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TFDEN 133 004 - NV Pro
TFDEN 133 004 - NV Pro
FD/CFD CONTROLLER
INSTRUCTION MANUAL
Vision device
NV-Pro
4th edition
・Before attempting to operate the robot, please read through this operating manual
carefully, and comply with all the safety-related items and instructions in the text.
・The installation, operation and maintenance of this robot should be undertaken only
by those individuals who have attended one of our robot course.
・When using this robot, observe the low related with industrial robot and with
safety issues in each country.
・This operating manual must be given without fail to the individual who will be actually
operating the robot.
・Please direct any queries about parts of this operating manual which may not be
completely clear or any inquiries concerning the after-sale service of this robot to any
of the service centers listed on the back cover.
CONTENT
CONTENT
1 Outline
1.1 Outline of function of vision sensor ..................................................................................... 1-1
1.1.1 What is a vision sensor?................................................................................................. 1-1
1.1.2 Layout ............................................................................................................................. 1-1
1.1.3 Coordinate system.......................................................................................................... 1-2
1.1.4 Correction methods ........................................................................................................ 1-4
1.2 Feature ................................................................................................................................ 1-6
3 Calibration
1
CONTENT
2
CONTENT
7 Stereo measurement
7.1 Stereo measurement........................................................................................................... 7-1
7.1.1 Stereo measurement method ......................................................................................... 7-1
7.1.2 Registration of measurement condition.......................................................................... 7-2
7.2 Standard setting .................................................................................................................. 7-3
7.2.1 Standard setting.............................................................................................................. 7-3
7.2.2 Exposure condition ......................................................................................................... 7-5
7.3 Image processing ................................................................................................................ 7-9
7.3.1 Registration of Image processing ................................................................................... 7-9
3
CONTENT
8 Combined measurement
8.1 Registration of measurement condition .............................................................................. 8-1
9 Hardware
9.1 System configuration........................................................................................................... 9-1
9.1.1 Vision sensor unit ........................................................................................................... 9-1
9.1.2 CPU board ...................................................................................................................... 9-2
9.1.3 Image input board........................................................................................................... 9-4
9.2 Connection .......................................................................................................................... 9-5
9.2.1 Connection of camera .................................................................................................... 9-5
9.2.2 Setting of camera............................................................................................................ 9-6
9.2.3 Connection of input and output signals .......................................................................... 9-8
9.2.4 Input signal connector CNIN........................................................................................... 9-8
9.2.5 Output signal connector CNOUT1, CNOUT2, power connector CNP24 ....................... 9-9
9.3 Replacement procedure.................................................................................................... 9-12
9.3.1 Replacement of CPU board.......................................................................................... 9-12
9.3.2 Replacement of image input board............................................................................... 9-13
9.3.3 Replacement of battery................................................................................................. 9-14
9.4 Maintenance parts............................................................................................................. 9-15
9.4.1 List of maintenance parts.............................................................................................. 9-15
4
CONTENT
10 System setting
10.1 Vision sensor constant ...................................................................................................... 10-1
10.1.1 Vision sensor constant setting.................................................................................... 10-1
10.2 License .............................................................................................................................. 10-2
10.2.1 Import of license ......................................................................................................... 10-2
10.2.2 Export of license ......................................................................................................... 10-5
10.3 Setting of vision sensor unit .............................................................................................. 10-7
10.3.1 Camera setting ........................................................................................................... 10-7
10.3.2 Signal setting .............................................................................................................. 10-8
10.3.3 Communication setting ............................................................................................. 10-10
10.3.4 Date and time setting................................................................................................ 10-12
11 Troubleshooting
11.1 Robot controller error codes.............................................................................................. 11-1
5
CONTENT
NOTE
6
1 Outline
Camera
Hand
Unpositioned
workpiece
1.1.2 Layout
There are two ways of laying out camera mounting, mounting camera on the hand fixed at the end of a robot
and mounting it on the jig fixed to the ground.
The former camera is called a hand camera, and the latter is called a fixed camera.
Fixed camera
Hand camera
Hand
Workpiece
1-1
1.1Outline of function of vision sensor
Flange coordinate
Visual sensor
coordinate
(fixed camera) Tool coordinate Machine
coordinate
World coordinate
1-2
1.1Outline of function of vision sensor
Image coordinate
Input image
Y axis
The flange coordinate system has its origin at the center of flange face of a robot, and its direction at zero
degree is as shown in the figure below. This coordinate system serves as the reference when setting of tools is
executed.
X
Y
Z
Fig. 1.1.4 Flange coordinate system
Since tool coordinate system, camera coordinate system in the case of a hand camera and vision sensor
coordinate system are in reference to flange coordinate system, the positions of those coordinates change as
attitude of the robot changes as shown in the figure below.
