Rally URCap Manual de usuario
Pally URCap
User Manual
Version 2.9.1
Table of Contents
1 - Document Revision Information 6
2 - License 7
3 - Requirements 8
3.1 - Software Requirements 8
3.2 - Hardware Requirements 8
3.2.1 - Supported external hardware 8
3.3 - Compatibility notes 8
3.3.1 - Compatibility notes for version 2.6 and above 9
3.3.1.1 - Path planning 9
3.3.1.2 - ProductCount 9
3.3.2 - Compatibility notes for version 2.7.1 and above 9
3.3.2.1 - Pallet confirmation variables 9
3.3.3 - Compatibility notes for version 2.8 and above 9
3.3.3.1 - Execution of beforeZone and afterZone callbacks 9
3.3.3.2 - Execution of beforeGrab callback 9
3.3.3.3 - Waiting time at pickup and release positions 10
3.3.4 - Compatibility notes for version 2.9 and above 10
3.3.4.1 - URCap API 1.12 10
3.3.4.2 - Definition of multi-zone grippers (gripper.json) 10
3.3.4.3 - Multi-pick fewer boxes 10
3.3.4.4 - Optional posData in zones.json 10
3.3.4.5 - New callback onNextTask 10
3.4 - Compatibility with CB 3.0 robots 11
3.4.1 - Memory usage limitations on CB 3.0 11
3.4.2 - Computational limitations on CB 3.0 11
4 - Functional description 12
4.1 - The palletizer workflow 12
4.2 - Pallet patterns 12
4.3 - Pallet completion state 13
4.4 - Pickup position 13
4.4.1 - Single pick and multi-pick 14
4.4.2 - Gripper alignment at the pickup position - offset grip 14
4.4.3 - Gripper rotation at the pickup position - gripper optimization 15
4.4.4 - Grip quality value - smart acceleration 15
4.5 - Path planning 16
4.5.1 - The path planning algorithm 16
Version 2.9.1
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4.5.2 - Approaching the target position 18
4.5.3 - Pallet lip 20
4.5.4 - Return path 20
4.5.5 - User-defined path 20
4.6 - Shim papers 20
4.7 - Lifting column 20
4.7.1 - Positioning the lifting column for each layer 21
4.7.2 - Positioning the lifting column for each box - dynamic positioning 21
4.7.3 - Custom positioning - zones 22
4.8 - Zones 22
4.9 - User extensions - Callbacks 24
5 - Physical Installation - Best Practice 26
5.1 - Robot installation 26
5.1.1 - Check joint positions first 26
5.1.2 - Robot position on the base column 26
5.1.3 - Attach the gripper properly 27
5.1.4 - Lifting column 28
5.2 - Layout 29
5.2.1 - Supported pickup positions 30
5.2.2 - Suggested sensor placements 33
5.3 - Dimensions 34
5.3.1 - Pallet 34
5.3.2 - Pickup from Conveyor 34
5.3.3 - Important parameters to be measured 37
5.4 - Gripper 37
5.5 - I/O Connections 38
6 - Installing and Configuring the URCap 39
6.1 - Installation settings 39
6.1.1 - Overview 39
6.1.2 - License 40
6.1.3 - Gripper 41
6.1.4 - Lifting column 46
6.1.5 - Input/Output 50
6.1.5.1 Using MODBUS or General Purpose Boolean Registers 50
6.1.5.2 Input/Outputs in Pally 51
6.1.6 - Patterns 53
6.1.7 - Advanced 54
6.2 - Program settings 56
6.2.1 - Pickup 57
Version 2.9.1
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6.2.1.1 Calibration Box 57
6.2.1.2 Primary Pickup 58
6.2.1.3 Secondary Pickup 62
6.2.2 - Pallet 63
6.2.3 - Movement 65
6.2.4 - Advanced 69
6.3 - Callbacks 76
6.4 - Examples: typical configuration scenarios 79
6.4.1 - Classic setup with one optimal pickup position 79
6.4.2 - One pickup position with products coming in from the side 79
6.4.3 - One pallet position and one pickup position on the opposite side 81
6.4.4 - Two parallel pickup positions 82
6.4.5 - Two opposite pickup positions 85
6.4.6 - Limited space, walls other object 86
7 - Using the palletizer program 87
7.1 - Creating the main program 87
7.2 - Starting the program 87
7.3 - Using the program 88
7.3.1 - Single Product Mode 88
7.3.2 - Dual Product Mode 90
7.3.3 Partial Pallet 95
7.3.3.1 Edit Total Boxes 96
7.3.3.2 Edit Start Conditions 97
7.4 - Recovery from error 98
7.5 - Shutting down the robot 98
8 - Creating Patterns 98
8.1 - The pallet pattern definition file 98
