Table of Contents
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Chapters
Table of Contents
Related Manuals for Columbia/Okura A1600
Summarization of Contents
Safety
WARNING TO ALL PLANT PERSONNEL
Crucial safety warnings for plant personnel regarding machine operation and hazards.
SAFETY PRECAUTIONS
General guidelines for working with palletizing equipment to prevent accidents.
Precautions Before Use
Steps to ensure safe operation before the robot is put into use.
Precautions Before Daily Operation
Pre-operation checks before powering on the main system.
Precautions when the Main Breaker is turned ON
Checks to perform after turning on the main power breaker.
Precautions Before Automatic Operation
Essential checks and procedures before initiating automatic operation.
Precautions During Automatic Operation
Guidelines for safe operation while the robot is running automatically.
Precautions During Programming
Safety measures to follow when programming the robot's movements.
Precautions During Maintenance
Safety procedures to observe when performing maintenance on the robot.
Precautions for the INFEED ASSEMBLY
Specific safety measures for the infeed assembly area.
Precautions for the PALLET DISPENSER
Safety measures related to the operation of the pallet dispenser.
Precautions for the SHEET DISPENSER
Safety measures for the sheet dispenser operation.
Precautions for Emergency Stop Situations
Procedures for responding to and using emergency stop functions.
Precautions for handling Abnormalities
Guidelines for safely addressing system abnormalities or unexpected behavior.
BRAKE RELEASE PROCEDURE
Procedure to manually move robot arm without motor power using motor brake release.
ENTERING PERIMETER GUARDING
Procedures for safely entering the robot's perimeter guarding area.
TYPICAL MINIMUM LOCKOUT/TAGOUT SYSTEM
Outlines the general purpose and responsibility for lockout/tagout procedures.
Specifications
General Specifications
Provides an overview of the robot's general technical specifications.
Model A1600 Specifications
Detailed technical specifications for the A1600 robot model.
Model A700 Specifications
Detailed technical specifications for the A700 robot model.
Electrical Specifications
Lists electrical requirements, including power supply and dimensions.
A1600 Operation Envelope
Visual representation of the A1600 robot's movement range and dimensions.
A700 Operation Envelope
Visual representation of the A700 robot's movement range and dimensions.
Capacity Restraints
Explains factors affecting handling capacity, such as load weight and cell layout.
Rate Charts
Graphical data illustrating palletizing rates (bags/hour and cases/hour) based on load and rotation angle.
T-axis Details
Details inertia, hand dimensions, and forces applied to the product.
Arm Components
Identifies the various parts that make up the robot arm assembly.
Panel Dimensions (UL type)
Shows the physical dimensions of the control panel from different views.
Robot Assembly Drawings
Provides detailed assembly diagrams for the robot models.
Operation
Daily Operation Procedures
Provides clear, step-by-step instructions for daily robot operation.
Operator Interface
Details the components of the operator interface, including pushbuttons and touch panel.
Pattern Programming
Introduction
Overview of pattern creation and editing using the robot's Main Control Panel and DIYSPII software.
Install DIYSPII Software (From CD)
Step-by-step guide for installing the DIYSPII software from the provided CD.
Install Patterns
Instructions for installing pre-programmed patterns onto the PC after DIYSPII installation.
Save Patterns to Back Up
Procedure for creating a backup of palletizing patterns.
DIYSPII COMMAND DEFINITIONS
Comprehensive list and explanation of all commands available within the DIYSPII software.
STANDARD MOVEMENT PATTERNS
Explains standard movement patterns concept and programming for cases and bags.
Program Composition (Memory Explanation)
Explains the structure and elements of a robot program stored in memory.
Coordinate Systems
Defines and illustrates the various coordinate systems used for robot positioning.
PROGRAM EDITING
Guides on editing existing programs by copying, deleting, and modifying parameters.
Specialized Movement Types
Covers practical teaching methods and programs not using standard movement patterns.
Multi-Stacking
Explains layout patterns involving multiple pallets and stations.
RP Mode
Describes creating programs using "RP" mode for pyramid-shaped bagged product stacking.
SMOV calculation
Details how SMOV command executed step, location data, and acceleration/deceleration time are displayed.
Non-Palletizing Movement Types
Explains creating programs for tasks other than standard palletizing or depalletizing.
DIYSPII COMMAND DEFINITIONS
Commands related to job selection and robot registration.
COMMANDS ON THE "REGISTRATION" MENU
Parameters for robot type, move area, accuracy, and communication settings.
Accuracy
Determines how accurately the robot locates its position.
Smov Parameter
Coefficients used to create smooth robot arm rotation for increased speed.
Communication
Sets communication parameters between robot controller, PLC, and PC.
Memory switch
Enables or disables additional functions and parameters for robot operation.
End effector and station
Standardized measurements for pick-up and set-down positions, including terminology.
Clamp End Effector Parameters
Details parameters like product gap, type, and finger configuration for clamp end effectors.
Finger Style (Bag and Fork) End Effector Parameters
Details parameters for finger-style end effectors, including length and width.