Flange coordinate
Flange coordinate
Camera
coordinate
Camera
coordinate
Tool coordinate
Tool coordinate
1-3
1.1Outline of function of vision sensor
“World coordinate reference shift” and “flange coordinate reference shift” are single-purpose correction
operations for this vision sensor.
“World coordinate reference shift” is the correction method when workpiece on a jig is measured and grasped.
Robot position is corrected in accordance with the gap of workpiece.
Amount of robot shift
“Flange coordinate reference shift” is a correction method when workpiece grasped by a robot is measured
and set at the correct position as shown in the figure below. Position of robot is corrected so that position and
attitude of workpiece is same as those at the time of teaching. In this case, position of workpiece is measured as
the workpiece is grasped by the robot.
Correction is made
so that position of
workpiece is same
as that at the time
of teaching
Workpiece
Jig
Both hand camera and fixed camera can be used in either method.
1-4
1.1Outline of function of vision sensor
With “world coordinate reference shift” and “flange coordinate reference shift”, calculation of the amount of
correction is executed taking attitude of robot in consideration.
For example, with “world coordinate reference shift”, position of workpiece is detected on world coordinate by
calculating the position of workpiece on world coordinate using installation attitude, robot attitude at the time of
measurement, position of vision sensor coordinate and result of recognition. Therefore, position of workpiece
can be detected correctly even when position of camera is different from that at the time of teaching. Utilizing the
features, when position of camera is moved and workpiece is moved to the vicinity of image center in the first
measurement and the second measurement is further executed, there is no need to calculate the final amount of
shift by adding amount of shift using robot language, etc.
Flange coordinate
Robot attitude
Position of visual
sensor coordinate
Recognition
Visual sensor
result
coordinate
Workpiece Machine coordinate
Installation
Position of workpiece on attitude
world coordinate World
coordinate
1-5
1.2Feature
1.2 Feature
Function of vision sensor has features described below.
● Simple operation
Operation of vision sensor is very simple, since function of vision sensor is built in the robot controller.
Setting of parameters and measurement conditions of vision sensor can be carried out by the same
operation as setting of robot parameter, since all the operation are carried out using the teach pendant of
robot.
Since images taken in by camera are displayed on the teach pendant, setting of measurement conditions
can be executed at the time of teaching confirming images up close to recognition work.
● Lighting control
Single-purpose on/off signals for lighting and laser pointer are installed.
Automatic on/off of lighting at optimum timing is possible.
1-6
1.3Workflow
1.3 Workflow
Following works are executed for automatic operation of a robot using vision sensor function.
Initial setting
Environment settings such as connection of camera and lighting are carried out.
Connection of external units Camera and lighting
are connected
Environment setting of
Registration of camera
visual sensor model, etc. are carried out.
Calibration
Camera-related calibration is executed.
Parameters of camera
Camera calibration model are obtained.
Automatic operation
After creation of robot work program, automatic operation of robot is executed.
Program selection
Measurement and
Automatic operation correction of position
by visual sensor
1-7
1.3Workflow
NOTE
1-8
2 Basic operation of vision sensor
If [31 vision sensor] is not displayed in service menu, vision sensor function is not
effectively set. Confirm vision sensor constant setting.
4 Select [1 vision sensor setting] from menu and press [Enter] key.
≫Vision sensor setting screen is displayed.
Vision sensor unit and CPU unit for robot control are connected by Ethernet.
INFO. In order to display vision sensor unit setting screen, communication processing between vision
sensor unit and CPU unit is carried out, so that initiation of communication may take much time.
Usually it takes 2 to 3 seconds.
In the vision sensor unit setting screen, title bar icon becomes a camera mark.
INFO.
Vision sensor setting screen can also be displayed directly using soft keys.
INFO. Refer to “Set up” chapter for details
If a message saying “Connection to vision sensor failed” is displayed, problems such as failure of
POINT connection of communication setting or Ethernet cable are possible.
Confirm and try again in normal condition.
2-1
2.2Registration of measurement conditions
2-2
2.2Registration of measurement conditions
By pressing [R] key without pressing [Execute] key in 5, screen returns to that of 4.
POINT
2-3
2.2Registration of measurement conditions
Selection can also be made by inputting measurement condition number and pressing [Enter]
POINT key.
Entering non-existing number is for new registration.
2-4
2.2Registration of measurement conditions
4 Select measurement condition of copy source from the list and press
f11[Copy] key.
≫Copy destination selection screen appears.
When number of already registered measurement condition was selected as copy destination and
POINT copy was executed, a confirmation message as shown below is displayed.
As the number of measurement condition of copy destination, same number as in the copy
POINT source cannot be selected. Select number from 1 to 999 as the number of measurement
condition of copy destination.
2-5
2.2Registration of measurement conditions
2-6
2.3Registration of calibration
If there are already registered calibrations, they are displayed in the list.
