3HAC066561 AM Conveyor Tracking RW 7-En

ROBOTICS
Application manual
Conveyor tracking
Trace back information:
Workspace 22B version a1
Checked in 2022-05-23
Skribenta version 5.5.019
Application manual
Conveyor tracking
RobotWare 7.7
Document ID: 3HAC066561-001

Revision: H
© Copyright 20192022 ABB. All rights reserved.

Specifications subject to change without notice.
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be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

Table of contents
Table of contents
Overview of this manual ................................................................................................................... 9
Network security ............................................................................................................................... 11
Open source and 3rd party components in RobotWare ................................................................. 12
1 Introduction to conveyor tracking 13

1.1 Physical components ......................................................................................... 13
1.2 Features .......................................................................................................... 15
1.3 Limitations ....................................................................................................... 17
1.4 Principles of conveyor tracking ............................................................................ 18
2 Conveyor tracking modules 23

2.1 Network based conveyor tracking module ............................................................. 23
3 Installation 37
3.1 Hardware connections ....................................................................................... 37
3.2 Installing the encoder for conveyor tracking ........................................................... 38
3.2.1 Encoder location ..................................................................................... 39
3.2.2 Encoder cables ....................................................................................... 40
3.3 Connecting the encoder to the CTM ...................................................................... 41
3.4 Connecting a camera to the CTM ......................................................................... 45
3.5 Connecting the sync switches to the CTM .............................................................. 46
4 Conveyor Tracking tab in RobotStudio 47
5 Configuration and calibration 55

5.1 About software installation and configuration ......................................................... 55
5.2 Configuring conveyor tracking module ................................................................. 56
5.3 Verifying the installation of encoders and sensors .................................................. 59
5.4 Configuration of robot controllers ........................................................................ 61
5.5 Calibrating CountsPerMeter ............................................................................... 64
5.6 Calibrating the conveyor base frame ..................................................................... 65
5.7 Defining conveyor start window and sync separation ............................................... 69
5.8 Avoiding robot reach problems ............................................................................ 70
5.9 Using a trigger output on the CTM ........................................................................ 71
5.10 Defining the robot adjustment speed ..................................................................... 72
5.11 Additional adjustments ....................................................................................... 73
5.12 Configuring a track motion to follow a conveyor ...................................................... 74
5.13 Installing conveyor tracking software .................................................................... 76
5.14 Installing additional conveyors work areas for conveyor tracking ................................ 77
6 Programming 79
6.1 Programming conveyor tracking .......................................................................... 79
6.2 Working with the object queue ............................................................................. 80
6.3 Activating the conveyor ...................................................................................... 81
6.4 Defining a conveyor coordinated work object ......................................................... 82
6.5 Waiting for a work object .................................................................................... 83
6.6 Programming the conveyor coordinated motion ...................................................... 84
6.7 Dropping a work object ...................................................................................... 85
6.8 Entering and exiting conveyor tracking motion in corner zones .................................. 86
6.9 Information on FlexPendant ................................................................................ 87
6.10 Programming considerations ............................................................................... 88
6.11 Finepoint programming ...................................................................................... 89
6.12 Operating modes .............................................................................................. 90
Application manual - Conveyor tracking 5

3HAC066561-001 Revision: H
Table of contents
7 System parameters 91
7.1 Introduction ...................................................................................................... 91
7.2 Topic Motion .................................................................................................... 92
7.3 Topic Process .................................................................................................. 94
8 RAPID reference 97
8.1 Instructions ...................................................................................................... 97
8.1.1 WaitWObj - Wait for work object on conveyor ............................................... 97
8.1.2 DropWObj - Drop work object on conveyor ................................................... 100
8.1.3 CnvPredictReach - High speed conveyors ................................................... 101
9 Advanced queue tracking 107

9.1 Introduction to advanced queue tracking ............................................................... 107
9.2 Working with the object queue ............................................................................. 109
10 Circular conveyor tracking 111

10.1 Introduction to circular conveyor tracking .............................................................. 111
10.2 Encoder type selection and location ..................................................................... 113
10.3 Installation and configuration ............................................................................... 114
10.4 Additional motion settings ................................................................................... 115
10.5 Calibrating the conveyor base frame ..................................................................... 116
10.6 Manually calibrating the conveyor base frame ........................................................ 117
10.7 TCP measurement method ................................................................................. 118
11 Accelerating conveyors 121

11.1 Introduction to accelerating conveyors .................................................................. 121
11.2 System parameters ........................................................................................... 122
11.3 Predicting speed changes ................................................................................... 123
11.4 UseAccProfile - Use acceleration profile ................................................................ 124
12 Indexing conveyors 127

12.1 Description of indexing conveyor options .............................................................. 127
12.2 Tracking indexing conveyors ............................................................................... 128
12.2.1 Setting up tracking for an indexing conveyor ................................................ 128
12.2.2 System parameters ................................................................................. 129
12.2.3 Using indexing conveyor tracking from RAPID .............................................. 130
12.2.4 RecordProfile ......................................................................................... 131
12.2.5 WaitAndRecProf ..................................................................................... 132
12.2.6 StoreProfile ............................................................................................ 134
12.2.7 LoadProfile ............................................................................................ 135
12.2.8 ActivateProfile ........................................................................................ 136
12.2.9 DeactProfile ........................................................................................... 137
12.2.10 CnvGenInstr ........................................................................................... 138
12.3 Indexing conveyor with servo control (Indexing Conveyor Control) ............................. 141
12.3.1 Introduction to indexing conveyors with servo control .................................... 141
12.3.2 Setting up a servo controlled indexing conveyor ........................................... 144
12.3.3 System parameters and configuration files ................................................... 145
12.3.4 Testing the indexing conveyor setup ........................................................... 150
12.3.5 Calibrating the base frame ........................................................................ 151
12.3.6 indcnvdata ............................................................................................. 152
12.3.7 IndCnvInit .............................................................................................. 153
12.3.8 IndCnvEnable and IndCnvDisable .............................................................. 154
12.3.9 IndCnvReset .......................................................................................... 155
12.3.10 IndCnvAddObject .................................................................................... 156
12.3.11 RAPID programming example .................................................................... 157
12.3.12 Minimizing trigger time ............................................................................. 160
6 Application manual - Conveyor tracking

Table of contents
13 Conveyor tracking and MultiMove 161

13.1 About conveyor tracking and MultiMove ................................................................ 161
13.2 Configuration example for UnsyncCnv .................................................................. 163
13.3 Configuration example for SyncCnv ...................................................................... 165
13.4 Tasks and programming techniques ..................................................................... 167
13.5 Independent movements, example UnsyncCnv ....................................................... 169
13.6 Coordinated synchronized movements, example SyncCnv ........................................ 171
13.7 Motion principles ............................................................................................... 174
13.8 Combining synchronized and un-synchronized mode ............................................... 175
14 Troubleshooting 177
14.1 Overview ......................................................................................................... 177
14.2 Event messages ............................................................................................... 178
14.3 System parameters ........................................................................................... 182
14.4 Robot path characteristics .................................................................................. 183
14.5 Power failure .................................................................................................... 185
14.6 Collision detection ............................................................................................. 186
14.7 Technical support .............................................................................................. 187
Index 189

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Overview of this manual

About this manual
This manual describes the options Conveyor Tracking, Indexing Conveyor Control,
and Tracking Unit Interface for OmniCore. Conveyor tracking, or line tracking, is
when the robot follows a work object mounted on a moving conveyor.
The option Indexing Conveyor Control is used when the servo for an indexing
conveyor is controlled by the robot controller.
The Tracking Unit Interface is used to establish communication with a remote
Conveyor Tracking Module.
Usages
The manual describes how the options are installed, programmed, and operated.
Note
It is the responsibility of the integrator to conduct a risk assessment of the final

application.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.
References
The manual contains references to the following information products:
Reference Document ID
Operating manual - OmniCore 3HAC065036-001
Operating manual - Integrator's guide OmniCore 3HAC065037-001
Operating manual - RobotStudio 3HAC032104-001
Application manual - Controller software OmniCore 3HAC066554-001
Technical reference manual - RAPID Instructions, Functions and 3HAC065038-001
Data types
Technical reference manual - RAPID Overview 3HAC065040-001
Technical reference manual - RAPID kernel 3HAC065039-001
Technical reference manual - System parameters 3HAC065041-001
Revisions
The following revisions of this manual have been released.
Revision Description
A Released with RobotWare 7.0.
B Released with RobotWare 7.0.1.
"Cyber security" replaced by "Cybersecurity" in entire manual.
Continues on next page

Continued
Revision Description
C Released with RobotWare 7.1.
• Removed obsolete RAPID objects.
UseReachableTargets, GetMaxUsageTime, ResetMaxUsageTime
• New event message 50024: Corner path failure added in section Event
messages on page 178.
• Updated the section CnvPredictReach - High speed conveyors on
page 101.
D Released with RobotWare 7.2.
• Note added in section Working with the object queue on page 109 saying
that for CTM, the ERR_CNV_OBJ_LOST error is not supported.
• Minor corrections.
E Released with RobotWare 7.3.
• Information regarding the adjustment speed parameter updated in About
software installation and configuration on page 55, Configuring conveyor
tracking module on page 56, Defining the robot adjustment speed on
page 72, Topic Process on page 94, Event messages on page 178, Sys-
tem parameters on page 182 and Robot path characteristics on page 183.
F Released with RobotWare 7.4.
• Reference to information about firewall settings in Integrator's Guide
added in section Connecting the CTM to the robot controller on page 43.
• CTM connection information updated in section Connecting the CTM
to the robot controller on page 43.
G Released with RobotWare 7.6.
• Added clarification about sharing of encoders between different work
areas, see Configuring conveyor tracking module on page 56 and
Configuration of robot controllers on page 61.
H Released with RobotWare 7.7.
• Updated descriptions for DSQC2000 regarding advanced queue tracking.

Network security
Network security
Network security
This product is designed to be connected to and to communicate information and
data via a network interface. It is your sole responsibility to provide, and
continuously ensure, a secure connection between the product and to your network
or any other network (as the case may be).
You shall establish and maintain any appropriate measures (such as, but not limited
to, the installation of firewalls, application of authentication measures, encryption
of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB
Ltd and its entities are not liable for damage and/or loss related to such security
breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.

Open source and 3rd party components in RobotWare

ABB products use software provided by third parties, including open source
software. The following copyright statements and licenses apply to various
components that are distributed inside the ABB software. Each ABB product does
not necessarily use all of the listed third party software components. Licensee
must fully agree and comply with these license terms or the user is not entitled to
use the product. Start using the ABB software means accepting also referred
license terms. The third party license terms apply only to the respective software
to which the license pertains, and the third party license terms do not apply to ABB
products. With regard to programs provided under the GNU general public license
and the GNU lesser general public license licensor will provide licensee on demand,
a machine-readable copy of the corresponding source code. This offer is valid for
a period of three years after delivery of the product.
ABB software is licensed under the ABB end user license agreement, which is
provided separately.
For RobotWare, there is license information in the folder \licenses in the RobotWare
distribution package.
For OleOS, the Linux based operating system used on the conveyor tracking
module (CTM), a list of copyright statements and licenses is available in the file
/etc/licenses.txt located on the CTM board and accessible via the console port or
by downloading the file over SFTP.
For the CTM application, a list of copyright statements and licenses is available in
the file /opt/ABB.com/ctm/licenses.txt located on the CTM board and accessible
via the console port or by downloading the file over SFTP.

1 Introduction to conveyor tracking
1.1 Physical components

Option Conveyor Tracking

A typical installation when using the option Conveyor Tracking includes the following
components:
A B
C
D
IRB
E
xx1200001074
A Synchronization switch
B Conveyor
C Encoder, 24 V
D Encoder interface
E Robot controller
IRB Robot
The encoder and synchronization switch are connected to the encoder interface.
Option Indexing Conveyor Control

A typical installation when using the option Indexing Conveyor Control includes
the following components:
B D
C
IRB
E
xx1200001075
A Infeeder
B Sensor
C Motor unit

Continued
D Indexed conveyor
E Robot controller
IRB IRB robot
An extra drive unit and SMB needs to be installed, see .

1.2 Features
1.2 Features
Accuracy
In automatic mode, at 150 mm/s constant conveyor speed, the tool center point
(TCP) of the robot will stay within +/- 2 mm of the path. This distance is maintained
whether the conveyor is in motion or not. This is valid as long as the robot is within
its dynamic limits with the added conveyor motion. This figure depends on the
calibration of the robot and conveyor and is applicable for linear conveyor tracking
only.
Object queue
For the option Conveyor Tracking, a queue is maintained of up to 254 objects that
have passed the synchronization switch. For the option Indexing Conveyor Control,
the queue can contain up to 100 objects.
Start window
A program can choose to wait for an object that is within a window past the normal
starting point, or wait for an object to pass a specific distance, or immediately take
the first object in the object tracking queue. Objects that go beyond the start window
are automatically skipped.
RAPID access to queue and conveyor data

A RAPID program has access to the number of objects in the object queue, and
the current position and speed of the conveyor. A RAPID program can also remove
the first object in the tracking queue or all objects in the queue.
Maximum distance
A maximum tracking distance can be specified to stop the robot from tracking
outside of the working or safety area.
Track follows conveyor

If the robot is mounted on a linear track, then the system can be configured so that
the track will follow the conveyor and maintain the relative position to the conveyor.
The TCP speed relative the work object on the conveyor will still be the programmed
speed.
Enter and exit conveyor tracking in corner zones

It is possible to enter and exit conveyor tracking via corner zones as well as via
fine points. Use corner zones to achieve a minimum cycle time.
Exit and re-enter conveyor tracking to same object

It is possible to exit and re-enter to the same object on the conveyor unlimited
times until the object moves outside the working area, reaches the maximum
distance, or is explicitly dropped by the RAPID program.

1.2 Features
Continued
Multiple conveyors
Up to six conveyors are supported with the option Conveyor Tracking. Each encoder
must be connected to an encoder interface.
Up to two indexed conveyors can be used with the option Indexing Conveyor
Control.
Coordinated finepoint
A finepoint can be programmed while moving relative to the conveyor. This conveyor
coordinated finepoint will ensure that the robot stops moving relative to the conveyor
and will follow the conveyor while the RAPID program continues execution. The
robot will hold the position within +/- 0.7 mm depending on calibration of the robot
and conveyor.
Calibration of linear conveyors

A calibration method is provided for easy calibration of the position and direction
of the conveyor motion in the robot work space. The linear conveyor may take any
position and orientation.

1.3 Limitations
1.3 Limitations
Small orientation error with SingArea\Wrist

There can be a small orientation error of the TCP while following the conveyor and
make long motions with SingArea\Wrist. This error can be eliminated by using
several short movements with SingArea\Wrist.
Robot mounted on track

If the robot is mounted on a track and the track is to be used to follow the conveyor
motions, then the track and conveyor must be parallel.
The motion on the track and the motion on the conveyor must have the same
direction of positive motion. See Configuring a track motion to follow a conveyor
on page 74.
Calibrating circular conveyors

There are no built-in methods for calibrating circular conveyors. This can be evaded
by calculating a quaternion orientation manually or with other tools during base
frame calibration.
Additional axes
For the option Conveyor Tracking, each conveyor is considered an additional axis.
Thus the system limitation of 6 active additional axes must be reduced by the
number of active and installed conveyors.
The first installed conveyor will use measurement node 6 and the second conveyor
will use measurement node 5. These measurement nodes are not available for
additional axes and no resolvers should be connected to these nodes on any
additional axes measurement boards.
For the option Indexing Conveyor Control, each conveyor is considered as two
additional axes.
Object queue lost on restart or power failure

If the system is restarted or if the power supply fails, then the object queue will be
lost.
Minimum and maximum speed

The minimum conveyor speed to maintain smooth and accurate motions depends
on the encoder selection. It can vary from 4 mm/s to 8 mm/s. See Minimum and
maximum counts per second on page 38.
There is no explicit maximum speed for the conveyor. Accuracy will degrade at
speeds above the specification and with high speed robot motions or with very
high conveyor speeds (> 500 mm/s) and the robot will no longer be able to follow
the conveyor.
WaitWObj after DropWObj

If a WaitWObj instruction is used immediately after a DropWObj instruction, it may
be necessary to add a WaitTime 0.1; after the DropWObj instruction.

1.4 Principles of conveyor tracking
Description
In conveyor tracking, the robot Tool Center Point (TCP) will automatically follow a
work object that is defined on the moving conveyor. While tracking the conveyor
the robot controller will maintain the programmed TCP speed relative to the work
object even if the conveyor runs at different speeds.
The options Conveyor Tracking and Indexing Conveyor Control are built on the
coordinated work object, as with coordinated motion with additional axes. See .
Conveyor as a mechanical unit

In the option Conveyor Tracking, the conveyor is treated as a mechanical unit. It
has all features of a mechanical unit except that it is not controlled by the robot
controller. In the option Indexing Conveyor Control, the conveyor is treated as a
mechanical unit and controlled by the robot controller.
As a mechanical unit, the conveyor can be activated and deactivated. The position
of the conveyor is shown on the FlexPendant, and in the robtarget when a position
is modified (ModPos).
Conveyor coordinated work object

The robot movements are coordinated to the movements of a user frame connected
to the conveyor mechanical unit. For example a user frame is placed on the
conveyor and connected to its movements.
A movable work object is used with the name of the conveyor mechanical unit.
The conveyor tracking coordination will be active if the mechanical unit is active
and the conveyor coordinated work object is active. When the conveyor coordinated
work object is used, in jogging or in a move instruction, the data in the uframe
component will be ignored and the location of the user coordinate system will only
depend on the movements of the conveyor mechanical unit. However the oframe
component will still work giving an object frame related to the user frame and also
the displacement frame can be used.
Waiting for a work object on the conveyor

The difference between a conveyor coordinated work object and a work object that
is coordinated to another type of mechanical unit is that there is no work object
for coordination until an object appears on the conveyor. There must be a work
object present on the conveyor before the robot can coordinate the TCP positions
to the conveyor.
For the option Conveyor Tracking, work objects on the conveyor are detected by
the synchronization switch that is connected to the encoder interface. The unit
tracks all objects that have past the synchronization switch and are within specified
distances in the work area.
For the option Indexing Conveyor Control, the work object is created when the
defined number of objects (that is, number of indexes) have passed. Before starting
coordinated motion with the conveyor, the RAPID program must first check if there
is a work object available on the conveyor. If an object is available then execution

Continued
continues and the motions can use the coordinated work object. If there is no
object, then the RAPID program waits until a work object is available.
Connecting to a work object

The RAPID instruction WaitWObj is used to wait for a work object on the conveyor
before starting conveyor coordinated motion. When the WaitWObj instruction is
successful then the conveyor work object is said to be connected to the RAPID
program. See WaitWObj - Wait for work object on conveyor on page 97.
Once a RAPID program has connected to a work object on the conveyor then robot
motion instructions and jogging commands can use this work object just as any
other work object. When using the conveyor connected coordinated work object
then all motions are relative to the work object on the conveyor.
The robot can switch between the conveyor coordinated work object and another
coordinated work object in the system, but only one conveyor work object can be
connected.
Disconnecting from a work object

The work object will remain connected until one of the following occurs:
• A DropWObj instruction is issued
• The maximum distance defined for the conveyor is reached
• Controller is restarted
• Power failure
The connection to the work object will not be lost when deactivating the conveyor
mechanical unit, and will return on re-activation.
The instruction DropWObj ends the connection before the maximum distance is
reached.
After a DropWObj instruction is issued it is possible to immediately wait for and
connect to the next work object in the conveyor object queue.
Start window and queue tracking distance

The object queue is based on a set of distances relative to the conveyor and
synchronization switch. See the following figure.
A B
z y
7 6 5 4 3 2 1 x
C D E
F G
xx1200001076
B Work object user frame
C Minimum distance (minimum distance)
D Start window width (StartWinWidth)

Continued
E Working area
F Queue tracking distance (QueueTrckDist)
G Maximum distance (maximum distance)
1-7 Objects on conveyor
The conditions and states of objects 1 to 7 can be described as in the following

table.
For descriptions of the system parameters StartWinWidth and QueueTrckDist see
Type Conveyor Ici (DSQC2000) on page 95. For descriptions of the system
parameters minimum distance and and maximum distance see Type Conveyor
systems on page 94.
Objects Description
1 This object is connected as indicated by the coordinate frame attached to the
position of the object on the conveyor.
2 Object 2 is outside the start window and is no longer tracked. This object will
be skipped and cannot be connected by a WaitWObj instruction. It is skipped
because the conveyor speed is such that coordination with the object could
not be completed before the object moves outside the maximum distance or
work area of the robot.
3 and 4 These objects are within the start window and are tracked. If object 1 is and 4
dropped via a DropWObj instruction then object 3 is the next object to be con-
nected when a WaitWObj instruction is issued. Because objects 3 and 4 were
in the start window, the WaitWObj instruction will not wait but return immediately
with object 3.
5 and 6 These objects lie within the queue tracking distance and are tracked. If objects
and 6, 3, and 4 were not present, then a WaitWObj instruction would stop pro-
gram execution until object 5 entered the start window.
7 This object has not yet passed the synchronization switch and has not yet been
registered.

Continued
Coordinate systems
D
z y
A B C
z y z y x
x x
E F
G H
0.0 m
z y
J x z
K x
y
xx1200001077
B Base frame for conveyor
C User frame
D Object frame
E Minimum distance
F Start window width
G Queue tracking distance
H Maximum distance
J World frame
K Base frame for robot
The preceding figure shows the principle coordinate frames used in conveyor
tracking. See the following table.
Coordinate system Relative to
Base frame of robot World frame
World frame N.a.
Base frame of conveyor World frame
User frame, coordinated to conveyor World frame via base frame of conveyor
Object frame (not shown) User frame
Key frames and positions

The two key frames in conveyor tracking are the base frame for the conveyor and
the user frame in the conveyor coordinated work object. The position of user frame
in the conveyor coordinated work object is determined from the position of the
conveyor base frame and the linear position of the conveyor in meters.
The encoder interface provides the position of the conveyor relative the
synchronization switch and the Queue Tracking Distance. When the conveyor
position is 0.0 meters, the user frame for the conveyor coordinated work object

Continued
coincides with the base frame of the conveyor. As the conveyor moves, then the
user frame in the conveyor coordinated work object moves along the x-axis of the
conveyor base frame.
See Operating manual - OmniCore and Technical reference manual - RAPID
Overview.

2 Conveyor tracking modules
2.1 Network based conveyor tracking module

Description
The CTM is a network based conveyor interface that provides connections for 4
encoders and 8 cameras.
xx1800000346
The CTM uses network communication to share conveyor speed and position data
with one or more robot controllers. It contains a WAN port, which is used to connect
to the robot controllers and two LAN ports that can be used for installation and
service purposes. It can be located either inside the robot controller or inside a
separate cabinet. To improve the quality of the signals keep the CTM close to the
encoders and the sensors.
Each of the encoder inputs support one 2 phase encoder. Each of the camera
connections consist of a digital sync input, a 24 V digital trigger output, and a
camera power output. The camera connection can also be used for other sync
input sources, for example photocells.

