AUTOSS

VENAIR-SPAIN:
WRAPING SYSTEM OPERATION MANUAL

AUTOSS Co. LTD

Tel: +84 28 3750 4970
Email: autoss.robot@gmail.com
 CONTENTS
1 INTRODUCTION ........................................................................................................................................ 1
1.1 Overview: ......................................................................................................................................... 1
1.2 Components ..................................................................................................................................... 1
1.2.1 Robot and tool ......................................................................................................................... 1
1.2.2 Rotary machine ........................................................................................................................ 2
1.2.3 Infeed ....................................................................................................................................... 3
1.2.4 Rotary table (Outfeed) ............................................................................................................. 4
2 SAFETY ...................................................................................................................................................... 6
2.1 Emergency-stop: .............................................................................................................................. 6
2.2 Limit switch at safety gate: .............................................................................................................. 7
2.3 Infeed area sensor: .......................................................................................................................... 7
3 EQUIPMENTS INSTRUCTIONS .................................................................................................................. 9
3.1 Robot instructions ............................................................................................................................ 9
3.2 Rotary table...................................................................................................................................... 9
3.2.1 Jogging the device .................................................................................................................... 9
3.2.2 Move Rotary table to a specific position ............................................................................... 10
3.2.3 Search-home .......................................................................................................................... 11
3.3 Rotary machine .............................................................................................................................. 12
3.3.1 Jogging the device .................................................................................................................. 12
3.3.2 Test wrapping procedure without robot ............................................................................... 13
3.3.3 Test plastic sheet material handler ........................................................................................ 14
3.3.4 Manually search home and open gripper .............................................................................. 15
4 OPERATION ............................................................................................................................................ 16
4.1 Power up system ............................................................................................................................ 16
4.2 Move robot to home position........................................................................................................ 17
4.3 Search-home for Rotary machine and Rotary Table ...................................................................... 19
4.4 Feed plastic sheet material to Rotary machine ............................................................................. 22
4.5 Final check system to get started .................................................................................................. 24
4.6 Start system ................................................................................................................................... 27
4.7 Feeding unwrapped tube into INFEED: .......................................................................................... 28
4.8 Taking wrapped tubes out of OUTFEED. ........................................................................................ 30
4.9 Hold system.................................................................................................................................... 31
4.10 Resume the system ........................................................................................................................ 32
5 TROUBLESHOOTING ............................................................................................................................... 34
5.1 System errors ................................................................................................................................. 34
5.1.1 Emergency stop...................................................................................................................... 34
5.1.2 Safety gate opens ................................................................................................................... 34
 5.1.3 Start home errors ................................................................................................................... 36
5.1.4 Resume system errors............................................................................................................ 37
5.1.5 Low air pressure ..................................................................................................................... 37
5.2 Infeed errors .................................................................................................................................. 39
5.2.1 Gripping unwrapped-tube error ............................................................................................ 39
5.2.2 Person is in infeed area .......................................................................................................... 39
5.2.3 Footswitch is pressed but infeed area sensor does not sense .............................................. 40
5.2.4 QR reader cannot read QR code on the unwrapped tube ..................................................... 41
5.3 Outfeed errors ............................................................................................................................... 42
5.3.1 Rotary table is at wrong position: .......................................................................................... 42
5.3.2 There is already a tube in position that robot is about to place a wrapped tube: ................ 43
5.4 Rotary machine and Rotary table errors........................................................................................ 45
5.4.1 Servo OFF: .............................................................................................................................. 45
5.4.2 Search-home timeout error ................................................................................................... 46
5.4.3 Rotary Machine: Wrapping procedure timeout error ........................................................... 46
 USING THIS MANUAL
This manual describes system and equipment instructions. Read this manual carefully
to ensure correct usage of the system. Keep this manual in a safe place so that it can be
referred to whenever necessary
Please contact Autoss customer service for more detail technical support