2-7
2.3Registration of calibration
Press [R] key without pressing [Execute] key in 5 to return to screen of 4 without creation of
POINT calibration data.
2-8
2.3Registration of calibration
Selection can also be made by inputting calibration number and pressing [Enter] key.
POINT Entering non-existing number is for new registration.
2-9
2.3Registration of calibration
4 Select calibration of copy source from the list, and press f11[Copy].
≫Copy destination selection screen appears.
When number of already registered calibration number was selected as copy destination and
POINT copy was executed, a confirmation message as shown below is displayed.
As the calibration number of copy destination, same number as in the copy source cannot be
POINT selected. Select number from 1 to 99 as the calibration number of copy destination.
2-10
2.3Registration of calibration
4 Select calibration to be deleted from the list and press f11[Delete] key while
pressing [Enable] key.
+ ≫Confirmation message as shown below is displayed.
2-11
2.4System setting
2-12
2.5System environment
2-13
2.6Area setting
Depending upon screens for setting areas, content of explanation is partially different from that
POINT explained here.
In that case, since operation guide is displayed at top left of the screen, operation can be
executed following it.
Areas to be
added
Areas to be
masked
Area shifting
Areas can be shifted by operating cursor keys.
Amount of operation by one cursor input can be adjusted with [Step increase] key and [Step decrease] key.
Present amount of operation is the shift step at left bottom of screen and unit is pixel.
Before shifting After shifting
Amount of operation
Center position
2-14
2.6Area setting
Size change
Area size can be changed by operating cursor keys while pressing [Enable] key.
Following operations can be executed with the cursor keys.
Height contraction Width contraction
Height expansion Width expansion
Amount of operation by one cursor input can be adjusted with [Step increase] key and [Step decrease] key.
Present amount of operation is the shift step at left bottom of screen and the unit is pixel.
Before size change After size change
Amount of operation
Size
Rotation
In rotatable areas (rotary rectangle, oval), areas can be rotate by changing operation mode to [Rotate] and
operating cursor keys while pressing [Enable] key. Changing of operation mode is executed using [Operation
mode change] key. Operation mode is interchanged between [Rotate] and [Size] bi input of this key.
Following operations can be executed with the cursor keys.
Counterclockwise rotation
or
Clockwise rotation
or
Amount of operation by one cursor input can be adjusted by pressing [Step increase] key and [Step decrease]
key. Present amount of operation is the rotation step at left bottom of screen and the unit is degree.
Operation mode
Amount of operation
Rotation angle
2-15
2.6Area setting
Oval Circle
Following keys are used for area addition and mask addition.
In order to clear set area, set mask area that covers all the area that has been set.
INFO.
2-16
2.6Area setting
[Maximum area]
Area can be set in image size by key operation depending upon screens.
In that case, press [Maximum area] key.
[Area fill]
In free area setting, display of set area is interchangeable between indication by filling and indication by
contour (area boundary) only.
In that case, press [Area fill]/[area boundary] key. Method of display changes alternately by pressing the key.
Area
boundary
Fig. 2.6.6 Area fill/boundary display
2-17
2.7Vision sensor monitor
If [59 Vision sensor monitor] is not displayed in monitor menu, vision sensor function
is not effectively set. Confirm setting of vision sensor constants.
2 Select [59 Vision sensor monitor] from menu, and press [Enter] key.
≫Following screen is displayed.
Vision sensor unit and CPU unit for robot control are connected by Ethernet.
INFO. In order to display vision sensor unit setting screen, communication processing between vision
sensor unit and CPU unit is carried out, so that initiation of communication may take much time.
Usually it takes 2 to 3 seconds.
In monitor screen for vision sensor unit, title bar icon becomes a camera mark.
INFO.
Vision sensor monitor screen can also be displayed directly using soft keys.
INFO. Refer to “Set up” chapter for details
If a message saying “Connection to vision sensor failed” is displayed, problems such as failure of
POINT connection of communication setting or Ethernet cable are possible.
Confirm and try again in normal condition.
2-18
2.7Vision sensor monitor
Soon after camera image monitor is displayed, images taken in from camera may not be
POINT displayed in some cases. Camera images are updated at the time of execution of measurement.
2-19
2.7Vision sensor monitor
3 Set parameters.
In order to cancel content of editing, press [R] key before pressing [Execute] key to
end display selection screen.
2-20
2.7Vision sensor monitor
POINT Content of editing of display selection is cleared when power source is turned on.
2-21
2.7Vision sensor monitor
2-22
2.7Vision sensor monitor
3 Select one out of date, measurement condition number and trouble code as
reference for rearrangement.
In order to cancel content of editing, press [R] key before pressing [Execute] key to
end screen for trouble history rearrangement.
POINT Content of editing of trouble history rearrangement is cleared when power source is turned on.
2 Set each parameter in menu to set method for trouble history monitor display.
In order to cancel content of editing, press [R] key before pressing [Execute] key to
end display selection screen.