Continued
Functions
Ethernet connections
The CTM includes WAN and LAN Ethernet ports. The WAN port of the CTM must
be connected to the same Ethernet network as the robot controllers. The robot
controllers should be connected to the same network with any of their public
network ports (see Operating manual - Integrator's guide OmniCore). If the CTM
is only used by one robot controller, for example an internally mounted CTM, the
WAN port of the CTM should be connected to any of the robot controllers public
network or private network ports (see Operating manual - Integrator's guide
OmniCore).
Power distributions
The CTM has two power inlets, power inlet (X1) and an optional camera power
inlet (X20). The power inlet is 24 V, it supplies power to all main function on the
CTM module, as shown in the following figure:
xx1800000347
The Camera power (X20) and its ground connection are separated from the rest
of the CTM power. The camera power can only be routed from the power inlet
through the CTM's current protection circuits to the individual outputs in the camera
connectors (X21-X28), as shown in the following figure:
xx1800000348
The 24V_INP, 24VDC, CAM_PWR, and 3V3 are covered by diagnostics functions
and their levels are displayed in RobotStudio.

Continued
Encoder power outputs

Each encoder connection (X11 - X14) supports an encoder power output. The
encoder power output is 24 V with diagnostics functions, which is controlled by a
high side driver circuit. In case of an overload or short circuit on the CTM, it is
turned off. This output also contains a Discovery function, which can detect if an
encoder is connected to the power. A constant test current of approximately 5 uA
checks the output of the Discovery function, if the output is off it is activated. This
test current will cause an unconnected trigger output pin to float at 10 V, even
when the output signal is turned off. This power output is always on, except during
startup, as shown in the following figure:
xx1800000349
Encoder inputs
Each encoder connection (X11-X14) supports a two phase encoder. The inputs
are isolated and open ended to support NPN, PNP, and Push-Pull type encoders.
The encoder can be powered from the CTM or by an external power supply, as
shown in the following figure:
xx1800000350

Continued
Sync inputs
Each camera connector (X21 - X28) has a sync input which is isolated through
opto couplers. These couplers are single ended, share a common GND with the
CTM board, and support PNP and push-pull sensors. It is recommended to use
the sync power output to power the sync sensor signal, as shown in the following
figure:
xx1800000351
Trigger outputs
Each camera connector (X21 - X28) has a trigger output. This output is a 24 V
digital output with diagnostics functions, which is controlled by a high side driver
circuit. In case of an overload or short circuit on the CTM, it is turned off. This
output also contains a Discovery function, which can detect if an encoder is
connected to the power. A constant test current of approximately 5 uA checks the
output of the Discovery function, if the output is off it is activated. This test current
will cause an unconnected trigger output pin to float at 10 V, even when the output
signal is turned off.
The following figure shows a drawing of the trigger output.
xx1800000352
Technical specification DSQC2000, CTM
General
Power supply 24 VDC (-15/+20%), typically 200 mA
(Current not including power outputs)

Continued
General
Operating temperature +5°C - +65°C
Ethernet LAN 2 switched LAN ports, 100 Mbit (Only for installation
and service purposes )
Ethernet WAN 1 WAN port, 100 Mbit
Dimensions 137 x 128 x 40 mm
xx2000002184
Encoders 4 pcs (X11-X14)

Power output 24 VDC, max 120 mA
With connection discovery and overload protection/dia-
gnostic
Frequency 0 - 20 kHz
Input current 5.2 mA at 24 VDC
Voltage levels 15 VDC < '1' < 30 VDC, -3 VDC< '0' < 5 VDC
Supported encoder types PNP, NPN, and Push-Pull

Continued
Cameras 8 pcs (X21-X28)

Camera power output Supplied from X20 camera power inlet
(normally 24 VDC, maximum 250 mA)
With overload protection
Sync input signal
Power output 24 VDC, 120 mA
gnostic
Input Current 5.2 mA at 24 VDC
Voltage levels 15 VDC < '1' < 30 VDC, -3 VDC< '0' < 5 VDC
Trigger output
Digital output 24 VDC, Max 120 mA
gnostic
Minimum load 0.1 mA
(Floating pins will drift towards voltage rails)
LED indicators
The CTM module has the following LED diagnostics and information:
• Module Status LED – BiColor LED displays the module status.
Status LED Description
During startup
• Red (steady): Default at power up
OS loading
• Red (blinking): Startup completed OK
Run-time
• Green (steady): Up and running, OS
loading completed OK
xx1800000353
• Module Discovery LED – Indicates the connection status of the CTM module
with a RobotStudio client.

Continued
Discovery LED Description

During startup
• LED off
OS loading
• LED off
Run-time
• Green (blinking): Connected and selec-
ted by a RobotStudio client.
xx1800001604
• On the CPU board, there are three Ethernet connection status LEDs and a
LED displaying the power status.
Ethernet Link Status Description
LED 1 - Ethernet LAN 1 LED
• Green LED: Ethernet LAN 1, 100 Mbit
link enabled
• Ethernet port 1, Connector X5
LED 2 - Ethernet LAN 2 LED
• Green LED: Ethernet LAN 2, 100 Mbit
link enabled
LED 3 - Ethernet WAN port LED
• Green LED: Ethernet WAN, 100M bit
link enabled
xx1800000354
CPU board power status Description

LED 4 - Power Status
• Green LED: 3.3 VDC power is OK
xx1800000355
• Each encoder input has two status LEDs, one for each input pair.

Continued
CPU board power status Description

LED_ENC (1 - 4) A & B LEDs
For each encoder connection (X11 - X14)
there is a LED displaying the input level of
each encoder pair.
xx1800000356
• A LED displaying the status of the camera power inlet.

Camera power status LED Description
LED_CAM_PWR
Displays the power status of the optional
camera power inlet.
xx1800000357
• Each camera connection has two status LEDs, one for the sync signal input
and one for the trigger signal output.
Camera status LED Description
LED_SYNC (1 - 8) LEDs
For each camera connection (X21 - X28) there
is a LED displaying the input stage of the
sync input signal.
LED_Trig (1 - 8) LEDs
For each camera connection (X21 - X28) there
is a LED displaying the output stage of the
trigger output signal.
xx1800000358

Continued
Buttons
The CTM module has the following two user interactive buttons:
Buttons Description
White SW1 button
• Short press: Devices connected to a
RobotStudio client is highlighted.
• Press and hold while the CTM is re-
booting: CTM resets to default factory
settings.
WARNING
Resetting the CTM to default factory

settings will reinstall the current ver-
sion of the firmware and reset all the
passwords to default. It will reset con-
figured updates, for example, Sync
Separation settings for encoders will
xx1800001605 be reset to 0. Configured network set-
tings will not be affected.
Black SW2 button

• Short press: CTM is restarted (warm
start).
• Long press: CTM is rebooted.
Connectors
X1 – CTM power inlet connector
X1 Pin number Name Function

1 GND CTM power inlet
2 24V_INP
xx1800000359
X3 – Console port for debugging

1 (Not connected)
2 SCI_RX Console receive
3 SCI_TX Console transmit
xx1800000360
4 (Not connected)
5 GND
6 (Not connected)
7 (Not connected)
8 (Not connected)
9 (Not connected)

Continued
X5-X6 – Ethernet connections

X5 – LAN port 1 connection
1 TX1+ Transmit pair
2 TX1- Transmit pair
3 RX1+ Receive pair
4 i
5 i
xx1800000361
6 RX1- Receive pair

7 i
8 i
i Connected to a resistor network (provides a common mode termination)

X6 – LAN port 2 connection
3 RX2+ Receive pair
4 i
5 i
xx1800000361
6 RX2- Receive pair

7 i
8 i

X7 – WAN port connection
3 RX3+ Receive pair
4 i
5 i
xx1800000361
6 RX3- Receive pair

7 i
8 i

Continued
X11-X14 – Encoder connections

1 ENC1PWR Encoder 1 power
output
2 GND
xx1800000362
3 ENC1A+ Encoder input 1,
Pair A
4 ENC1A-
5 ENC1B+ Encoder input 1,
Pair B
6 ENC1B-

output
2 GND
xx1800000362
Pair A
4 ENC2A-
Pair B
6 ENC2B-

output
2 GND
xx1800000362
Pair A
4 ENC3A-
Pair B
6 ENC3B-

output
2 GND
xx1800000362
Pair A
4 ENC4A-
Pair B
6 ENC4B-
X20 – Camera power inlet

1 CAM_GND Camera power
inlet
2 CAM_PWR
xx1800000363

Continued
X21-X28 – Camera connections

1 CAMPWR1 Camera 1 power
output
2 CAMPWRGND
xx1800000364 3 SYNC1 Sync 1 input sig-
nal
4 SYNCPWR1 Power output for
sync signal
5 GND GND for trigger
and sync power
6 TRIG1 Trigger 1 output

output
2 CAMPWRGND
nal
sync signal
and sync power

output
2 CAMPWRGND
nal
sync signal
and sync power

output
2 CAMPWRGND
nal
sync signal
and sync power

Continued

output
2 CAMPWRGND
nal
sync signal
and sync power

output
2 CAMPWRGND
nal
sync signal
and sync power

output
2 CAMPWRGND
nal
sync signal
and sync power

output
2 CAMPWRGND
nal
sync signal
and sync power

3 Installation
3.1 Hardware connections
3 Installation
3.1 Hardware connections
Introduction to hardware installation

For the option Conveyor Tracking or PickMaster 3, the conveyor is connected to
the robot controller using an encoder and the conveyor tracking module (CTM-01,
DSQC2000). See Installing the encoder for conveyor tracking on page 38.
For the option Indexing Conveyor Control, the conveyor is controlled by a motor
unit (ABB or other). See Installing the additional axis for servo control on page 144.

3 Installation
3.2 Installing the encoder for conveyor tracking
3.2 Installing the encoder for conveyor tracking
Selecting encoder type

The encoder provides a series of pulses indicating the motion of the conveyor.
This is used to synchronize the motions of the robot to the motion of the conveyor.
The encoder has two pulse channels, A and B, that differ in phase by 90°. Each
channel will send a fixed number of pulses per revolution depending on the
construction of the encoder.
The number of pulses per revolution for the encoder must be selected in relation
to the gearing between the conveyor and the encoder. The pulse ratio from the
encoder should be in the range of 1250 -2000 pulses per meter of conveyor motion.
The pulses from channels A and B are used in quadrature to multiply the pulse
ratio by 4 to get counts. This means that the control software will measure 5000
to 10000 counts per meter for an encoder with the pulse ratio given above. Reducing
the number of measured counts below 5000 will reduce the accuracy of the robot
tracking. Increasing the number of measured counts above 10000 will have no
significant effect as inaccuracies in robot and cell calibration will be the dominating
factors for accuracy.
The encoder must be of 2 phase type for quadrature pulses, to register reverse
conveyor motion, and to avoid false counts due to vibration etc. when the conveyor
is not moving.
Output signal Typical spec, Open collector PNP output encoder
Voltage 10-30 V
(normally supplied by 24 VDC from DSQC2000, CTM-
01)
Current 50-100 mA
Phase 2 phase with 90 degree phase shift
Duty cycle 50%
An example encoder is the Lenord & Bauer GEL 262.
Minimum and maximum counts per second
Minimum speed The lower limit on the number of counts per second before the en-
coder signals zero speed is 40 counts per second. If the speed of
the conveyor is lower, zero speed will be indicated.
At 10,000 counts per meter, the minimum conveyor speed is 4 mm/s.
Maximum speed The upper limit on the number of counts per second before the en-
coder can no longer keep track of the counts along the conveyor is
20,000 counts per second.
At 10,000 counts per meter, the maximum conveyor speed is 2,000
mm/s.

3 Installation
3.2.1 Encoder location
3.2.1 Encoder location
Description
The encoder is normally installed on the conveyor drive unit. The encoder can be
connected to an output shaft on the drive unit, directly or via a gear belt
arrangement.
Prerequisites
If the encoder is connected directly to a drive unit shaft, a flexible coupling must
be used to prevent applying mechanical forces to the encoder rotor. Do not use a
coupling using a plastic or rubber hose. If the drive unit includes a clutch
arrangement, the encoder must be connected on the conveyor side of the clutch.
If the conveyor drive unit is located a long distance away from the robot then the
conveyor itself can be a source of inaccuracy as the conveyor will stretch or flex
over the distance from the drive unit to the robot cell. In such a case it may be
better to mount the encoder closer to the robot cell with a different coupling
arrangement.

3 Installation
3.2.2 Encoder cables
3.2.2 Encoder cables
Description
The encoder should be connected to the robot by a screened cable to reduce noise.
The noise immunity will be better with screened twisted pair cable. Cable length,
pulse frequency and environmental conditions must be taken in account, case by
case.
The cable screen can by grounded in one of the following ways:
• Grounded in the controller end, open in the encoder end.
• Grounded in both ends.
• High frequency connection with a capacitor between screen and ground in
the encoder end.
The method for screen connection depends on the environment and can be different
from case to case. Parameter like cable length, encoder frequency and other
equipment with power electronics (motor-drive) and so on influence on the
electromagnetic environment.
PWR
GND
A+
A-
B+
B-
GND GND
xx1800001539
PWR Power
GND Ground
A+, A- Encoder signal A
B+, B- Encoder signal B

3 Installation
3.3 Connecting the encoder to the CTM
Description
An encoder is connected to a single encoder interface in the CTM. If multiple robots
are following the same conveyor, its speed and position are supplied by the CTM
to all the robot controllers through a network communication.
The conveyor tracking module CTM (DSQC2000) can be located either inside the
robot controller or a cabinet close to the conveyor encoder (to reduce the cable
length between the CTM and the encoder).
Encoder connections
The CTM has four independent encoder connections supporting PNP, Push-Pull,
and NPN encoders.
xx1800000365
The configurations support the Connection Discovery functions and overload

protection/diagnostic of the encoder power output.

3 Installation
Continued
If the encoder is externally powered, then the CTM power pins must not be
connected. This configuration removes the connection discovery and overload
protection and diagnostic functions of the encoder power output.
xx1800000366
Connecting to multiple encoder modules

An encoder requires additional power supply, when connecting to several encoder
interfaces. This extra power supply can be acquired by an external power source
or from the connected encoder interfaces by using a diode on the power outputs
to prevent parallel wiring of the power supplies.
xx1800000367
These configurations do not support overload protection and also do not provide
the functions connection discovery and overload diagnostic of the encoder power.

3 Installation
Continued
Connecting the CTM to the robot controller

The CTM must be powered by a 24 V power supply and connected to Ethernet.
There are three main installation methods for the Ethernet communication. The
power supply connection and Ethernet connection may vary between the different
robot controllers, see the product manual for the robot controller.
Note
When connecting the CTM to the WAN port on the robot controller, you first have
to enable the firewall for CTM by setting Enable on Public Network to YES for
the Network Service RobICI. See Operating manual - Integrator's guide OmniCore,
section "Firewall settings", for more information.
Mounted in robot controller, sharing conveyor info with other controllers

When the CTM module is connected to the same network as the robot controllers,
the conveyor information may be shared from the CTM module to all the robot
controllers.
xx1800000368
Mounted outside robot controller, sharing conveyor info with other controllers
The CTM module can be mounted externally, that is outside the robot controller.
xx1800000369

3 Installation
Continued
Mounted inside robot controller, no sharing of conveyor info

If the conveyor is not shared with any other robot controller, the CTM may be
installed inside the controller using the Private network. This will reduce the number
of external WAN ports required on the robot controller.
xx2100002143
Note
The WAN port is used on the CTM and LAN 2 is used on the main computer.

3 Installation
3.4 Connecting a camera to the CTM
3.4 Connecting a camera to the CTM
Description
The CTM contains 8 camera connections to connect cameras or sync signals. The
cameras can be powered separately or through the CTM.
The sync signal input supports PNP and Push-Pull type sensors and can be
powered by the Sync_Pwr output or externally. The trigger output is a 24 V digital
output signal.
The configuration shown in the following figure, supports overload protection on
CameraPower, Sync_Power, and Trig_output. The Connection Discovery function
and the overload protection/diagnostics exist on Sync_Power and Trig_output.
xx1800000371
The configuration shown in the following figure, does not supports overload
protection on CameraPower. The Connection Discovery function and the overload
protection/diagnostics exist on Sync_Power and Trig_output.
xx1800000372

3 Installation
3.5 Connecting the sync switches to the CTM
3.5 Connecting the sync switches to the CTM
Description
The sync input signal in each of the camera connectors can also be used as a sync
switch. It can be powered by Sync_Pwr output or externally and supports PNP and
Push-Pull type sensors, as shown in the following figure:
xx1800000375

4 Conveyor Tracking tab in RobotStudio

Introduction
The Conveyor Tracking tab contains a tree view browser displaying the connected
DSQC2000 units and other related objects. It is used as a user interface to configure
settings and monitor live signals of the DSQC2000 tracking units.
Note
While in the tree view browser or any of the related object dialogues, pressing
F1 will open the Application manual - Conveyor tracking.
To open the Conveyor Tracking tab:
Action
1 Click Conveyor Tracking from the Configuration group, in the Controller tab.
The Conveyor Tracking tab opens.
Connecting and adding a CTM

Connecting a CTM
One of the following methods can be used to connect the CTM to the computer:
1 Connecting the CTM through a WAN port
This method is recommended only after a fixed IP address is configured for
the CTM - WAN interface, see Network settings on page 48.
Connect the computer with a fixed IP address to the same WAN network,
through a network switch or a direct connection. Configure the computer’s
IP address with the CTM’s subnet.
Example:
CTM - WAN interface 192.168.8.xx
Computer network interface 192.168.8.246
The default factory setting for WAN is Obtain an IP address automatically

(DHCP client). To connect a WAN with this setting a DHCP server is required
on the network.
2 Connecting through a LAN port
This method is recommended for the initial setup of a CTM with default factory
settings. It can also be used for debugging, when there is a connection
problem with the CTM.
Configure the fixed IP address of the computer with the subnet of the CTM
– LAN interface. The LAN interface has IP address 192.168.126.200.
Example:
CTM - LAN interface 192.168.126.200
Computer network interface 192.168.126.246

Continued
Adding a CTM
To add a CTM, a connection must be established between the computer and the
CTM:
Action
1 Click Add CTM.
The Add CTM dialog box displays all the detected CTMs.
2 Select the CTM from the list and click OK.
The CTM is added to the tree view object browser.
Identifying a CTM in RobotStudio

If RobotStudio is connected to a network with multiple CTMs, it may become difficult
to identify a particular CTM. This can be avoided by a direct connection via LAN
port, for more information, see Connecting a CTM on page 47, section Connecting
through a LAN port.
To simplify identification, it is recommended to assign a unique and descriptive
name for every CTM, for more information, see Rename on page 49.
One of the following methods can also be used to identify a CTM:
• Select the device in the tree view browser, its corresponding green discovery
LED will start blinking on the CTM module.
• Press the white SW1 button on the CTM module once, a green dot will start
blinking on the corresponding CTM symbol in the tree view browser.
WARNING
Do not press the SW1 button while the CTM is restarting, this will reset the
CTM to default factory settings and any updates or upgrades will be lost.
Network settings
The WAN port of the CTM is connected to the robot controllers through an Ethernet
network. To establish communication between the robot controllers and the CTM,
a fixed IP address must be assigned to the CTM. The IP address should be located
on the same subnet as the network interface of the connected robot controllers.
To change the network settings:
Action
1 Right-click the CTM in the tree view browser, select Network settings, and then
click WAN interface.
2 Enter the IP address, the Subnet mask, and the Default gateway (optional) and
then click OK.
Authenticate
A CTM has the following two predefined users:
User Default pass- Description
word
abbadmin abbadmin It is an advanced user and is used for advanced
maintenance and troubleshooting.

Continued
User Default pass- Description

word
ctmuser ctmuser It is a normal user and is used for everyday mainten-
ance and troubleshooting.
Note
Login as an advanced user to upgrade the firmware.

To use some features of a CTM, a login is required. If you are using the default
credentials, login is automatic to the Conveyor Tracking tab. Otherwise,
authentication is requested whenever required.
Note
It is recommended to change the password to improve security.

Appropriate credentials are required to make any modifications to the CTM
configuration and firmware.
WARNING
You cannot recover a lost password, so ensure the password is not lost or
forgotten.
To login as a user:
Action
1 Right-click the CTM and click Authenticate > Login as a Different User.
2 Enter the required credentials and click Login.
To log off the current user:

Action
1 Right-click the CTM and click Authenticate > Log Off.
To change the password of the current user:

Action
1 Right-click the CTM and click Authenticate > Change password.
2 Change the password and click OK.
Rename
You can rename the CTM, the encoders, and the sensors.
To rename any object:
Action
1 Right-click the object in the tree view browser and then click Rename.
The Rename dialog box opens.
2 Enter a new name for the object and then click OK.
The new names are stored in the CTM and will be displayed in RobotStudio, once
it is restarted.

Continued
Configuring an encoder
You can configure some settings of an encoder, for example, Speed filter.
To configure an encoder:
Action
1 Right-click the encoder in the tree view browser and then click Configure encoder.
The Configure encoder tab opens.
2 Modify the settings and click Apply.
An encoder can be configured as used or not used. This change in configuration

will affect how the encoder is displayed in the tree view browser. To tune the
encoder speed filtering, you can define the Low-pass filter cut off frequency in
the Speed filter section.
Configuring a sensor
You can configure some settings of a sensor, for example, Sync Separation.
To configure a sensor:
Action
1 Right-click the sensor in the tree view browser and then click Configure sensor.
The Configure sensor dialog box opens.
2 Modify the settings and click Apply.
Sync separation is used to filter an unstable signal in the sync input signal. It
defines the minimum encoder distance (counts) between two sync pulses from the
sensor. When the actual distance is shorter than this value, then the second sync
pulse is ignored.
The sensor type can be configured as I/O Sensor, Camera, or Not used. This
change in configuration will affect how the sensor is displayed in the tree view
browser.
Note
It is recommended to set the same sync separation value for all the encoders.
The camera pulse width defines the pulse length (ms) used with the camera trigger
signal.
Note
For high speed conveyors, the pulse length must be shorter than the time between
consecutive camera images, so that:
Camera pulse width in ms < 1000 * (Trigger distance in mm / Max conveyor speed
in mm/s)
Restart
Overview
A restart or reboot of a CTM can be performed using the tree view browser.

Continued
Restart
A restart is required after modifying the settings of the CTM.
To restart the CTM:
Action
1 Right-click the desired CTM in the tree view browser and then click Restart.
Reboot
A reboot is slower than a restart, it corresponds to the restart after cycling the
power.
To reboot the CTM:
Action
1 Right-click the desired CTM in the tree view browser and then click Reboot.
Signals
There are 3 types of live signals: encoder, sensor, and other. You can sort and
filter the signals by various properties:
Signal property Description
Name Name of the signal
Type Signal value type, for example, float
Value Signal live value
Unit Signal value unit, for example, Hz
Category Signal category, for example, Public or Internal
Sensor Sensor number (1-8)
Encoder Encoder number (1-4)
Function Signal name used in the robot controller, for example, TrigVis
Label Connector on the CTM, for example, X11
Description Information on what the signal represents
List all signals

To list all the signals:
Action
1 Right-click the desired CTM in the tree view browser and then click Signals.
List all encoder signals

To list all the encoder signals:
Action
1 Right-click the desired encoder in the tree view browser and then click Signals.
List all sensor signals

To list all the sensor signals:
Action
1 Right-click the desired sensor in the tree view browser and then click Signals.

