Conveyor Tracking Programming

CONVEYOR TRACKING PROGRAMMING

The XRC Conveyor Tracking function dynamically adjusts robot positions based on the
conveyor’s specified direction and rate of travel in order to maintain a constant speed
relative to the workpiece. The direction of travel is defined in a User Frame coordinate
system. The tracking is based on pulse counts from an encoder attached to the conveyor
motor. The pulse counts are converted to a linear distance in millimeters, and the job is
shifted by an ever increasing amount. This and all other attributes of the conveyor operation
are set into a Condition File completed by the programmer and set for USED.

Figure 1 shows a limit switch for the Conveyor Home Position. This is where the controller
starts tracking the part The job is initially taught with the conveyor not moving.

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

When the Conveyor Home Position Input Signal turns ON, the conveyor current value is
automatically reset to zero millimeters. The XRC can synchronize a robot with a conveyor
continuously over a maximum distance of 21 meters.
NOTE: If the moving distance during synchronization exceeds 21 m, ALARM 5022:
“CONVEYOR POSITION LIMIT” occurs, and the robot stops.

XRC Conveyor Tracking Training Page 1 © MOTOMAN

Conveyor Tracking Programming

Sensor Tracking and Motion Instructions

Conveyor Tracking, Sensor Instructions SYSTART and SYEND are included on the
Inform List under the SENSOR category.

SYEND
SYEND CV#(1)
This instruction indicates the end of a conveyor synchronized operation sequence.
Register the SYEND instruction after the last step location where the end of tracking is
desired.

When the conveyor home-position limit switch is ON, the conveyor home-position is
updated. Executing the SYEND instruction clears the conveyor home-position registered
status. Therefore, insert the SYEND instruction before the SYSTART and synchronized
motion steps.

SYSTART
SYSTART CV#(1) STP=1000.00 OL=200.00
This instruction indicates the start of a conveyor synchronized operation sequence using the
Condition File in the tag CV#( ). The robot starts follow-up motion by SYMOVJ,
SYMOVL, or SYMOVC instructions in the job after the SYSTART instruction.

Depending on the settings in the CV Condition File, the controller waits either indefinitely or
a designated amount of time for the limit switch to sense the part. Upon triggering the
switch, the position is reset to zero. When the current position value reaches the Start
Tracking Position tag in millimeters (STP) or Pulse Counts (STPP), the synchronized motion
instructions begin execution.

The Over Limit tag (OL), expressed in millimeters, specifies that if the next part activates
the trigger and travels past the STP by more than this allowable limit (while the robot is still
tracking the previous part) then at the next SYSTART command the robot will wait for
another part and not attempt to track the one that exceeded the set limit.

SYMOVJ, SYMOVL, SYMOVC

The Conveyor Tracking Motion Types are Synchronous Joint (SYMOVJ) for BASE
movement only, Linear (SYMOVL), and Circular (SYMOVC). These perform the
designated motion type and synchronize the Command Position to the current location of
the conveyor specified in the Condition File tag CV#( ).

The SYMOV_ instructions are the only ones that will command the robot to track with the
conveyor. Any standard MOV_ instructions will cause the robot to move to a fixed
Command Position that is not shifted by the Conveyor Tracking. The speed tags,
VJ=Joint_speed, V=Control_point_speed, and VR=Angle_speed mean the same as with
the standard motion types.

XRC Conveyor Tracking Training Page 2 © MOTOMAN

 Conveyor Tracking Programming

To access the Synchronous Motion Types in the Edit Buffer line, hold SHIFT and press the
MOTION TYPE key. Simply press the MOTION TYPE key to sequence through the
three choices SYMOVJ, SYMOVL, and SYMOVC. Repeat SHIFT + MOTION TYPE
to toggle back to the standard MOVJ, MOVL, MOVC, and MOVS.

=> MOVL V=66 MOVL (standard interpolation)

SYMOVL (conveyor
=> SYMOVL V=66 CV#(1)
synchronized interpolation)

Figure 2 Edit Buffer Line

NOTE: SYMOVJ can be used only when the BASE is selected for synchronization.
If SYMOVJ is executed when the ROBOT is used, Alarm 4583: “CAN NOT
USE SYMOVJ DURING TRACKING” occurs and the manipulator stops.
SYMOVJ VJ=50.00 CV#(1) CTP=100.000
SYMOVL V=200.0 CV#(1) CTP=100.000
SYMOVC V=200.0 CV#(1) CTP=100.000