POINT Content of editing of trouble history rearrangement is cleared when power source is turned on.
2-23
2.7Vision sensor monitor
2-24
2.8Backup
2.8 Backup
Data and log files registered in vision sensor unit cannot be backed up with ordinary backup.
Work of backup of data and log files registered in vision sensor unit is explained here.
NVBK2012-04-08-1630-08
Backup time in seconds
Backup time in hours (24 h notation)
Backup day
Backup month
Backup year(western calendar, 4-digit)
Fig. 2.8.1 Backup folder name
2-25
2.8Backup
Inserting USB memory into the robot controller (RC External Memory)
Only insert and remove the USB memory when the robot controller power is
switched off.
Inserting or removing the USB memory when the power is on may corrupt the
CAUTION data saved on the USB memory.
1 Turn power for robot control unit OFF, and open door.
Mount the USB memory to the CNUSB2 or CNUSB3 on the CPU board.
The CPU board is mounted in the rack unit of the controller.
Pay attention to the direction of theUSB memory when inserting it. The USB memory
cannot be inserted to the port in wrong direction.
Front (Internal)
正面図(内部) Enlarged rack unit diagram
ラックユニット拡大図
Rack unit
ラックユニット CPU基板
CPU Board
CNUSB3
CNUSB2
USB Memory
USBメモリ
There are 2 USB ports in the CPU board. The USB memory will work
irrespective of which USB port it is connected to. However, do not connect 2
IMPORTANT USB memories at the same time.
2 Close the door of the controller, and turn the power on.
2-26
2.8Backup
Inserting USB memory into the teach pendant (TP External Memory)
During LED of the USB memory has been flashing, please don't remove the
USB memory from the USB port. Data may break.
IMPORTANT
1 Open the USB cap from the back of the teach pendant.
USB Cap
Only connect USB memory to the USB port when operating files. When the TP
external storage memory is not being used, always close the USB cap on the
back of the teach pendant.
Leaving the USB cap open for long periods may hinder the dust protection and
CAUTION waterproofing properties, which may lead to failure.
2-27
2.8Backup
2.8.3 Backup
Method of backup of vision sensor is explained.
1 Operator qualification shall be expert or higher.
2 Select teaching mode.
3 Select [Service][31 Vision sensor].
≫Such menu as shown below is displayed.
4 Select [2 vision sensor file backup] from menu, and press [Enter] key.
≫Vision sensor backup screen is displayed.
5 Select a device for the backup destination, and press [Enter] key.
2-28
2.8Backup
7 Press f12[Execute].
≫Following confirmation message is displayed.
When external storage (USB memory) is not inserted, error message is displayed and backup is
POINT not executed.
Never turn off power of control unit or cut network during backup, or backup data may be
damaged.
CAUTION
2-29
2.8Backup
4 Select [3 Vision sensor file restore] from menu, and press [Enter] key.
≫Vision sensor backup restoration screen is displayed.
5 Select folder for backup restoration data, and press [Enter] key.
2-30
2.8Backup
6 Select folder for backup restoration data, and press [Enter] key.
7 Press f12[Execute].
≫Following message is displayed.
Since license file is usually also backed up when backup is executed, backup
restoration can be executed without particular action. If license has been modified
after backup for some reason such as damage of dongle, select [No] for confirmation
of restoration of license file.
10 Press [Enter] key to end vision sensor backup restoration.
When external storage (USB memory) is not inserted, error message is displayed and backup is
POINT not executed.
Following message is displayed when correct license file was not restored in vision sensor.
POINT “License trouble of vision sensor was detected. Confirm, license file.”
Re-import license file. Refer to chapter of “Maintenance” for details.
Never turn off power of control unit or cut network during backup, or backup data may be
damaged.
CAUTION
2-31
2.8Backup
NOTE
2-32
3 Calibration
Camera
Calibration
plates of
various
positions
and angles
Fig. 3.1.1 Camera calibration
When change of camera position, change of lens, and adjustment of focus and
diaphragm of lens are executed after completion of calibration work, the state becomes
different from the content registered by calibration.
Be sure to do calibration work again, or correct measurement is impossible.
CAUTION If re-calibration is not executed, erroneous correction will be done and interference with
surrounding jigs and human disasters may occur.
3-1
3.1What is calibration?
Frame
Dot diameter
Fig. 3.1.2 Calibration plate
Although calibration plate shown above is recommended, calibration plates without corner mark and frame or
with different number of dots are also available. Although calibration can be executed with either type,
conditions of the plate used as calibration parameter must be correctly set.
In order to execute calibration in high precision, select dot diameter of at least no less than 10
INFO. pixels when image is input by camera.
Further, select plate size of about 1/4 to 1/3 of vision field.