Continued
Backup and Restore

You can save a backup of the CTM settings. The backup will contain:
• Data about the CTM configurations, including encoder and sensor parameters
and new names. While restoring the backup, these settings are applied to
the target CTM.
• Network settings
• Firmware version information
Creating a backup of the CTM

Keeping a backup is recommended to simplify the task of replacing the CTM with
a new unit.
To create a backup of the CTM:
Action
1 Right-click the CTM in the tree view browser and then select Create Backup… .
The Create Backup from CTM dialog box opens.
2 Enter a Backup Name.
3 Enter or select a save Location and click OK.
A backup of the CTM is created in the entered location.
Restoring a backup
To restore a backup of the CTM:
Action
1 Right-click the CTM in the tree view browser and then select Restore Backup…
.
The Restore from Backup to CTM dialog box opens.
2 Enter or browse to the required Location, select backup folder and click Open.
The backup of the CTM saved in the folder is displayed in the list of the Available
backups section.
3 Select the required backup from the list and click OK.
The CTM’s settings will be restored according to the backup, after a restart of the
CTM.
Firmware upgrade
A firmware upgrade is normally provided by ABB, as a .cab file.
WARNING
It is recommended to backup the CTM configurations, as a firmware upgrade

may result in the factory default network settings.
To upgrade the firmware of the CTM:
Action
1 Login as an advanced user to upgrade the firmware, see Authenticate on page 48.
2 Right-click the CTM and then click Firmware Upgrade.
The Firmware Upgrade dialog box opens.
It displays the current version of the firmware.

Continued
Action
3 Click Browse, navigate to the .cab file and then click Open.
The Verify Software dialog box opens.
It displays the publisher of the file.
4 If the publisher is trusted, click Yes.
The Firmware Upgrade dialog box opens.
It displays the new firmware version.
5 Verify it and click Upgrade, to download it.
The CTM will restart after the download and installation.
After a firmware upgrade, you may have to restore the network settings of the CTM.
Restore a backup (see Restoring a backup on page 52) or manually enter the
correct network settings.

5 Configuration and calibration
5.1 About software installation and configuration

5.1 About software installation and configuration
Introduction
This section is a step-by-step instruction on how to install, connect, configure and
calibrate conveyor work areas for conveyor tracking. This includes robot controller,
conveyor tracking module, encoders and sensors for object detection.
The encoder and conveyor tracking module descriptions in this chapter are not
valid for the option 606-2 Indexing Conveyor Control.
Installed software on delivery

The conveyor tracking functions and the RAPID instructions are specified in the
license. The conveyor software is already installed on delivery.
The Conveyor Tracking option installs one conveyor work area to the robot
controller configuration (that is, in the system parameters). To add more conveyor
work areas, see Installing additional conveyor work areas for conveyor tracking
on page 77.
The PickMaster 3 option has a Conveyor Configuration suboption, that can be used
to specify how many conveyor work areas should be installed (0 – 6).

5.2 Configuring conveyor tracking module
Introduction
The conveyor tracking module (CTM, DSQC2000) provides an interface to monitor
up to 4 encoders and 8 object detecting sensors. Encoders and sensors can be
shared for usage with different conveyor work areas. One CTM unit can be used
simultaneously by up to 40 robot controllers. To be able to use a CTM, the robot
controller needs the software option Tracking Unit Interface.
Cybersecurity for installations with CTM

For information on addressing security threats in a network installation with CTM
and ABB robots, see Operating manual - Integrator's guide OmniCore.
Connecting a robot controller to the CTM

The robot controller is connected to the CTM through an Ethernet network.
The CTM has 3 network interfaces: WAN and 2 LAN. The WAN interface is used
to communicate with robot controllers.
If the CTM is shared by more than one robot controller, it should be connected to
the public network port on the robot controller. When used with a single robot
controller, additionally it is possible to connect a CTM on the private network, for
example, LAN 2 of the robot main computer.
xx1800000382
Note
To establish a communication between the robot controller and the CTM, the IP
address of the robot controller must be on the same subnet as the CTM.
To setup and verify a communication between the CTM and the robot controller:
Action
1 Configure the IP address of the CTM, see Network settings on page 48.

Continued
Action
2 Configure a RobICI device. For example, CTM1, in the robot controller, see Con-
figuring CTM in the robot controller on page 61.
3 To configure the IP address of the RobICI device, use the IP address of the CTM.
In RobotStudio, right-click the RobICI device in the RobICI Device Type under
the I/O System tree and select Edit RobICI Device(s). Assign the IP address to
the Server IP address field.
4 If CTM is connected to the public network of the robot controller, configure the
IP address of the robot controller.
5 Restart the robot controller.
6 Check the state of the I/O devices. The communication is established, if the CTM1
is in Running state.
Examples
Example 1
If the CTM is connected to the public network of the robot controller:
CTM WAN interface 192.168.8.48
Robot controller, RobICI device IP address 192.168.8.48
Robot controller, IP address 192.168.8.50
To view or change the IP address of the robot controller on the public network,
edit the network settings in RobotStudio. See Operating manual - Integrator's guide
OmniCore.
Example 2
If the CTM is connected to the private network of the robot controller:
CTM WAN interface 192.168.125.20
Robot controller, RobICI device IP address 192.168.125.20
Robot controller, Private Network IP address 192.168.125.1
It is not possible to change the IP address of the private network of the robot
controller.
Configuring the CTM with RobotStudio

The CTM unit is configured using RobotStudio. You can connect a computer with
RobotStudio to the WAN or LAN port of the CTM.
In the Controller tab click on Conveyor Tracking from the Confiuration group. A
Conveyor Tracking tab is displayed.
You can search for any conveyor tracking units on the network, see Connecting
and adding a CTM on page 47.
Minimum configuration
The setup of The IP address of the WAN interface is the minimum configuration
required, see Network settings on page 48. A communication between the CTM
and a robot controller can be established only after the IP address is defined.

Continued
You can change the following parameters:

• Name of the CTM and name of individual encoders and sensors, see Rename
on page 49.
• Encoder parameters, see Configuring an encoder on page 50.
• Sensor parameters, see Configuring a sensor on page 50.

5.3 Verifying the installation of encoders and sensors
Description
The CTM provides functionality that simplifies the verifications of installed encoders
and sensors. These verifications can be done by connecting RobotStudio to the
CTM. The verifications are based on the monitoring of certain CTM signals and
are independent of robot controllers.
Verifying if the encoder is electrically connected to the power

This test is only applicable if the encoder is powered by the encoder interface.
To verify if the encoder is electrically connected to the power:
Action
1 Open the signals for the encoder, see List all encoder signals on page 51.
2 Restart the CTM.
3 Verify the value of TwoPhaseEncX:PowerWired.
If the value is 1, it indicates that the encoder is connected to the power supply.
If the value is 0, it indicates that the encoder is not connected to the power supply.
Verifying if the trigger signal is electrically connected to a camera

To verify if the trigger signal is electrically connected to a camera:
Action
1 Open the signals for the sensor, see List all sensor signals on page 51.
2 Verify if the value of DigoutX:Wired is 1, else check the connection of the trigger
signal and the GND with the camera.
Verifying the encoder function

To verify the encoder function:
Action
The encoder function can be checked by monitoring the signal EncX:position that
displays the encoder count for encoder X.
2 Move the conveyor and verify if the EncX:position changes accordingly.
3 If the value does not change or is unstable, verify if the encoder is properly in-
stalled, electrically and mechanically.
Verifying the sensor function

To verify the sensor function:
Action
1 Open the signals for the sensor, see List all sensor signals on page 51.
The sensor function can be checked by monitoring the signal syncXencY:Value,
it displays the encoder count for encoder Y at the latest sync input event on sensor
X.
2 Move the conveyor Y a short distance.
3 Generate a sync input from the sensor, for example by detecting a object with an
I/O sensor or by triggering an image with a camera sensor.

Continued
Action
4 Verify if the syncXencY:Value is same as the value of the EncY:position.
5 If the value is not the same, verify if the encoder is properly installed, electrically
and mechanically.
Verifying the direction of positive motion

To verify the direction of positive motion:
Action
The EncX:position signal displays the encoder count for encoder X.
2 Move the conveyor towards the robot and verify if the signal value increases or
decreases.
The EncX:position signal displays the encoder count for encoder X.
3 If the signal value increases, the direction of positive motion is correct.
If the signal value decreases, reverse the A and B inputs from the encoder to the
encoder interface.
Identifying the gear ratio

Open the signals for the encoder, see List all encoder signals on page 51.
The gear ratio defines the motion distance of the conveyor as a function of
measured encoder counts.
The gear ratio can be used configure the system parameter CountsPerMeter for
the conveyor work area. It can be identified with the following procedure:
Action
1 Record the first encoder count C1 as EncX:position.
2 Move the conveyor forward for at least1 meter. Measure the actual movement
distance D. For a linear conveyor, D is measured in meter. For a rotational con-
veyor, D is measured in radians.
3 Record a second encoder count C2 as EncX:position.
4 Calculate the gear ratio = (C2 – C1) / D.

5.4 Configuration of robot controllers
Configuring CTM in the robot controller

In the robot controller configuration, the CTM is represented as a RobICI I/O device
on the RobICI network. The RobICI network is an internal ABB communication
protocol, see Operating manual - Integrator's guide OmniCore.
The option Conveyor Tracking installs one RobICI device to the RobICI network.
The option PickMaster 3 installs one RobICI device if 1-6 conveyor work areas
have been selected in the sub-option Conveyor Configuration.
Additional RobICI devices can be added using RobotStudio. There are templates
available to setup Conveyor Tracking Device 2, Conveyor Tracking Device 3, and
Conveyor Tracking Device 4. However, one RobICI device (with 4 encoder inputs)
is sufficient in most scenarios. For example, in a scenario with 5-6 conveyor work
areas, some of them are typically located on the same conveyor belt and can share
the same encoder.
To add a device in RobotStudio, in the controller tab, select Configuration -> I/O
System -> RobICI Device. Right-click and select New RobICI Device. Update Use
values from template: by selecting the appropriate template. Click OK to save the
new device.
The following needs to be configured for a RobICI device:
• The configured IP address of the CTM.

Continued
Configuring a conveyor work area using CTM

For each conveyor work area, a selection needs to be made on which encoder and
which sensor that shall be used for conveyor tracking.
xx1800000384
The selection is made by modifying the DeviceMap of nine I/O signals that belongs
to the conveyor work area. The nine signals are mapped to the configured CTM
device. The value in the DeviceMap column represent encoder and sensor numbers.
Note
One encoder may be used in parallel by multiple conveyor work areas on the
same robot controller, or on different robot controllers. One sensor may also be
used by multiple conveyor work areas, however, the sensor trigger function
should not be operated simultaneously by more than one work area.
Example 1
In this example, conveyor work area 1 is used with encoder 1 and sensor 1 on
CTM1. The DeviceMap is adjusted accordingly:
Name Device DeviceMap DeviceMap digits
represent
c1Counts CTM1 Enc1:position Encoder 1
c1CountsPerSec CTM1 Enc1:velocity Encoder 1

Continued

represent
c1SpeedBandWidth CTM1 e1_SpeedBand- Encoder 1
Width:SetPoint
c1TrigVis CTM1 Digout1:Setpoint Sensor 1
c1TrigAutoMode CTM1 Cam1:Connect Sensor 1
c1TrigAutoDist CTM1 Cam1:Interval Sensor 1
c1TrigAutoEncNo CTM1 Cam1Enc:DeviceNo Sensor 1
c1SoftSync CTM1 Sync1Enc1:SyncTrig Sensor 1, encoder 1
c1CntFromEnc CTM1 Sync1Enc1:Value Sensor 1, encoder 1
Example 2
represent
Width:SetPoint
Example 3
represent
Width:SetPoint

5.5 Calibrating CountsPerMeter
5.5 Calibrating CountsPerMeter
Description
If the exact gear ratio between the encoder and the conveyor is unknown (typically
the case) then the system parameter CountsPerMeter must be calibrated using
either a tape-measure or the robot TCP as a measuring device.
If the robot TCP is used as the measuring device then an accurately defined tool
must be used.
If the gear ratio is identified for the encoder, see Identifying the gear ratio on
page 60, its value can be used for CountsPerMeter. Alternatively, the method
mentioned in the Calculating and calibrating CountsPerMeter on page 64 section
can be used.
Calculating and calibrating CountsPerMeter

The counts from the encoder can be found by reading a predefined I/O signal. For
example CNV1 the signal name is c1counts. Note the counts for the current
conveyor position (named counts_1 in the formula below) and then move away
the conveyor at least 1 meter. Read the counts again (named counts_2) and
measure the distance the conveyor is moved (named measured_meters). The
accuracy will be best if this distance is large as possible within the work space.
Use a tape-measure (or differences in robot tool position) to find the exact distance.
Use this formula to calculate CountsPerMeter:
Use this procedure to modify CountsPerMeter.

1 Open the Configuration Editor and select Topics and Process.
2 Select the type Conveyor Ici.
3 Select CountsPerMeter and change the value.

5.6 Calibrating the conveyor base frame
Introduction to the conveyor base frame

The accuracy of the conveyor tracking depends on the accuracy of the conveyor
base frame calibration. For linear conveyors, use a method that uses the robot
TCP to measure the position and orientation of the conveyor in the work space.
Prerequisites
Before calibrating the base frame of the conveyor the values for the CountsPerMeter
and QueueTrkDist must be correct. See Calibrating CountsPerMeter on page 64.
The conveyor base frame calibration method will use the measurement of 4
positions of the same object on the conveyor to determine the conveyor base frame
(B), as shown in the following figure.
B
A Z
Y
QueueTrkDist X
p_1 p_2 p_3
0.0 m C
xx1200001098
B Base frame
C Conveyor distance
Before defining the 4 positions, an object must be defined on the conveyor.
Creating the work object (option Conveyor Tracking)

Use this procedure to create a work object. To create a work object for a servo
controlled indexing conveyor, see Creating the work object on page 151.
1 Step forward through a RAPID program containing the two instructions:
ActUnit CNV1;
WaitWObj wobjcnv1;
Define the conveyor coordinated work object, see Defining a conveyor
coordinated work object on page 82.
2 Run the conveyor until an object passes the sync switch and the 0.0 m point.
The WaitWObj instruction will end execution.
3 Stop the conveyor.
4 Calibrate the base frame, see Calibrating the base frame on page 66.
Note
Once an object is on the conveyor and beyond the 0.0 m point, it is possible to
use the base frame calibration method to define the conveyor position and
orientation in the work space.

Continued
Creating the work object when the conveyor is not moving (option Conveyor Tracking)
The controller uses the signal doCxxNewObjStrobe to create an object using the
current encoder counter and will generate a pulse on the signal doCxxCntToEncStr.
Use these RAPID instructions as an example to create a work object when the
conveyor is not moving.
ActUnit CnvMecUnit;
WaitTime 0.5;
DropWObj WorkObject;
WaitTime 0.5;
!
CONNECT NewObj WITH ObjTrap;
ISignalDO cxxCntToEncStr,1,NewObj;
PulseDO cxxNewObjStrobe;
WaitUntil NewObjReported=TRUE;
TRAP ObjTrap
WaitTime 0.2;
NewObjReported:=TRUE;
RETURN;
ENDTRAP
Limitations
The conveyor speed must be zero
All other objects in the queue will be removed
Creating the work object (option PickMaster)

Load and run the RAPID program PrepareCalib.prg. It is located in the HOME
folder.
Select the conveyor work area, CNVX, which needs calibration and let the program
execution complete.
Calibrating the base frame

Use this procedure to calibrate the conveyor base frame (applicable for both
Conveyor Tracking and Indexing Conveyor Control).
If the PickMaster option is used, see Application manual - PickMaster® 3.
1 On the FlexPendant, open the Calibration window and select the conveyor.
2 Tap Base Frame.
3 Tap 4 Point.
4 Select the first point, Point 1. This point will be the origin for the user frame
in the conveyor coordinated work object.
5 Point out Point 1 on the object on the conveyor with the robot TCP.
6 Modify the position by tapping ModPos.
7 Move the conveyor in the positive direction and repeat the above for the
points 2, 3, and 4.
8 Tap OK to calculate the base frame for the selected conveyor mechanical
unit.

Continued
A dialog with the calibration result is shown. The calculation log shows the
conveyor base frame expressed in the world coordinate system, see
Calculation result for the base frame on page 67.
9 To save the calculation result in a separate file for later use in a PC:
a Tap File.
b Specify a name and a location where to save the result.
c Tap OK.
10 If the estimated error is:
• Acceptable, tap OK to confirm the new user frame.
• Not acceptable, tap Cancel and redefine.
11 Restart the controller and verify the results of the calibration. See Verifying
the base frame calibration on page 67.
Calculation result for the base frame
Field Description
Unit The name of the mechanical unit for which the definition of base
frame has be done.
List contents Description
Method Displays the selected calibration method.
Mean error The accuracy of the robot positioning against the reference point.
Max error The maximum error for one positioning.
Cartesian X The x coordinate for the base frame.
Cartesian Y The y coordinate for the base frame.
Cartesian Z The z coordinate for the base frame.
Quaternion 1-4 Orientation components for the base frame.
Verifying the base frame calibration

If the PickMaster 3 option is used, see Application manual - PickMaster® 3, section
Verifying the calibrations.
After restarting the controller, use this procedure to verify the conveyor base frame
calibration.
1 Create a work object, see:
• Creating the work object (option Conveyor Tracking) on page 65, for
Conveyor Tracking.
• Calibrating the base frame on page 151, for Indexing Conveyor Control.
2 Move the robot tool center point back to the previously chosen point 1 on
the work object.
3 In the Jogging window, read the X, Y, Z position of the tool center point.
Make sure to use the correct tool and wobjcnv1.
4 The robot TCP x, y, and z position in the work object coordinates should be
0.0 mm (or very close to that).

Continued
5 In the Jogging window, select the work object wobjcnv1 and coordinate
system WObj and jog the robot in the x, y, and z directions of the conveyor.
Verify that the x-direction is in the direction of positive motion of the conveyor.

5.7 Defining conveyor start window and sync separation
5.7 Defining conveyor start window and sync separation
Start window
The start window is the length along the conveyor in which objects are tracked
and are ready for connection. When a WaitWObj instruction is issued the system
will connect to the first object inside the start window or wait otherwise.
If an object goes beyond the start window then it is no longer tracked and it is not
available for connection. Such objects are automatically skipped. The purpose of
the start window is to provide a buffer of objects for speed variations of the
conveyor. If an object is connected within the start window then it should be certain
that the motion coordinated to the object can be completed before the working
area limit or maximum distance is reached.
Note
It is recommended to configure a non zero start window, otherwise all objects

will be skipped and no object will be available for connection (default value is 10
m).
Sync separation
The parameter Sync Separation is used to filter out unwanted sync signals from a
synchronization switch. This parameter establishes a minimum distance that the
conveyor must move after one sync signal before a new sync signal is accepted
as a valid object.
Defining start window and sync separation

Sync separation is configured for each encoder directly on the tracking unit, see
Configuring the CTM with RobotStudio on page 57.
The start window is configured on the robot controller for the conveyor work areas.
Use this procedure to define the start window.
1 Open the Configuration Editor and select the topic Process.
3 Select the parameter StartWinWidth and change the value.

5.8 Avoiding robot reach problems
5.8 Avoiding robot reach problems
Description
A strategy is required to avoid coordination of motion beyond the reach of the
robot.
With the Conveyor Tracking option, it is possible to setup maximum and minimum
distances of the conveyor, to simplify this task.
With the PickMaster 3 option, coordination of motion beyond the reach of the robot
can be prevented with the instruction UseReachableTargets.
Maximum and minimum distances

It is possible to monitor the position of the conveyor and automatically drop any
connected objects that move outside the maximum or minimum specified distance.
The purpose is to prevent coordination of motion beyond the work area of the robot
for both forward and backward operation of the conveyor.
It is recommended to set a negative value of the parameter minimum distance,
otherwise all objects will be dropped as soon as they are connected. To have a
positive minimum value to enter the work area it is recommended to use the optional
argument \RelDist with the WaitWObj instruction.
Defining maximum and minimum distances

Use this procedure to define the distances.
2 Select the type Conveyor systems.
3 Select CNV1.
4 Select the parameters maximum distance and minimum distance and change
the values.
6 Select ICI1.
7 Select the parameter Supervise max_dist Off and set the value to No.
See Topic Process on page 94.

5.9 Using a trigger output on the CTM
5.9 Using a trigger output on the CTM
Description
The trigger output signals in the CTM are primarily intended to control image
acquisition of cameras.
A trigger output can be operated in two ways, manual mode or auto mode. Auto
mode is used when a fixed distance is required between consecutive images.
Manual mode is used when image acquisition should be controlled by a signal, for
example from a RAPID program.
The DO signal, cXTrigAutoMode, is used to switch modes, where the value 1
activates auto mode and 0 activates manual mode.
Manual mode
In manual mode, the DO signal, cXTrigVis, can be used to set or reset the trigger
output, for example from a RAPID program.
Auto mode
In auto mode, the trigger output will be pulsed by the CTM at a selected frequency
according to the encoder distance.
The supervised encoder (1, 2, 3, or 4) is selected by the GO signal,
cXTrigAutoEncNo.
The distance interval (number of counts) is selected by the GO signal,
cXTrigAutoDist.
The pulse length of the signal can be modified by configuring the CTM through
RobotStudio, see Configuring a sensor on page 50.
PickMaster 3 Option
With the PickMaster 3 option, select cXTrigVis as the trigger signal in the PickMaster
application, see Application manual - PickMaster® 3. Auto mode selection, encoder
selection, and distance interval is fully managed by PickMaster. The pulse length
can be modified by configuring the CTM through RobotStudio, see Configuring a
sensor on page 50.

5.10 Defining the robot adjustment speed
5.10 Defining the robot adjustment speed
Adjusting the speed

When entering conveyor tracking, the robot must adjust its speed to the speed of
the conveyor. The speed with which the robot catches up to the conveyor for the
first motion is controlled by the parameter adjustment speed.
See Type Conveyor systems on page 94 on how to derive a proper value for this
parameter.
Defining the robot adjustment speed

Use this procedure to define the robot adjustment speed.
2 Select the type Conveyor systems and select CNV1.
3 Select the parameter adjustment speed and change the values.
See Type Conveyor systems on page 94.

5.11 Additional adjustments
5.11 Additional adjustments
Description
There are more parameters that can be adjusted in the motion system.
Regulating CPU load and accuracy

The parameter Path Resolution specifies the period of the path planner in planning
steps along the path (no units). Step calculations require lots of CPU time and if
steps cannot be calculated in time to keep the robot on the path then error 50082
Deceleration Limit may occur. As conveyor tracking increases the general CPU
load then the parameter Path Resolution can be increased if this error occurs. See
Type Motion Planner on page 92.
Defining the mechanical unit parameters

The mechanical unit parameters define the name used in RAPID, and the conditions
for activation and deactivation.
These parameters can be changed to ensure activation of the conveyor. See Type
Mechanical Unit on page 92.
Defining additional robot parameters

Some parameters in the type Robot (topic Motion) can need adjustments. See
Type Robot on page 92.