NOTES:
- Rotary machine and Rotary machine are the same device
- Rotary table and Rotary table are the same device
 1 INTRODUCTION
1.1 Overview:
Brief description: user feeds unwrapped tube into Infeed, Robot moves to infeed,
camera reads the QR code and recognize which type the tube is, then robot moves the
tube to Rotary machine and start the wrapping procedure. After finishing wrapping
procedure, robot moves the tube and places it on Rotary table (Outfeed).
There are 4 main components in this system:
- Robot and Tool (QR code reader and gripper)
- Infeed (including 4 stations)
- Rotary machine
- Rotary table (Outfeed)

1.2 Components
1.2.1 Robot and tool
The tool attached to robot has 2 components, the QR code reader and the gripper

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1.2.2 Rotary machine

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1.2.3 Infeed

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1.2.4 Rotary table (Outfeed)

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 2 SAFETY
There are several safety checks before the system ready to operate
- There are 3 Emergency-Stop Buttons:
o At HMI junction box
o At Outfeed junction box
o On Robot Teach-Pendant
- Limit switch at safety gate
- Safety sensor at Infeed area
2.1 Emergency-stop:
When any of 3 E-stop buttons is pressed, the whole system will stop immediately. All
previous states will be reset, user needs to start over the system, the tube is in wrapping
procedure will fail

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2.2 Limit switch at safety gate:
When safety gate opens meanwhile the system is working, system will be held, and be
able to resume after the safety gate is closed.
When user enters inside fences area, user must go through the safety gate and
leave it open, once the safety gate is opened, safety condition would be not satisfied
and system would not start unexpectedly

2.3 Infeed area sensor:

When user enter Infeed area sensor area, there are 2 situations
o If the robot is not in wrapping procedure, the robot will be held, and resume after a
few seconds after user exits Infeed area sensor
o If the robot is in wrapping procedure, the robot will not be stopped, preventing
damage quality of wrapping-tube.

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 3 EQUIPMENTS INSTRUCTIONS
3.1 Robot instructions
- Refer to manual “01-Quickguide-KUKA_V8 x_DIN_A6_(R01)_en”
3.2 Rotary table
3.2.1 Jogging the device
- Step1: On the HMI, enter manual mode, then select Rotary table
- Step2: Press and hold for 3s button “Reset” to reset all previous states.

- Step3: Press button “Servo On” to turn on the servo for both Rotary Machine and
Rotary Table motors. Wait for 2 lamps above the button are lit.

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 - Step4: Enter desired speed for jogging, press button “JOG-” for jogging counter-
clockwise and “JOG+” for jogging clockwise

3.2.2 Move Rotary table to a specific position

- Step1: Enter Manual mode (Refer to 3.2.1 Jogging the device)
- Step2: Reset (Refer to 3.2.1 Jogging the device)
- Step3: Turn on servo (Refer to 3.2.1 Jogging the device)
- Step4: There are 5 defined positions can be used: 0, 90, 180, 270, 360
degree. User presses button corresponding to position that want to be tested

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 Notes: When user presses a button, the button keeps display as being pressed. If user
presses that button again, it will back to normal display, but it does not stop the movement.
Meanwhile Rotary table moves to specific position, and corresponding lamp will be lit.

3.2.3 Search-home
Searching-home is a procedure that device moves back to a position that defined as
home-position.
- Step1: Enter Manual mode (Refer to 3.2.1 Jogging the device)
- Step2: Reset (Refer to 3.2.1 Jogging the device)
- Step3: Turn on servo (Refer to 3.2.1 Jogging the device)
- Step4: Press button “Search-home”. The Rotary machine will start search-
home procedure first, then the Rotary table. Wait until both lamps above the
button “search-home” lit, search-home procedure is done.