Y axis
X axis X axis
Y axis X axis
Y axis
軸
(a) With corner mark (b)Without corner mark
Fig. 3.1.3 Calibration coordinate
3-2
3.1What is calibration?
Positional relation of
Positional relation of flange coordinate
camera coordinate and and visual sensor Calculated by visual
visual sensor coordinate coordinate sensor registration
Visual sensor
Calculated by camera calibration coordinate
( Calibration coordinate at
the first plate measurement)
Position at the first plate World coordinate
measurement
Positional relation of Registered as user
world coordinate and coordinate
visual sensor coordinate
Fig. 3.1.4 Vision sensor coordinate
While vision sensor coordinate is registered based upon calibration coordinate at the first plate
POINT measurement, meanings of the two coordinate are different.
Although calibration coordinate is a fixed coordinate, vision sensor coordinate shifts in
accordance with change of robot attitude.
Calibration cannot be correctly executed unless type of mounting of camera and focal length are
POINT correctly set.
Be sure to confirm content of setting before work.
3-3
3.2Preparation for calibration
When calibration plate is installed on a jig, make its position at the first plate measurement for
vision sensor coordinate registration at the same height as measurement surface of workpiece.
IMPORTANT If heights of the two are different, precision of measurement is deteriorated.
When calibration plate is placed on a jig, position of plate is changed by hand. Therefore, same
INFO. position is difficult to be reproduced. However, the first plate measurement position alone is an
important position for installation for setting vision sensor coordinate and camera coordinate. It is
convenient to have the position reproducible as far as possible in preparation for the case when
work needs to be repeated due to mistake, etc.
3-4
3.2Preparation for calibration
キャリブレーション
Calibration tool
ツール
大 Sharp
地に固 定した
edge
fixed on ground
鋭利な先端
Change robot attitude drastically from step to step and make aiming as correctly as
possible. That is the point for high precision.
4 Select [Constant setting][3 Machine constant][1 Tool Constant] to display tool
setting screen, and select optional tool number.
≫Tool setting screen is displayed.
3-5
3.2Preparation for calibration
6 Move cursor to program number, and input number of program created before.
Maximum error represents probability of tool length obtained. The smaller the value,
the higher the accuracy of tool length obtained is.
Error of each step is also displayed. When errors are big, correct positions starting
from the step with biggest numerical value in descending order.
After correction of positions, re-execute procedure from 5.
8 If there is no problem, select [Yes], and press [Enter] key.
≫ Tool length automatic setting screen ends, and original tool setting screen
returns.
At this time, set value is not stored yet.
9 Press f12[Complete] key.
≫Set content is stored and machine constant menu screen returns.
Calibration tool setting is completed by this point.
Step 2 record
Step 3 record position
position
Calibration tool
y x
(z)
3-6
3.2Preparation for calibration
Set the user coordinate number, which was set here, in calibration parameter, and register vision
POINT sensor coordinate position.
Origin of calibration
coordinate
Change robot attitude drastically from step to step and make aiming as correctly as
possible. That is the point for high precision.
4 Select [Constant setting][3 Machine constant][1 Tool Constant] to display tool
setting screen, and select optional tool number.
≫Tool setting screen is displayed.
3-7
3.2Preparation for calibration
Maximum error represents probability of tool length obtained. The smaller the value,
the higher the accuracy of tool length obtained is.
Error of each step is also displayed. When errors are big, correct positions starting
from the step with biggest value in descending order.
After correction of positions, re-execute procedure from 5.
8 If there is no problem, select [Yes], and press [Enter] key.
≫Tool length automatic setting screen ends, and original tool setting screen returns.
At this time, set value is not stored yet.
9 Press f12[Complete] key.
≫Set content is stored and machine constant menu screen returns.
Calibration tool setting is completed by this point.
3-8
3.2Preparation for calibration
Step 2 record
Step 3 record position
position
Pointer
y x
(z)
Number of program
created in 10 is set.
Number of tool registered
in 9 is set.
Set the tool number, which was set here, in calibration parameter and register vision sensor
POINT coordinate position.
3-9
3.2Preparation for calibration
3-10
3.2Preparation for calibration
Lighting is set.
In the section for lighting, check number of lighting to be turned on when images are
captured.
3-11
3.2Preparation for calibration
3-12
3.2Preparation for calibration
1 Operate robot so that distance between camera and calibration plate and
distance between camera and workpiece to be measured are almost identical.
6 Adjust robot attitude so that X and Y axes of calibration coordinate and red
lines of image fit in.
Adjust attitude of camera or calibration plate so that XY plain of calibration plate and
light axis of camera bisect at right angles.
3-13
3.2Preparation for calibration
Camera
Light
axis
3-14
3.3Single camera calibration
<page 2>
3-15
3.3Single camera calibration
3-16
3.3Single camera calibration
Visual sensor
coordinate position
Visual sensor coordinate
Positional relation of
flange coordinate and
visual sensor coordinate
3-17
3.3Single camera calibration
3-18
3.3Single camera calibration
3-19
3.3Single camera calibration
6 Adjust exposure time at the time of calibration while looking at images being
captured.