5.12 Configuring a track motion to follow a conveyor
Track following a conveyor

If the robot is mounted on a track, and the track is parallel to the conveyor, then
the motion can be configured so that the track follows the conveyor. The robot and
the track must be configured for coordinated track motion. See Operating
manual - OmniCore for information on configuring coordinated motion.
Once the robot and track are configured for coordinated motion, then conveyor
tracking will automatically use the track to follow the conveyor. The track will
maintain the same position relative to the object as the object moves on the
conveyor as it was during programming.
The track and robot base frame must be defined so that positive motion of the track
is in the same direction as the conveyor. In some installations this may require a
re-definition of the track’s direction of positive motion and calibration position.
Example configuration of track and conveyor directions

The following figure shows an example configuration.
YA
A XA
YB
XIRB
B XB YIRB
-|+ IRB
xx1200001099
A Conveyor
The arrow shows the direction of movement for the conveyor
B Track motion
The -|+ shows the direction of movement for the track
Conveyor quaternion 1, 0, 0, 0
Robot base quaternion 0.7071, 0, 0, 0.7071
Track base quaternion 1, 0, 0, 0

Continued
Recommendations for programming

Avoid moving the track when programming the conveyor coordinated instructions
in the RAPID program. All motions of the track relative to the conveyor are saved
and played back during conveyor tracking. Tracks typically have an acceleration
ability that is far below that of the robot joints. If the track must move relative to
the object then this will require an acceleration that will cause a reduction of the
robot’s TCP speed along the path in order to maintain coordination.
Tracking the conveyor with a robot instead of a track

If the robot base is not coordinated with the track axis, then the robot will do
conveyor tracking without using the track. If the robot base frame is coordinated
with the track, and conveyor tracking with the robot (instead of the track) is wanted,
then change the parameter Track Conveyor With Robot in the type Robot (topic
Motion). See Type Robot on page 92.

5.13 Installing conveyor tracking software
5.13 Installing conveyor tracking software
Reloading saved Motion parameters

If the CNV1 mechanical unit does not appear on the FlexPendant then the Motion
parameters must be reloaded manually in RobotStudio, from the robot controller
<system name>\...\cnv\cnv1_moc.cfg.

5.14 Installing additional conveyors work areas for conveyor tracking
5.14 Installing additional conveyors work areas for conveyor tracking
Installing additional conveyor work areas for conveyor tracking

The option Conveyor Tracking installs one conveyor work area in the configuration
(that is, in the system parameters). The PickMaster 3 option installs 0-6 conveyor
work areas depending on the selected Conveyor Configuration. If additional
conveyors work areas should be tracked with the same robot controller then the
parameters for the additional conveyor work areas must be loaded manually. Up
to 6 conveyor work areas can be installed on one controller.
For Indexing Conveyor Control, see Installing the additional axis for servo control
on page 144.
Installing additional conveyors work areas

Use this procedure to install additional conveyor work areas for conveyor tracking,
for DSQC2000:
1 If the encoder is not connected to a preconfigured RobICI device, add a new
RobICI device via RobotStudio, see Configuring CTM in the robot controller
on page 61.
Note
Several conveyor work areas can share the same encoder interface on a
DSQC2000, for example two robots picking objects from the same conveyor.
2 In RobotStudio, load the files cnvici2_eio.cfg, cnvici2_prc.cfg, and

cnv2_moc.cfg. (Repeat for additional conveyors.)
These files are found in the installation folder of Robotware, for example,
C:\Users\Username\AppData\Local\ABB
\RobotWare\RobotWare_version\options\cnv.
3 Restart the system.
4 For each conveyor work area, define the correct DeviceMap for the I/O signals,
see Configuring a conveyor work area using CTM on page 62.
5 Restart the system.

6 Programming
6.1 Programming conveyor tracking
6 Programming
6.1 Programming conveyor tracking
Prerequisites
To create a program that uses conveyor tracking and a conveyor coordinated work
object, a work object must be present in the start window. An object must be moved
into the start window. If there are several objects already on the conveyor, then it
can be necessary to first clear the object queue and then move the conveyor.

6 Programming
6.2 Working with the object queue
I/O signals and the object queue

There are several I/O signals that allow a user or a RAPID program to monitor and
control the object queue. The following table shows the I/O signals that impact the
object queue.
I/O signal Description
c1ObjectsInQ Group input showing the number of objects in the object queue.
c1Rem1PObj Remove first pending object from the object queue. Setting this signal will
cause the first pending object to be dropped from the object queue. Pending
objects are objects that are in the queue but are not connected to a work
object.
Note
It takes some time for the signal to apply. After setting the signal, it is
therefore advisable to wait for 0.15 s before a new work object is connected.
c1RemAllPObj Remove all pending objects. Setting this signal will empty all objects from
the object queue. If an object is connected, then it is not removed.
Note
therefore advisable to wait for 0.15 s before a new work object is connected.
c1DropWObj Setting this signal will drop the tracked object and disconnect that object.
The object is removed from the queue. This should not be set from RAPID,
use a DropWobj instruction instead.

6 Programming
6.3 Activating the conveyor
6.3 Activating the conveyor
Activation
As an additional axis and mechanical unit the conveyor must be activated before
it can be used for work object coordination. The usual ActUnit instruction is used
to activate the conveyor and DeactUnit can be used to deactivate the conveyor.
As an additional axis and mechanical unit the conveyor must be activated before
it can be used for work object coordination. The usual ActUnit instruction is used
to activate the conveyor and DeactUnit can be used to deactivate the conveyor.
By default, the conveyor is installed non-active on start. The conveyor can be
configured to always be active at start. See Type Mechanical Unit on page 92.
Handling of the objects queue after activation (DSQC2000 only)

The object queue is handled by the controller only after the conveyor activation.
It is not recommended to access any conveyor related IO signal or RAPID instruction
before activating the conveyor.

6 Programming
6.4 Defining a conveyor coordinated work object
6.4 Defining a conveyor coordinated work object
Settings for wobjcnv1

Use these settings to define a new conveyor coordinated work object, wobjcnv1
(data type wobjdata).
Data Data type Description

ufprog bool Defines if a fixed user coordinate system is
(user frame programmed) used.
Set to FALSE for a movable user coordinate
system, that is, coordinated to conveyor.
ufmec string The conveyor mechanical unit with which the
(user frame mechanical unit) robot movements are coordinated. Specified
with the name that is defined in the system
parameters, for example CNV1.
For more information about data types, see Technical reference manual - RAPID
Instructions, Functions and Data types.
For more information about defining work objects, see Operating
manual - OmniCore.

6 Programming
6.5 Waiting for a work object
6.5 Waiting for a work object
Waiting for a work object

Motions that should be coordinated with the conveyor cannot be programmed until
an object on the conveyor has been connected with a WaitWObj instruction.
If the object on the conveyor is already connected from a previous WaitWObj or
if connection was established during activation, then execution of a second
WaitWObj instruction will cause an error. This error can be handled in an error
handler.
See WaitWObj - Wait for work object on conveyor on page 97.

6 Programming
6.6 Programming the conveyor coordinated motion
6.6 Programming the conveyor coordinated motion
Programming the conveyor

1 Create a program with the following instructions:
ActUnit CNV1;
ConfL/Off;
MoveL waitp, v1000, fine, tool;
WaitWObj wobjcnv1;
2 Single-step the program past the WaitWObj instruction.
If there is an object already in the start window on the conveyor then the
instruction will return, else execution will stop while waiting for an object on
the conveyor.
3 Run the conveyor until a work object is created.
The program exits the WaitWObj and is now connected to the object. Stop
the conveyor with the object in an accessible position on the workspace.
4 Program the MoveL, MoveC, PaintL, or PaintC instructions using the
wobjcnv1 conveyor coordinated work object.
5 End the coordinated motion with a fixed-frame work object (not coordinated
to the conveyor). Note that this is the only way to end the use of the work
object.
6 Add a DropWObj wobjcnv1; instruction.
7 If this is the end of the program, or the conveyor is no longer needed, then
add a DeactUnit CNV1; instruction.
Note
In the case of CTM (DSQC2000 only) it is recommended to leave the

conveyor active to avoid missing objects.
Example
The following program shows an example for a conveyor tracking program.
ConfL\Off;
MoveJ p0, vmax, fine, tool1;
ActUnit CNV1;
WaitWObj wobjcnv1;
MoveL p10, v1000, z1, tool1\Wobj:=wobjcnv1;
MoveL p40, v500, fine, tool1;
DropWObj wobjcnv1;
MoveL p0, v500, fine;
DeactUnit CNV1;

6 Programming
6.7 Dropping a work object
6.7 Dropping a work object
Introduction
A connected work object can be dropped once conveyor coordinated motion has
ended. Make sure that the robot motion is no longer using the conveyor positions
when the work object is dropped. If motion still requires the positions then a stop
will occur when the object is dropped.
It is not necessary to be connected in order to execute a DropWObj instruction.
No error will be returned if there was no connected object.
Finepoints
Conveyor coordinated motion does not end in a finepoint. As long as the work
object is coordinated to the conveyor, the robot motion will be coupled to the
conveyor even in a finepoint. A fixed-frame or non-conveyor work object must be
used in a motion instruction before dropping the conveyor work object.
Corner zones
Take care when ending coordination in a corner zone and executing the DropWObj
instruction as the work object will be dropped before the robot has left the corner
zone and the motion still requires the conveyor coordinated work object.

6 Programming
6.8 Entering and exiting conveyor tracking motion in corner zones
6.8 Entering and exiting conveyor tracking motion in corner zones
Enter and exit coordinated motion

Once a WaitWObj instruction has connected to a work object on the conveyor then
it is possible to enter and exit coordinated motion with the conveyor via corner
zones.
Example
WaitWObj wobjcnv1
! enter coordination in zone
MoveL p20, v1000, z50, tool1;
! exit coordination in zone
DropWObj wobjcnv1;
The move instruction ending coordination must be a fixed work object, for example
ufprog is TRUE.
Take care when exiting coordination in a corner zone and executing a DropWObj
instruction.
The following example shows an incorrect method for ending coordination in corner
zones:
...
! exit coordination in zone
DropWObj wobjcnv1;
This will cause an error, because the work object is dropped while robot is still in
corner zone.

6 Programming
6.9 Information on FlexPendant
6.9 Information on FlexPendant
Available information on the FlexPendant
Information Available in app

The conveyor position and speed Jog
The conveyor position is displayed in meters, and the conveyor speed
in m/s. The speed will be 0 m/s until an object has passed the synchron-
ization switch.
The position in millimeters of the conveyor object Jog
This value will be negative if a Queue Tracking Distance is defined. When
an object passes the synchronization switch then the position will be
automatically updated.
All signals that are defined for conveyor tracking I/O

6 Programming
6.10 Programming considerations
6.10 Programming considerations
Performance limits
Conveyor tracking will be lost if joint speed limits are reached, particularly in
singularities. Ensure that the path during tracking does not exceed the acceleration,
speed, and motion capabilities of the robot.
Motion commands
Only linear and circular motion instructions are allowed for conveyor tracking, that
is MoveL and MoveC.
Do not start tracking with a MoveC instruction as the resulting circle diameter will
depend on the conveyor position. Always start tracking with a MoveL.
Finepoints
Finepoints are allowed during conveyor tracking. The robot will hold the TCP still
relative to the conveyor and RAPID execution will continue, see Finepoint
programming on page 89.
ConfL
The RAPID instruction ConfL\Off must be executed before coordination with the
conveyor. The purpose is to avoid configuration errors that would otherwise occur
as the robot changes configuration during conveyor tracking.
Other RAPID limitations

The instructions StorePath and RestoPath do not function during conveyor
tracking.
A Search instruction will stop the robot when hit or if the search fails. Make the
search in the same direction as the conveyor moves and after the search stops
continue with a move to a safe position. Use an error handler to move to a safe
position if the search fails.
EoffsSet, EoffsOn, and EoffsOff have no effect for the conveyor additional
axis, but can affect conveyor tracking with coordinated track. They also have effect
on the sensor taught position.
Power fail restart is not possible with the synchronization option.
It is possible to use worldzone in conveyor tracking but during tracking the robot
may move outside worldzone borders due to the position adjustment at servo level.
Hence, taking margin is recommended when defining the worldzone.

6 Programming
6.11 Finepoint programming
6.11 Finepoint programming
Example with SetDO

While tracking the conveyor it is possible to use a finepoint. The following program
example shows how motion may be stopped with respect to the conveyor so that
an I/O signal may be set:
WaitWObj wobjcnv1
MoveL p2, v500, fine, tool1\Wobj:=wobjcnv1;
SetDO release_gripper;
WaitTime 0.1;
DropWObj wobjcnv1;
In the above example the SetDO will be executed after the robot arrives at p2. The
robot will then track the conveyor for 0.1 seconds while the WaitTime instruction
is executed. It will then move to p3 and on to p4 via a corner zone before ending
coordination with a fixed work object (wobj0 in this case).
Example with stoppointdata

Finepoints can also be programed with stoppointdata. To make the robot follow
the conveyor during 0.1 second, the following program can used.
VAR stoppointdata followtime:=[3,FALSE,[0,0,0,0],0,0.1, "",0,0];
WaitWObj wobjcnv1MoveL p1, v500, z20, tool1\Wobj:=wobjcnv1;
MoveL p2,v500,z1\Inpos:=followtime,tool1\WObj:=wobjcnv1;
SetDO release_gripper;
DropWObj wobjcnv1;
For coordinated movements the \Inpos event will not occur for instructions Break
and WaitTime. Instead, use the data type stoppointdata.

6 Programming
6.12 Operating modes
6.12 Operating modes
Operation in manual reduced speed mode (<250 mm/s)

When the conveyor is not moving, then the forward and backward hard buttons
on the FlexPendant can be used to step through the program. New instructions
can be added and programmed positions can be modified (ModPos).
To simplify programming, the conveyor may be moved to new positions between
instructions. The robot will return to the correct position when forward or backward
button is pressed.
The robot will recover as normal if the enabling device is released during motion.
The robot cannot perform coordinated motions to the conveyor while in manual
reduced speed mode and the conveyor is moving.
Operation in automatic mode

Once a WaitWObj instruction has been executed, then it is no longer possible to
step through the program with forward and backward hard buttons while the
conveyor is moving.
Action Description
Start and stop The robot will stop and no longer track the conveyor if the stop button
is pressed, or a Break or StopMove instruction is executed, between
the WaitWObj and DropWObj instructions. The conveyor coordinated
work object will not be lost but if the conveyor is moving then the object
will quickly move out of the working area. Restart from the current instruc-
tion is not possible and the program must be restarted from the Main
routine or with a WaitWObj instruction.
Emergency stop When the emergency stop is pressed the robot will stop immediately. If
the program was stopped and restarted after a WaitWObj then the co-
ordinated work object will not be lost, but if the conveyor is moving then
the object will quickly move out of the working area. It is not possible to
restart from the current instruction and the program must be restarted
either from the Main routine or with a WaitWObj instruction.
Operation in manual full speed mode (100%)

Operation in manual mode (100%) is similar to operation in automatic mode. The
program can be run by pressing and holding the start button, but once a WaitWObj
instruction has been executed then it is no longer possible to step through the
program with the forward and backward buttons while the conveyor is moving.
Action Description
Stop and restart When the start button is released, or emergency stop is pressed, the
robot will stop immediately. If the program was stopped after a WaitWObj
then the coordinated work object will not be lost but if the conveyor is
moving then the object will quickly move out of the working area. It is
not possible to restart from the current instruction and the program must
be restarted either from the Main routine or with a WaitWObj instruction.

7 System parameters
7.1 Introduction
7 System parameters
7.1 Introduction
About system parameters

This chapter describes system parameters used for all conveyor tracking options.
Some parameters that are specific for only one option are presented in procedure
context if they need to be changed.
All basic system parameters and the system parameter principles are listed in
Technical reference manual - System parameters.
System parameters are modified using the Configuration Editor in RobotStudio.

7 System parameters
7.2 Topic Motion
7.2 Topic Motion
Type Mechanical Unit

The instance is named CNV1. See Defining the mechanical unit parameters on
page 73, and Activating the conveyor on page 81.
Parameter Description
Name The name of the unit, usually CNV1, CNV2 etc.
This name is used in the Jogging window and from the program, for
example when a unit should be activated.
Activate at Star- Defines if the conveyor should be activated automatically at start.
tup
Note
This parameter should not be used when combining synchronized and

un-synchronized mode, see Combining synchronized and un-synchron-
ized mode on page 175.
Deactivation For- Defines if the conveyor is allowed to be deactivated.

bidden
Type Motion Planner

The instance is named motion_planner. See Regulating CPU load and accuracy
on page 73.
Path Resolution The parameter corresponds in some sense to the distance between two
points in the path. Increasing path resolution means increasing the dis-
tance, which leads to a decrease in the resolution of the path.
Process Update Determines how often the process path information is calculated.
Time
Use spline para- Defines how long the robot waits when starting from a finepoint, that is
meters how many positions will be calculated in advance by the motion planner.
Default value is motion_planner_1 for the first robot.
Using 3steps mp1 will give a shorter time when starting from finepoint
but with the risk that sometimes the robot will stop with warning 50024
(Corner zone executed as finepoint) on first move. mp1 stands for mo-
tion planner 1, that is, robot 1.
Type Robot
The instance is named ROB_1, ROB_2 etc. See Additional adjustments on page 73,
and Configuring a track motion to follow a conveyor on page 74.
Corvec correc- Defines how often corrections of robot positions are done. Default is 1.
tion level Increasing the value gives corrections more often. Should be set to 2 or
3 to get good accuracy during conveyor acceleration.
For IRB 360 with high payloads (6-8 kg), for YuMi robots, and for big ro-
bots like IRB 6700, it should be set to 1.
Track Conveyor If Yes, then the robot will track the conveyor without using the track axis
With Robot even if robot is coordinated with the track. Default value is No.

7 System parameters
7.2 Topic Motion
Continued
Max accel for This parameter should only be used when conveyor speed is higher than
conveyor track- 600 mm/s, when the robot has to pick a part on the conveyor, and when
ing increase of max_external_pos_adjustment and Stop_ramp is not an op-
tion.
Defines the max acceleration allowed for the robot during conveyor
tracking. The aim of this parameter is to reduce adjustment in servo task
as big adjustment values can cause speed supervision errors or
max_external pos adjustment error (50163). The drawback of too low
acceleration is an increase of cycle time.
Default value is 1 (limit not used), max value is 100 (m/s 2 ).
Max External Pos Defines the maximum position adjustment allowed in the servo task. Can
Adjustment be increased for big robots with heavy load and high conveyor speed if
error 50163 occurs. First verify that Adjustment speed and Adjustment
accel are correctly defined (see Type Conveyor systems on page 94).
Default value 0.2, maximum 0.8, minimum 0.1. Defined in meters. If in-
creased, Start ramp and Stop ramp should also be increased to 20 or 30
(see Type Conveyor systems on page 94).
Type Single
The instance is named CNV1. See Calibrating the conveyor base frame on page 65.
Base frame x Defines the x, y, and z-direction of the base frame position in Base frame
Base frame y y relation to the world frame (in meters).
Base frame z
Base frame q1-q4 Defines the quaternions of the base frame orientation in relation to the
world frame. That is, the orientation of the conveyor base coordinate
system.
Type Single Type

The instance is named CNV1.
Mechanics Defines what type of mechanics the single type uses.
Type Transmission
The instance is named CNV1.
Rotating Move Defines if the conveyor is rotating (Yes) or linear (No).

7 System parameters
7.3 Topic Process
7.3 Topic Process
Type Conveyor systems

The instance is named CNV1. See Avoiding robot reach problems on page 70, and
Defining the robot adjustment speed on page 72.
Adjustment The speed (in mm/s) at which the robot should catch up to the conveyor.
speed The general recommended value is 130 % of the conveyor speed. As
minimum, the value should be more than 100 % with some margin. If the
robots speed is very fast compared to the conveyor speed, a further in-
crease of the value is often necessary.
If the value is set too low, robot movements may become jerky or the
conveyor tracking accuracy may become reduced. On the other hand,
if the value is set too high, the drive system may become overloaded,
causing motion supervision errors. Generally, the maximum recommen-
ded value is 200 %. For IRB360 in applications with high robot speed,
the maximum recommended value is 500 %.
minimum dis- The minimum distance (in millimeters) that a connected object can have
tance before being automatically dropped. If an object is dropped during co-
ordinated motion, then the motion is stopped and an error is produced.
Note that if the minimum distance is set to a positive value, then all ob-
jects are dropped as soon as they are connected.
maximum dis- The maximum distance (in millimeters) that a connected object can have
tance before being automatically dropped. If an object is dropped during co-
ordinated motion, then the motion is stopped and an error is generated.
Stop ramp The number of samples used to ramp down the correction when tracking
is stopped.
The default value of this parameter is 5, and this is a suitable setting for
an IRB 360 with payload in the range 0-1 kg. For an IRB 360 with payload
1-8 kg, the value of this parameter should be increased to avoid vibrations
and overload of the mechanical structure. A value of at least 10 should
be chosen for a robot with 8 kg payload.
When tracking with a track axis this parameter should be increased to
30.
For a robot switching between conveyors increasing the stop ramp will
increase the distance needed to reach accurate tracking on next convey-
or. For example, for an IRB 360 10 steps of 12 ms at 5 m/s this means
0.6 meters.
Start ramp The number of samples used to ramp up the correction when tracking
is started.
The default value of this parameter is 5, and this is a suitable setting for
an IRB 360 with payload in the range 0-1 kg. For an IRB 360 with payload
1-8 kg, this parameter should be increased to avoid vibrations and
overload of the mechanical structure. A value of at least 10 should be
chosen for a robot with 8 kg payload.
When tracking with a high speed conveyor this parameter can be in-
creased.
During the ramping the accuracy of tracking is not reached so be careful
when increasing this parameter. For an IRB 360 the best choice is to use
the default value (5) if the load is not higher than 1 kg.
When switching between 2 conveyors with short distance between pick
and place the use of time interpolation is the optimal solution. For ex-
ample, put the robot in a wait position just above the pick conveyor with
a very short distance to pick position. In this case a low speed or time
interpolation should also be used.

7 System parameters
7.3 Topic Process
Continued
Adjustment accel The maximum acceleration (in mm/s2) at which robot should catch up
to the conveyor. By default no limitation.
For big robots and heavy load or limited robot acceleration (like use of
AccSet or PathAccLim) it can be necessary to set Adjustment accel
according to the robot performances.
With robot on track or trolley tracking with the track the performance of
the track is automatically used. This parameter must be adjusted when
the robot cannot continue its path but remains tracking the same position
on the conveyor.
For big robots like IRB 6600 Adjustment accel should be set around 1000
if conveyor speed is higher than 150 mm/s.
Speed filter The number of samples used for average filter of conveyor speed. Max-
length imum value is 50. Default value 1, which equals no filter. Should be used
only in case of high level of noise on conveyor speed and speed reduction
on robot due to this noise.
Acc dependent Specifies the acceleration dependent filter. Default value is 1 m/s 2 . To
filter value get good accuracy during acceleration this value should be set
equal to the maximum acceleration of the conveyor. A low value means
harder filtering. If there is a problem with noise this parameter should
be reduced. If an IRB 360 is used for fast picking this parameter should
be set to 0, this will turn off the filtering to improve the response times.
syncfilter ratio Defines how fast the robot should adjust the speed to the conveyor
speed. Default value is 0.8. For IRB 360 this can be reduced to 0.5 to
improve the accuracy in fast pick and place applications with low payload
(0-1 kg). A too low value might result in jerky movements.
Type Conveyor Ici (DSQC2000)
CountsPerMeter Gives the number of quadrature pulses per meter of motion of the con-
veyor. Should be in the range of 5000-10000 for linear conveyors.
QueueTrckDist The queue tracking distance (meters) defines the placement of the 0.0
meter point relative to the synchronization switch on the conveyor. All
objects in this distance are tracked. The position returned for the object
will be negative, relative to the 0.0 m point.
All objects in this distance are tracked, but connection is not allowed
until an object has passed 0.0 meters.
StartWinWidth This distance defines the start window (meters). The start window defines
the area that if a program starts using an object within the window, then
all program coordination can end before the maximum distance or work
area is reached. All objects within this window are tracked and are eligible
for use in a coordinated work object. A WaitWObj instruction will connect
to the first object in the window.
PosUpdateTime Defines how often the system reads the speed and position of the con-
veyor from the I/O system.