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3.3 Rotary machine
3.3.1 Jogging the device
- Step1: Enter Manual mode (Refer to 3.2.1 Jogging the device)
- Step2: Reset (Refer to 3.2.1 Jogging the device)
- Step3: Turn on servo (Refer to 3.2.1 Jogging the device)
- Step4: Enter desired speed for jogging, press button “JOG-” for jogging
counter-- clockwise and “JOG+” for jogging clockwise

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3.3.2 Test wrapping procedure without robot
User can start wrapping procedure without signal from robot, this procedure is the
same as the procedure with robot.
- Step1: Enter Manual mode (Refer to 3.2.1 Jogging the device)
- Step2: Reset (Refer to 3.2.1 Jogging the device)
- Step3: Turn on servo (Refer to 3.2.1 Jogging the device)
- Step4: Press button “Start rotating”, the rotary machine will start the wrapping
procedure, including rotate the rotor, and operate plastic sheet handler

- Step5: Press button “Stop rotating” to stop the wrapping procedure

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3.3.3 Test plastic sheet material handler
There are 4 components in the plastic sheet material handler, corresponding to 4
buttons on HMI screen.

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3.3.4 Manually search home and open gripper
User can execute search-home procedure for Rotary machine (not including Rotary
table) by pressing button Search-home on junction box attached on Rotary machine
User also can open gripper without using HMI be pressing button open gripper on the
junction box attached on Rotary machine

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 4 OPERATION
4.1 Power up system
- Power up the Robot Controller

- Power up Controller Cabinet

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4.2 Move robot to home position
- Step1: On the teach-pendant, login to robot system
- Step2: Using teach-pendant to move robot to safe area, preventing unexpected
movement when robot comes home.
- Step3: Execute program “checkhome” to move robot to home position

- Step4: Select program “main”

- Step5: Switch to External mode (EXT)

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- Step6: Turn on Robot Driver

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4.3 Search-home for Rotary machine and Rotary Table
- Step1: On the HMI, login to system

- Step2: Enter Manual Mode

- Step3: Enter the Rotary Machine Screen (or Rotary table screen)

- Step4: Press and hold for 3s button “Reset” to reset all previous states.

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 - Step5: Press button “Servo On” to turn on the servo for both Rotary Machine and
Rotary Table motors. Wait for 2 lamps above the button are lit.

- Step6: Press button “Search-Home” to execute search-home procedure. Wait until

the both Rotary Machine and Rotary table return to home-position. When the Rotary
machine or Rotary table at home, corresponding lamp will be lit.

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 Note:
- Search-home procedure include both Rotary Machine and Rotary table. Rotary
Machine execute search-home procedure first, then the Rotary table
- “Search-Home” button on Rotary Machine screen and Rotary table screen have the
same function.
- “Servo-on” button on Rotary Machine screen and Rotary table screen have the
same function
- “Reset” button on Rotary Machine screen and Rotary table screen have the same
function

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4.4 Feed plastic sheet material to Rotary machine
Before starting the system, plastic sheet material must be add to the Rotary machine,
or when plastic sheet material runs out, the same procedure can be applied

- Step1: Hold the system by pressing button “Stop” on HMI

- Step2: Make sure the system is stopped, user must enter working area
through the safety gate and leave it open, once the safety gate is opened, safety
condition would not be satisfied and system would not start unexpectedly
- Step3: Remove the old plastic sheet. Notes: The bolt is left-hand thread

- Step4: Insert a new one. Note the direction

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 - Step5: Press and hold button “Open Gripper” on the junction-box attached to Rotary
machine

- Step6: Feed the head of plastic sheet to the Gripper. Note the direction
- Step7: Release the button, the gripper will close and hold the head of plastic sheet

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4.5 Final check system to get started
When robot, Rotary machine, Rotary table are all at home, switch to auto mode.
- Step1: From the Mode Selection screen, Enter the Auto Mode

- Step2: Enter the Controller Screen

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- Step3: Press button “Reset” a pop-up will appear.

- Step4: Select “Reset system” on the option-list

- Step5: Press and hold button “OK” until the pop-up disappears.

