Conveyor Tracking Setup

CONVEYOR TRACKING SETUP

After the installation of the hardware, the XRC system requires setup be performed to allow
the controller to calculate the direction and speed of the conveyor movement.

Conveyor
control Conveyor home-position
panel limit switch

Synchronized section
Motor

Conveyor
moving direction

Encoder
(detects the conveyor
moving amount)

Manipulator
XRC

Figure 1 Typical Conveyor System

For Conveyor Tracking to function properly, an accurate Tool Control Point and a properly
defined User Frame are required.

XRC Conveyor Tracking Training Page 1 © MOTOMAN

Conveyor Tracking Setup

TOOL Calibration
Automatic TCP definition calibrates the X, Y, and Z dimensions (offsets, in millimeters, from
the wrist flange of the T-axis ) for the Tool Data. The desired orientation in degrees for Rx,
Ry, and Rz must be entered manually. Usually the Z+ direction of operation in TOOL
Coordinate should be the same as the application direction, such as wire feed, dispensing,
water jet, or laser direction.

To define a TCP automatically, follow these steps:

1. Put a pointer (with the sharp end up) on the fixture. Ensure that the pointer is placed
so that it will not move.
2. Press the TEACH mode button on the Playback Panel.
3. Press TOP MENU, cursor to the ROBOT icon and press SELECT.
4. Cursor to TOOL and press SELECT.
5. Press the AREA key to move the cursor to the Menu Area, cursor to UTILITY and
press SELECT.
6. Cursor to CALIBRATION and press SELECT.

NOTE: To clear existing data, press the AREA key to highlight DATA, press SELECT.
With cursor on CLEAR DATA, press SELECT. Cursor to [YES] on the “Clear
data?” screen and press SELECT.
7. Press TEACH LOCK and turn Servos On. Choose any COORD except TOOL.
8. If TC1 is not highlighted, press SELECT. Cursor to TC1 and press SELECT.
9. Jog the robot to the pointer until the desired tool control point is located at the tip of
the pointer; press MODIFY and ENTER. The first point, TC1, is now accepted and
the bullet is set (z).
10. Repeat Steps 8 and 9 four more times, selecting TC2 through TC5.

Figure 2 Pointer

NOTE: Obtain as much variation as possible when changing the robot’s orientation
between the five TC points.

XRC Conveyor Tracking Training Page 2 © MOTOMAN

 Conveyor Tracking Setup

NOTE: If necessary to view the position where a TC point was set, use the FWD key
to move to the desired TC point. When the highlighted TC number stops
flashing, the robot is at that TC point set location.
11. After entering all five TC points, cursor to COMPLETE and press SELECT.
Once calculations are completed, the tool display screen, which shows the newly calculated
XYZ dimensions of the tool, is displayed.

12. If desired, move the cursor to Rx, Ry, Rz to enter tool angle dimensions manually.
The TCP is now defined. To ensure accuracy of the TOOL data, use the “rotate-about”
keys Rx, Ry, and Rz in RECT or TOOL Coordinates to rotate the tool’s orientation about
the TCP. The TCP should not move off of the point location when rotated. Also check the
X, Y & Z directions of operation in TOOL Coordinates; the Z+ should operate in the
direction of the application such as the direction of a gripper’s handling process, the
direction of dispensing sealant, or the direction of the paint spray pattern.

Creating a User Frame for the Conveyor Direction

The User Frame defines to the controller the orientation and direction of movement of the
conveyor. Without an accurate User Frame, motion synchronized to the conveyor will not
be accurate. Creating User Frames is a function available under the ROBOT icon.
NOTE: Previously defined frames will indicate the bullet as set (z). These frames
may be modified using the same keystrokes.

To define/modify a User Frame, complete the following steps:

1. In Teach mode TOP MENU, cursor to the ROBOT icon and press SELECT.
2. Cursor to USER COORDINATE and press SELECT.
3. Cursor up/down to find the desired User Frame number and press SELECT.
4. Ensure that the active “SET POS:” is set to ORG.
5. With SERVO READY button on, press TEACH LOCK and enable Servo Power.
6. Choose any COORD other than USER; jog the robot TCP to the desired origin point.