8 RAPID reference
8.1.1 WaitWObj - Wait for work object on conveyor
8 RAPID reference
8.1 Instructions
Description
WaitWObj (Wait Work Object) connects to a work object in the start window on
the conveyor mechanical unit.
Example
WaitWObj wobj_on_cnv1;
The program connects to the first object in the object queue that is within the start
window on the conveyor. If there is no object in the start window then execution
stops and waits for an object.
Arguments
WaitWObj WObj [\RelDist][\MaxTime][\TimeFlag]
WObj
Work Object
Data type: wobjdata
The moving work object (coordinate system) to which the robot position in the
instruction is related. The mechanical unit conveyor is to be specified by the ufmec
in the work object.
[\RelDist]
Relative Distance
Data type: num
Waits for an object to enter the start window and go beyond the distance specified
by the argument. If the work object is already connected, then execution stops
until the object passes the distance. If the object has already gone past the relative
distance then execution continues.
[\MaxTime]
Maximum Time
Data type: num
The maximum period of waiting time permitted, expressed in seconds. If this time
runs out before the sensor connection or relative distance is reached, the error
handler will be called, if there is one, with the error code ERR_WAIT_MAXTIME. If
there is no error handler, the execution will be stopped.
[\TimeFlag]
Timeout Flag
Data type: bool

8 RAPID reference
Continued
The output parameter that contains the value TRUE if the maximum permitted
waiting time runs out before the sensor connection or relative distance is reached.
If this parameter is included in the instruction, it is not considered to be an error if
the maximum time runs out. This argument is ignored if the MaxTime argument is
not included in the instruction.
Program execution
If there is no object in the start window then program execution stops. If an object
is present, then the work object is connected to the conveyor and execution
continues.
If a second WaitWObj instruction is issued while connected then an error is returned
unless the \RelDistoptional argument is used.
More examples
Example 1
WaitWObj wobj_on_cnv1\RelDist:=500.0;
If not connected, then wait for the object to enter the start window and then wait
for the object to pass the 500 mm point on the conveyor. If already connected to
the object, then wait for the object to pass 500 mm.
Example 2
If not connected, then wait for an object in the start window. If already connected,
then continue execution as the object has already gone past 0.0 mm.
Example 3
WaitWObj wobj_on_cnv1;
The first WaitWObj connects to the object in the start window. The second
WaitWObj will return immediately if the object is still connected, but will wait for
the next object if the previous object had moved past the maximum distance or
was dropped.
Example 4
WaitWObj wobj_on_cnv1\RelDist:=500.0\MaxTime:=0.1\Timeflag:=flag1;
The WaitWobj will return immediately if the object has passed 500 mm but
otherwise will wait 0.1 seconds for an object. If no object passes 500 mm during
this 0.1 seconds the instruction will return with flag1=TRUE.
Limitations
20 is required to connect to the first object in the start window. Once connected,
a second WaitWObj instruction with \RelDist optional argument will take only
normal RAPID instruction execution time.
Error handling
If following errors occur during execution of the WaitWobj instruction, the system
variable ERRNO will be set. These errors can then be handled in the error handler.
ERR_CNV_NOT_ACT The conveyor is not activated.

8 RAPID reference
Continued
ERR_CNV_CONNECT The WaitWobj instruction is already connected.

ERR_CNV_DROPPED The object that the instruction WaitWobj was waiting for has been
dropped by another task.
ERR_WAIT_MAXTIME The object did not come in time and there is no Timeflag.
ERR_CNV_OBJ_LOST The object has passed the StartwindowWidth without being con-
nected.
Syntax
WaitWObj
[ WObj ':=']< persistent (PERS) of wobjdata> ';'
[ '\' RelDist ':=' < expression (IN) of num > ]
[ '\' MaxTime ':=' <expression (IN) of num>]
[ '\' TimeFlag ':=' <variable (VAR) of bool>] ';'
Related information
For information about See

DropWObj DropWObj - Drop work object on conveyor
on page 100
The data types wobjdata, num, and bool Technical reference manual - RAPID Instruc-
tions, Functions and Data types

8 RAPID reference
8.1.2 DropWObj - Drop work object on conveyor
8.1.2 DropWObj - Drop work object on conveyor
Description
DropWObj (Drop Work Object) is used to disconnect from the current object and
the program is ready for the next.
Example
MoveL *, v1000, z10, tool, \WObj:=wobj_on_cnv1;
MoveL *, v1000, fine, tool, \WObj:=wobj0;
DropWObj wobj_on_cnv1;
MoveL *, v1000, z10, tool, \WObj:=wobj0;
Arguments
DropWObj WObj
WObj
Work Object
Data type: wobjdata
The moving work object (coordinate system) to which the robot position in the
instruction is related. The mechanical unit conveyor is to be specified by the ufmec
in the work object.
Program execution
Dropping the work object means that the object is not longer tracked. The object
is removed from the object queue and cannot be recovered.
Limitations
If the instruction is issued while the robot is actively using the conveyor coordinated
work object then the motion stops.
The instruction can be issued only after a fixed work object has been used in the
preceding motion instructions with either a fine point or several (>1) corner zones.
Syntax
DropWObj
[ WObj ':='] < persistent (PERS) of wobjdata> ';'
Related information
For information about See

WaitWObj WaitWObj - Wait for work object on conveyor
on page 97
The data type wobjdata Technical reference manual - RAPID Instruc-
tions, Functions and Data types

8 RAPID reference
8.1.3 CnvPredictReach - High speed conveyors
RobotWare - OS
Description
This section describes the CnvPredictReach.sys module that is used to predict if
the picking and placing positions are within the work area of the IRB 360, when
using high speed conveyors (speeds higher than 800 mm/s). This module can only
be used for simple and repeatable picking and placing programs, it cannot be used
with buffer or stop and go conveyors.
Example: Initialization of data structure

RECORD cnvpickeroptimdata
bool Tpumessage;
num firststeppredictionratio;
num maxfirststeppredictiontime;
num secondsteppredictionratio;
num maxsecondsteppredictiontime;
num maxfirstcyclepredictiontime;
bool wait_end_of_pp_movement;
string pickconveyor;
string placeconveyor;
ENDRECORD
Default value
TASK PERS cnvpickeroptimdata defaultcnvpickeroptimdata
:=[FALSE,0.35,0.6,0.3,0.75,0.6,TRUE,"CNV1","CNV2"];
Example: Picking and placing

Initialization phase
InitCnvPredictReach
Safepos,resettimearea,1,defaultcnvpickeroptimdata;
In the picking program example from Pickmaster you will need to add a call to
checkpick and trigg to pickenter and pickexit.
PROC Pick(num Index)
IF Index > 0 THEN
WObjPick:=ItmSrcData{Index}.Wobj;
GetItmTgt ItmSrcData{Index}.ItemSource,PickTarget;
CheckPick PickTarget.RobTgt,PickAct1,WObjPick;
TriggL\Conc,RelTool(PickTarget.RobTgt,0,0,-ItmSrcData{Index}.OffsZ)
,MaxSpeed,ItmSrcData{Index}.VacuumAct1\T2:=pickenter,z20,PickAct1\WObj:=WObjPick;
TriggL\Conc,PickTarget.RobTgt,LowSpeed,ItmSrcData{Index}.SimAttach1,z5\
Inpos:=ItmSrcData{Index}.TrackPoint,PickAct1\WObj:=WObjPick;
GripLoad ItemLoad;
TriggL
RelTool(PickTarget.RobTgt,0,0,-ItmSrcData{Index}.OffsZ),LowSpeed,
ItmSrcData{Index}.Ack\T2:=pickexit,z20,PickAct1\WObj:=WObjPick;
AccSet 100,100;
ELSE
ErrWrite "Missing item distribution", "Cannot pick because no item
distribution contains current work area." \RL2:="Please check
configuration";

8 RAPID reference
RobotWare - OS
Continued
SafeStop;
ENDIF
ERROR
AckItmTgt ItmSrcData{Index}.ItemSource,PickTarget,FALSE\Skip:=TRUE;
GetItmTgt ItmSrcData{Index}.ItemSource,PickTarget;
RETRY;
ENDPROC
Example: Double picking or single placing

Initialization phase
InitCnvPredictReach
For example when using the Pickmaster template, for double picking and single
placing.
LOCAL CONST string aiCnv1PosSigName:="c1Position";
LOCAL CONST string aiCnv1SpeedSigName:="c1Speed";
LOCAL VAR signalai aiCnv1Position;

LOCAL VAR signalai aiCnv1Speed;
PROC EnumerateWorkAreas()
VAR num PickNumber:=1;
VAR num PlaceNumber:=1;
VAR num OtherNumber:=1;
InitCnvPredictReach
FOR i FROM 1 TO MaxNoSources DO

IF (ItmSrcData{i}.Used) THEN

8 RAPID reference
RobotWare - OS
Continued
IF (ItmSrcData{i}.SourceType = PICK_TYPE) THEN

PickWorkArea{PickNumber}:=i;
WObjPick:=ItmSrcData{i}.Wobj;
IF use_3areas THEN
InitPickArea 1,3,PickAct1 ,WObjPick,SafePos,FALSE;
ELSE
InitPickArea 1,2,PickAct1 ,WObjPick,SafePos,TRUE;
ENDIF
Incr PickNumber;
ELSEIF (ItmSrcData{i}.SourceType = PLACE_TYPE) THEN
PlaceWorkArea{PlaceNumber}:=i;
WObjPlace:=ItmSrcData{i}.Wobj;
InitPickArea 2,1,PickAct1 ,WObjPlace,SafePos,FALSE;
IF use_3areas THEN
InitPickArea 3,2,PickAct1 ,WObjPlace,SafePos,FALSE;
ENDIF
Incr PlaceNumber;
ELSE
OtherWorkArea{OtherNumber}:=i;
Incr OtherNumber;
ENDIF
InitIoaliasfromitmsrc i;
ENDIF
ENDFOR
ENDPROC
InitIoaliasfromitmsrc is simple alias definition for QuickAck

function
PROC InitIoaliasfromitmsrc(num Index)
IF ItmSrcData{Index}.Wobj.ufmec = "CNV1" THEN
AliasIO aiCnv1PosSigName,aiCnv1Position;
AliasIO aiCnv1SpeedSigName,aiCnv1Speed;
ELSEIF ItmSrcData{Index}.Wobj.ufmec = "CNV2" THEN
ENDIF
ENDPROC
!***********************************************************

8 RAPID reference
RobotWare - OS
Continued
!
! Function IsQuickAckOk
!
! Checks if it's OK to make a fast acknowledge.
!
!***********************************************************
FUNC bool IsQuickAckOk(num Index)
VAR num CnvPos:=0;
VAR num DropDist:=0;
VAR num RealPos:=0;
VAR bool QuickAckOk:=FALSE;
VAR num SafeDist;
IF ItmSrcData{Index}.Wobj.ufmec = "" THEN

QuickAckOk:=TRUE;
ELSE
SafeDist:=200;
IF ItmSrcData{Index}.Wobj.ufmec = "CNV1" THEN
CnvPos:=aiCnv1Position*1000;
DropDist:=Cnv1DropDist;
SafeDist:=aiCnv1Speed*1000*0.35;
ENDIF
IF CnvPos < DropDist-SafeDist THEN
QuickAckOk:=TRUE;
ELSE
QuickAckOk:=FALSE;
ENDIF
ENDIF
RETURN QuickAckOk;
ENDFUNC
!**********************************************************
!
8 RAPID reference
RobotWare - OS
Continued
! Function QuickAck
!
! Makes a quick acknowledge. Returns FALSE if is
! wasn't possible.
!
! Example:
! PROC Place(num Index)
! Coordinated;
! WObjPlace:=ItmSrcData{Index}.Wobj;
! GetItmTgt ItmSrcData{Index}.ItemSource,PlaceTarget;
! MoveL\Conc,RelTool(PlaceTarget.RobTgt,0,0,-ItmSrcData{Index}
.OffsZ),MaxSpeed,z20,Gripper\WObj:=WObjPlace;
!
TriggL\Conc,PlaceTarget.RobTgt,LowSpeed,ItmSrcData{Index}.VacuumRev1\T2:=
ItmSrcData{Index}.VacuumOff1,z5\Inpos:=ItmSrcData{Index}.TrackPoint,Gripper\WObj:=WObjPlace;
! GripLoad load0;
! IF QuickAck(Index, PlaceTarget) THEN
! MoveL
RelTool(PlaceTarget.RobTgt,0,0,-ItmSrcData{Index}.OffsZ),LowSpeed,
z20,Gripper\WObj:=WObjPlace;
! ELSE
! TriggL RelTool(PlaceTarget.RobTgt,0,0,-ItmSrcData{Index}.OffsZ)
,LowSpeed,ItmSrcData{Index}.Ack,z20,Gripper\WObj:=WObjPlace;
! ENDIF
! UnCoordinated;
! ENDPROC
!
!
!***********************************************************
FUNC bool QuickAck(num Index, itmtgt ItemTarget \switch Nack)
VAR bool QuickAckOk:=FALSE;
VAR bool AckNack:=TRUE;
IF Present(Nack) THEN
AckNack:=FALSE;
ENDIF
IF IsQuickAckOk(Index) THEN
AckItmTgt ItmSrcData{Index}.ItemSource,ItemTarget,AckNack;
QuickAckOk:=TRUE;
ENDIF
RETURN QuickAckOk;
ENDFUNC
Note
For CTM (DSQC2000 only), the signal definitions signalai must be replaced by
signalao since the signals need to be configured as analog output.

9 Advanced queue tracking
9.1 Introduction to advanced queue tracking

Introduction
When queue tracking mode is enabled in the conveyor I/O configuration, the job
queue is external, which means it can be handled by the RAPID code. If the queue
tracking mode is disabled, then the queue is handled internally.
System parameters
The following signals are used for advanced queue tracking and must be defined
in the system parameters, topic I/O, type Signal.
c1ObjectsInQ Group input showing the number of objects in the object queue. These
objects have passed the synchronization switch but have not gone out-
side the start window.
c1Rem1PObj Remove first pending object from the object queue. Setting this signal
will cause the first pending object to be dropped from the object queue.
Pending objects are objects that are in the queue but are not connected
to a work object.
Note
therefore advisable to wait for 0.15 s before a new work object is connec-
ted.
c1RemAllPObj Remove all pending objects. Setting this signal will empty all objects
from the object queue. If an object is connected, then it is not removed.
Note
therefore advisable to wait for 0.15 s before a new work object is connec-
ted.
c1DropWObj Setting this signal will drop the tracked object and disconnect that object.
The object is removed from the queue. This should not be set from
RAPID, use the DropWobj instruction instead.
c1NewObjStrobe This DO signal is pulsed when a new object is detected.
c1CntFromEnc This 32-bit GI signal indicates the location (counter value) of the latest
detected object. The signal is updated at every object detection.
The signal can only detect new values when the conveyor is moving. To
create a new object when the conveyor is not moving it is required to
pulse cxNewObjStrobe. A new object will be created at the current con-
veyor position.
Note
The 32-bit signal is now default, but the old 16-bit signals are still suppor-
ted: c1CntFromEnc1 (low word) and c1CntFromEnc2 (high word).

Continued

c1CntToEncStr Used in queue tracking mode. When this DO signal is pulsed, the object
location that is specified by c1CntToEnc will be moved to the first position
of the object queue. As a result, the next work object to be tracked will
target this object location.
c1CntToEnc Used in queue tracking mode. This 32-bit GO signal specifies a desired
object location (counter value) that shall be tracked.
For DSQC2000, the use of cxCntToEnc is not meant to add objects to
the queue but only to select objects to be picked from the queue.
Therefore, cxObjectsInQ is not incremented after a pulse of cxCntToEnc-
Str. If the counter value set using cxCntToEnc does not match any exist-
ing object in the queue, the controller will connect to the first available
object issuing the internal error Invalid count_to_enc_strobe on cnv x.
Therefore, creating new objects at arbitrary counter positions is not
supported. On the other hand, if the counter value selected using cxCnt-
ToEnc is valid and available for connection, the controller will automat-
ically drop all the objects from the queue which are older than the selec-
ted object. To avoid automatic dropping, it is recommended to select the
oldest object for connection and perform the pick/place operations using
the relative offset to the connected object.
c1PosInJobQ For DSQC2000, this signal has no effect.
c1EncSelec • 0 = Encoder A selected
• 1 = Encoder B selected
(DSQC377 only)
c1SoftSync DO signal that can be used to simulate the detection of a new virtual
object. When the signal is pulsed, a new object with the current location
(counter value) will enter the queue.
c1PassStw DO indicating that an object has passed out of the start window without
being connected (object lost). If the RAPID program is waiting in a
WaitWobj instruction, the program pointer will be moved to the nearest
error handler.
RAPID
If two RAPID instructions WaitWObj and DropWObj needs to be executed
subsequently (without any other instruction in between), it is recommended to use
WaitTime of at least 10 ms before DropWObj, to allow the correct internal state
change of the object queue inside the controller.

Signal values
The option Conveyor Tracking provides several I/O signals that allow a user or
RAPID program to monitor and control the object queue. The table in System
parameters on page 107, shows the I/O signals that impact the object queue. The
counter values have to do with the queue tracking function. Positions detected on
the encoder node are sent to the main computer to be stored in the job queue
handled by the robot controller. Values are returned to the encoder when object
is ready to be tracked.
Handling the object queue in RAPID

To handle the object queue in RAPID the program must store the counter value
for each new object on the conveyor and write it to the conveyor board when the
user wants to track this object.
The RAPID program needs the following elements:
SetDO c1PosInJobQ, 1;
! Connect a trap routine to the detection of new objects on the

conveyor
CONNECT NewObj WITH NewObjOnConvey;
ISignalGI c1CntFromEnc, NewObj;
TRAP NewObjOnConvey
! A new object is detected; Read its position from input group
signal
ObjectPosition := GInputDnum(c1CntFromEnc);
RETURN;
ENDTRAP
TRAP TrackNewObj
! To track a selected object, write its reference to output group
signal
SetGO c1CntToEnc, ObjectPosition;
WaitTime 0.02;
! Activate the written reference
PulseDO c1CntToEncStr;
RETURN;
ENDTRAP
Passed start window signal

In some applications it is important to know if an object has gone through the start
window without being connected. The encoder interface allows the robot controller
software to detect when an object has passed the start window without being
connected and is thus lost. The detection of the lost object is done on the next
WaitWObj instruction. The next WaitWObj instruction, following after an object
has moved outside the start window, will return with the error ERR_CNV_OBJ_LOST.
This error can be handled in the RAPID error handler.

Continued
A DO signal, c1PassStw, can be selected to indicate if an unconnected object is

passing the start window. Go to system parameters, Process -> Conveyor Ici ->
ObjLost signal and set it to c1PassStw. This signal will go high when an object has
left the start window without being connected.
Note
For CTM (DSQC2000) the ERR_CNV_OBJ_LOST error is not supported. The object
that has moved outside the start window without connection will be dropped and
WaitWObj will connect to the next object in the queue. If enabled, the signal
ObjLost will be pulsed.
Simulation mode
The simulated encoder starts when the simulation signal is set. The simulation
encoder counts is set to the real encoder counts when the simulation signal is set.
If the simulation signal is reset the encoder value returns to real encoder position.
The simulation speed is defined with the parameter SimulationVel in the type Signal,
in the topic I/O.

10 Circular conveyor tracking
10.1 Introduction to circular conveyor tracking

Introduction
Circular conveyors can be tracked with the option Conveyor Tracking. The principle
for configuring circular conveyor tracking is to define values in radians instead of
meters. Then configure as described in Installation on page 37, and Configuration
and calibration on page 55.
This chapter will where there are differences in the configuration compared to
linear conveyors.
Example
The figure below shows an example of circular conveyor tracking with example
units and distances.
Direction of
rotation
2.44 rad
Radius = 6 m
minimum distance
Y
Sync switch
X
maximum distance
QueueTrkDist
0.0 rad
StartWinWidth
XIRB
YIRB
IRB
xx1200001101
CountsPerMeter 40000 counts per radian

At 6 m radius, one count = 0.15 mm
minimum distance -100 milliradians
At 6 m radius, = -600 mm
Conveyor base frame Base frame x = 8.0 m
Base frame y = 0.0 m
Base frame z = 0.0 m

Continued
The x-axis is rotated 2.44 rad Base frame q1 = 0.3420

from the world X (XIRB) Base frame q2 = 0.0000
Base frame q3 = 0.0000
Base frame q4 = 0.9397
SyncSeparation 0.005 rad
At 6 m radius = 30 mm
QueueTrkDist 0.017 rad
maximum distance 420 milliradians
StartWinWidth 0.017 rad

10.2 Encoder type selection and location
10.2 Encoder type selection and location
Prerequisites
The goal in selecting an encoder for circular conveyor tracking is to have 0.1 mm
to 0.2 mm resolution per count at the maximum radius of conveyor tracking.
Example
In the Example on page 111, following at a 6 meter radius in order to have 0.15 mm
per count, we must have 40,000 counts per radian at the center of the table. The
counts are quadrature encoded (four counts per pulse), thus the encoder must
give 10,000 pulses per radian of circular conveyor movement. For a full revolution
there are 2p radians per revolution, giving a requirement for 10000 × 2p = 62831.85
pulses per revolution of the circular conveyor.
Selecting gear ratio

If an encoder with 1000 pulses per revolution is selected, then we require a gear
ratio of 1 to 62.83185 between the circular conveyor and the encoder shaft.
Note
The maximum value for CountsPerMeter in the encoder software is 50000. This
should be considered when selecting gearing and encoder.

10.3 Installation and configuration
10.3 Installation and configuration
Software installation
The conveyor work area and conveyor tracking software are connected and installed
in the same way as for linear conveyors.
Defining CountsPerMeter
The value of the parameter CountsPerMeter should be known from the selection
of the encoder and the gear ratio between the circular conveyor and the encoder
shaft. If the value is not known, then it is possible to measure the value following
the same steps as outlined for a linear conveyor with extra equipment for measuring
the change in angle of the conveyor between position_1, and position_2.
Defining the queue tracking distance

Before proceeding with conveyor setup and calibration it is necessary to define
the desired queue tracking distance (QueueTrckDist). The queue tracking distance
establishes the distance between the synchronization switch and the 0.0 rad point
on the circular conveyor. The conveyor work area will keep track of all objects that
have passed the synchronization switch but have not yet passed the 0.0 rad point.
Related information
Calibrating CountsPerMeter on page 64

10.4 Additional motion settings
10.4 Additional motion settings
Conveyor start window and sync separation

For circular conveyor tracking these distances are defined in radians.
Conveyor maximum and minimum distances
Note
For circular conveyor tracking these distances are defined in milliradians.
Conveyor adjustment speed

The same as for linear conveyors.
Motion System parameters

Mechanical Unit parameters

Transmission and Single Type parameters

The motion configuration of the conveyor must be adjusted to account for a circular
motion of the conveyor. There are two parameters that must be adjusted.
Parameter Type Description
Rotating Move Transmission Defines if the conveyor is rotating (Yes) or
linear (No).
Mechanics Single Type Defines the mechanical structure of the con-
veyor.
Select EXT_ROT.