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- Step6: Press button “Clear Message”, a confirm pop-up will appear.

- Step7: Press button “OK” to confirm operation.

After all above step: Controller screen should have lamps states like following photo

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 There must be no message in message textbox and 6 following lamps must be ON for
the system be able to get started.
- RB servo (Robot driver is ON)
- RT servo (Rotary Table’s servo is ON)
- RM servo (Rotary Machine’s servo is ON)
- RB home (Robot is at home)
- RT home (Rotary Table is at home)
- RM home (Rotary Machine is at home)

4.6 Start system

- Step1: On the HMI, press button “START” on DASHBOARD screen or
CONTROLLER screen, a popup will appear

- Step2: Press and hold button “HOME” until the popup disappear, and the system
will be started.

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4.7 Feeding unwrapped tube into INFEED:
There are 4 stations at Infeed area. When user wants to feed new unwrapped tube into
a station, follows these steps below:
- Step1: Make sure the station is empty. When user enters the Infeed area, infeed
area sensor will sense, the robot will be held, unless robot is in the Wrapping procedure.
- Step2: Use your right foot to step on the footswitch to open the clamp

- Step3: Put the unwrapped tube into the clamp. Make sure the red light on the sensor
is lit

- Step 4: Release your foot on the footswitch, the clamp will be closed.
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 -
- Step 5: Exit the INFEED area, after a few seconds, robot will continue working

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4.8 Taking wrapped tubes out of OUTFEED.
There would be 8 wrapped tubes in the outfeed when it is full. When OUTFEED is full,
the yellow light at the OUTFEED will be lit.

Step1: Take out 2 wrapped tubes at ready position

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 - Step2: Press the button on the junction-box to turn the Rotary table 90 degrees to
the next positions

- Step3: Repeat Step1→Step2 for 3 more times, and the OUTFEED will be empty
and be at the 0 Degree Position
4.9 Hold system
Holding system make the system temporary stops and be able to continue. To operate
the hold function, press button “Stop” on HMI

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 Notes: if user holds system meanwhile the robot is in wrapping procedure, the robot
will stop, but the Rotary Machine has larger momentum, therefore it takes more time to
stop. This may damage to the quality of wrapping tube.
4.10 Resume the system
- Step1: On the HMI, press button “START” on DASHBOARD screen or
CONTROLLER screen, a popup will appear

- Step2: Press and hold button “RESUME” until the popup disappears, and the
system will resume from previous states.

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 5 TROUBLESHOOTING
This chapter explains some frequently abnormal situations that may occur and
corrective actions for each error. Read this chapter carefully to ensure correct checking
and fixing problem of the system.
Please contact Autoss customer service for more detail technical support
5.1 System errors
5.1.1 Emergency stop
When a dangerous situation occurs, may cause serious injured or damage and needs
to be stopped quickly, presses “E-Stop” button immediately. All system, all moving
parts will be stopped. Once the E-Stop button is pressed, all current states will be reset.
System will not be able to resume, it needs to start over.
5.1.2 Safety gate opens
Whenever safety gate is opened, the whole system will be held immediately. If there is
no unexpected situation occurs, there is only one situation that user needs to use the
safety gate while system is working: replacing plastic sheet material.
If user opens safety gate, the system will be held, and message “Safety gate error” will
be displayed on HMI. User just needs to close the gate, clears the message on HMI, and
resumes the system.
- Step1: Enter Controller screen on HMI

- Step2: Check the message display, there would be message “Safety gate error”

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 - Step3: Press button clear message, as popup will appear

- Step4: Press OK on the popup

- Step5: Resume the system. Press button “START” on Controller screen or
Dashboard screen. A popup will occur. Press and hold button “RESUME” until the popup
disappears, the system will resume

