-hour shift. If possible, stretch between breaks. Safety Perfect Pick HD User Manual - OPEX Corporation...
  • Page 24 Safety Perfect Pick HD User Manual - OPEX Corporation...

  • Page 25: Introduction

    Overview ........26 Main Components ......27 Perfect Pick HD User Manual...

  • Page 26: Overview

    A software application that controls the real-time activities and tracks inventory movements. Inventory Control System (ICS) This term is used to describe the software, such as CORTEX, that provides both the Warehouse Management System and the Warehouse Control System. Introduction Perfect Pick HD User Manual - OPEX Corporation...

  • Page 27: Main Components

    Main Components Figure 14 identifies the main components of the Perfect Pick HD. Figure 15 shows details of the Pick Station. Storage locations (both sides of the machine) Pick station Tote iBOT Figure 14: Perfect Pick HD main components Introduction...
  • Page 28 Host monitor Cortex monitor iBOT with tote Break-Away panel Workstation Clear To Pick light (partially shown) Start button E-Stop switch Pick Station controls Put Away Complete light Figure 15: Pick Station detail Introduction Perfect Pick HD User Manual - OPEX Corporation...
  • Page 29 - Totes are stored two deep on both the left and right sides of the machine (the number of tote locations varies with height and load size). The Perfect Pick HD can be expanded over time by adding racking modules and/or additional iBOTs.
  • Page 30 - Overflowing contents, which could spill or collide with the Perfect Pick HD frame, iBOTs, or the storage columns. - Tote walls bulging from being overstuffed. This can cause totes to get stuck when placed in the outside column positions. Introduction Perfect Pick HD User Manual - OPEX Corporation...
  • Page 31 Figure 18: Optional Bin Locator Light Introduction Perfect Pick HD User Manual - OPEX Corporation...
  • Page 32 Introduction Perfect Pick HD User Manual - OPEX Corporation...

  • Page 33: Operation

    Replenish mode ......49 The OPEX Integrated Workstation ....57 How to park the iBOTs .

  • Page 34: Overview

    “Replenish mode” on page 49. Starting up the system The Perfect Pick HD Host PC will launch the Host software as part of the system’s start-up routine. If you mistakenly close the Host software, or if the Host software does not start with the machine, you can start it manually.
  • Page 35 2. The Login screen will appear (Figure 20). Select a Username from the drop- down list. Figure 20: Login screen 3. If required, enter the password for the selected Username. 4. Click Login. Operation Perfect Pick HD User Manual - OPEX Corporation...

  • Page 36: Navigating The Host Software

    Figure 21: Main window Navigating the Host software The Perfect Pick HD Host software provides the main interface with the system’s controls. Used primarily by the OPEX technician (or qualified personnel), the Host software is used to select and run jobs, remove/insert iBOTs, run diagnostic tests, and view statistical reports on the machine.
  • Page 37 Figure 22: Host software interface 5. Click the Run button found in the Menu bar. The Run screen opens. The run screen offers several tabs for viewing different elements of the machine and Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 38 Figure 23: Run Screen - iBOTs tab 6. On this screen, buttons are available for conserving iBOT power, and parking the iBOTs. For more on parking the iBOTs, go to page 58. Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 39 7. On the top of the screen, click START (Figure 24). Figure 24: Start button location 8. If you need to run the Perfect Pick HD in Replenish mode, go to “Replenish mode” on page 49. If you plan to run in the normal mode, go to “Continuous mode”...

  • Page 40: Continuous Mode

    In normal operations, you will primarily use this mode. 1. Start up the Perfect Pick HD system, as described in “Starting up the system” on page 34. When you start up the Perfect Pick HD system, it auto- matically starts the Cortex system, and displays the Welcome screen (Figure 25).
  • Page 41 2. Log in to the software, and select Auto mode (Figure 26). Figure 26: Auto Mode 3. Press the green Start button at the Pick Station (Figure 27). Start button Figure 27: Start button Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 42 (Item detail), a photo of the item, how many of the items need to picked (Quantity), and the location of the item within the tote (Tote Location). An iBOT could present one large tote, or a compartmentalized tote. Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 43 Item image Figure 29: Cortex Run screen - detail 6. To the right of the Perfect Pick HD is the OPEX Workstation - a conveyor with containers (for more details on the OPEX Workstation, see “The OPEX Integrated Workstation” on page 57). As the containers advance toward the...
  • Page 44 QC monitoring, or to have the items packaged for shipping. The other Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 45 Labeler Light bar Figure 31: Light Bar Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 46 (the labeler is shown in Figure 31). 9. Figure 33 shows an example where 32 items are needed for the first container, and one is needed for the second container. These quantities are Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 47 In this example, the blue button. The monitor then points to the next container that needs the item . Once that is filled, push that container’s colored button on the light bar. Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 48 QC monitoring, or to have the items boxed for shipping. The OPEX Cortex Inventory Control System will provide information as to when the job is finished. Operation...