Conveyor
ORG XX
moving direction

Figure 3 User Frame ORG and XX Points

XRC Conveyor Tracking Training Page 3 © MOTOMAN

Conveyor Tracking Setup

7. Press MODIFY, ENTER. The bullet for ORG will be set (z) .
8. Press SELECT, cursor to XX and SELECT it.
9. Jog the robot TCP to the desired XX point.

NOTE: The XX point should be in the direction of conveyor movement at a location

consistent with the ORG from the side of the conveyor so that the it runs
parallel to the conveyor. The accuracy of this ray created from ORG through
XX is critical to the conveyor tracking.
10. Press MODIFY, ENTER. The bullet for XX will be set (z).
11. Press SELECT, cursor to XY and SELECT it.
12. Jog the robot TCP to the desired XY point. The placement of this point is not critical.

NOTE: For convenience of jogging, the XY point may be programmed as directly

vertical from the XX point, when teaching a frame on a conveyor.

XY

ORG XX

Figure 4 Conveyor Side View

13. Press MODIFY, ENTER. The bullet for XY will be set (z).
14. When all three points have been correctly taught, cursor down to COMPLETE and
press SELECT.
15. To name the User Frame, cursor right to the [ name area ] and press SELECT.
Cursor and SELECT up to 16 characters from the alphanumeric screen, then press
ENTER.

NOTE: To view/verify the set position of ORG, XX, or XY, choose the desired “SET
POS:” (as in steps 4, 8, or 11 above), then press the FWD key until the
highlighted “SET POS:” for ORG, XX, or XY stops flashing.

XRC Conveyor Tracking Training Page 4 © MOTOMAN

 Conveyor Tracking Setup

Setting the Conveyor Condition File

The Conveyor Condition File defines all of the information the controller needs to perform
the conveyor tracking. To access the available files, the controller must be in Management
Mode. From TOP MENU, choose ROBOT, then CV CONDITION. The Page Key
becomes active for paging to the desired file number.

DATA EDIT DISPLAY UTILITY

L
CONVEYOR COND FILE R1 C S
FILE NO. :1
1 USED STATUS :NOT USED
2 PORT NO. :CN1
3 BROKEN LINE DETECT :OFF
4 ENCODER INPUT :ENCODER
5 ENCODER SIGN :FORWARD
6 CORRECTION :FORWARD
7 TRACKING :ROBOT AXIS
8 USER COORD NO. :01
9 BASE AXIS :X
10 POSITIONAL RESOLUTION :0.00 µ/p
11 VIRTUAL CONVEYOR SPEED :0000.0 mm/sec
12 AVERAGED TRAVEL TIME : 0 ms
13 RESET SIGNAL MONITORING :10000 ms
14 CONVEYOR SPEED DOWN MODE :EXECUTE
15 CONVEYOR LOWER LIMIT SPD : 0 mm/sec
16 VIRTUAL ENCODER INPUT :IN#000
17 VIRTUAL ENCODER OUTPUT :OUT#000
!

Figure 5 Conveyor Condition File

(1) USED STATUS:

A file must be set for USED to become functional. A total of 3 Conveyor
Condition Files are available per JANCD-XSL02 circuit board. If any
NOT USED CV#( ) file is referenced in the job, ALARM 4531:
“UNDEFINED CONVEYOR COND FILE” occurs.
(2) PORT NO. :
CN1, CN2, or CN3 identify the port as attached to the board for the
encoder information. For example, if the encoder cable is connected to
CN07, then set as the first port, CN1.
(3) BROKEN LINE DETECT:
When DETECTION is set ON, the Major Alarm 1400: “ENCODER
ERROR (CONVEYOR)” will occur if no encoder communication is
detected. When detection is OFF, no notification will appear if encoder
communication is not detected.

