Obviously, the only option is to begin counting from the actual number of products.
There is no enough information for further advice, and it's unclear what is the complication.
You already described the solution. What do you want to know?
It is unclear whether your pallet load is only one product per layer. If no, the solution will be not simple.
If yes, your p.2 is the solution.
When your program does not find product in pickup position, do not proceed to pickup. Instead, increment the picked product counter and jump back to pickup position decision, then re-execute pickup.
Just noticed you mentioned using skip condition.
Since it means seeking physical product, why do you need to count them?
When your program does not find product in pickup position, do not proceed to pickup. Instead, increment the picked product counter and jump back to pickup position decision, then re-execute pickup.
If i understand correctly doing this will bring robot every time back to starting (seek) position before doing next pick attempt? Could it be done in one continuous move to not hurt the cycle time?
Yes, iam seeking for the product, i just need product number further down the process.
If so, seek until found, then calculate the product layer number from the found elevation.
This assumes firm pallet height and firm height of the product.
And of course, the seek sensor resolution must be times better than the product height.
maybe, changing your sensor with a Distance sensor can be one of the best solutions.
I have faced the same problem, first I only use a photosensor to detect the workpiece, and I have to use the Skip function because the sensor only inputs the On and Off sensor to the robot, in the end, I have to start from the top of the pallet.
then, I tried to change the sensor to a distance sensor and input the distance to register. after that, I can go to start picking positions in pallet without using the Skip function.