Vacuum Style End Effector Parameters
Details parameters for vacuum-style end effectors, including cup dimensions.
End Effector Offsets
Explains how offsets account for product pickup points not centered on the T-axis flange.
Pallet Parameters
Defines pallet size, product overhang limits, and forklift direction.
Stopper Direction
Aligns pattern display with laptop screen position relative to the robot.
"High Speed Sheet Pick"
Specific procedure for picking sheets at high speed.
"Step Basics (Side View)"
Explains step commands and options for palletizing, including side-view diagrams.
"Step Basics (Top View)"
Illustrates step basics using a top-down view of pallet coordinates.
PALLET ORIENTATION EXAMPLE
Demonstrates different pallet orientations relative to the robot.
CONVEYOR POSITION
Defines the pick-up point on the station conveyor.
HT -STATION POSITION
Explains station angle determination based on product travel and robot's Hx-axis.
POSITION TERMINOLOGY
Defines terms related to pallet and hand coordinate origins and their references.
CASE POSITION EDITING
Covers editing case positions and drop height, with trainee practice examples.
CHANGING DROP HEIGHT
Explains PZ measurement from the robot base casting to the T-axis pivot.
CHANGING POSITION
Shows how pallet coordinates can be set up with different origins.
PRODUCT OVERHANG
Defines overhang values and their relation to product stability and load width.
STEP OVERLAP
Explains how step overlap affects robot accuracy and capacity.
Maintenance
Preventative Maintenance
Schedule and types of inspections to ensure optimal robot performance and longevity.
Inspection Types
Defines four types of inspections: Routine, A, B, and C.
Inspection Schedule
Table correlating inspection types with operational hours and years.
Inspection Items
Detailed inspection points for various robot components and end effectors.
Lubricant List
Lists recommended lubricants, brands, and application amounts for various points.
Bolt Fastening Torque
Prescribed tightening torque values for fasteners on the robot arm.
Hand Inspection
Procedures for inspecting robot hands for proper function and wear.
Cable Harness Inspection (Cables and air hoses)
Checks for tight connections, damage, kinks, and interference in cable harnesses.
Robot Bearing lubrication
Procedures for lubricating R-axis bearing and gear reducers for D, O, and T axes.
Over-Travel Limit Switch Inspection
Verifies the correct operation of over-travel limit switches.
Emergency Stop Switch Inspection
Checks the functionality of all emergency stop switches.
Discharge Exit Switch Inspection
Verifies the operation of discharge exit sensors.
Trapped key Lock Inspection
Ensures trapped key locks function correctly on all doors.
Air filter cleaning
Instructions for cleaning air filters on the controller to prevent overheating.
Control Board Inspection
Checks controller boards for damage, dust, and secure connections.
Fan Operation Inspection
Verifies controller fans are working correctly after filter cleaning.
Loose Fastener Inspection
Confirms that terminal screws are properly tightened.
Maintenance Menu Display
Navigational overview of the maintenance menu structure.
Maintenance Procedures (hardware)
Detailed procedures for hardware maintenance tasks.
Level the Hand (Collision Shield)
Procedure for leveling the robot hand to prevent damage from interference.
Hand lubrication (LM -linear bearing)
Steps for lubricating the hand's linear bearings.
Memory Backup Battery
Information on maintaining program and system data using backup batteries.
Encoder Memory Backup Battery Replacement
Procedure for replacing the encoder backup battery.
Battery Replacement Date
Steps to set the battery replacement date after exchanging batteries.
Servo amp replacement
Procedure for replacing servo amplifiers on the robot.
Reset Robot Memory
Resets the robot controller to factory default settings.
Mechanical Stop Replacement-A1600
Details replacement procedures for mechanical stops on the A1600 robot.
Inspection C component list
Lists components for Inspection C and their replacement criteria.
Maintenance Procedures (software on panel)
Procedures for maintaining robot software settings on the control panel.
Password Setting
Sets passwords for accessing main menus like Automatic, Teaching, and System Storage.
Origin Position, Storing (0-90-0)
Stores the robot's origin position as a reference for calculations.
Setting T-Axis Origin -Attaching the Hand
Procedure for setting the T-axis origin and attaching the robot hand.
Encoder setup
Required when encoder cable or motor connector is disconnected or an alarm occurs.
Peripheral Equipment Name Input
Names conveyors and other peripheral equipment operated via the "Conveyor Manual" screen.
Hand Manual Operation Name Input
Names hand functions operated through the "Robot Manual" screen.
Hour Meter
Registers accumulated operating time for Main Power, Motor Power, and Automatic Operation.
Counter Revision
Initializes counters to layer 1, product 1 for pallet-specific or all pallet settings.
Setting of Timer value
Configures stop position, centering, and press height for each station.
Conveyor information
Disables or enables the OXPA PLC for conveyor control.
Robot SETUP
Explains various system parameters for robot configuration.
System Storage menu
Overview of system parameters that may need resetting after component replacement.
Soft Limit Screen
Displays soft limits, teaching area, origin offset, and R-area values.
Communication Setting
Determines serial communication parameters for robot to external sources.