XRC Conveyor Tracking Training Page 5 © MOTOMAN

Conveyor Tracking Setup

(4) ENCODER INPUT:

If this item is set for ENCODER, then the Virtual Encoder Input, as
designated by file item (16), enables/disables Virtual operation whenever
the conveyor is not running. If no input is designated, (IN#***), then
Virtual operation is unavailable when ENCODER is set.
NOTE: If set for ENCODER, and therefore it is using the Universal Input to toggle
Virtual ON/OFF, the switch cannot be changed during tracking otherwise
Major Alarm: “CANNOT CHANGE CONVEYOR MODE” will occur.
If this item is set to VIRTUAL ENCDR, then the system will always default
to virtual operation whenever the conveyor is not running.
Virtual operation can be used in TEACH or PLAY mode for many
purposes. The system will wait at the SYSTART until the Limit Switch is
tripped and then track at the constant VIRTUAL CV SPEED specified in
item (11).
(5) ENCODER SIGN:
FORWARD creates a direct correlation between actual encoder pulse
data and the synchronized tracking signed (+/-) direction. The display on
CV MONITOR for the CONVEYOR CURR POS (PULSE) and the
CONVEYOR SPEED (mm/sec) also have same sign, direct correlation.
REVERSE inverts the sign (+/-) to not only change the display on the
CV MONITOR for CURR POS (PULSE) and SPEED (mm/sec), but also
to compensate by reversing the direction of tracking.
For example, REVERSE would be used when the encoder/motor runs
in a negative direction while the conveyor operates in the desired, correct
direction. By setting REVERSE, and also ensuring that the setting for (6)
CORRECTION is set FORWARD, all data displays become positive for
the user’s convenience.
(6) CORRECTION:
FORWARD creates a direct correlation to (5) regarding tracking direction.
The signs on the CV MONITOR display for CURR POS (mm) and
CORRECT POS (mm) match those on the CURR POS (PULSE) and
CONVEYOR SPEED (mm/sec).
REVERSE not only inverts the signs on the CV MONITOR for the
CURR POS (mm) and CORRECT POS (mm) to the opposite of the signs
on CURR POS (PULSE) and CONVEYOR SPEED (mm/sec), but also
compensates by reversing the existing direction of tracking.
(7) TRACKING:
ROBOT AXIS tracking must be set If the robot is fixed, and also (8) must
specify a defined User Frame number.
BASE AXIS tacking must be set when the robot is on a traveling base
axis, and also (9) must be set for X, Y, or Z with regard to travel direction
as it correlates to the Robot Frame.

XRC Conveyor Tracking Training Page 6 © MOTOMAN

 Conveyor Tracking Setup

(8) USER COORD NO.:

A User Frame number (01 through 24) must be set for referencing X+
(as defined by the ray ORG -> XX ) for the direction of the conveyor
movement when (7) is set for ROBOT AXIS.
(9) BASE AXIS:
The X, Y, or Z setting identifies the direction of the traveling base axis
movement with respect to Robot Frame when (7) is set for BASE AXIS.
(10) POS RESOLUTION:
The Positional Resolution, 0.01 to 999.99, defines the ratio of microns
per pulse count for the conveyor travel to encoder pulse data ratio.
(11) VIRTUAL CV SPEED:
VIRTUAL CV SPEED must be set for desired constant velocity (-3,276.8
to 3,276.7 mm/sec).
(12) AVERAGED TRAVEL TIME:
If the travel rate of the conveyor is erratic, increase the Averaged Travel
Time setting (0 to 3000 ms) to smooth the position adjustment of the
robot. When set to zero, this function is not used.
(13) RESET SIG. MONITOR:
Upon execution of the SYSTART instruction, the Reset Signal Monitor
waits (1 to 65536 ms) for the “Start trigger” to perform the conveyor-home-
position-reset.
CAUTION! If this monitored signal is not activated within the
specified amount of time, the controller will continue
to the next line of instruction in the job! Programming
additional instructions such as GETS B000 SB008
and JUMP *LABEL IF B000 = 0 is a must.
When set to zero, the monitoring is nonfunctional, and therefore the
system will wait indefinitely for the signal.
(14) CONVEYOR SPEED DOWN MODE:
If the conveyor speed falls below the lower limit set in (15) for a
continuous 0.1 second, then one of the following three actions will occur
as set.
EXECUTE Job continues to run even if conveyor completely stops.
PAUSE JOB Job motion stops, but controller continues to track;
whenever speed increases above limit for at least 0.1 sec,
the job resumes.
ALARM Alarm 4532: “CONVEYOR SPEED DOWN” occurs.
(15) CV LOWER SPEED LIMIT:
If the conveyor speed drops below the set lower speed limit (mm/sec) for
a continuous 0.1 second, then the CONVEYOR SPEED DOWN MODE
as referenced by (14), EXECUTE, PAUSE JOB, or ALARM, will occur.

