RobotStudio™ 6.

03
Conveyor Tracking
Conveyor Tracking

The information in this manual is subject to change without notice and should not 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, damages 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, and
contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at
its then current charge.

© Copyright 2016 ABB All right reserved.

ABB AB
Robotics Products
SE-721 68
Västerås Sweden

2016-06-23 ABB

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1. Prepare the Station.................................................................................. 4

1.1. Create a Solution ............................................................................................4
1.2. Prepare the Station Layout .............................................................................5
1.3. Create a System .............................................................................................6
1.4. Create a Conveyor Mechanism.......................................................................8
1.5. Create Connection ..........................................................................................9
1.6. Add an Object to the Object Source..............................................................12
2. Program the Robot ........................................................................... 13
2.1. Place an Object on the Conveyor .................................................................13
2.2. Create Targets and a Path ............................................................................15
2.3. Finalize the Program in the RAPID Editor .....................................................16
3. Running the Simulation ................................................................... 17
3.1. Set the Conveyor Speed ...............................................................................17
3.2. Change the Start Window .............................................................................18
4. Add a Second Robot to the Station................................................ 19
4.1. Prepare the Second Robot System...............................................................19
4.2. Add a Second Conveyor Connection ............................................................19
4.3. Transfer the RAPID Program to the Second Robot ......................................20

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Conveyor Tracking

Overview
In this module we will learn how to set up and program robots that use Conveyor Tracking to work with
moving objects.

1. Prepare the Station

1.1. Create a Solution

Overview
We will start with creating a solution for the exercise. A solution is a file structure that helps the user to
keep all the files belonging to a RobotStudio project in a good structure. A solution can contain one or
more station files plus other related files.

1. On the File tab, select New>Solution with Empty Station. Name the solution Conveyor Tracking
Cell and click Create.

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1.2. Prepare the Station Layout

Overview
Now we will prepare the station layout with one robot and one conveyor.

1. Import the library file \Courseware\Libraries\Belt conveyor.rslib.

2. Disconnect the Belt Conveyor from library.
3. From the ABB Library import an IRB1200 5kg robot with standard connectors.

4. Import the library file \Courseware\Libraries\SpindleTool.rslib.

5. Attach the SpindleTool to the robot.
6. Set the position of the robot to: X=0 mm, Y= -500 mm, Z=0 mm, RX=0, RY=0, RZ= 90.
7. Save the station.
Note: When the solution was created, an empty station was saved to the solutions sub folder \Stations.
Now when save is pressed, that station will be overwritten.

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1.3. Create a System

Overview
A system used with conveyor tracking must have the software option 606-1 Conveyor Tracking included.

1. In the Home tab, select Robot System>From Layout…

2. Name the system IRB1200_CNV_1. The system will be placed in the solutions sub folder \Systems.
Select the newest RobotWare you have installed on your computer (the latest version of RobotWare is
automatically installed with RobotStudio).

3. Click Next twice.

4. In the System Options window, click Options (to add the Conveyor Tracking option).

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5. To quickly find the correct option, type in conv in the Filter field.

6. Select Motion Coordination and the option 606-1 Conveyor Tracking and the dependency chain 709-1
DeviceNet Master/Slave + 606-1 Conveyor Tracking.

7. Click Close to close the options window.

8. Verify that the system is correctly configured, then click Finish to start the system.

Note: When the system starts you will get a warning about the conveyor not being mapped in the
Output Window. We will fix that once we have a conveyor defined in our station.

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1.4. Create a Conveyor Mechanism

Overview
In order to simulate conveyor tracking in RobotStudio we need a Conveyor Mechanism. This
mechanism will move objects that can be tracked by one or more robots in a station.

1. In the Modeling tab, click on Create Conveyor.

2. Select Selection Level Surface and Snap Mode End. In the Create Conveyor window, ensure the
reference is set to World and then place the cursor in any of the Positions fields. Click in the corner
of the conveyors top surface as on the picture below.

This Position will be the Conveyor Reference Frame that will later be used to calculate the system’s
Base Frames. It will also be used to position the objects that are moved on the conveyor.

