Do you have a backup of your programs (+ the line number of this trajectory) + the log file.
At home, thyssenkrupp integrated 2 UR, I had the same phenomena + emergency stops for overload or bad payload or collision. All my problems came from poor programming of my trajectories (acceleration, speed, choice of movement)
You have a great project, many companies are already offering this. I know companies that started integrating AGVs in 1995.
Start by already looking at the existing. Each of the societies is inspired by the others to improve it.
Attention to the security !!!!!!!!!!
Some axes can be moved manually.
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KUKA Commissioning Manual
Chapter 5.6.6 Options for moving the robot without a robot controler
Move the joystick with the brake opener
1. Stop the robot control to protect it from being reactivated (e.g. with a padlock).
2. Connect the brake opener to the robot base:Remove the existing X30 connector from the A1 interface. Connect the X20 connector of the brake opener to the A1.
3 interface. Select the brakes to be opened (major axles, wrist axles) with the selection switch at the brake opener.
4. Press the push button on the handheld controller. The brakes on the major axes or wrist axes open and the robot can be moved manually.
If each carton has a different and random orientation. Put a camera rather than your 2 sensors. The cost will be largely profitable over the time you will take to create, and develop your solution. As well as on the maintenance time on the life of the machine (especially at the beginning of the life of your machine)