Calibration options
The accuracy of the circular conveyor tracking depends on the accuracy in
specifying the conveyor base frame. There are two methods to calibrate the base
frame for a circular conveyor:
1 Enter the orientation and position of the base frame based on drawings of
the robot installation and simple TCP measurements.
2 Use the robot TCP as a measuring tool and measure several points along
the conveyor with some trigonometric calculations to calculate the conveyor
base frame position and quaternion.
We recommend using the second method, with TCP as measuring tool. See TCP
measurement method on page 118.

10.6 Manually calibrating the conveyor base frame
10.6 Manually calibrating the conveyor base frame
Orientation
The definition of the quaternion for conveyor orientation will also define the location
of the 0.0 radian point on the circular conveyor. The direction of the x-axis will
define the 0.0 radian point while the direction of the z-axis will define the direction
of positive rotation using the right-hand-rule.
The graphic below shows two installations, one with clockwise rotation and the
other with counterclockwise rotation and the corresponding quaternions. In cases
where the 0.0 rad point is not an even multiple of 90° from the world frame,
calculation of the conveyor orientation quaternion must be done using manual
calculations of the quaternion. The TCP can be used to help make measurements,
see TCP measurement method on page 118.
QueueTrkDist
Direction of
rotation Direction of
rotation
0.0 rad X 0.0 rad

X
Y Y
XIRB XIRB
XIRB XIRB
IRB IRB
xx1200001102
Quaternion 0.7071, 0, 0, 0.7071 Quaternion 0, 0.7071, -0.7071, 0
Base frame position and start window start calibration

The conveyor base frame x, y, and z position must be specified relative to the world
frame. This position must be calculated from the installation drawings or by using
the robot as a measuring tool. Using the robot, one point can be marked on the
edge of the circular conveyor and the TCP position is recorded for several points
and the center point of the circle can be found. This is described in detail in the
following section.

10.7 TCP measurement method
Recommendation
This section describes how to use TCP measurements and RAPID programs to
calculate the conveyor base frame position and quaternion for a circular conveyor.
This method uses three measured points on the circular conveyor to calculate the
center of rotation. The three points should be spaced as far apart as possible
around the periphery.
Calculating the x and y positions for the base frame

Use this procedure to calculate the x and y positions for the base frame.
1 Use Wobj0 on the FlexPendant. Pick out a reference point on the circular
conveyor, jog the TCP to this point and record p_0.
2 Run the conveyor to another position. Jog the TCP to the reference point
and record p_1.
3 Run the conveyor to a third position, jog the TCP to the reference point and
record p_2.
4 Use the function CNVUTL_cirCntr with the points p_0, p_1, and p_2, to
calculate the center of the circle, p_centre.
The system module cnv_utl.sys can be found in Robotware.
5 Take the x and y values from p_centre and enter them into the base frame
values for the conveyor, converting to meters, see Topic Motion on page 92.
These are shown in Orientation on page 117. The z value will be entered later,
once the work object zero position has been chosen.

Continued
Defining the base frame orientation and start window start calibration
The base frame quaternion defines where the 0.0 rad point is for the robot motion.
The following figure shows an example of the angles that are used when defining
the base frame orientation for the circular conveyor.
Baseθ
p_centre, X, Y Pθ
S
TPθ
p_0, X_0, Y_0
Qθ
0.0 rad
XIRB
YIRB
IRB
xx1200001103
R Direction of rotation
S Synchronization switch
Qθ Queue tracking distance angle
TPθ Angle shown on FlexPendant
Pθ Angle calculated from p_0 position
Baseθ Base frame angle to be converted to a quaternion
Calculating the quaternion

Use this procedure to calculate the quaternion for the base frame orientation.
1 Define a temporary conveyor base frame quaternion as 1, 0, 0, 0.
2 Define a conveyor coordinated work object, wobjcnv1.
3 Step forward through a RAPID program containing the two instructions:
ActUnit CNV1;
WaitWObj wobjcnv1;
4 Run the conveyor until an object passes through the sync switch and beyond
the queue tracking distance. The WaitWObj instruction will end execution.
Stop the conveyor.

Continued
5 Using wobjcnv1, move the robot TCP to the desired zero position on the
work object and record this point, p_0. Write down the X_0, Y_0, and Z_0
coordinates of the point p_0 as shown on the FlexPendant (wobjcnv1 must
be selected as work object).
6 Write down the angle shown in the Jogging window for the CNV1 conveyor.
This is angle , see example measurement points in Defining the base
frame orientation and start window start calibration on page 119.
7 Calculate P from the X_0 and Y_0 coordinates of p_0 and the atan function.
X_0 and Y_0 should both be positive when using the atan function. Check
the value, it may be necessary to add 90 degrees:
8 Calculate the value of Base.
9 Calculate the quaternion for the base frame taking into account the direction
of rotation:
Counter clockwise rotation:
q1 = cos(Base /2)
q2 = 0.0
q3 = 0.0
q4 = sin(Base /2)
Clockwise rotation:
q1 = 0.0
q2 = cos(Base /2)
q3 = –sin(Base /2)
q4 = 0.0
10 Enter the value for z (in meters) from p_0, and the values for the quaternions,
q1, q2, q3, and q4, into the base frame for the conveyor, see Topic Motion
on page 92.

11 Accelerating conveyors
11.1 Introduction to accelerating conveyors
11.1 Introduction to accelerating conveyors
Description
This section describes how to optimize the tracking performance of accelerating
and decelerating conveyors for the option Conveyor Tracking. This might be needed
for example if good accuracy is needed during start and stop of the conveyor. To
get good accuracy during tracking of accelerating conveyors it is important that
all system parameters in the system are defined correctly. This chapter describes
the parameters that are important for accelerating and decelerating conveyors.
See System parameters on page 122.
To further improve the accuracy it is possible to predict the speed change of the
conveyor. This is done using a special RAPID function together with an I/O signal
that is set just before the acceleration starts. See Predicting speed changes on
page 123.
For indexing conveyors, see Indexing conveyors on page 127.
Prerequisites
The conveyor and encoder must be set up and calibrated correctly, see
Configuration and calibration on page 55.

11.2 System parameters
Defining the system parameters

Use this procedure to define parameters that are important for an accelerating
conveyor.
1 Set the speed filters.
See Speed filters on page 122.
2 Change update rate of robot positions. See Update rate of robot path on
page 122.
3 Verify the performance of the system.
Speed filters
The filter parameters need to be changed. For both the filters there is a trade off
between noise reduction and accuracy during acceleration. To get good accuracy
during acceleration the filter values should be set according to the recommendations
below. If there is too much noise in the system this might lead to disturbances in
the robot movement and then the filter parameters should be decreased until this
disturbances disappear.
Acc dependent Specifies the setting of the acceleration dependent filter. Default value
filter value is 1 m/s2. To get good accuracy during acceleration set it equal
Type Conveyor to the maximum acceleration of the conveyor. A low value gives harder
Systems filtering. If there is a problem with noise the value should be kept low.
If IRB 360 is used for fast picking with low payload, this parameter should
be set to 0. This will turn off the filtering to improve the response times.
The encoder speed filter should be set, see Configuring an encoder on page 50.
Update rate of robot path

It is possible to define how often the robot path should be updated due to new
conveyor position.
Corvec correc- Defines how often corrections of robot path shall be done. Default is 1.
tion level Should be set to 2 or 3 in order to get good accuracy during acceleration.
Type Robot Set to 1 if the prediction of speed changes functionality is used, see
Predicting speed changes on page 123.
For IRB 360 with high payloads (6-8 kg), and for big robots like IRB 6600,
it should be set to 1. Increasing it for big robots can lead to jerky move-
ments.

11.3 Predicting speed changes
11.3 Predicting speed changes
Introduction
It is possible to predict the speed change of a conveyor and use this prediction to
improve the accuracy during tracking of an accelerating conveyor. The prediction
is based on constant acceleration.
The prediction is setup from the RAPID instruction UseAccProfile and activated
from an I/O signal. It is possible to have two independent profiles defined at the
same time connected to two separate I/O signals. One could be used for starting
and one for stopping the conveyor.
To access this RAPID instruction load the module Indexing_cnv.sys from the
conveyor tracking option directory.
Setting up the signals

One or two I/O signals must be defined (one for each profile). These signals
activates the prediction and should be set a predefined time before the speed
change occurs.
First define the digital input I/O signals, see Technical reference manual - System
parameters.
The names of the signals are used in the parameters Sensor start signal and Sensor
stop signal. These parameters belong to the type Conveyor systems in the topic
Process.
Sensor start sig- Name of the digital input signal to synchronize the prediction and the
nal speed change. The signal must be set a predefined time before the speed
change of the conveyor. How far ahead the signal should be set is con-
figured in the RAPID instruction UseAccProfile.
Sensor stop sig- Name of the digital input signal to synchronize the prediction and the
nal speed change. The signal must be set a predefined time before the speed
change of the conveyor. How far ahead the signal should be set is con-
figured in the RAPID instruction UseAccProfile.
The system parameters that affect the accuracy during acceleration are described
in System parameters on page 122.

11.4 UseAccProfile - Use acceleration profile
Description
UseAccProfile is used to predict conveyor movement with constant acceleration
or deceleration.
The profile uses either the acceleration for the conveyor or the time that it takes
for the conveyor to accelerate or decelerate. If two profiles are defined, acceleration
value needs to be used instead of a time value.
The prediction of the conveyor acceleration is started by setting the I/O signal
configured in Sensor start signal or Sensor stop signal. For best result this signal
must be set at least 150 ms before the conveyor is starting to accelerate or
decelerate.
The settings for the acceleration can be changed during program execution.
Example
VAR intnum intno1;
VAR triggdata trigg1;
...
CONNECT intno1 With Acc_Dec;
TriggInt trigg1, 0.5\Time, intno1;
Resetset sensor_start_signal_DO;
UseACCProfile CNV1, 0.4, 0, 1\acc, \stop_sig;
SetDO STARTSTOP_CNV, 1;
TriggL p0, v20, trigg1, z10, tool1\Wobj:=wobjconv;
MoveJ p_start, v1000, fine, tool1;
TRAP Acc_Dec PulseDO \HIGH, sensor_start_signal_DO;

WaitTime 0.35;
SetDO STARTSTOP_CNV, 0;
ENDTRAP
In this example the start and stop of the conveyor is controlled by the I/O signal
STARTSTOP_CNV. The deceleration profile is setup with a trigger_time of 0.4
s, end velocity of 0 m/s and the deceleration is 0.2 m/s 2 . This means that the
conveyor will decelerate from the current speed down to zero speed with a
deceleration of 0.2 m/s 2 and that the sensor stop signal is going to be set 0.4 s
before the conveyor is starting to decelerate.
The stop is triggered from a TriggL instruction.
As seen in the trap routine the sensor_start_signal is set 0.35 s before the stop
order to the conveyor. However in the setup of the profile it is said that this signal
is coming 0.4 s before the stop. In this case it might be that there is a delay in the

Continued
communication with the conveyor controller of 0.05 s and this is compensated in

this way.
Trigg
V1
V2
T1 T2
xx1200001104
In the preceding figure, the profile from the example is shown. V1 is the speed
before the deceleration and can in this case be for example 0.2 m/s. V2 is the speed
after deceleration, in this case it is 0 m/s. T1 represents the time between the Trigg
is coming and the conveyor is starting to decelerate, in this example 0.4 s. T2 is
the length, in time, of the deceleration.
Arguments
UseAccProfile MechUnit, Trigger_time, V_end, Acc_time[\acc | time],
[\start_sig | stop_sig];
MechUnit
Mechanical Unit
Data type: mechunit
The moving mechanical unit object (coordinate system) to which the robot position
in the instruction is related.
Trigger_time
Data type: num
The time between the start_sensor_signal is set and the time when the conveyor
is starting to accelerate or decelerate. The time should not be smaller then 0.15 s.
The value is given in seconds. In case of to small Trigger_time the profile might
not be used.
V_end
Data type: num
Velocity to be reached at the end of acceleration or deceleration. In case of a stop
this should be 0 m/s. The value is given in m/s.
Acc_time
Data type: num
Time from the start of the acceleration until the conveyor reaches the final speed
(V_end). If [\acc] is set then this value is considered to be an acceleration value
in m/s 2 describing the acceleration of the conveyor.
[\acc | time]
Data type: switch
Set to acc to use acceleration.

Continued
Set to time to use acceleration time.
[\start_sig | stop_sig]
Data type: switch
Set to start_sig to use the signal configured as Sensor start signal to trigger
the profile. Set to stop_sig to use the signal configured as Sensor stop signal to
trigger the profile.
Program execution
To get the best possible accuracy during acceleration or deceleration it is important
that the Trigger_time is the same as the time between setting the Sensor start
signal and the time when the conveyor starts to accelerate or decelerate. The larger
the difference is between these two times the poorer accuracy will be achieved.
If two profiles are configured in the system at the same time it is very important
that the \acc option is used. This is to secure a good behavior when for example
there is a mix between a start and a stop profile. This could happen when the
conveyor for example is stopping and a start order is given so that the stop ramp
never is finished.
Limitations
Before UseAccProfile is executed, the Sensor start signal and Sensor stop signal
must be reset.

12 Indexing conveyors
12.1 Description of indexing conveyor options
12.1 Description of indexing conveyor options
Indexing conveyors
An indexing conveyor advances in steps instead of running continuously. One step
is one index, and one or several indexes creates the work object. The conveyor
belt can have pockets or magazines for the products, which makes them perfectly
aligned for picking.
There are two ways to track indexing conveyors. If the conveyor is not controlled
by the ABB robot controller then recorded profiles must be used, see Tracking
indexing conveyors on page 128. If the conveyor is controlled by the ABB robot
controller the option Internal Conveyor Control should be used to get the best
possible accuracy. See Indexing conveyor with servo control (Indexing Conveyor
Control) on page 141.

12.2.1 Setting up tracking for an indexing conveyor
12.2 Tracking indexing conveyors
12.2.1 Setting up tracking for an indexing conveyor
Introduction
This section describes how to track an indexing conveyor using the option Conveyor
Tracking. As the conveyor is not controlled by the robot controller, is not possible
to know exactly how the conveyor speed is changing. Instead, this method uses
predicted speed changes. The repeatability is very important for the accuracy.
Therefore, this method cannot be used if the conveyor movements are not
repeatable. Then the option Indexing Conveyor Control with the conveyor controlled
by the robot controller should be used.
To get good accuracy for indexing conveyors it must be possible to predict how
the speed of the conveyor is changing. The prediction is based on a recorded
profile of the conveyor during acceleration.
A new I/O signal must be defined and connected. RAPID instructions are used to
handle prediction of conveyor position during speed changes.
Setting up tracking for an indexing conveyor

Use this procedure to set up tracking for an indexing conveyor.
1 Define a new I/O signal, topic I/O. See Technical reference manual - System
parameters.
2 Connect the I/O signal to the conveyor system, topic Process. See System
parameters on page 129.
3 Define speed filter parameter. See System parameters on page 129.
4 Record the profile. See RecordProfile on page 131.
5 Store the profile. See StoreProfile on page 134.
6 Load and/or activate the profile for production. See LoadProfile on page 135,
and ActivateProfile on page 136.

12.2.2 System parameters
12.2.2 System parameters
Topic Process
This parameter belongs to the type Conveyor systems in the topic Process.
Sensor_start_sig- Name of the digital input signal to synchronize recorded profile and new
nal index movement. The signal must be set before start of conveyor
movement. For example when a cam to move the conveyor the sensor
can be placed to be triggered 100 ms before conveyor moves.

12.2.3 Using indexing conveyor tracking from RAPID
12.2.3 Using indexing conveyor tracking from RAPID
Introduction
There are two ways to use the indexing conveyor tracking functionality from RAPID.
One is to use the instruction CnvGenInstr, the other to use the predefined RAPID
functions located in the RAPID module named Indexing_cnv.sys. The RAPID
instructions in Indexing_cnv.sys encapsulates the functionality in CnvGenInstr
to make it easier to use. To access these RAPID instructions, load the module
Indexing_cnv.sys from the conveyor tracking option directory.

12.2.4 RecordProfile
12.2.4 RecordProfile
Description
RecordProfile resets all profile data and records a new profile of the conveyor
movement as soon as the sensor_start_signal is set.
To be able to make a recording it is important that a connection to a work object
is made before the recording is started. This means that a WaitWobj instruction
has to be executed before the recording starts.
Example
ActUnit CNV1;
WaitWobj wobj_on_cnv1;
RecordProfile CNV1, 1, "index_profile";
WaitTime 0.2;
PulseDO \HIGH sensor_start_signal_DO;
SetDO STARTSTOP_CNV 1;
A profile of the conveyor is recorded as soon as the sensor_start_signal is set. In

this example, the signal STARTSTOP_CNV starts the conveyor movement.
Arguments
RecordProfile MechUnit, Record_duration, Profile_type
MechUnit
Data type: mechunit
Record_duration
Duration of speed
Data type: num
Specifies the duration of record in seconds. Must be between 0.1 and
pos_update_time * 300.
Profile_type
Type of profile
Data type: string
Value Description
index_profile Recording is started by sensor_start_signal.
start_stop_profile A start and stop movement can be recorded. sensor_start_signal is used
to record start movement and sensor_stop_signal is used to record
stop_movement.
stop_start_profile Same as for start_stop_profile but the sensor_stop_signal is used
first.
stop_move_pro- The recording is started with sensor_stop_signal.
file

12.2.5 WaitAndRecProf
Description
WaitAndRecProf resets all profile data and records a new profile of the conveyor
movement as soon as the sensor_start_signal is set.
This instruction does the same as the instruction RecordProfile but it also
handles the connection to a work object on the conveyor. This instruction is
intended for use in PickMaster where the instruction WaitWobj is not available.
Example
WaitAndRecProf CNV1, 1, "index_profile";
A profile of the conveyor is recorded as soon as the sensor_start_signal is set.
Program execution
Use this procedure to execute the instruction WaitAndRecProf.
Arguments
WaitAndRecProf MechUnit, Record_duration, Profile_type
MechUnit
Data type: mechunit
Record_duration
Duration of speed
Data type: num
Specifies the duration of record in seconds. Must be between 0.1 and
pos_update_time * 300.
Profile_type
Type of profile
Data type: string
Value Description
index_profile Recording is started by sensor_start_signal.
start_stop_profile A start and stop movement can be recorded. sensor_start_signal is used
to record start movement and sensor_stop_signal is used to record
stop_movement.
stop_start_profile Same as for start_and_stop_profile but the sensor_stop_signal is
used first.
stop_move_pro- The recording is started with sensor_stop_signal.
file

Continued
Note
It is possible for the recording to fail and due to this no object gets created. As
a result, the routine WaitAndRecProf is blocked in waitwobj with the message
Waiting for sync signal. To simulate an object, use RAPID
command PulseDO \PLength:=0.1,c1SoftSyncSig;. After recording the
profile, it is recommended to store the file and verify it. The first column is time,
the second column is position, and the third column is speed.

12.2.6 StoreProfile
12.2.6 StoreProfile
Description
StoreProfile activates and saves a recorded profile in a file.
Example
ActUnit CNV1;
WaitWobj wobj_on_cnv1;
RecordProfile CNV1, 1, "index_profile";
WaitTime 0.2;
WaitTime 2;
StoreProfile CNV1, 0, "Profile.log";
A profile of the conveyor movement is recorded as soon as the sensor_start_signal
is set and is stored in file profile.log.
Arguments
StoreProfile MechUnit, Delay, Filename
MechUnit
Data type: mechunit
Delay
Data type: num
The delay in seconds can be used to shift the record in time. It must be between
0.01 and 0.1. If the value is 0 (zero) no delay is added. The delay is not saved in
the profile, it is only used for the activation. If the delay should be used together
with a saved profile the delay has to be specified again in the instruction
LoadProfile.
Filename
Data type: string
Name of the file where the profile is stored.

12.2.7 LoadProfile
12.2.7 LoadProfile
Description
LoadProfile loads a recorded profile from a file.
Example
LoadProfile CNV1, 0, "profile.log";
WaitTime 0.2;
!
! Work against the conveyor
!
A saved profile of the conveyor movement is loaded and used for prediction of
conveyor movement as soon as sensor_start_signal is set. Error warning
SYS_ERR_MOC_CNV_REC_FILE_UNKNOWN if the file is not found.
Arguments
LoadProfile MechUnit, Delay, Filename
MechUnit
Data type: mechunit
Delay
Data type: num
0.01 and 0.1. If the value is 0 (zero) no delay is added. The delay is not saved in
the profile, it is only used for the activation.
Filename
Data type: string
Name of the file where the profile is stored.

12.2.8 ActivateProfile
12.2.8 ActivateProfile
Description
ActivateProfile activates a profile that was just recorded to use it without
having to save it before.
If the system is restarted, all unsaved records are lost. Therefore, use LoadProfile
after restarts.
Do not use ActivateProfile after LoadProfile.
Example
ActivateProfile CNV1, 0;
WaitTime 0.2;
!
! Work against the conveyor
!
A profile of the conveyor is activated and used for prediction of conveyor movement
as soon as the sensor_start_signal is set. Error warning
SYS_ERR_MOC_CNV_REC_NOT_READY if record not finished.
Arguments
ActivateProfile MechUnit, Delay
MechUnit
Data type: mechunit
Delay
Data type: num
0.01 and 0.1. If the value is 0 (zero) no delay is added.

12.2.9 DeactProfile
12.2.9 DeactProfile
Description
DeactProfile deactivates a profile.
Example
DeactProfile CNV1;
A profile of the conveyor movement is deactivated and no longer used for prediction
of conveyor movement.
Arguments
DeactProfile MechUnit
MechUnit
Data type: mechunit

12.2.10 CnvGenInstr
12.2.10 CnvGenInstr
Description
CnvGenInstr sends a command to the conveyor process attached to the conveyor
mechanical unit.
Example
CnvGenIstr CNV1, CNV_ACTIV_REC, mycnvdata;
The controller will activate the record.
Arguments
CnvGenInstr MechUnit, cnvcmd, Data
MechUnit
Data type: mechunit
cnvcmd
Command
Data type: num
List of possible commands:
• CNV_START_REC
• CNV_STOP_REC
• CNV_ACTIV_REC
• CNV_USE_FREC
• CNV_RESET_ALPROF
• CNV_DEACT_PROF
• CNV_STORE_PROF
Data
Data
Data type: cnvgendata
This structure is used to send num or string as parameters for different commands.
Program execution
All commands must be sent at least 0.2 seconds before start of conveyor movement.
More examples
Example1
VAR cnvgendata mycnvdata:=[0,0,0,0,"",""];
CnvGenInstr CNV2,CNV_START_REC,mycnvdata;
mycnvdata.value1:=1;
In this example, data.value1 specifies the duration of recording in seconds. This
value must be between 0.1 and pos_update_time * 300.