8.2 - Project overview 99
8.3 - Layer types 100
8.3.1 - Box position 101
8.3.2 - Box rotation 101
8.3.3 - Box order 101
8.3.4 - Enforced single/multi-grip 101
8.3.5 - Gripper rotation at pickup 102
8.3.6 - Left and right pallet layout 102
8.3.7 - Inverse approach 103
8.3.8 - Shim paper 103
8.4 - Layers 103
8.5 - Zones 103
Version 2.9.1
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8.5.1 - Conditions 104
8.5.2 - Position transformation 105
8.5.3 - Location of the zone definitions 105
8.6 - Uploading new patterns 105
9 - Advanced configuration variables 106
9.1 - Naming conventions 106
9.2 - Changing configuration variables at startup 106
9.3 - Changing configuration at runtime 106
9.4 - List of available configuration variables 106
9.4.1 - Speed and acceleration 107
9.4.2 - Calibration points 107
9.4.3 - Path planning 108
9.4.4 - Gripper 110
9.4.5 - Lifting column 110
9.4.6 - Other/Special 111
10 - PalletManager daemon process 114
10.1 - Using the PalletManager daemon 114
10.2 - Pallet dimensions 114
10.3 - Product dimensions 114
10.4 - Pallet completion state 115
11 - Troubleshooting 116
Version 2.9.1
© Rocketfarm AS 2021. All rights reserved.
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1 - Document Revision Information
Date
Description
Author
15.11.2018
Initial draft
CM,LÅ,AL
08.02.2019
Checklist for new robot setup
CM
12.02.2019
Functional description, typical setup examples
CM
25.02.2019
Comments resolved, screenshots updated
CM
24.05.2019
Lifting column, shim paper, updated screenshots
CM
29.08.2019
Gripper and TCP configuration rewritten
CM
04.10.2019
Added gripper optimization, grippers with offset
CM
19.10.2019
Adding description of ‘Partial Pallet’-feature
ME
27.03.2020
Installation process with new GUI
ME
18.05.2020
Description of json format, new functions in 2.5.0
CM
26.05.2020
New Advanced tab in installation node
ME
28.09.2020
New functions in 2.6.0
CM
11.01.2021
Updates related to 2.6.1
CM
29.01.2021
Dual product mode updated for v2.7.0
ME
26.04.2021
Updates related to 2.7.1, new illustrations
CM
14.06.2021
Updates related to 2.8.0
CM
01.09.2021
Explanation of Smart Exit parameters, v2.8.1
CM
25.10.2021
v2.9.0, new gripper.json format, automatic single pick,
updated screenshots.
CM
22.12.2021
Vention MachineMotion V2 added
CM
Version 2.9.1
© Rocketfarm AS 2021. All rights reserved.
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2 - License
© Rocketfarm AS 2021. All rights reserved.
Disclaimer
The information contained herein is the property of Rocketfarm AS and shall not be
reproduced in whole or in part without prior written approval of Rocketfarm AS. The
information herein is subject to change without notice and should not be construed as a
commitment by Rockerfarm AS. Rocketfarm AS assumes no responsibility for any errors or
omissions in this document.
The Pally logo is a registered trademark of Rocketfarm AS.
Version 2.9.1
© Rocketfarm AS 2021. All rights reserved.
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3 - Requirements
3.1 - Software Requirements
URCap API version 1.12 or higher is required.
CB-series: Polyscope version 3.15 or higher is required.
E-series: Polyscope version 5.10 or higher is required.
3.2 - Hardware Requirements
Due to size limitations, the palletizer URCap requires a UR10 robot.
On CB-series robots, only CB-series version 3.1 is fully supported.
CB 3.0 robots may be used with some limitations, see Compatibility with CB 3.0 robots
3.2.1 - Supported external hardware
Lifting columns
● Ewellix LiftKit
● Vention MachineMotion V1 and V2
● Custom lifting column with 24V digital Up/Down signal
Grippers
● UniGripper CoLight
● Schmalz FXCB - Foam
● Schmalz FXCB - Suction cups
● Custom vacuum gripper with 24V digital signal
● Custom gripper
● Grippers with one or more individually controllable grip areas
3.3 - Compatibility notes
!