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 Note: if safety gate opens while the robot is in wrapping procedure, the robot and the
Rotary machine will be held, but the Rotary machine has larger momentum so it takes
more time to stop, so the quality of wrapping-tube maybe damage.
5.1.3 Start home errors
Start home: start system from initial states, all components must be at home position.
To start from home position, the system components (Robot, Rotary machine, Rotary
table) must be at home position, if any component is not at home and user presses button
“Home” on the Start popup, the system would not start and alarm(s) will be displayed on
HMI message box.
Alarm list:
o Start at home but Robot is not home
o Start at home but Rotary Machine is not home
o Start at home but Rotary Table is not home

Solution:
- Step1: Check that robot, Rotary machine, Rotary table are all at home
- Step2: Reset the system
- Step3: Start over the system. Refer section “4. Operation”

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5.1.4 Resume system errors
Resume system: when user holds the system, or an error occurs and causes the
system to be held, the system can be resumed after fixing the error. But there are situations
may cause the system cannot resume, in those cases, if user presses button “Resume”
on Start popup, the system will not resume, and the alarm “Start resume but system
doesn't allow resume” will be displayed message box on HMI

Solution: Start over the system. Refer section “4. Operation”

5.1.5 Low air pressure
When air-pressure is low (below a set point), the system will be held, and alarm
message will be displayed on HMI

Solutions:
- Step1: Check all pneumatic devices maybe leak: compressor, pipes and valves.
Until the air pressure is restored, the system would not be able to resume
- Step2: Enter Controller screen on HMI
- Step3: Check the message display, there would be error “Low air pressure”
- Step4: Press button clear message, a popup will appear

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 - Step5: Press OK on the popup

- Step6: Resume the system. Press button “START” on Controller screen or

Dashboard screen. A popup will occur. Press and hold button “RESUME PROCESS” until
the popup disappears, the system will resume

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5.2 Infeed errors
5.2.1 Gripping unwrapped-tube error
When user feeds unwrapped tube into infeed, there are chances that the sensor’s lamp
is lit but the tube is in wrong position. This may causes the robot still reads the QR code,
but when robots move down to grip, the gripper cannot completely close (tube header is
slightly not at center of gripper), the system will be held, and alarm message “Gripper fault”
will be displayed on HMI.

Solutions: the system cannot resume in this situation it needs to start over
- Step1: user uses teach-pendant open gripper manually
- Step2: user uses teach-pendant move robot a safe position for robot home-
procedure
- Step3: Start over the system. Refer section “4. Operation”
5.2.2 Person is in infeed area
There is an area sensor at infeed, when user enters infeed area feeding unwrapped
tube, there are 2 situations:
- If robot is not in wrapping procedure, the robot will be held. After user exit infeed
area, 6 seconds later the robot will resume.

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 - If robot is in wrapping procedure, the robot will not be held, preventing damage to
quality of wrapping-tube.
Both situation, there is alarm message “Person is in infeed area” displays on HMI.
There is no action needed for this situation, system will operate normally after human exit
Infeed area

5.2.3 Footswitch is pressed but infeed area sensor does not sense
There are 2 situations that this error may occur
- Infeed area sensor is damaged
- User operates system improperly (user presses foot-switch sensor from inside
fences area or presses footswitch and avoids trigging the infeed area sensor on purpose)
When this error occurs, the system will be held, alarm message “Infeed area sensor is
working incorrectly” will be displayed on HMI, and the system is able to resume after fixing
the problems.

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5.2.4 QR reader cannot read QR code on the unwrapped tube
When QR reader cannot read the QR code attached on the tube, the robot will skip
that infeed-station and moves to the next one, and that infeed-station will be locked.
An infeed-station being locked means that robot will not pick unwrapped tube from that
infeed-station, robot will skip the locked infeed-station until user unlocks it from HMI
Dashboard screen
Reasons that QR reader cannot read the QR code:
- QR code pad is missing
- QR code pad is at wrong position
- QR code is blur, covered by dust
Solution: system will not stop in this situation, user must be aware of this
- Step1: user enter infeed area, checks the QR code pad condition, fixes the
problems or replace a new unwrapped tube
- Step2: enter the Controller screen on HMI, clear the message

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 - Step3: enter the Dashboard screen, unlock the locked infeed-station.