3. In the Conveyor Geometry list, select Belt Conveyor (if the Belt Conveyor not is disconnected from
library (Step 1.2.2), it will not be visible in the list).
It is not necessary to select a Conveyor Geometry, but it’s a good practice to have a part associated
with the conveyor. After the conveyor is created, the Belt Conveyor will be embedded in the conveyor
mechanism and will not be visible in the browser anymore.
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4. In the Conveyor Length field, enter the value 5000 mm. This means that the object(s) moving on the
conveyor will move 5000 mm, and then be deleted from the station.
5. Keep the check box Repeating checked. This means that an endless stream of objects will be created
and moved on the conveyor during simulation.
6. Click Create.
7. In the Layout browser, rename the conveyor to Conveyor 1.

1.5. Create Connection

Overview
A Conveyor Connection must be created in order for the system to track a moving workobject. Creating
this connection creates a correctly configured workobject.

1. In the Modeling tab, click on Create Connection.

2. In the Create Connection window we can see that there are preset values in all parameter fields.

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Conveyor
The name of the conveyor mechanism. In this exercise our conveyor Conveyor 1.

Mechanical Unit
The system mechanical unit that should be simulated. In this exercise CNV1 in the system IRB1200_CNV_1.

Offset
The connection will be created along the x-axis of the Conveyor Reference Frame with the specified Offset. The
preset value in Offset will place the connection in front of the robot mechanism.

Connection Window – Start Window Width

The allowed Start Window for the robot. For more information regarding this, please check the Conveyor Tracking
option manual.

Work Area – Minimum Distance

The allowed Minimum Distance for the robot. For more information regarding this, please check the Conveyor
Tracking option manual.

Work Area – Maximum Distance

The allowed Maximum Distance for the robot. For more information regarding this, please check the Conveyor
Tracking option manual.

Base Frames
Depending on the situation you may want to change the setting in the Base Frames option group. A guiding principle
is that the conveyor itself will never be moved by creating or modifying a connection.

Base Frames – Use Station Values

The station layout will be kept and the Base Frame values in the system will be changed to match the station layout.

Base Frames – Use Controller Values

The system’s Base Frame values will be kept and the station layout will be aligned to them.

Base Frames – Align Task Frame

Only used with Use Station Values. The systems Task Frame will be aligned with the conveyor connection, which
means that the conveyor (CNV1) Base Frame will be zero in position and orientation.

3. Change the Start Window Width to 500 mm.

4. Click Create. Note that the system is restarted for updating the Start Window.
5. Click Close.
6. In the Controller tab, click on Edit System.

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7. Verify that the Base Frames values are as expected; that is the conveyor base frame has a definition of
zero, and the base frame of the robot is displaced from that position. Click OK.

8. In the File tab, click Save Station As and then Save. The station will be saved in a new file with ‘_1’
added as a suffix to the filename.

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1.6. Add an Object to the Object Source

Overview
The objects moving on the conveyor during simulation are generated from the conveyor’s Object source.
A list with multiple objects can be added to the source.

1. Import the geometry \Courseware\Geometry\Product_A.

2. Right click on Conveyor 1 – Object source and select Add Object.

3. In the Part drop down, select Product_A. This will be the object that the Object source creates copies
of, and that will be moved on the conveyor.
4. Set the Pitch value to 400mm. This is the distance the conveyor must travel before the next object is
created.
5. Set the Offset position to X=0, Y=50, Z=0. Don´t change the Offset orientation. This will create the
copies with a 50mm offset in +Y from the Conveyor Reference Frame.

6. Click Create and then Close. Note that Product_A will be invisible when Create was clicked.
7. Save the station with Save Station As.

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2. Program the Robot

Overview
Now that we have the station and system prepared we can program the robot. Most of the operations used
for programming with conveyor tracking are initiated from the Layout browser.

2.1. Place an Object on the Conveyor

Overview
To be able to create targets and paths on the object Product_A it must be placed on the conveyor and
jogged to the correct position in front of the robot.

