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ConveyorTech stop motion when receive a zero coordinate

  • ZorgCat
  • December 10, 2020 at 3:25 PM
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  • ZorgCat
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    • December 10, 2020 at 3:25 PM
    • #1

    Hi, I have a KR10 R900 robot running KSS 8.6.6

    I've been trying to get Conveyor Tech to work and for most part it does. The system consists of a camera that sends the robot a coordinate to go to, while following the conveyor, and it does.

    But my problem is how can I make the robot do nothing when a zero coordinate is given, i.e. camera sees nothing, and then carry on with its following. Any suggestions??

    I've included the code below, up to the case statement where the movement is initiated.


    Code
    ;FOLD DECLARATIONS
        DECL INT ret
        DECL INT err
        ;DECL CHAR JUMP
    ;ENDFOLD (DECLARATIONS)
      ;FOLD INI
      ;FOLD BASISTECH INI
      GLOBAL INTERRUPT DECL 3 WHEN $STOPMESS==TRUE DO IR_STOPM ( )
      INTERRUPT ON 3
      BAS (#INITMOV,0 )
      ;ENDFOLD (BASISTECH INI)
      ;FOLD USER INI
      ;Make your modifications here
      ;ENDFOLD (USER INI)
        XPick=XPickNominal
      ;ENDFOLD (INI)
      ;FOLD CONV INI
      CONV_REINIT_MD()
      ;Alarm outputs initialisations
      $OUT[Z_EMS_OUT_NBR[1]]=TRUE
      $OUT[Z_DIST_ALARM_OUT_NBR[1]]=TRUE
      $OUT[Z_EMS_OUT_NBR[2]]=TRUE
      $OUT[Z_DIST_ALARM_OUT_NBR[2]]=TRUE
      $OUT[Z_EMS_OUT_NBR[3]]=TRUE
      $OUT[Z_DIST_ALARM_OUT_NBR[3]]=TRUE
      $OUT[Z_EMS_OUT_NBR[4]]=TRUE
      $OUT[Z_DIST_ALARM_OUT_NBR[4]]=TRUE
      $OUT[Z_EMS_OUT_NBR[5]]=TRUE
      $OUT[Z_DIST_ALARM_OUT_NBR[5]]=TRUE
      ;Interrupts Conveyor 1
      INTERRUPT DECL Z_ALARM_DIST_INT_NBR[1] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[1]]>=R_ALARM_DIST_CONV[1] DO INT_CONV_ALARM(1)
      INTERRUPT DECL Z_MAX_DIST_INT_NBR[1] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[1]]>=R_MAX_DIST_CONV[1] DO INT_CONV_MAX_DIST(1)
      INTERRUPT DECL Z_EMS_INT_NBR[1] WHEN $STOPMESS==TRUE DO INT_CONV_EMS(1)
      ;Interrupts Conveyor 2
      INTERRUPT DECL Z_ALARM_DIST_INT_NBR[2] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[2]]>=R_ALARM_DIST_CONV[2] DO INT_CONV_ALARM(2)
      INTERRUPT DECL Z_MAX_DIST_INT_NBR[2] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[2]]>=R_MAX_DIST_CONV[2] DO INT_CONV_MAX_DIST(2)
      INTERRUPT DECL Z_EMS_INT_NBR[2] WHEN $STOPMESS==TRUE DO INT_CONV_EMS(2)
      ;Interrupts Conveyor 3
      INTERRUPT DECL Z_ALARM_DIST_INT_NBR[3] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[3]]>=R_ALARM_DIST_CONV[3] DO INT_CONV_ALARM(3)
      INTERRUPT DECL Z_MAX_DIST_INT_NBR[3] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[3]]>=R_MAX_DIST_CONV[3] DO INT_CONV_MAX_DIST(3)
      INTERRUPT DECL Z_EMS_INT_NBR[3] WHEN $STOPMESS==TRUE DO INT_CONV_EMS(3)
      ;Interrupts Conveyor 4
      INTERRUPT DECL Z_ALARM_DIST_INT_NBR[4] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[4]]>=R_ALARM_DIST_CONV[4] DO INT_CONV_ALARM(4)
      INTERRUPT DECL Z_MAX_DIST_INT_NBR[4] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[4]]>=R_MAX_DIST_CONV[4] DO INT_CONV_MAX_DIST(4)
      INTERRUPT DECL Z_EMS_INT_NBR[4] WHEN $STOPMESS==TRUE DO INT_CONV_EMS(4)
      ;Interrupts Conveyor 5
      INTERRUPT DECL Z_ALARM_DIST_INT_NBR[5] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[5]]>=R_ALARM_DIST_CONV[5] DO INT_CONV_ALARM(5)
      INTERRUPT DECL Z_MAX_DIST_INT_NBR[5] WHEN $SEN_PREA_C[Z_SEN_PREA_NBR[5]]>=R_MAX_DIST_CONV[5] DO INT_CONV_MAX_DIST(5)
      INTERRUPT DECL Z_EMS_INT_NBR[5] WHEN $STOPMESS==TRUE DO INT_CONV_EMS(5)
      $ADVANCE=1
      ;ENDFOLD CONV INI
    