External PLC Communication Setup
Configures Centronics communication, typically set to NO.
Memory Switch
Enables or disables additional functions and parameters for robot operation.
Axis Accuracy
Sets accuracy of the robot, robot type, job number, and SMOV parameters.
Servo Parameters
Modifies motion control behavior of servo amplifiers for smooth or tuned motion.
Spare Parts
Lists common electrical spare parts for efficient maintenance.
Troubleshooting
Diagnostic Menus
Provides access to screens for diagnosing robot errors and conditions.
Error content display
Shows recent robot error messages, including details like message number, date, and time.
Data memory content
Allows checking and modification of internal and external data memory.
Deviation trace
Displays deviation values (max and current) for each robot axis.
Acceleration and deceleration time
Shows trace data for position, acceleration, and deceleration times over the last 12 steps.
Operation Ready Condition
Summarizes conditions required for motor power ON and operation start.
I/O monitor (Relay Actuation X,Y,M)
Monitors and modifies internal and external inputs/outputs (relays) for programs.
Executed sequence command
Lists the 40 newest executed robot sequences.
Overlap trace
Displays the overlap trace state for the last 12 steps.
RISC output data
Displays position data as an instruction value to the servo motor control board.
Operation Trace
Shows the last 112 operation histories from the touch panel.
PLC & Tie-in Trace
Displays the last 90 special commands executed from the Built-in PLC.
Task Counter
Monitors the execution status of each task within a program.
Damaged File List
Lists files that were found to be damaged during a power-on check.
Servo Current Setting
Shows and registers offset values for servo motor current.
Servo Torque indicate
Displays motor rotation speed and desired torque for axes with switches ON.
Problems with Error Messages
Lists error messages, their causes, and remedies.
Problems with No Error Message
Addresses common issues that occur without specific error messages.
Electrical
Controller
Information regarding panel layouts and parts for A1600 and A700 controllers.
Cables
Diagrams showing the wiring of robot arms to the control panel.
PC Boards
Block diagrams and explanations of internal PC boards and their connections.
Peripheral Equipment Control
Details how the Okura controller manages peripheral equipment like conveyors.
Electrical Drawings
Provides internal and external cable drawings for A700 and A1600 models.
Installation
System Installation
Checklist and procedures for installing the complete robot system.
Factory Set Procedures
Factory preset procedures for limiting devices and axis adjustments.
ROBOTIC PALLETIZER TECHNICAL TRAINING
WHO IS COLUMBIA/OKURA?
Company background and expertise in robotic material handling.
TRAINING OUTLINE
Overview of available training programs, duration, and requirements.
BASIC TRAINING - OPERATION
Covers fundamental operational procedures, safety, and troubleshooting.
PLC TRAINING
Covers robot interaction with PLCs, including start/stop circuits and error handling.
SAFETY
Discusses safety references and key topics for discussion and feedback.
SAFETY OVERVIEW
Visual identification of safety features like emergency stops and guarding.
PHYSICAL LAYOUT
Explains reference materials and components of the robot's physical arrangement.
PHYSICAL REVIEW
Identifies major components of the robotic palletizing cell in a photograph.
AUTOMATIC MODE (PT. 1) – SCREEN DESCRIPTION & START SEQUENCE
Details automatic mode screens and the robot startup sequence.
TYPICAL PROBLEMS
Lists common operational issues, their causes, and potential solutions.
SYSTEM CONTROL
Illustrates the system architecture of robot control, PLC, and PC interaction.
MOTOR POWER
Explains the flow of electrical power to servo motors and their control components.
COORDINATE SYSTEMS
Defines and illustrates the various coordinate systems used for robot positioning.
Arm (A), Hand (H), and Pallet (P) Coordinates
Visualizes coordinate systems and their relationships for robot programming.
THE 4 AXES
Defines the movement and direction for each of the robot's four axes (R, D, O, T).
ELEMENTS OF A PROGRAM
Outlines the three main components of a robot program: Parameters, Sequence, and Steps.
PATTERN PROGRAM BASICS
Introduces fundamental concepts of pattern programming with examples.
STEP BASICS (SIDE VIEW)
Explains step commands and options for palletizing, including side-view diagrams.
STEP BASICS (TOP VIEW)
Illustrates step basics using a top-down view of pallet coordinates.
PALLET ORIENTATION EXAMPLE
Demonstrates different pallet orientations relative to the robot.
CONVEYOR POSITION
Defines the pick-up point on the station conveyor.
HT -STATION POSITION
Explains station angle determination based on product travel and robot's Hx-axis.
POSITION TERMINOLOGY
Defines terms related to pallet and hand coordinate origins and their references.
CASE POSITION EDITING
Covers editing case positions and drop height, with trainee practice examples.
CHANGING DROP HEIGHT
Explains PZ measurement from the robot base casting to the T-axis pivot.
CHANGING POSITION
Shows how pallet coordinates can be set up with different origins.
PRODUCT OVERHANG
Defines overhang values and their relation to product stability and load width.
STEP OVERLAP
Explains how step overlap affects robot accuracy and capacity.
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