Operations of exposure time adjustment are shown below.
<Key operation>
・Exposure time change: right-left key
・Step change: up-down key ← amount of change at the time of exposure time
change
・End after storing change: [Enter] key
・End without storing change: [Reset] key
<F key operation>
・f7[live display]: Image is displayed live
・f8[Image capture]: Image capturing is executed.
・ f10[Automatic exposure reference setting]: Reference brightness value for
automatic exposure is acquired.
If plate measurement failed, causes that can be considered are failure of plate to be
within calibration area in the screen, inappropriate exposure time due to too bright or
too dark lighting, detection failure of plate due to uneven lighting on the plate, and
errors in plate condition setting or camera setting.
Correct conditions and re-try from the beginning.
3-20
3.3Single camera calibration
Confirm if dot patterns are correctly detected in each image, and if “vision sensor
coordinate” indicates calibration coordinate on the plate seen from camera
coordinate at the time of index 1. Origin of camera coordinate lies near lens
mounting position of camera. Position of origin cannot be specifically determined
depending upon lens characteristics, etc., and should be considered as rough
indication. (There is about ± 10 mm of change)
15 If the result is correct, press f12[Store] key.
≫Result of camera calibration is stored in file. The front screen of image display
screen returns.
3-21
3.3Single camera calibration
6 Repeat works of 4 and 5 until dots of calibration plate become clearly seen.
3-22
3.3Single camera calibration
1 In image display screen, press f12[Save Image Calib.] key while pressing
[Enable] key.
+ ≫Camera calibration is executed.
If calibration succeeds, plate detection images to which calibration results are
applied are displayed one by one for the images to which plate measurements are
executed.
At the end, detection image of index 1 is displayed again, and camera parameters
are displayed.
When calibration completed, press [Complete] key at the end to store parameters. Although
POINT calibration results are stored by each registration work, if parameters at the time of registration
are changed in image display screen, changed content is not stored without “input” operation at
the front of calibration setting screen.
Be sure to execute storage, so that setting at the time of registration can be confirmed later.
When calibration plate is fixed on hand in the case of hand camera or fixed camera, it is
INFO. convenient to create program for calibration beforehand.
For example, measurement positions are created by shifting recording positions using “program
change” function based upon calibration reference position recorded beforehand.
In the case of hand camera, rotation shift is possible while keeping position of plate at the center
of image by setting result of vision sensor coordinate position as tool constant.
In the case of fixed camera, rotation shift is possible while keeping position of plate at the center
of image by using the tool in which calibration coordinate is registered.
3-23
3.3Single camera calibration
3-24
3.4Cross laser calibration
<page 2>
3-25
3.4Cross laser calibration
3-26
3.4Cross laser calibration
3-27
3.4Cross laser calibration
Set number of
designated coordinate
Flange
Positional relation
coordinate
of world coordinate
and visual sensor
coordinate.
Visual sensor coordinate position
Visual sensor
coordinate position
Visual sensor coordinate
Positional relation of
flange coordinate and
visual sensor coodinate
3-28
3.4Cross laser calibration
3-29
3.4Cross laser calibration
Laser slit calibration measures laser slit light with which calibration plate is irradiated. The measurement is
executed at no less than three positions changing positional relations of plate and cameras as shown in the
figure below.
Calibration plate
(a) Reference position (b) Position with longer distance (c) Position with shorter distance
Fig. 3.4.1 Examples of measurement patterns of laser slit calibration
3-30
3.4Cross laser calibration
When image is not displayed, press f8[image capture] key to display image.
5 Press [Calib. Mode chg.] key while pressing [Enable] key.
≫Screen is switched to laser slit measurement, and [laser slit] is displayed at right
+ top.
3-31
3.4Cross laser calibration
Set exposure time so that laser slit light can be seen thinly and clearly.
<Bad example>
Exposure time at the time of calibration does not need to be same as that at the time
of measuring actual workpiece.
8 After completion of exposure adjustment, press [Enter] key.
≫Exposure adjustment screen ends, and the front screen of image display Is
displayed.
In order to cancel exposure time change, press [R] key.
9 Press f10[Region Setting] key, and start setting of object area for calibration
plate detection (calibration area).
≫Area setting screen is displayed.
Area setting here is limited to rectangular area.
If setting has been finished, work of 12 is executed.
10 Set calibration area.
Set so that whole calibration plate enters the area.
Usually whole screen is selected as calibration area by pressing f9[maximum area]
key.
11 After completion of calibration area setting, press [Enter] key.
≫Area setting screen ends, and the front screen of image display is displayed.
In order to cancel exposure time change, press [R] key.