1. In the Object Source in the Layout browser, right click on Product_A and then click on Place on
Conveyor.

Now Product_A should be visible on the conveyor positioned with its Local Origin placed with an
offset of +Y 50mm (that we defined in the Conveyor Connection) from the Conveyor Reference
Frame.

2. Before we jog the conveyor into position Product_A in front of the robot, it must be attached to the
workobject that should be used.
In the Layout browser, right click on Product_A, then click on Attach Workobject and select

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wobj_cnv1, that was automatically created with the connection.

3. In the Layout browser, right click on Conveyor 1 and then click on Jog in the context menu.
Alternatively, left click on Conveyor 1 and then click on Conveyor Tools –Modify, and then Jog.

4. Select Connection Connection [CNV1] and jog the conveyor to position 0. This is the position where
the workobject will be connected to the conveyor and the robot will start tracking the workobject.

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2.2. Create Targets and a Path

Overview
When creating targets and paths involving conveyor tracking, the same tools are used as for programming
in a static workobject. For more information regarding this, please check the Basic and Graphical
Programming modules.

1. With the tool tSpindle and workobject wobj_cnv1 active, create a path that goes around the outer rim
of Product_A. The path should start in the right corner away from the robot (see picture below) use
linear motion, and have an approach and depart target 50mm above the first/last target on the surface.
Use speed v500 and z1 for the zone.

2. Rename the path to Product_A.

3. Rename the targets in the path by adding the prefix pProdA_.
4. Right click on Product_A and click Reachability in the context menu to verify that the robot can
reach all targets in the path.

5. Create a new empty path and name it main. Note that the path will be set to Simulation Entry Point
when it´s named main.

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6. Jog the robot to the values in the picture below.

7. Set wobj0 as active workobject.

8. With main as active path, teach an instruction with the following template, speed and zone selected:

9. Rename the taught target to HomePos.

10. Add a procedure call in main to Product_A.

11. Synchronize the two paths to RAPID.

12. Save the station with Save Station As.

2.3. Finalize the Program in the RAPID Editor

Overview
For everything to work we need to add some RAPID commands, this will we do from the RAPID Editor.
For more information regarding the editor, please check the Programming and simulating IOs module.

1. In the RAPID tab, double click on Module1 to open up the Rapid Editor.
2. Edit the main procedure to add instructions in the sequence as shown below.

To find information about a RAPID instruction, left click on the instruction and then press F1, this
will open the RAPID Reference manual and display information for that specific instruction.
3. Press Apply All.

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3. Running the Simulation

Overview
Now that we have a program in the robot we can run a simulation and test different scenarios.

3.1. Set the Conveyor Speed

Overview
During simulation the conveyor speed can be changed. This makes it possible to test different conveyor
speeds to verify if the robot has had time to finish the path on the active object before the next object in
queue passes the connection point.

1. In the Layout browser, right click on Conveyor 1 and select Motion.

Alternatively, left click on Conveyor 1 and then click on Conveyor Tools –Modify, and then Motion.

2. Set the Speed to 75mm/s. Keep the Conveyor Motion window open.

3. In the Layout browser, right click on Conveyor 1 and select Clear to reset the conveyor to the start
position.
Alternatively, left click on Conveyor 1 and then click on Conveyor Tools –Modify, and then Clear.

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4. In the Simulation tab, click Simulation Play and verify that robot can execute the program and track
the moving objects.

5. Increase the Conveyor Speed to 125mm/s, now will the robot not finish the path on the active object
before the next object in queue passes the connection point. After a while the positions will be outside
reach for the robot. Also notice that you can start and stop the conveyor in the motion dialog box.

3.2. Change the Start Window

Overview
The Start Window is the window on the conveyor where the moving object must be for the robot to
connect to it. If the object have passed the window, the robot will skip that object and wait for the next
object in queue.
In RobotStudio the Start Window is displayed as a yellow box. To hide this box, uncheck Visible on the
Connection.

1. Keep the Conveyor Speed at 125mm/s.

2. In the Layout browser, right click on Connection [CNV1] and select Modify Connection.
Alternatively, left click on Connection [CNV1] and then click on Conveyor Connection Tools –

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Modify, and then Modify Connection.