Please read the following compatibility notes carefully before upgrading an
existing Pally installation in production. Some changes in the recent versions may
require new customer acceptance tests and/or modifications in the main robot
program. Always make a full backup before upgrading.
Version 2.9.1
© Rocketfarm AS 2021. All rights reserved.
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3.3.1 - Compatibility notes for version 2.6 and above
3.3.1.1 - Path planning
The path planning algorithm has significantly changed in version 2.6. It is recommended to
test existing projects with full pallets of all products after upgrading to version 2.6.
3.3.1.2 - ProductCount
Since version 2.6 the "ProductCount" variable is now properly initialized to 0. In earlier
versions it was initialized to -1 incorrectly. It is necessary to update custom code in callbacks
that rely on the ProductCount variable.
3.3.2 - Compatibility notes for version 2.7.1 and above
3.3.2.1 - Pallet confirmation variables
From version 2.7.1 the pallet confirmation variables "rf_PS1_ok" and "rf_PS2_ok" should be
updated with the following script command:
palletmanager_daemon.write_key_value_static(name, value)
The old method palletmanager_daemon.write_key_value(0, name, value) has
no longer effect on the pallet confirmation state.
Programs that directly update the pallet confirmation variables should be verified.
3.3.3 - Compatibility notes for version 2.8 and above
3.3.3.1 - Execution of beforeZone and afterZone callbacks
From version 2.8.0 the beforeZone callback will be invoked when the lifting column has
already reached the specified position but palletizing has not yet started. Similarly, the
afterZone callback will be invoked after palletizing the last box has finished but the lifting
column is still in the position as specified by the current zone. Programs that use a lifting
column and have user code in beforeZone and afterZone callbacks should be verified.
3.3.3.2 - Execution of beforeGrab callback
From version 2.8.0 the pipeline architecture for all path planning calculations has been
redesigned such that all calculations are already done when the program enters the
beforeGrab callback. Changing some path-planning related internal rf_-variables in
beforeGrab for smart exit or collision radius calculations will no longer have any effect on the
next movement. Programs that modify internal (rf_) path planning variables directly in
beforeGrab should be verified.
Version 2.9.1
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3.3.3.3 - Waiting time at pickup and release positions
From version 2.8.0 the waiting time at pickup and release positions has been optimized, in
order to minimize the occurrence of protective stops caused by too early or too late change
in the payload and center of gravity. The waiting time may become shorter or longer than in
previous versions. Projects that are sensitive to the waiting times at pickup and release
positions should be verified. For further information, see the new variables
rf_joint_deviation_max and rf_joint_deviation_err under 9.4.6 - Other/Special
3.3.4 - Compatibility notes for version 2.9 and above
3.3.4.1 - URCap API 1.12
From version 2.9.0 the minimum required URCap API version is 1.12. which may require the
robot to be upgraded to a significantly newer version of Polyscope. Always make a full
backup before upgrading.
3.3.4.2 - Definition of multi-zone grippers (gripper.json)
From version 2.9.0 the structure of gripper.json has been changed. The zone positions are
now defined in accordance with the tool coordinate system, which means the X and Y
directions are inverted. This applies to all new gripper.json files that have the new format
with the "properties" structure included, otherwise the old behavior is kept for compatibility
reasons.
3.3.4.3 - Multi-pick fewer boxes
From version 2.9.0 the optimizer will try to pick fewer boxes when the specified (maximum)
amount of boxes cannot be palletized for some reasons, including out of reach issues and
too small gripper size. In contrast to older versions that failed immediately with "This position
cannot be palletized" the program will now retry with fewer boxes. This may introduce
unpredictable behavior when the calibration of an existing system is modified.
3.3.4.4 - Optional posData in zones.json
From version 2.9.0 the "posData" values in zones.json are made optional. This makes it
possible to use zones in combination with lifting column dynamic positioning.
3.3.4.5 - New callback onNextTask
From version 2.9.0 a new callback "onNextTask" will be automatically generated into the
existing program tree when the Pally program node is opened in the Program Robot menu
for the first time. The program has to be saved in order to keep the new structure.
Version 2.9.1
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