3-32
3.4Cross laser calibration
If plate measurement failed, causes that can be considered are failure of plate to be
within calibration area in the screen, inappropriate exposure time due to too bright or
too dark lighting, detection failure of plate due to uneven lighting on the plate, and
errors in plate condition setting or camera setting.
If laser slit measurement failed, causes that can be considered are failure of plate to
be appropriately irradiated with laser slit light and trouble in checking length and
width because portions other than laser slit light was detected.
Correct conditions and re-try from the beginning.
3-33
3.4Cross laser calibration
When calibration completed, press [Complete] key at the end to store parameters. Although
calibration results are stored by each registration work, if parameters at the time of registration
POINT are changed in image display screen, changed content is not stored without “input” operation at
the front of calibration setting screen.
Be sure to execute storage, so that setting at the time of registration can be confirmed later.
When calibration plate is fixed to hand in the cases of hand camera or fixed camera, it is
convenient to create program for calibration beforehand.
For example, measurement positions are created by shifting recording positions using “program
INFO. change” function based upon calibration reference position recorded beforehand.
In the case of hand camera, rotation shift is possible while keeping position of plate at the center
of image by setting result of vision sensor coordinate position as tool constant.
In the case of fixed camera, rotation shift is possible while keeping position of plate at the center
of image by using the tool in which calibration coordinate is registered.
3-34
3.4Cross laser calibration
3-35
3.5Stereo calibration
<Page 2>
3-36
3.5Stereo calibration
When common exposure time is set, exposure time value set for left camera is used for image
POINT capturing of right camera.
3-37
3.5Stereo calibration
Visual sensor
coordinate position
Visual sensor coordinate
Positional relation of
flange coordinate and
visual sensor coodinate
3-38
3.5Stereo calibration
3-39
3.5Stereo calibration
6 Adjust exposure time at the time of calibration while looking at images being
captured.
Operations of exposure time adjustment are shown below.
<Key operation>
・Exposure time change: right-left key
・Step change: up-down key ← amount of change at the time of exposure time
change
・End after storing change: [Enter] key
・End without storing change: [Reset] key
<F key operation>
・f7[live display]: Image is displayed live
・f8[Image capture]: Image capturing is executed.
・ f10[Automatic exposure reference setting]: Reference brightness value for
automatic exposure is acquired.
3-40
3.5Stereo calibration
If plate measurement failed, causes that can be considered are failure of plate to be
within calibration area in the screen, inappropriate exposure time due to too bright or
too dark lighting, detection failure of plate due to uneven lighting on the plate, and
errors in plate condition setting or camera setting.
Correct conditions and re-try from the beginning.
12 When correct measurement is confirmed to be possible, press f11[Plate
Measure] key while pressing [Enable] key.
+ ≫Plate measurement is executed, and result of plate measurement is displayed.
Index increases by 1.
3-41
3.5Stereo calibration
Confirm if dot patterns are correctly detected in each image, and if “vision sensor
coordinate” indicates calibration coordinate on the plate seen from camera
coordinate at the time of index 1. Origin of camera coordinate lies near lens
mounting position of camera. Position of origin cannot be specifically determined
depending upon lens characteristics, etc., and should be considered as rough
indication. (There is about ± 10 mm of error.)
15 If the result is correct, press f12[Store] key.
≫Result of camera calibration is stored in file. The front screen of image display
screen returns.
3-42
3.5Stereo calibration
Screen switching
When image display is executed, two screens displaying images of both cameras of stereo camera are
displayed. This display can be switched to display of either one of the camera images (one screen display).
The switching is executed in steps of first selecting camera for one screen display and of switching to one
screen display.
By pressing key, background color of camera numbers at the top of image display changes between
right and left cameras. When the background color is green, the camera is selected.
After selecting camera for one-screen display by this operation, press f7[Single display] key while pressing
[Enable] key.
Screen is switched to one-screen display. In order to return to two-screen display, press f7[Double display] key
while pressing [Enable] key.
Exposure adjustment
When f9[exposure adjust] key is pressed, following screen is displayed.
3-43
3.5Stereo calibration
Area setting
In area setting, range of plate detection is set. Setting is executed by each camera. Usually maximum area is
set. Only when there is element of detection error, avoid setting of maximum area.
Following screen switching procedure, select camera for which area is set.
After selection of camera, when f10[Area setting] key is pressed, following screen is displayed.
3-44
3.5Stereo calibration
3-45
3.5Stereo calibration
NOTE
3-46
4 Teaching and application instruction
There are two types of shift amount; that before and after workpiece is grasped by hand.
For the former, “measurement of shift amount” is performed before workpiece is grasped by hand. From the
shift amount of workpiece obtained as the result, the position of hand is corrected according to the shift amount
of workpiece, and take-out of workpiece is executed. This “correction of shift amount” is called world coordinate
reference shift.