    ;JUMP:
    ; Clear Buffer
    ret = CONV_DELETE_ALL_WPS(1,err)
    ; CP_VEL_MODE should be 5, so DLIN can be used
    $CP_VEL_MODE=5
    
    ; Move to home position
      ;FOLD PTP HOME  Vel= 100 % DEFAULT;%{PE}%MKUKATPBASIS,%CMOVE,%VPTP,%P 1:PTP, 2:HOME, 3:, 5:100, 7:DEFAULT
      $BWDSTART = FALSE
      PDAT_ACT=PDEFAULT
      FDAT_ACT=FHOME
      BAS (#PTP_PARAMS,100 )
      SET_CD_PARAMS( 0)
      $H_POS=XHOME
      PTP  XHOME
      ;ENDFOLD
     
      WAIT FOR rCameraY>0
    
    ; Initialise Conveyor
    ;Fold Conveyor.INI_OFF LinConveyor1 ;%{PE}
     ;Fold ;%{h}
     ;Params IlfProvider=KukaRoboter.Conveyor.InlineForms.ConveyorIniOffInlineForm; ConveyorName=LinConveyor1; ConveyorId=1
     ;EndFold
     CONV_INI_OFF(1)
    ;EndFold
      
    ; Switch ON Conveyor
    ;Fold Conveyor.ON LinConveyor1 ;%{PE}
     ;Fold ;%{h}
     ;Params IlfProvider=KukaRoboter.Conveyor.InlineForms.ConveyorOnInlineForm; ConveyorName=LinConveyor1; ConveyorId=1
     ;EndFold
     CONV_ON(1)
     ;EndFold
     
    ; Start Conveyor Tracking
    ;Fold Conveyor.FOLLOW LinConveyor1, Movement 1, Cancel on: Max_time 60, Input 1, Input-Level TRUE, Flag 1, Flag-Level TRUE, WaitDist 1300, MaxDist 1500 ;%{PE}
     ;Fold ;%{h}
     ;Params IlfProvider=KukaRoboter.Conveyor.InlineForms.ConveyorFollowInlineForm; ConveyorName=LinConveyor1; ConveyorId=1; Movement=1; Cancel on: Max_time=60; Input=1; Input-Level=TRUE; Flag=1; Flag-Level=TRUE; WaitDist=1300; MaxDist=1500
     ;EndFold
     CONV_FOLLOW (1, 1, 60, 1, TRUE, 1, TRUE, 1300, 1500)
     CONV_MOV (1, 1)
     ;EndFold
    
    
    ; Stop Conveyor Tracking
    ;Fold Conveyor.Quit LinConveyor1, Stop after error FALSE, Reset SEN_PREA_C TRUE ;%{PE}
     ;Fold ;%{h}
     ;Params IlfProvider=KukaRoboter.Conveyor.InlineForms.ConveyorQuitInlineForm; ConveyorName=LinConveyor1; ConveyorId=1; Stop after error=FALSE; Reset SEN_PREA_C=TRUE
     ;EndFold
     CONV_QUIT(1,FALSE)
     CONV_RESET_SEN_PREA(1)
     ;EndFold
     
    
    
    LOOP  
     ;IF rCameraY==0 then 
        ;GOTO JUMP 
     ;ENDIF
     
    ;FOLD LIN Pre Vel=2 m/s CPDAT12 Tool[1]:MainTool Base[0] ;%{PE}
    ;FOLD Parameters ;%{h}
    ;Params IlfProvider=kukaroboter.basistech.inlineforms.movement.old; Kuka.IsGlobalPoint=False; Kuka.PointName=Pre; Kuka.BlendingEnabled=False; Kuka.MoveDataName=CPDAT12; Kuka.VelocityPath=2; Kuka.CurrentCDSetIndex=0; Kuka.MovementParameterFieldEnabled=True; IlfCommand=LIN
    ;ENDFOLD
    $BWDSTART = FALSE
    LDAT_ACT = LCPDAT12
    FDAT_ACT = FPre
    BAS(#CP_PARAMS, 2.0)
    SET_CD_PARAMS (0)
    PTP XPre
    ;ENDFOLD
    