12.2.10 CnvGenInstr
Continued
Example 2
CnvGenInstr CNV2,CNV_STOP_REC,mycnvdata;
This example can be used if CNV_START_REC has been sent with duration 0.
Example 3
CnvGenInstr CNV2,CNV_ACTIV_REC,mycnvdata;
mycnvdata.value1:=0;
In this example, data.value1 specifies a delay added to record in seconds. This
value must be between 0.01 and 0.1 seconds.
If value1=0 default value: then signal delay is used. Ready for use of profile on
next index movement. Error warning SYS_ERR_MOC_CNV_REC_NOT_READY if record
not finished.
Example 4
CnvGenInstr CNV2,CNV_USE_FREC,mycnvdata;
mycnvdata.string1:="myprofile": string1 must contain the name of the file where
to read the recorded profile.
The file must have been created by the command CNV_STORE_PROF. Ready for
use of profile on next index movement.
Error warning SYS_ERR_MOC_CNV_REC_FILE_UNKNOWN if record file not found.
Example 5
CnvGenInstr CNV2,CNV_RESET_ALPROF,mycnvdata;
Reset all profile data, ready for a new START_REC.
Example 6
CnvGenInstr CNV2,CNV_DEACT_PROF,mycnvdata;
Stop using profile.
Example 7
CnvGenInstr CNV2,CNV_STORE_PROF,mycnvdata;
mycnvdata.string1:="myprofile";string1 must contain the name of the file to store
the profile.
Limitations
As access to files can take a lot of time it is recommended not to use
CNV_USE_FREC and CNV_STORE_PROF while robot is moving.
Repeatability error between record and real cycles must be less than 120 ms. A
delay between sensor_start_signal and conveyor movement must not vary more
than 120 ms.
Error handling
No error handling for this instruction. In case of emergency stop of robot or conveyor
the command CNV_DEACT_PROF should be used before restarting the robot.
Syntax
CnvGenInstr
[ MechUnit ':=']< var of mechanical unit > ';'
[ Command ':=']< expression (IN) of num> ';'

12.2.10 CnvGenInstr
Continued
[ Data ':=']< var of cnvgendata> ';'

12.3.1 Introduction to indexing conveyors with servo control
12.3 Indexing conveyor with servo control (Indexing Conveyor Control)
Description of Indexing Conveyor Control

The option Indexing Conveyor Control includes RAPID instructions and one RAPID
data type. A typical installation includes an infeed conveyor transporting the
products in a row at high speed to the indexing conveyor. A photo eye (sensor)
mounted on the infeeder detects products and sends a trig signal to the robot
controller. The controller starts the indexing movement after a specified time, that
is, when the product has entered the pocket on the indexing conveyor. The
FlexPicker picks the products from the indexing conveyor, even during indexing
movement, and puts them in a box on the output conveyor.
The robot controller controls the FlexPicker and the indexing conveyor. The output
conveyor and the infeeder have their own drive systems.
Conveyor tracking will be used both on the indexing conveyor and the output
conveyor, but no encoder and encoder interface is needed on the indexing conveyor
since the position and speed are known as a part of the path planning in the robot
controller.
Note
The option Indexing Conveyor Control requires that the robot controller has
additional drive units.

Continued
Schematic overview
xx1000001425
A Robot with gripper

B Output conveyor with empty cartons, for example from carton erector
C Robot picks products from indexing conveyor and places in cartons
D Full cartons, for example to carton closer
E Indexing conveyor with pockets
F Photo eye
G Product infeeder
Terminology
In context of controlling and moving the conveyor this is referred to as M7 in this
document.
In context of tracking the conveyor, it is referred to as CNV1. Hence, the conveyor
will be configured as two different mechanical units, M7 and CNV1.
Indexing mode is when the system listens (or waits) for a signal from the sensor
that a product is available.
In indexing mode it is not possible to jog or use Move instructions. To disable
indexing mode, execute IndCnvReset or move the program pointer to the routine
Main (PP to Main).

Continued
Limitations
When using the option Indexing Conveyor Control, up to two indexing conveyors
and two conventional (non-indexing) conveyors with encoder boards can be used
per controller. Up to two IRB 360 robots can be configured in a MultiMove system.
To be able to have two robots working on the same indexing conveyor, the queue
tracking mode (see Introduction to advanced queue tracking on page 107) or
PickMaster 3 must be used.

12.3.2 Setting up a servo controlled indexing conveyor
12.3.2 Setting up a servo controlled indexing conveyor
Installing the additional axis for servo control

For the option Indexing Conveyor Control, the indexing conveyor should be running
as an additional axis in the robot controller. See .
Installing the software

The conveyor tracking RAPID instructions, data types, and mechanical unit CNV1
are specified in the key string and do not need to be installed. If the system consists
of more than one conveyor, three more files must be installed per conveyor. The
files to install are stored on the controller.
The second conveyor to install is called CNV2 and the Motion configuration file is
named cnv2_moc.cfg. The other two files to install for internally controlled conveyors
are cnvint2_prc.cfg and cnvint2_eio.cfg.

12.3.3 System parameters and configuration files
Topic I/O
Type Unit
Verify that the I/O unit Qtrack1 is defined as Virtual in the type Unit.
Parameter Value
Connected To Bus Virtual1
Type Unit Type

Verify that the I/O unit type used for the photo eye is defined as Change of State.
Parameter Value
Connection 1 type Change Of State (COS)
Type Signal
In the type Signal, configure a digital input signal for the photo eye which will trigger
an indexing movement of the conveyor.
Parameter Value
Name DI_Eye
Type of Signal Digital Input
Topic Controller
When running a MultiMove system and the indexing conveyor is running in a
separate motion task, the following must be added.
Type Mechanical Unit Group

In the type Mechanical Unit Group.
Parameter Value
Mechanical Unit Group M7
Mech Unit 1 M7
Use Motionplanner motion_planner_3
Type Tasks
In the type Task.
Parameter Value
Use Mechanical Unit Group M7
Type Motion System

In the type Motion System.
Parameter Value
Name motion_planner_3
dyn_ipol_type 1

Continued
Note
Verify that the motion_planner_3 has dyn_ipol_type defined as 1. To edit this

parameter, create a backup and edit moc.cfg. This cannot be changed using
RobotStudio.
Topic Process
Type Conveyor systems
In the type Conveyor systems, verify that the following parameters are set.
Parameter Value
Syncfilter Ratio 0.0001
Acc Dependent Filter Value 0
Type Conveyor Internal

The instance is named INTERNAL1.
Eio unit name Name of the simulated I/O unit.
Connected signal Name of the digital input signal for connection.
Position signal Name of the analog input signal for conveyor position.
Velocity signal Name of the analog input signal for conveyor speed.
Null_speed signal Name of the digital input signal indicating zero speed on the convey-
or.
DropWObj signal Name of the digital output signal to drop a connected object.
ObjLost signal Name of the digital input signal to indicate that an object has gone
past the start window without being connected.
RemAllPObj sig Name of the digital input signal to remove all Pobj.
Rem1PObj sig Name of the digital input signal to remove one Pobj.
Pos Update time Defines how often position and velocity output signals are updated.
Supervise max_dist Boolean to remove supervision of maximum and minimum distance.
Off Default value is YES.
New object strobe Name of digital output signal showing a new object in queue.
Objects in queue Name of group output signal showing the number of objects in
queue.
Count1 from encoder Name of group output for new object position low word.
Count2 from encoder Name of group output for new object position high word.
Single to track Name of the single that is moving the indexing conveyor. (Indexing
Conveyor Control.)

Continued
Topic Motion
Type Arm
In the type Arm, enable Independent Joint and add joint limits.
Parameter Value
Independent Joint On
Independent Upper Joint Bound 2E+07
Independent Lower Joint Bound -2E+07
Type Single Type

In the type Single Type, the parameter Pocket size defines the distance the conveyor
will move when triggered by the photo eye (the size of one pocket), see the following
graphic. It is very important for conveyor tracking accuracy that the pocket size is
given correctly. Use measuring tape and measure at least ten pockets to have a
an average for one pocket.
Time before indexing move defines the time from the photo eye is triggered until
the conveyor movement starts. The recommended value is 0.3 (300 ms). Depending
on the robot payload and deceleration distance, this value can be decreased (might
be needed to increase for some applications). If it is important to use a value as
small as possible, see Minimizing trigger time on page 160.
Parameter Value
Mechanics FREE_ROT
Indexing move Yes
Time before indexing move 0.3
Pocket size 0.05
xx1200001105
A Pocket size

Continued
Type Transmission
The transmission must be represented by two integer parameters, Transmission
Gear High and Transmission Gear Low. This is needed to avoid loosing accuracy
after a very big number of indexing movements. These parameters are computed
in a way that makes it possible for the controller to move the indexing conveyor
exactly one pocket instead of for example 50 mm which could be the measured
pocket size.
A B
C
E
D
xx1200001106
A Pockets
B Motor
C Gearbox
D Gear wheel teeth
E Belt teeth
See the following example for the calculation of the parameters Transmission Gear
High, Transmission Gear Low, and Transmission Gear Ratio. With this setup, the
parameter Rotating Move must be set.
Calculation example:
D = Number of gear wheel teeth
A = Number of pockets
Transmission Gear Low = D * A = 20 * 36 = 720
G = Gear box ratio
E = Number of belt teeth
Transmission Gear High = G * E * 360 = 10 * 108 * 360 = 388800
Transmission Gear Ratio = Transmission Gear High / Transmission Gear Low =
388800 / 720 = 540 / 1 = 540
In this example we use the gear box ratio 10, this means 10 motor revolutions
correspond to one gear wheel revolution. The Transmission Gear High /
Transmission Gear Low ratio can be given as 388800 / 720 but 540 / 1 is easier to
comprehend.
Parameter Value
Rotating move YES

Continued
Parameter Value
Transmission Gear Ratio 540 (from example)
Transmission Gear High 540 (from example)
Transmission Gear Low 1 (from example)
To change the direction of movement of the axis, change sign of the transmission
parameters Transmission Gear Ratio and Transmission Gear High.
Type Acceleration Data

For an indexing conveyor the acceleration data is given in m/s 2 even though the
parameter Rotating Move is set. The indexing movement will be a symmetric
triangular motion profile.
If different values are given for acceleration and deceleration, the smallest value
will be used when creating the motion path.
To avoid vibrations and overload of the mechanical structure, the values for
acceleration and deceleration should not be set higher than the robot capacity at
the given payload.
Parameter Value
Nominal Acceleration 25
Nominal Deceleration 25

12.3.4 Testing the indexing conveyor setup
12.3.4 Testing the indexing conveyor setup
Testing
Create a RAPID program using the code from the example below. Speed and
acceleration are given in mm/s respectively mm/s 2 . To avoid vibrations and overload
of the mechanical structure, the values for acceleration and deceleration should
not be set higher than the robot capacity at the given payload.
In this example an indexing movement will be performed each time the digital input
signal DI_Eye is triggered.
RAPID example
MODULE MainModule
VAR indcnvdata indcnvdata1:=[0,0,0,0,0,0,0];
PROC main()
indcnvdata1.speed := 2000;
indcnvdata1.acceleration := 25000;
indcnvdata1.productsperpick := 6;
indcnvdata1.productsperindex := 1;
ActUnit M7;
IndCnvInit M7, DI_Eye, indcnvdata1;
IndCnvEnable M7;
WHILE TRUE DO
WaitTime 1;
ENDWHILE
ENDPROC
ENDMODULE

12.3.5 Calibrating the base frame
12.3.5 Calibrating the base frame
Creating the work object

To calibrate the base frame, first create the work object. Then calibrate and verify
the calibration.
Use this procedure to calibrate the base frame for CNV1.
1 Jog the mechanical unit M7 to the correct position according to the infeeder.
2 Perform a fine calibration of M7 in this position.
3 Activate the mechanical units M7 and CNV1.
ActUnit M7;
ActUnit CNV1;
4 Initialize the indexing conveyor by executing the following RAPID instruction
where indcnvdata1 is setup as described in Testing the indexing conveyor
setup on page 150.
5 To make sure there are no objects in the object queue execute the RAPID
instruction:
PulseDO \PLength:=0.1,c1RemAllPObj;
6 Add a new object to the object queue by executing the RAPID instruction:
IndCnvAddObject M7;
7 To be able to jog M7 during calibration it is necessary to reset the indexing
functionality by executing the RAPID instruction:
IndCnvReset M7;
Calibrating the base frame

Start the base frame calibration routine of CNV1 and move the conveyor to the
calibration positions by jogging the mechanical unit M7. See Calibrating the base
frame on page 66.
Continue with verifying the calibration, see Verifying the base frame calibration on
page 67.

12.3.6 indcnvdata
12.3.6 indcnvdata
Description
The data type indcnvdata contains information about the indexing movement
and the number of pockets that the work object holds.
Example
indcnvdata1.speed:= 2000;
indcnvdata1.accuracytuning := 0;
Components
speed
Conveyor speed in mm/s. Normally this parameter is set to a high value to create
a motion profile that is triangular.
acceleration
Conveyor acceleration in mm/s 2 . This value cannot be higher than what is
configured in Acceleration Data, see Type Acceleration Data on page 149.
To avoid vibrations and overload of the mechanical structure, the values for
acceleration and deceleration should not be set higher than the robot capacity at
the given payload.
productsperpick
The number of pockets that offsets each work object. If there is one product in
each pocket this parameter defines how many products the robot will pick in each
robot cycle.
productsperindex
Use this parameter to set how many products that should enter each pocket before
executing an indexing movement.
accuracytuning
This parameter can be used to tune the synchronization between robot and indexing
conveyor and requires a high speed camera. The tuning value is default 0 and can
be adjusted +-10ms.

12.3.7 IndCnvInit
12.3.7 IndCnvInit
Description
IndCnvInit used to set up the indexing conveyor functionality.
Example
Arguments
IndCnvInit MechUnit, Signal, indcnvdata1;
MechUnit
Mechanical Unit
Data type: mechunit
The name of the mechanical unit.
Signal
Signal
Data type: signaldi
The name of the digital input signal that triggers the indexing movement.
indcnvdata
Data type: indcnvdata
IndCnvData speed, acceleration, productsperpick, productsperindex, accuracytuning
Error handling
The following recoverable errors are generated and can be handled in an error
handler. The system variable ERRNO will be set to:
ERR_INT_NOTVAL Not valid integer, decimal value

ERR_NO_ALIASIO_DEF The signal variable is a variable declared in RAPID. It has not
been connected to an I/O signal defined in the I/O configura-
tion with instruction AliasIO.
ERR_NORUNUNIT If there is no contact with the I/O unit

12.3.8 IndCnvEnable and IndCnvDisable
12.3.8 IndCnvEnable and IndCnvDisable
Description
IndCnvEnable is used to set the system in indexing mode. An indexing movement
will be executed when the signal is triggered (indexing mode).
IndCnvDisable is used to stop listening to the digital input signal. No indexing
movement will be performed even if the signal is triggered.
Note
It is not possible to jog or run Move instructions on the indexing conveyor until
a IndCnvReset instruction has been executed.
Example
IndCnvEnable M7;
IndCnvDisable M7;
Arguments
IndCnvEnable MechUnit;
IndCnvDisable MechUnit;
MechUnit
Mechanical Unit
Data type: mechunit
Error handling
The following recoverable errors are generated and can be handled in an error
handler. The system variable ERRNO will be set to:
ERR_INDCNV_ORDER An instruction requires execution of IndCnvInit before it is

executed.

12.3.9 IndCnvReset
12.3.9 IndCnvReset
Description
IndCnvReset ends indexing mode and sets the system to normal mode which
makes it possible to jog and run Move instructions.
Example
IndCnvReset M7;
Arguments
IndCnvReset MechUnit;
MechUnit
Mechanical Unit
Data type: mechunit

12.3.10 IndCnvAddObject
12.3.10 IndCnvAddObject
Description
To manually add an object to the object queue, the RAPID instruction
IndCnvAddObject can be executed.
Example
IndCnvAddObject M7;
Arguments
IndCnvAddObject MechUnit;
MechUnit
Mechanical Unit
Data type: mechunit

12.3.11 RAPID programming example
Description
In this example an IRB 360 is picking a batch of products from an indexing conveyor
(CNV1) and placing the products on the outfeed conveyor (CNV2). The outfeed
conveyor is not controlled by the robot controller.
Example code
MODULE MainModule
TASK PERS wobjdata wobj1:= [FALSE,FALSE,"CNV1",[[0,0,0],
[1,0,0,0]],[[0,0,0],[1,0,0,0]]];
TASK PERS wobjdata wobj2:= [FALSE,FALSE,"CNV2",[[0,0,0],
[1,0,0,0]],[[0,0,0],[1,0,0,0]]];
CONST robtarget WaitPos:= [[-129.82,1.57,-
924.52],[0,0.999848,-0.0174063,0],
[0,0,0,0],[0,9E+09,9E+09,9E+09,0,0]];
CONST robtarget Cnv1_Above:= [[24.81,40.73,34.42],
[0.000115829,-0.753048,0.657965,-0.000112099],
[0,1,0,0],[171.015,9E+09,9E +09,9E+09,277.57,400]];
CONST robtarget Cnv1_Below:= [[24.81,40.73,-9.77],
[0.000115827,-0.75306,0.657952,-0.000112101],
[0,1,0,0],[171.015,9E+09,9E +09,9E+09,277.57,400]];
CONST robtarget Cnv2_Above:= [[-23.46,-1.68,201.85],
[1.72038E-05,0.997874,0.0651587,-0.000988565],
[0,0,0,0],[158.015,9E+09,9E +09,9E+09,277.57,0]];
CONST robtarget Cnv2_Below:= [[-23.46,-1.68,55.28],
[1.72335E-05,0.997876,0.0651288,-0.000988564],
[0,0,0,0],[158.015,9E+09,9E +09,9E+09,277.57,0]];
PERS tooldata Tool_2:=[TRUE,[[0,0,56.5],[1,0,0,0]],
[2,[0,0,26],[1,0,0,0],0,0,0.0016]];
VAR triggdata EaciPick;
VAR triggdata EaciPlace;
VAR speeddata speed_eaci;
VAR num prod_cnt;
CONST stoppointdata
stoppoint_eaci:=[3,FALSE,[0,0,0,0],0,0.035,"",0,0];
PROC main()
indcnvdata1.speed := 2000;
prod_cnt := 0;
speed_eaci.v_tcp:= 5000;
speed_eaci.v_ori:= 10000;
! Activate mechanical units

ActUnit M7;
ActUnit CNV1;

Continued
ActUnit CNV2;
! Remove from queue and drop objects

DropWObj wobj1;
IF c2Connected = 1 THEN
DropWObj wobj2;
ENDIF
! Set up pick and place trigg data

TriggEquip EaciPick, 2, 0.05 \DOp:=EaciSuck, 1;
TriggEquip EaciPlace, 2, 0.05 \DOp:=EaciSuck, 0;
! Set indexing conveyor CNV1 in indexing mode and start listening

to the photo eye signals
IndCnvInit M7, DI_Eye, indcnvdata1;IndCnvEnable M7;
! Go to init position
MoveL WaitPos, v1000, fine, Tool_2;
WHILE TRUE DO
! CNV1 Pick
WaitWObj wobj1\RelDist:=300;
MoveL Cnv1_Above, speed_eaci, z20, Tool_2\WObj:=wobj1;
TriggL Cnv1_Below, speed_eaci, EaciPick,
z1\Inpos:=stoppoint_eaci, Tool_2\WObj:=wobj1;
IF prod_cnt >= 1 THEN
DropWObj wobj2;
ENDIF
! CNV2 Place
WaitWObj wobj2\RelDist:=50;
TriggL Cnv2_Below, speed_eaci, EaciPlace,

z1\Inpos:=stoppoint_eaci, Tool_2\WObj:=wobj2;
prod_cnt := prod_cnt + 1;
TPErase;
TPWrite " Number of products: "\Num:=prod_cnt;
DropWObj wobj1;
ENDWHILE
! Move program pointer to the instructions below to enable e.g.

jogging
! Stop listening to the photo eye signals
IndCnvDisable M7;

Continued
! Set indexing conveyor in normal mode

IndCnvReset M7;
ENDPROC
ENDMODULE

12.3.12 Minimizing trigger time
12.3.12 Minimizing trigger time
Trigger time
If the parameter Time before indexing move is set too short, the error 50423 IndCnv
Time before indexing move too low can occur.
To minimize the time between the trigger from the photo eye and start of the
conveyor movement, follow the description below:
1 Set Time before indexing move to a high value, for example 0.4 s.
2 If trigger time is critical there is a chance to reduce the time by changing the
parameters as suggested in Possible solutions on page 160.
3 Run the full application with the robot coordinated to CNV1 and with full robot
payload.
4 Run the service routine IndCnvOptimalTimeBefore to get a proposed
optimal time before.
5 Update Time before indexing move to match the value proposed by the
service routine.
There is a risk that the value suggested by the service routine
IndCnvOptimalTimeBefore is too small so some extra 10 ms margin might be
needed.
Possible solutions
Change the following parameters in the type Motion Planner.
Parameter Value
Dynamic Resolution 0.3333
Path Resolution 0.3333
Queue Time 0.032256
Group Queue Time 0.016128
Possible limitations
If the error 50082 Deceleration limit occurs, return to the original setting of Queue
Time (which is 0.064512), in the type Motion Planner (topic Motion).
If the error 50226 Motor reference error occurs, return to the original setting of
Group Queue Time (which is 0.032256), in the type Motion Planner (topic Motion).

13 Conveyor tracking and MultiMove
13.1 About conveyor tracking and MultiMove

Examples of use
Here are some examples of applications where conveyor tracking is combined
with MultiMove:
• Several robots can work on the same object moving on a conveyor.
• Several robots can cooperate to pick objects on a conveyor.
Additional information
If the option Indexing Conveyor Control is used for a conveyor in a MultiMove
system, then some additional parameters must be defined. See System parameters
and configuration files on page 145. See also Indexing conveyor with servo control
(Indexing Conveyor Control) on page 141.
Two application examples

This manual describes two examples of robot system setups to demonstrate how
conveyor tracking can be combined with MultiMove. They are called UnsyncCnv
and SyncCnv. See Configuration example for UnsyncCnv on page 163, and
Configuration example for SyncCnv on page 165.
UnsyncCnv
In the example UnsyncCnv, two robots work independently on one work piece for
each robot. They do not cooperate in any way and do not have to wait for each
other. There is one conveyor mechanical unit for each robot.
xx1200001107

Continued
SyncCnv
In the example SyncCnv, two robots arc weld on the same work piece. The work
object is moved by a conveyor. One conveyor mechanical unit is used in a separate
motion planner.
xx1200001108

13.2 Configuration example for UnsyncCnv
About this example

This section describes how to configure the example UnsyncCnv, with two
independent robots. The robots are handled by one task each.
Configuration
Task
Task Type MotionTask Use Mechanical Unit

Group
T_ROB1 NORMAL Yes rob1
Mechanical Unit Group
Name Robot Mech Unit 1 Use Motion Planner

rob1 ROB_1 CNV1 motion_planner_1
rob2 ROB_2 CNV2 motion_planner_2
Motion Planner
Name
motion_planner_1
motion_planner_2
Mechanical Unit
Name Allow Move of Activate at Star- Deactivation Use Brake Relay

User Frame tup Forbidden
ROB_1 No Yes No
ROB_2 No Yes No
CNV1 Yes No No rob1_brake

Continued
Illustration
xx1200001109

13.3 Configuration example for SyncCnv
About this example

This section describes how to configure the example SyncCnv, with two robots
and one positioner. Each mechanical unit is handled by a separate task.
Configuration
Task

Group
T_CONV3 NORMAL Yes conv3
Mechanical Unit Group

rob1 ROB_1 motion_planner_1
rob2 ROB_2 motion_planner_2
conv3 CNV3 motion_planner_3
Motion Planner
Name
motion_planner_1
motion_planner_2
motion_planner_3
Mechanical Unit

ROB_1 No Yes No
ROB_2 No Yes No
CNV3 Yes Yes No rob1_brake

Continued
Illustration
xx1200001110
Calibration overview
For unsynchronized movements each conveyor must be calibrated with its motion
group robot (after the base calibration of the robot):
• Cnv1 with Robot_1
• Cnv2 with Robot_2
For synchronized movements Cnv3 is calibrated with one robot only: Robot_1.