  • Page 49: Replenish Mode

    Replenish mode is used for restocking inventory. 1. Start up the Perfect Pick HD system, as described in “Starting up the system” on page 34. When you start up the Perfect Pick HD system, it auto- matically starts the Cortex system, and displays the Welcome screen (Figure 35).
  • Page 50 2. Log in to the software, and select Auto mode (Figure 36). Figure 36: Auto Mode 3. The monitor displays the run screen (Figure 37) and the iBOTs will move, in preparation for the job. Figure 37: Run Screen Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 51 Figure 38: Start button 5. The job starts, and the screen now shows the number of items to be replenished (Figure 39), and the location in the tote where to place the Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 52 NOTICE: When running in Replenish mode, you should never restock a tote with items piled higher than the top of the tote. Overfilling the tote will likely cause jams in the machine. Operation Perfect Pick HD User Manual - OPEX Corporation...

  • Page 53: Zeros

    1. Perform steps 1 to 3 as described in “Replenish mode” on page 49. 2. Click the Current menu tab, then press the Make Adjustment button (Figure 41). Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 54 Figure 41: Current > Make adjustment 3. Use the Up/Down Arrow buttons to adjust the quantity in the tote (Figure 42). Figure 42: Adjust Quantity Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 55 4. When the correct quantity is displayed, click Confirm. 5. The screen adjusts to the newly-entered amount. If this amount is correct, click the container (Figure 43). Figure 43: Confirm Amount Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 56 Click Dismiss. Figure 44: Printing message 7. (Depending on how your system is set up), Clicking Dismiss prints a confir- mation page. Operation Perfect Pick HD User Manual - OPEX Corporation...

  • Page 57: The Opex Integrated Workstation

    Once the operator completes an order, the container is transferred for final shipment and another order indexes forward on the workstation’s conveyor. The OPEX Workstation is closely integrated with the Perfect Pick HD’s hardware and software systems, reducing latencies and optimizing overall system performance.

  • Page 58: How To Park The Ibots

    OPEX technician or authorized personnel. These instructions are provided for informational purposes only. 1. At the Perfect Pick HD controls, click the Diagnostics button to display the Diagnostics screen (see Figure 46). Note: If you are on the Run Screen, clicking the iBOTs tab will also display the following information.
  • Page 59 Power button in Diagnostics makes the iBOTs stop sending constant status updates to the machine to save energy. Operation Perfect Pick HD User Manual - OPEX Corporation...
  • Page 60 Operation Perfect Pick HD User Manual - OPEX Corporation...

  • Page 61: Specifications

    Wireless Transceiver......64 Contacting OPEX Service ..... . . 66...

  • Page 62: Specifications

    Up to 1,000 dual cycles per hour Up to 146,400 unique storage locations Up to 26,400 cubic feet of dense storage Performance Up to 12,200 totes * all within a single aisle of Perfect Pick HD Specifications Perfect Pick HD User Manual - OPEX Corporation...
  • Page 63 1 position Short dividers (up to 3 per tote) - 5 available positions Figure 47: Tote dividers (drawing not to scale) Specifications Perfect Pick HD User Manual - OPEX Corporation...

  • Page 64: Wireless Transceiver

    Servicing of the transceiver is limited to properly trained OPEX technicians. No end-user servicing is permitted. Changes or modifications not expressly approved by OPEX Corporation could void the user’s authority to operate the equipment. Module cannot be co-located with other antenna or transmitter except as specified in the grant condition of equipment authorization;...

  • Page 65: Industry Canada Information / Industrie Canada L'information

    à une formation adéquate des techniciens OPEX. Pas de service de l'utilisateur final est autorisé. Les changements ou modifications non expressément approuvés par OPEX Corporation pourraient annuler l'autorité de l'utilisateur à utiliser l'équipement. Module ne peut pas être co-localisé avec autre antenne ou émetteur, sauf comme indiqué...

  • Page 66: Contacting Opex Service

    IC : 7175A-2048910 Model 2048910 (Earlier Version/Version Précédente) IC : 7175A-2054710 Model 2054710 (Current Version/Version Actuelle) Contacting OPEX Service OPEX Technical Support can be reached at: 1-800-673-9288 856-727-1950 OPEX Technical Support 835 Lancer Drive Moorestown, NJ 08057 Specifications Perfect Pick HD User Manual - OPEX Corporation...

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