    
    ;Fold Conveyor.Skip LinConveyor1, Skip to part index 1, Movement 1, Cancel on: Max_time 60, Input 1, Input-Level TRUE, Flag 1, Flag-Level TRUE, WaitDist 1300, MaxDist 1500 ;%{PE}
     ;Fold ;%{h}
     ;Params IlfProvider=KukaRoboter.Conveyor.InlineForms.ConveyorSkipInlineForm; ConveyorName=LinConveyor1; ConveyorId=1; Skip to part index=1; Movement=1; Cancel on: Max_time=60; Input=1; Input-Level=TRUE; Flag=1; Flag-Level=TRUE; WaitDist=1300; MaxDist=1500
     ;EndFold
     CONV_SKIP(1, 1, 1, 60, 1, TRUE, 1, TRUE, 1300, 1500)
     CONV_MOV(1, 1)
    ;EndFold
    
    
    ;Fold Conveyor.Quit LinConveyor1, Stop after error FALSE, Reset SEN_PREA_C TRUE ;%{PE}
     ;Fold ;%{h}
     ;Params IlfProvider=KukaRoboter.Conveyor.InlineForms.ConveyorQuitInlineForm; ConveyorName=LinConveyor1; ConveyorId=1; Stop after error=FALSE; Reset SEN_PREA_C=TRUE
     ;EndFold
     CONV_QUIT(1,FALSE)
     CONV_RESET_SEN_PREA(1)
     ;EndFold
     
    
    ENDLOOP
      
    ; Move back to home position
    ;FOLD PTP HOME Vel=10 % DEFAULT ;%{PE}
    ;FOLD Parameters ;%{h}
    ;Params IlfProvider=kukaroboter.basistech.inlineforms.movement.old; Kuka.IsGlobalPoint=False; Kuka.PointName=HOME; Kuka.BlendingEnabled=False; Kuka.MoveDataPtpName=DEFAULT; Kuka.VelocityPtp=10; Kuka.CurrentCDSetIndex=0; Kuka.MovementParameterFieldEnabled=True; IlfCommand=PTP
    ;ENDFOLD
    $BWDSTART = FALSE
    PDAT_ACT = PDEFAULT
    FDAT_ACT = FHOME
    BAS(#PTP_PARAMS, 10.0)
    SET_CD_PARAMS (0)
    PTP XHOME
    ;ENDFOLD
    
    END
    
    DEF CONV_MOV(Z_CONV_NBR:IN,Z_MOV_NBR:IN)
    ;FOLD INI CONV_MOV
      INT Z_CONV_NBR,Z_MOV_NBR
      IF B_CALL_CONV_MOV THEN
        CONTINUE
        $OUT[Z_DIST_ALARM_OUT_NBR[1]]=TRUE
        CONTINUE
        $OUT[Z_DIST_ALARM_OUT_NBR[2]]=TRUE
        CONTINUE
        $OUT[Z_DIST_ALARM_OUT_NBR[3]]=TRUE
        CONTINUE
        $OUT[Z_DIST_ALARM_OUT_NBR[4]]=TRUE
        CONTINUE
        $OUT[Z_DIST_ALARM_OUT_NBR[5]]=TRUE
        CONTINUE
        $OUT[Z_EMS_OUT_NBR[1]]=TRUE
        CONTINUE
        $OUT[Z_EMS_OUT_NBR[2]]=TRUE
        CONTINUE
        $OUT[Z_EMS_OUT_NBR[3]]=TRUE
        CONTINUE
        $OUT[Z_EMS_OUT_NBR[4]]=TRUE
        CONTINUE
        $OUT[Z_EMS_OUT_NBR[5]]=TRUE
        B_QUIT_BECAUSE_MAX_DIST=FALSE
        B_QUIT_BECAUSE_EMS=FALSE
        SWITCH Z_CONV_NBR
        CASE 1 ;*** CONVEYOR 1 ***
          CONTINUE
          IF NOT $T1 THEN
               INTERRUPT ON Z_ALARM_DIST_INT_NBR[1]
             INTERRUPT ON Z_MAX_DIST_INT_NBR[1]
             INTERRUPT ON Z_EMS_INT_NBR[1]
          ENDIF
          SWITCH Z_MOV_NBR
    ;ENDFOLD INI CONV_MOV
    