13.4 Tasks and programming techniques
Introduction to tasks
Each task program can handle the movements for one robot and up to 6 additional
axes. Several tasks can be used, each containing a program quite similar to the
program of the main task in a single robot application. For more information about
tasks, see Multitasking in Application manual - Controller software OmniCore.
One task program per robot

Each task program can only handle one TCP. This means that you must have one
task for each robot.
Conveyor in separate tasks

Conveyors that move a work object can be handled by the same task program as
one of the robots for un-synchronized movements. For synchronized movements
where the conveyor should be able to move independently of the robots, it is best
to have a separate task program for the conveyor.
Modifying positions
When modifying positions it is not possible to just stop the conveyor and modify
the position. If this is done, there will be an offset in the position that corresponds
to the length of the conveyor movement. This is since the conveyor and the robots
belong to different mechanical unit groups, see Configuration example for SyncCnv
on page 165, and the position of the conveyor is not known to the robots at this
point.
To be able to modify positions, the conveyor must belong to the same mechanical
unit group as the robot. This is done by creating "fake" conveyors that are only
used for modifying positions.
Example
Below there is a configuration example for topic System. Conveyors CNV1 and
CNV2 are "fake" conveyors, and conveyor CNV3 is the real conveyor.
Task:
Group
T_ROB1 NORMAL Yes ROB1
T_ROB2 NORMAL Yes ROB2
T_CNV NORMAL Yes GCNV
Mechanical Unit Group:

ROB1 ROB_1 CNV1 motion_planner_1
ROB2 ROB_2 CNV2 motion_planner_2
GCNV CNV3 motion_planner_3

Continued
Mechanical Unit:
CNV3 Yes Yes No rob1_brake
In the configuration for topic Process, the "fake" conveyors CNV1 and CNV2 must
be connected to the same encoder as CNV3, and must be configured using the
same I/O signals as CNV3, see Combining synchronized and un-synchronized
mode on page 175.
The last step is to create unsynchronized RAPID procedures for each task with
move instructions where the positions can be modified.
Action
1 Create new work objects for the "fake" conveyors, for example wobj_CNV1 for ROB_1
and wobj_CNV2 for ROB_2.
(In the synchronized production program both robots uses the same work object, for
example wobj_CNV3.)
2 Copy the production procedures for robot 1, remove the synchronization, and replace
the work objects.
For example, the production procedure in synced task T_ROB1:
MoveL p101\ID:=10, v300, fine, tool1\WObj:=wobj_CNV3;
is copied to a new routine and modified:
MoveL p101, v300, fine, tool1\WObj:=wobj_CNV1;
3 Copy the production procedures for robot 2, remove the synchronization, and replace
the work objects.
For example, the production procedure in synced task T_ROB2:
is copied to a new routine and modified:
4 Modify the positions for each robot.

13.5 Independent movements, example UnsyncCnv
ROB1 task program

MODULE module1
TASK PERS wobjdata wobj1 := [ FALSE, TRUE, "", [ [500, -200,
1000], [1, 0, 0 ,0] ], [ [100, 200, 100], [1, 0, 0, 0] ]
];
TASK PERS wobjdata wobjcnv1 := [ FALSE, FALSE, "CNV1", [ [0,0,
0], [1, 0, 0 ,0] ], [ [0, 0, 0], [1, 0, 0, 0] ] ];
TASK PERS tooldata tool1 := ...
CONST robtarget p11 := ...
...
PROC main()
...
IndependentMove;
...
ENDPROC
PROC IndependentMove()
MoveL p11, v500, fine, tool1\WObj:=wobj1;
WaitWObj wobjcnv1\RelDist:=10;
MoveC p12, p13, v500, z10, tool1\WObj:=wobjcnv1;
MoveC p14, p11, v500, fine, tool1\WObj:=wobj1;
ENDPROC
ENDMODULE
ROB2 task program

MODULE module2
TASK PERS wobjdata wobj2 := [ FALSE, TRUE, "", [ [500, -200,
1000], [1, 0, 0 ,0] ], [ [100, 1200, 100], [1, 0, 0, 0] ]
];
TASK PERS wobjdata wobjcnv2 := [ FALSE, FALSE, "CNV2", [ [0,0,
0], [1, 0, 0 ,0] ], [ [0, 0, 0], [1, 0, 0, 0] ] ];
...
PROC main()
...
IndependentMove;
...
ENDPROC
PROC IndependentMove()
MoveL p22, v500, z10, tool2\WObj:=wobjcnv2;

Continued

ENDPROC
ENDMODULE

13.6 Coordinated synchronized movements, example SyncCnv
ROB1 task program

MODULE module1
VAR syncident sync1;
PERS tasks all_tasks{3} := [["ROB1"],["ROB2"],["CONV3"]];
PERS wobjdata wobjcnv3 := [ FALSE, FALSE, "CNV3", [ [0, 0, 0],
[1, 0, 0 ,0] ], [ [0, 0, 0], [1, 0, 0, 0] ] ];
...
PROC main()
...
SyncMove;
...
ENDPROC
PROC SyncMove()
MoveJ p100, v1000, z50, tool1;
WaitSyncTask sync1, all_tasks;
SyncMoveOn sync2, all_tasks;
MoveL p102\ID:=10, v300, fine, tool1\WObj:=wobjcnv3;
MoveC p103, p104\ID:=20, v300, z10, tool1\WObj:=wobjcnv3;
MoveL p105\ID:=30, v300, z10, tool1\WObj:=wobjcnv3;
MoveC p106, p101\ID:=40, v300, fine, tool1\WObj:=wobj1;
SyncMoveOff sync3;
UNDO
SyncMoveUndo;
ENDPROC
ENDMODULE
ROB2 task program

MODULE module2
PERS tasks all_tasks{3} := [["ROB1"],["ROB2"],["CONV3"]];
[1, 0, 0 ,0] ], [ [0, 0, 0], [1, 0, 0, 0] ] ];

...

Continued
PROC main()
...
SyncMove;
...
ENDPROC
PROC SyncMove()
MoveJ p200, v1000, z50, tool2;
MoveL p201, v500, fine, tool2 \WObj:=wobj2;
MoveL p202\ID:=10, v300, fine, tool2\WObj:=wobjcnv3;
MoveC p203, p204\ID:=20, v300, z10, tool2\WObj:=wobjcnv3;
MoveL p205\ID:=30, v300, z10, tool2\WObj:=wobjcnv3;
MoveC p206, p201\ID:=40, v300, fine, tool2\WObj:=wobj2;
SyncMoveOff sync3;
UNDO
SyncMoveUndo;
ENDPROC
ENDMODULE
CONV3 task program

MODULE module3
PERS tasks all_tasks{3} := [["ROB1"],["ROB2"], ["CONV3"]];
[1, 0, 0 ,0] ], [ [0, 0, 0], [1, 0, 0, 0] ] ];
CONST jointtarget angle_0 := [ [ 9E9, 9E9, 9E9, 9E9, 9E9, 9E9],
[ 0, 9E9, 9E9, 9E9, 9E9, 9E9] ];
...
CONST jointtarget angle_360 := [ [ 9E9, 9E9, 9E9, 9E9, 9E9, 9E9],[
360, 9E9, 9E9, 9E9, 9E9, 9E9] ];
PROC main()
...
SyncMove;
...
ENDPROC
PROC SyncMove()
MoveExtJ angle_neg20, vrot50, fine;
! Wait for the robots
WaitWObj wobjcnv3;

MoveExtJ angle_20\ID:=10, vrot100, fine;

Continued
MoveExtJ angle_160\ID:=20, vrot100, z10;
MoveExtJ angle_200\ID:=30, rot100, z10;
MoveExtJ angle_340\ID:=40, rot100, fine;
SyncMoveOff sync3;
DropWobj wobjcnv3;
UNDO
SyncMoveUndo;
ENDPROC
ENDMODULE

13.7 Motion principles
13.7 Motion principles
Robot speeds
When the movements of several robots are synchronized, all robots adjust their
speed to finish their movements simultaneously. This means that the robot
movement that takes the longest time will determine the speed of the other robots.

13.8 Combining synchronized and un-synchronized mode
13.8 Combining synchronized and un-synchronized mode
Introduction
For a combination of synchronized and un-synchronized mode is needed with a
single conveyor there must be two mechanical units for un-synchronized mode.
For example CNV1 and CNV2 can be connected to the same encoder. CNV3 can
be configured using the same I/O signals as CNV1 in the topic Process. Replace
default C2xx signals name with C1xx (that is, position_signal c2position becomes
position_signal c1position).
Configuration
The configuration file Proc.cfg will look like this:
Conveyor
-name "CNV1" -sensor_type "CAN" -use_sensor "CAN1"\
-adjustment_speed 250 -min_dist -600 -max_dist 20000\
-correction_vector_ramp_length 10
#
#
#
Conveyor CAN sensor

-name "CAN1" -eio_unit_name "Qtrack1" -connected_signal
"c1Connected"\
-position_signal "c1Position" -velocity_signal "c1Speed"\
-null_speed_signal "c1NullSpeed" -wait_wobj_signal "c1WaitWObj"\
-drop_wobj_signal "c1DropWObj" -data_timestamp "c1DTimestamp"\
-rem_all_pobj_signal "c1RemAllPObj"\
-rem_one_pobj_signal "c1Rem1PObj"
#
"c1Connected"\
#
"c1Connected"\

14 Troubleshooting
14.1 Overview
14 Troubleshooting
14.1 Overview
Introduction
This chapter details the various problem scenarios in conveyor tracking and how
to troubleshoot those scenarios.
In this chapter
This chapter contains the following topics:
Topics For more information
Event messages Event messages on page 178
System parameters System parameters on page 182
Robot path characteristics Robot path characteristics on page 183
Power failure Power failure on page 185
Collision detection Collision detection on page 186
Technical support Technical support on page 187

14 Troubleshooting
14.2 Event messages
14.2 Event messages
Overview
This section details the different event messages and the information required to
troubleshoot them.
Event messages
50082: Path calculation time exceeded
Description
The path calculation time for mechanical units running in motion planner arg1
exceeds internal limit. The motion task did not execute within its time limit.
Cause
The CPU load is high. For example, due to frequent EIO communication.
Recommended actions
The following are the recommended actions:
• Set the system parameter High Interpolation Priority for the affected
motion planner.
• Try to reduce the CPU load by one or more of the following actions:
- Reduce speed.
- Change AccSet.
- Avoid singularity (SingArea\Wrist).
- If the error occurs immediately after the start from finepoint, then
increase the configuration parameter Interpolation Buffer
Startup Adjust in the topic Motion and type Motion Planner.
• If using release 6.02.01 or 6.03.00 and the motion parameter
optimized_start_from_finepoint is set to 1, then set the parameter to
0.
50163: Position adjustment

Description
External position adjustment too large. TCP speed, orientation speed, or external
position speed exceed allowed robot performance.
Cause
The following are the probable causes:
• Dynamic limitations of the robot.
• Change in the robot’s direction at high speed.
Recommended actions
• Reduce the programmed TCP and orientation speeds.
• Modify the path.
• Ensure the program WaitWObj is closer to sync.
• Run in AUTO.

14 Troubleshooting
14.2 Event messages
Continued
• Tune adjustment_accel.
• Verify that the system parameter adjustment speed has a correct value, see
Type Conveyor systems on page 94. If the value is correct and the problem
remains, increasing it carefully within the recommended boundaries may
help.
Note
Start tracking in zone with change of robot’s direction. Avoid starting the robot
with a movement that is opposite in direction to the conveyor’s movement.
50366: Reference error

Description
An error has occurred in the reference calculation in motion planner arg1. Internal
status arg2. As a consequence, the controller goes to Motors Off.
Cause
The following are the probable causes:
• The robot path corrections are high.
• The programmed TCP speed is high.
• The robot is closely tracking the conveyor to a singularity. This usually
happens in six axis robots when axis 4 and 6 is in line. Often seen in
applications with roof hanging robots.
• The performance is reduced by the use of AccSet or PathAccLim
instructions.
• The corvec ramp is too short creating high acceleration.
Recommended actions
• Check the error logs for previous errors that could be causing the present
problem.
• Restart the program after moving the program pointer.
• Restart the controller.
• Set the robot speed slightly higher in RAPID.
• Start tracking after MoveJ with big zone. Add a short linear movement.
50376: Geometric interpolation failed

Description
Task. arg1.
Failed to interpolate the desired geometry.
Program ref. arg2.
(Internal code: arg3).
Cause
Interpolation can’t reach required divergence in the spline.
Recommended actions

14 Troubleshooting
14.2 Event messages
Continued

• Increase the zone size, move the programmed point, change the tool
orientation or change the interpolation method.
• If using Robotware 6.02.xx or lower or if the robot type is different from
IRB360, IRB1200 and IRB1600, make the following changes in MOC.cfg :
- SPLINE_PARAMETERS: -name "motion_special"
-max_spline_divergence 0.002
- MOTION_PLANNER: -name "motion_planner_1"
-std_servo_queue_time 0.193536 -use_motion_sup "rob1"
-use_jog_parameters "motion_planner_1" -use_for_jogging
-repos_installed -use_spline_parameters
"motion_special" -restricted_circlepoint
50496: Conveyor Tracking position error at pick

Description
Actual TCP position for robot arg1 is too far away from the ordered position on
conveyor arg2 due to ramping. Position error: arg3. As a consequence, the robot
may miss the picking or placing.
Cause
The ramping of correction is not finished when reaching pick position.
Recommended actions
• Increase the distance between pick and place positions to ensure that the
ramping is finished.
• Reduce programmed speed.
• Reduce ramping length. Set the configuration parameter Start ramp and
Stop ramp in Process > Conveyor systems > parameters.
• Increase the max allowed position error at pick or place position by setting
the configuration parameter Max tracking error at pick pos.
50024: Corner path failure

Description
Corner path executed as stop point due to some of the following reasons:
• Time delay.
• Closely programmed points.
• System requires high CPU load.
Recommended actions
• Edit MOC.cfg and add in motion_planner:
-optimized_start_from_finepoint 0 -ipol_buffer_startup_adj
2 -ipol_margin_for_servo_queue_time 0.4.
• Use programmed speed that is close to what the robot can do, for example
do not use vmax.

14 Troubleshooting
14.2 Event messages
Continued
• Use corvec_correction_level 1 instead of 3. This should also help if

the conveyor is running in constant speed.

14 Troubleshooting
Overview
This section describes the troubleshooting steps for system parameters used in
conveyor tracking.
Configuration process
As part of the configuration process (PROC.cfg), the following parameters should
be set to their corresponding values:
• adjustment_speed: This parameter should be set to a value according to
the description in Type Conveyor systems on page 94.
• adjustment_accel: This parameter is not used by default, but can be tuned
depending on the type of the robot. Suggested values for IRB340 is 50000
and for IRB660 is 7000.
• Acc_dependent_filter_value and sync_filter_speed_ratio:
The parameter Acc_dependent_filter_value is used by default (1). For
accelerating or indexing conveyors, it is recommended to turn it off (0). For
the same applications, sync_filter_speed_ratio should be set to 0.0001.

14 Troubleshooting
14.4 Robot path characteristics
Overview
This section describes the troubleshooting steps for robot path characteristics
used in conveyor tracking.
Changes to TCP speed

Avoid making major changes to the speed during conveyor tracking, especially in
case of larger robots.
Note
The programmed path should be close to the actual performance of the robot,
as a smooth path results in a path with better accuracy.
Changes to direction
• Avoid changing the direction of the robots at high speed.
• Avoid start tracking in zone with change of the robot direction.
• Avoid starting the robot’s movement in opposite to the direction of the
conveyor movement.
Changes to ramp length

The robot needs to ramp the conveyor tracking path corrections. During ramping,
the robot is not in the correct position in relation to the conveyor. The ramp length
can be tuned using Start ramp and Stop ramp in the process configuration.
• correction_vector_ramp_length: Increasing the value of this process
parameter (PROC.cfg) smoothens the movement but will also increase the
distance between the robot’s position in relation to the moving conveyor.
Use a long ramp to reduce the mechanical stress in robot, and ensure to
have a longer path to the pick or place position.
• correction_vector_stop_ramp: Increasing the value of this process
parameter (PROC.cfg) smoothens the movement at the end of tracking but
can affect the start tracking movement on next conveyor when switching
conveyor in zone.
Programming TCP speed

If the robot does not reach this speed, then avoid programing it to the maximum
speed (VelSet 100,10000;). Setting a speed that is close to the actual speed of
the robot results in a smoother path and a better accuracy. The actual robot TCP
speed can be viewed in Robotstudio signal analyzer.
If Robotstudio is not used, then the recommendation for IRB360 1.13 models is
VelSet 100,7000 and for IRB360 1.6 and 1.8 models, it is VelSet 100,6000;
For other models of robot, use VelSet 100,5000 in case of heavy load.
If Pickmaster is used, then verify that the RAPID variable low speed is really low
in InitSpeed routine MaxSpeed.v_tcp:=Vtcp; LowSpeed.v_tcp:=Vtcp/3;

14 Troubleshooting
Continued
Ensure that low speed is set for vertical movements and between picks in case of
multiple picks.
Jerky movements
Jerky or rough robot movements are usually due to major path corrections when
ramping out or when switching conveyors or during stop tracking.
Check the program with high TCP speed on vertical movements and eventually
limit acceleration by using the PathAccLim instruction.
Low value on configuration parameter adjustment_speed can cause jerky
movements. Verify that the system parameter adjustment speed has a correct
value, see Type Conveyor systems on page 94. If the value is correct and the
problem remains, increasing it carefully within the recommended boundaries may
help.
I/O problems
During tracking, if the robot controller loses I/O connection to the encoder interface,
then a sys_stop occurs. To jog the robot, you need to change the Wobj program
as the current one will be on the conveyor. Instead of trying to regain a position
on the conveyor, it is better to move the program pointer to the routine Main (PP
to Main) to clear the current path.

14 Troubleshooting
14.5 Power failure
14.5 Power failure
Description
During tracking, if the power fails, then the conveyor loses the connection. After
a restart, the previous path is not recalculated. Move the program pointer to the
routine main (PP to Main).

14 Troubleshooting
14.6 Collision detection
14.6 Collision detection
Description
After a collision is detected, the movement is retracted using the joint interpolation
method. The movement of the robot is related to the previous joint path and not
the conveyor. It is possible that the robot might move backward and collide again.
It is possible to avoid the retraction movement by using the switch \NoBackoff
in the instruction MotionSup.

14 Troubleshooting
14.7 Technical support
14.7 Technical support
Overview
For questions or problems with conveyor tracking, contact your local ABB Robotics
Service representative, see http://www.abb.com/.

Index
Index description, 141

indexing mode, 142
3 L
3rd party software, 12 licenses, 12
limitations
A Indexing Conveyor Control, 143
accelerating conveyors, 121
LoadProfile, 135
ActivateProfile, 136
activating conveyor, 81 M
additional axes, 17 M7
additional conveyors, 77 indexing conveyor, 142
motor, 37
B MultiMove, 161
base frame calibration, 65
independent, 161
C syncronized, 161
circular conveyor tracking, 111
CNV1
N
network security, 11
indexing conveyor, 142
CnvGenInstr, 138 O
conveyor base frame, 65 object queue, 109
coordinate systems, 21 open source software, OSS, 12
CountsPerMeter, 64
counts per meter, 64 P
principles of conveyor tracking, 18
D
DeactProfile, 137 Q
distance queue tracking, 107
maximum, 70 queue tracking distance, 64
minimum, 70 QueueTrckDist, 64
DropWObj, 100
DSQC2000, 37 R
RecordProfile, 131
E robot adjustment speed, 72
encoder
prerequisites, 39 S
selecting type, 38 software licenses, 12
speed
F robot, 72
frames, 21 start window, 69
StoreProfile, 134
H Sync Separation, 69
high speed conveyors, 101
T
I track motion, 17, 74
IndCnvAddObject, 156
indcnvdata, 152 U
IndCnvDisable, 154 UseAccProfile, 124
IndCnvEnable, 154
IndCnvInit, 153 W
IndCnvReset, 155 WaitAndRecProf, 132
Indexing Conveyor Control WaitWObj, 97

ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong New District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
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© Copyright 20192022 ABB. All rights reserved.

1 Introduction to conveyor tracking 13

2 Conveyor tracking modules 23

4 Conveyor Tracking tab in RobotStudio 47

5 Configuration and calibration 55

Application manual - Conveyor tracking 5

9 Advanced queue tracking 107

10 Circular conveyor tracking 111

11 Accelerating conveyors 121

12 Indexing conveyors 127

6 Application manual - Conveyor tracking

13 Conveyor tracking and MultiMove 161

Application manual - Conveyor tracking 7

Overview of this manual

It is the responsibility of the integrator to conduct a risk assessment of the final

Continues on next page

10 Application manual - Conveyor tracking

Application manual - Conveyor tracking 11

Open source and 3rd party components in RobotWare

12 Application manual - Conveyor tracking

1 Introduction to conveyor tracking

Option Conveyor Tracking

Option Indexing Conveyor Control

Continues on next page

An extra drive unit and SMB needs to be installed, see .

14 Application manual - Conveyor tracking

RAPID access to queue and conveyor data

Track follows conveyor

Enter and exit conveyor tracking in corner zones

Exit and re-enter conveyor tracking to same object

Continues on next page

Calibration of linear conveyors

16 Application manual - Conveyor tracking

Small orientation error with SingArea\Wrist

Robot mounted on track

Calibrating circular conveyors

Object queue lost on restart or power failure

Minimum and maximum speed

WaitWObj after DropWObj

Application manual - Conveyor tracking 17

1.4 Principles of conveyor tracking

Conveyor as a mechanical unit

Conveyor coordinated work object

Waiting for a work object on the conveyor

Continues on next page

Connecting to a work object

Disconnecting from a work object

Start window and queue tracking distance

Continues on next page

The conditions and states of objects 1 to 7 can be described as in the following

Continues on next page

Key frames and positions

Continues on next page

22 Application manual - Conveyor tracking

2 Conveyor tracking modules

Continues on next page

Continues on next page