3. Change the Start Window to 100mm and press Apply and Close, then wait until the controller have
restarted.

4. Reset the conveyor to the start position (Step 3.1.3).

5. Click Simulation Play. Note that after a while will the robot ignore objects that have passed the Start
Window. This will avoid the robot to go outside reach.
6. Stop and reset the simulation.
7. Change the Conveyor Speed back to 75mm/.
8. Save the station as Conveyor Tracking cell one robot one conveyor.
9. Create a Pack and Go file of the station in the \Solutions\Conveyor Tracking cell\Stations folder.

4. Add a Second Robot to the Station

Overview
Now we will add a second robot to the station that will work on the same conveyor.

4.1. Prepare the Second Robot System

1. Import another IRB1200 robot variant, the same as the first one.
2. Set its position as: X=1000 mm, Y= -500 mm, Z=0 mm, RX=0, RY=0, RZ= 90.
3. Import the library file \Courseware\Libraries\SpindleTool.rslib and attach it to the new robot.
4. Create a new system with the name IRB1200_CNV_2 and with the same options as the first robot.

4.2. Add a Second Conveyor Connection

1. In the Layout browser, create a new Connection to Conveyor 1 for the Mechanical Unit CNV1 in
IRB1200_CNV_2.
2. In the Create Connection window, change the Start Window Width to 500mm before you click
Create.

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4.3. Transfer the RAPID Program to the Second Robot

Overview
To copy the RAPID program from the first to the second robot, we will use the Transfer tool.
For more information regarding Transfer, please check the Transfer module.

1. In the Controller tab, click on Create Relation and create a relation between the two robots.

2. Transfer all RAPID data including tooldata and wobjdata from IRB1200_CNV_1 to IRB1200_CNV_2.

3. Clear the conveyor to the start position. (Step 3.1.3).

4. Run the simulation again and verify that the second robot also runs the program for Product_A.

5. Stop the simulation, reset the conveyor and save the station as Conveyor Tracking cell two robots one
conveyor.
6. Create a Pack and Go file of the station in the \Solutions\Conveyor Tracking cell\Stations folder.

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Challenge 1

Add Product_B to the conveyor simulation.

· Import the geometry\Courseware\Geometry\Product_B.

· Add Product_B to the Conveyor 1 - Object source. Set the Pitch to 400mm and the Offset to +Y
50mm.
· In the Object source for Product_A, change the Pitch to 500mm.

· Create a path that goes around the outer edge of Product_B.

· Include the new path to the RAPID program for the first robot.
· Transfer the program to the second robot (IRB1200_CNV_2).
· Run the simulation again and verify that the robots run the programs for Product_A and Product_B.
· Save the station as Conveyor Tracking cell two products one conveyor.
· Create a Pack and Go file of the station in the …\Solutions\Conveyor Tracking cell\Stations folder.

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Challenge 2

Add a second Conveyor to the station.

· Create a new Conveyor Mechanism (Conveyor 2). Position and Conveyor Length should be the
same as for Conveyor 1, but keep the Conveyor Geometry field empty.
· In Conveyor_1, delete the Connection for the second robot.
· Create a Connection in the new conveyor for the second robot (IRB1200_CNV_2).
· Remove Product_B from the Object source in Conveyor 1 and add it to the Object source in the new
conveyor. Set the Pitch to 400mm and the Offset to +Y 50mm.
· Change the Pitch back to 400mm for Product_A.
· Modify the RAPID programs so the first robot runs the path for Product_A, and the second robot runs
the path for Product_B.
· Set the Speed for Conveyor 2 to 75mm/s so both conveyors runs with the same speed.
· Run the simulation again and verify that the first robot run the path for Product_A, and the second
robot run the program for Product_B.
· Save the station as Conveyor Tracking cell two products two conveyors.
· Create a Pack and Go file of the station in the …\Solutions\Conveyor Tracking cell\Stations folder.

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© Copyright 2016 ABB All right reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
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