    ;FOLD CONVEYOR 1 MOVEMENT GROUP 1
          CASE 1
            CONTINUE
            WAIT FOR NOT $T1
      ; Calculate positions
    
       XProcess.Y = rCameraY
      
       XProcess02=XProcess
       XProcess02.Y = XProcess.Y + 10
    
     
      ; Move to positions using DLIN
    ;FOLD DLIN.MOVE Process Vel.CP=15m/s Vel.Ori1=2000deg/s Vel.Ori2=2000deg/s Acc.CP=50m/s^2 Acc.Ori1=5000deg/s^2 Acc.Ori2=5000deg/s^2 Tool[1]:MainTool Base[1]:FlangeBase(LinConveyor1) CONT
    ;FOLD ;%{h}
    ;Params IlfProvider=kukaroboter.conveyor.inlineforms.dlin.dlinmoveinlineform; Kuka.IsGlobalPoint=False; Kuka.PointName=Process; Kuka.Dlin.VelCp=15; Kuka.MoveDataName=XProcess; Kuka.VelocityPath=2; Kuka.CurrentCDSetIndex=0; Kuka.MovementParameterFieldEnabled=True; Kuka.Dlin.VelOri1=2000; Kuka.Dlin.VelOri2=2000; Kuka.Dlin.AccCp=50; Kuka.Dlin.AccOri1=5000; Kuka.Dlin.AccOri2=5000; Kuka.Dlin.Cont=CONT
    ;ENDFOLD 
    $BWDSTART = FALSE
    LDAT_ACT = LXProcess
    FDAT_ACT = FProcess
    CP_DYNLIN(15,2000,2000,50,5000,5000)
    SET_CD_PARAMS (0)
    LIN XProcess C_DIS C_DIS
    $OUT[234]=TRUE
    ;ENDFOLD
    ;FOLD DLIN.MOVE Process02 Vel.CP=15m/s Vel.Ori1=2000deg/s Vel.Ori2=2000deg/s Acc.CP=50m/s^2 Acc.Ori1=5000deg/s^2 Acc.Ori2=5000deg/s^2 Tool[1]:MainTool Base[1]:FlangeBase(LinConveyor1)
    ;FOLD ;%{h}
    ;Params IlfProvider=kukaroboter.conveyor.inlineforms.dlin.dlinmoveinlineform; Kuka.IsGlobalPoint=False; Kuka.PointName=Process02; Kuka.Dlin.VelCp=15; Kuka.MoveDataName=XProcess; Kuka.VelocityPath=2; Kuka.CurrentCDSetIndex=0; Kuka.MovementParameterFieldEnabled=True; Kuka.Dlin.VelOri1=2000; Kuka.Dlin.VelOri2=2000; Kuka.Dlin.AccCp=50; Kuka.Dlin.AccOri1=5000; Kuka.Dlin.AccOri2=5000; Kuka.Dlin.Cont=empty
    ;ENDFOLD 
    $BWDSTART = FALSE
    LDAT_ACT = LXProcess
    FDAT_ACT = FProcess02
    CP_DYNLIN(15,2000,2000,50,5000,5000)
    SET_CD_PARAMS (0)
    LIN XProcess02
    $OUT[234]=FALSE
    ;ENDFOLD
    
    ;ENDFOLD 
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    SkyeFire
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    • December 10, 2020 at 3:44 PM
    • #2
    Quote from ZorgCat

    But my problem is how can I make the robot do nothing when a zero coordinate is given, i.e. camera sees nothing, and then carry on with its following. Any suggestions??

    Set a default offset, branch around all the vision offsets if the camera feedback is zero.

  • ZorgCat
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    • December 14, 2020 at 10:09 AM
    • #3

    Hi, Sorry for the late reply, been a bit busy.

    Could you elaborate a little, maybe with an example? I am very new to KUKA, so a lot of seemingly simple things are a little difficult at times.

    Thanks in advance

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    SkyeFire
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    • December 14, 2020 at 4:25 PM
    • #4

    Well, your WAIT FOR rCameraY>0 is your first problem -- the robot is never going to do anything unless the camera value is greater than 0. That's another issue -- what happens if the camera sends over a negative value? Why only Y, what about X and Rz?

    You've also provided no information on where rCameraY comes from -- is it an input? An internal variable controlled by the SPS?

    You'll have to have some other means of signalling the robot to get past that line. This code as written makes no real sense -- what are you trying to accomplish here?

    Your code also falls into an endless loop with no exit condition whose structure makes no sense.

  • ZorgCat
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    • December 14, 2020 at 6:12 PM
    • #5

    I am still in the testing mode, slowly adding start and stop bits.