The CTP tag is automatically captured when the step position is recorded or modified.
It represents the Conveyor Teaching Position (CTP) in millimeters beyond the trigger
location.

limit switch

CTP Distance
Motor

Conveyor
moving direction

SYMOVL points

Encoder

NOP
SYEND CV#(1)
MOVJ VJ=0.78
MOVJ VJ=100.00
SYSTART CV#(1) STP=1000.000
SYMOVL V=500 CTP=987.459
SYMOVL V=500 CTP=987.459
SYMOVL V=500 CTP=987.459
SYMOVL V=500 CTP=987.459
SYMOVL V=500 CTP=987.459
SYMOVL V=500 CTP=987.459
SYEND CV#(1)
MOVJ VJ=100.00
END

Figure 3 Conveyor Position at Teaching

XRC Conveyor Tracking Training Page 3 © MOTOMAN

Conveyor Tracking Programming

Modifying SYMOV_ Position

Modification of a SYMOV_ position must be done with care, as all SYMOV_ positions
are related to the Current Conveyor position. The conveyor must be in a non-tracking
status when inserting or modifying points.

limit switch

Conveyor position Conveyor position

987.459 2000.459
Motor

Conveyor
moving direction

Encoder

limit switch

Conveyor position Conveyor position

987.459 2000.459
Motor

Conveyor
moving direction

Encoder

Figure 4 Modifying a Position

If the SYMOV_ has a CTP of 987.459 and the conveyor has a current position of
2000.459 as shown in Figure 4, forwarding to the SYMOV position will cause the robot to
attempt to move to the position shown in the bottom picture. This position may not be
within the reach of the robot.

Executing an SYEND instruction will stop the sensor tracking function.

XRC Conveyor Tracking Training Page 4 © MOTOMAN

 Conveyor Tracking Programming

Resetting the Conveyor

The conveyor must be in a non-tracking status when inserting or modifying points. This can
be verified by checking the CV TRACKING STATUS screen.
To display the Tracking Status screen, perform the following:
1. From TOP MENU, select ROBOT.
2. Cursor to CV MONITOR and press SELECT.
3. Use the PAGE Key to sequence through CONVEYOR POSITION, CONVEYOR
SPEED, to CV TRACKING STATUS.

DATA EDIT DISPLAY UTILITY

L
CV TRACKING STATUS R1 C S
INPUT STATUS TRACKING STATUS
LS#01 CV#01
LS#02 CV#02
LS#03 CV#03
LS#04 CV#04
LS#05 CV#05
LS#06 CV#06

Figure 5 Conveyor Tracking Status

The tracking status indicator should be OFF. If the Status is ON as shown (z), then
execute a SYEND instruction in the JOB CONTENT by INTERLOCK + FWD.
(The Tracking Status is also ended by XRC power OFF.)

Modifying SYMOV_ Positions

After resetting the conveyor, the system is now ready for starting another part through the
Conveyor Home Position limit switch. This will determine accurate part location for the
CTP tag on the modified SYMOV_ step.
To modify the SYMOV_ position, perform the following:
1. Start the conveyor so that the part activates the Limit Switch.
2. When the part is at a convenient location, stop the conveyor.
3. FWD to the original point in the job.
4. Use SHIFT+ MOTION TYPE to set the Edit Buffer Line to be SYMOV_ type.
5. Reposition the robot as desired, press MODIFY and ENTER.
The Step will now have the Command Position modified. The CTP on the line will be
updated to the location where the point was taught.

CAUTION! Manually changing the CTP on any SYMOV_ may cause a crash.

XRC Conveyor Tracking Training Page 5 © MOTOMAN

Conveyor Tracking Programming

Deleting SYMOV_ instruction Steps

After resetting the conveyor and starting another part through the Conveyor Home Position
limit switch, it is possible to FWD to a point so that the cursor is not blinking. The point
can then be deleted by pressing DELETE and ENTER (if the Edit Buffer is set to
SYMOV_ Motion Type.)

However, is may be easier to simply use the CUT function for one or more consecutive
SYMOV_ steps to be removed from a job.
To CUT steps from the job, perform the following:
1. Place the cursor on the instruction side of the job on the first step to be removed.
2. Press SHIFT + SELECT to highlight the address side.
3. Cursor up/down to highlight consecutive addresses to be CUT.
4. Press the Area Key to access the Menu Area, then cursor to EDIT and press
SELECT.
5. Cursor to CUT and press SELECT.
6. Cursor to YES on the “Delete?” window and press SELECT.

XRC Conveyor Tracking Training Page 6 © MOTOMAN