XRC Conveyor Tracking Training Page 7 © MOTOMAN

Conveyor Tracking Setup

(16) VIRTUAL ENCODER INPUT:

This Universal Input signals that virtual conveyor tracking is functional,
when item (4) is set for ENCODER. This allows the system to run in
TEACH or PLAY mode without the actual conveyor running. When the
Universal Input is OFF, then normal ENCODER operation is in effect.
When Item (4) is set as VIRTUAL ENCDR, then the system will default to
virtual operation whenever the conveyor is not running, regardless of this
setting for (16) Virtual Encoder Input.
(17) VIRTUAL ENCODER OUTPUT:
This Universal Output is ON while performing virtual tracking. It turns
OFF by the SYEND instruction.

Positional Resolution
Positional Resolution, item (10) in the Conveyor Condition File, defines the linear travel
distance in microns per encoder pulse count. Accuracy of this value is critical to ensure
consistent tracking.

Establishing Positional Resolution

Conveyor home-position
limit switch / Start Switch

1 meter dimension
Motor

Conveyor
moving direction

Encoder

Figure 6 Conveyor Positional Resolution

XRC Conveyor Tracking Training Page 8 © MOTOMAN

 Conveyor Tracking Setup

A suggested method to calculate the Positional Resolution is as follows:

1. A metric dimension must first be marked on the conveyor. This is frequently made
1 meter from the conveyor start switch to allow for easy calculations.
2. Using a square edged block/carton, start the conveyor and allow the block to pass the
Conveyor Start/Limit Switch. (0 Pulse Count Position)
3. Stop the conveyor when the leading edge of the block is at the 1 meter mark from the
start point.
4. From the TOP MENU, ROBOT, CV MONITOR, press the Page Key to display the
CONVEYOR POSITION screen; record the pulse counts of the current conveyor
position.
5. Using the following formula, calculate the ratio of microns per pulse count:

(Meters traveled by conveyor * 1,000,000) / (Pulse Counts moved on Encoder)

6. Enter this value into the Conveyor Condition File, POS RESOLUTION rounded to
two decimal place accuracy.

Verifying Positional Resolution

To verify the Positional Resolution setting, a simple job must be taught to test how well the
controller tracks the moving part.
NOTE: Refer to section on programming information.
The following job example may be used to test the accuracy of the POS RESOLUTION.

1
5

2
4

Conveyor

0000 NOP
0001 SYEND CV#(1)
0002 MOVJ VJ=25.00
0003 MOVJ VJ=25.00
0004 SYSTART CV#(1) STP=25.000
0005 SYMOVL V=200 CV#(1) CTP=100.000
0006 TIMER T=10.00
0007 SYMOVL V=200 CV#(1) CTP=100.000
0008 SYEND CV#(1)
0009 MOVJ VJ=25.00
0010 END

Figure 7 Positional Resolution Job

XRC Conveyor Tracking Training Page 9 © MOTOMAN

Conveyor Tracking Setup

Results of this job would indicate accuracy of the calculated value.

3 3
10 second tracking

Figure 8 Accurate Job Results

Conveyor moving
direction

10 second tracking 10 second tracking

Figure 9 Poor Job Results

Results shown in Figure 9 would require redefinition of the Positional Resolution value in the
Conveyor Condition File. Simple adjustment of the number may provide quicker accurate
results as compared to re-measuring.

NOTE: The POS RESOLUTION is critical for accurate conveyor tracking. The entire
Conveyor Condition File, which includes this data and all other important
conveyor operation settings, should be saved by accessing the TOP MENU,
FD/PC Card, SAVE, FILE/GENERAL DATA, and selecting the CONVEYOR
CONDITION DATA, CV.DAT file. Also, the USER COORDINATE DATA,
UFRAME.CND file and the TOOL DATA, TOOL.CND file should be saved.

XRC Conveyor Tracking Training Page 10 © MOTOMAN