    The camera is sending data to PLC and then I send the split data to Robot. For clarity I named it rCameraY as it is converted to real in the config file.

    rCameraY is a single variable and for the time the only one I care about as the robot has to go to the Y position given by the camera and then make a small movement in the Y+ while tracking once the trigger has been triggered. This is the only time the robot re4cieves data. But when the trigger is triggered and there is no data all i am trying to do is make robot not to go to the zero coordinate on the belt.

    I've tried encasing the DLIN movement in an IF rCameraY>0 statement but as soon as it receives 0 the robot just goes in the skip conveyor mode and never recovers

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    SkyeFire
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    • December 15, 2020 at 2:46 PM
    • #6

    Once the robot hits the Conveyor.Skip line, it's too late to branch. You need to either put a wait/branch above that, or use the Skip input or Flag (as shown in the manual) to abort the Conveyor following. Then you'll have to set up your PLC to send over that Skip input in the event that the camera has a zero measurement.

  • ZorgCat
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    • December 15, 2020 at 5:15 PM
    • #7

    OOOOOOOOh, I'll try that now, but will need to wait for more product at the end of the week to test that properly

  • ZorgCat
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    • December 15, 2020 at 5:39 PM
    • #8

    So, in the PLC I added a bit of code to set the skip signal high when the Y value is at 0 and low when else. And as soon as I input a 0 I get an error: 'Wait for sync signal aborted because maximum conveyor distance reached'

    Am I doing something wrong?

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    SkyeFire
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    • December 15, 2020 at 5:41 PM
    • #9

    Does the robot stop running? It should loop back around to Conveyor.Skip.

    If not, you may need to prevent the robot from reaching Conveyor.Skip until the camera sends a good measurement. Once the program pointer reaches Conveyor.Skip, the only way to continue is to get the conveyor sync input, and the only way to abort is to raise the Skip input or Flag.

  • ZorgCat
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    • December 16, 2020 at 9:05 AM
    • #10

    To clarify, the robot gets the sync trigger every second, its the same trigger that triggers the camera to take a photo and send, if any, positional data. As every second one of many shoots on the conveyor goes by where the product should be present.

    If I understand the manual correctly, isn't the Conveyor.skip is the command that tell the robot to pick or skip? As in normal operation the pointer generally sits in that command until it sees a product and then does the movement and back to the skip command via the Pre position.

    The weird thing is that when I was simulating the 0 coordinate in plc, and at the same time rising the Input high, a couple of times it did in fact stop for a second and carried on 'picking'. But mostly it just sends the pointer jumping between Pre and Conv.skip uncontrollably with the message of max conveyor distance reached and the robot just stops. The program running, but the robot not moving

    Now I don't understand whether I am sending the 0 for too long and just got lucky with a couple of really quick position sends, or am I still doing something wrong?

    Also, I tried preventing the pointer to get to the Conv.skip by putting a Wait rCamera>0 statement but it doesn't even stop there, just goes into error straight away, in fact, anything I put there pretty much either ignored or just sends it into error

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    SkyeFire
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    • December 16, 2020 at 2:16 PM
    • #11
    Quote from ZorgCat

    To clarify, the robot gets the sync trigger every second, its the same trigger that triggers the camera to take a photo and send, if any, positional data. As every second one of many shoots on the conveyor goes by where the product should be present.

    Why not block the sync signal unless/until the camera has a valid measurement?

    Quote from ZorgCat

    Now I don't understand whether I am sending the 0 for too long

    Probably. If the robot gets through the Conv.Quit and back to the Conv.Skip while the Skip input is still active, you'll probably just keep skipping.

    Quote from ZorgCat

    Also, I tried preventing the pointer to get to the Conv.skip by putting a Wait rCamera>0 statement but it doesn't even stop there, just goes into error straight away, in fact, anything I put there pretty much either ignored or just sends it into error

    This is so vague as to be utterly useless.

  • ZorgCat
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    • December 16, 2020 at 3:12 PM
    • #12
    Quote from SkyeFire

    Why not block the sync signal unless/until the camera has a valid measurement?

    Ffs...why didn't I think of this...?!! :bravo:

  • ZorgCat
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    • December 22, 2020 at 8:32 AM
    • #13

    It finally worked! My problem was that the trigger for the camera and robots was triggering at the same time and it took a significant 900ms for the camera to process the picture, so ended up creating an array buffer and effectively 'moving' or delaying the trigger to the next, and then editing robot calibration and tracking distances back one flight and it finally worked :grinning_squinting_face:

    Thanks SkyeFire

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