5.3 Outfeed errors

5.3.1 Rotary table is at wrong position:
When robot is about to place a wrapped-tube, the Rotary table (outfeed) must be at the
position that robot commands, if the Rotary table is at wrong position, the robot will not
place wrapped-tube. And Turing table motion error will occur. System cannot resume in
this situation.
Solution:
- Step1: Stop the system

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 - Step2: User grabs the wrapped-tube being gripped in robot tools, then uses teach-
pendant open gripper manually to take the wrapped-tube out.
- Step3: Start over the system again. Refer section “4. Operation”
5.3.2 There is already a tube in position that robot is about to place a
wrapped tube:
If the system is running normally, there is no situation that there is already a tube in
position that robot is about to place a wrapped tube. But if that situation occurs, the robot
will wait until the tube being in that position be removed.
(IMAGES)
Solution:
- Step1: Stop the system

- Step2: User enters inside fences area. User must go through the safety gate and
leave it open, once the safety gate is opened, safety condition would not be satisfied,
system would not start unexpectedly
- Step3: User removes the tube being in that position
- Step4: Get out working area inside fences, closes the safety gate
- Step5: Enter Controller screen on HMI

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- Step6: Check the message display, there would be error “Safety gate error”

- Step7: Press button clear message, as popup will appear

- Step8: Press OK on the popup

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 - Step6: Resume the system. Press button “START” on Controller screen or
Dashboard screen. A popup will occur. Press and hold button “RESUME PROCESS” until
the popup disappears, the system will resume

5.4 Rotary machine and Rotary table errors

5.4.1 Servo OFF:
- Before Rotary machine and Rotary table be able to operate, Servos must be ON. If
user turns off Servo while the Rotary machine or the Rotary table is running, motion will
stop immediately, and error will occur. There are several situations make this error occur
o User presses E-stop button, servos will be OFF
o User exits mode (exit screen Manual or Dashboard on HMI)
- Solution: turn on servo and start system all over again. Refer section “3.2 Rotary
table” and section “3.3 Rotary machine”

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5.4.2 Search-home timeout error
When the Rotary machine and Rotary table executing Search-home procedure, there
is a limit amount of time that if search-home procedure takes more than that, the system
will be held, and alarm message “Rotary machine search home timeout” or “Rotary table
search home timeout” will be displayed on HMI.
- Timeout value for the Rotary machine is 10 seconds
- Timeout value for the Rotary table is 60 seconds

Solutions:
- Step1: check and fix system components
o Check error display on HMI: servo off, motion command cannot be executed?
o Check mechanical parts may cause the device cannot be moved
o Check home sensor of device has error
- Step2: After checking and fixing problems, enter manual mode, reset, and start
Search-home procedure again. Refer section “3.2 Rotary table” and section “3.3 Rotary
machine”
5.4.3 Rotary Machine: Wrapping procedure timeout error
- All wrapping procedures take less than 6 minutes to complete, so if the Rotary
machine executes Wrapping procedure and does not receive a stop signal within 6
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minutes , the system will be held, and alarm message “Wrapping timeout” will be displayed
on HMI

Solution:
- Step1: User uses teach-pendant to move robot out of the Rotary machine area.
Refer section “3.1 Robot instruction”
- Step2: User grabs the wrapped-tube being gripped in robot tools, then uses teach-
pendant open gripper manually to take the wrapped-tube out. Refer section “3.1 Robot
instruction”
- Step3: User uses teach-pendant move robot to a safe position for Search-home
procedure. Refer section “3.1 Robot instruction”
- Step4: Start over the system. Refer section “4. operation”
Notes: If this error occurs again, please contact Autoss customer service for more detail
technical support

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