For the latter, “measurement of shift amount” is performed on grasped workpiece after it was grasped by hand.
Shift amount is obtained as that of workpiece on the hand, and correction operation is executed by moving hand
according to the shift amount so that position of workpiece fits the position instructed by teaching. This
“correction of shift amount” is called flange coordinate reference shift.
Fig. 4.1.1 Correction of shift amount before workpiece is grasped by hand (world coordinate reference shift)
Correction is
performed so that
position of workpiece
is same as that at
the time of teaching.
Workpiece
Jig
Fig. 4.1.2 Correction of shift amount after workpiece is grasped by hand (flange coordinate reference shift)
There is vision sensor coordinate shift besides world coordinate reference shift and flange
INFO. coordinate reference shift. This performs optional shift by obtaining shift amount with vision
sensor coordinate and using general shift instruction.
4-1
4.1Outline of teaching
Reset
Initiation of correction
Correction operation
・Workpiece take-out Correction of shift amount
・Workpiece placing
etc.
End of correction
Visual sensor
instruction
Other operations
Correction (shift)
instruction
Shift to operation end position
4-2
4.1Outline of teaching
Table 4.1.1
Application instruction used by vision sensor function
FN
Name SLIM Content
number
Vision reset VRESET FN330 Measurement result is cleared.
Vision start VSTART FN331 Measurement is executed with vision sensor.
Vision shift VSHIFT FN333 Shift amount is acquired from vision sensor.
Start and end of correction operation with shift amount
Vision location convert VLOCCVT FN342
obtained from vision sensor are specified.
Shift2 SHIFTR FN52 Shift is executed with the value stored in shift register.
User coordinate system is specified when user coordinate
Change coord. No. (shift) CHGCOORD FN113
system shift is executed by FN52.
Vision system functions should not be recorded at immediately after the jump with input signal
POINT
conditional function, and at the branch target step. If vision system functions are recorded at such
position, this program may not be performed correctly.
4-3
4.2Application instruction
Up to only eight measurement conditions can be read in at one time. When a new measurement
INFO. condition is read in, measurement condition with oldest access time is deleted from memory, and
measurement result is also deleted at the time.
When measurement conditions that have not been read in are specified, the instruction deals
with nothing.
4-4
4.2Application instruction
When world coordinate and flange coordinate are set as correction reference coordinate, shift
amount obtained is not that of workpiece but pseudo shift amount of correction reference
POINT coordinate in accordance with the shift amount of workpiece.
When rotation amount is included in detection result, the value may be widely different from shift
amount In some cases.
When world coordinate and flange coordinate are set as correction reference coordinate, be sure
to use FN342 VLOCCVT to execute correction.
Execution of other shifts such as FN52 VSHIFT results in operation that is widely different from
CAUTION actual correction amount. As a result, interference with surrounding equipment may occur.
Further, when contacted or caught by robot, death or serious damage may occur.
4-5
4.2Application instruction
As correction reference coordinate, be sure to specify same coordinate as specified for FN333
VSHIFT.
Erroneous specification will cause motion widely different from actual correction amount. This
may cause interference with surrounding equipment. Further, when contacted or caught by
CAUTION robot, death or serious damage may occur.
4-6
4.2Application instruction
4-7
4.3Basic teaching
Measurement condition :1
Hand clamp signal : O1
Hand clamp completion signal : I1
Camera
Hand
Work transportation
Workpiece take-out
Workpiece placing
Workpiece supply
4-8
4.3Basic teaching
5 Move robot so that camera is shifted to measurement position, and record the
position (step 4).
Camera
Measurement disance
Same as distance to plate
at the time of calibration
Workpiece Measurement
plane
Workpiece
Placed at reference position for teaching
(Nearly at the center of shift range of workpiece)
Accuracy of this position is 1 with “P” (in-position) mark. (A1P)
6 Set measurement condition at this position.
Refer to chapter for explanation of each measurement condition for measurement
condition setting.
7 Record measurement start instruction (FN331:VSTART)in step 5.
4-9
4.3Basic teaching
11 Shift hand to position for grasping workpiece, and record the position in
step9.
14 Shift hand to position above workpiece, and record the position in step 12.
4-10
4.3Basic teaching
Pallet
Jig
Workpiece
5 Shift hand to position above workpiece on pallet, and record the position in
step 4.
6 Shift hand to workpiece suction position, and record the position in step 5.
8 Shift hand to position to which workpiece is raised, and record the position
instep 7.
4-11
4.3Basic teaching
9 While keeping workpiece in sucked state, shift robot so that workpiece comes
to a position where it can be measured with fixed camera, and the position is
recorded in step 8.
16 Record input wait instruction for workpiece seating confirmation in step 14.
4-12
4.3Basic teaching
4-13
4.3Basic teaching
NOTE
4-14
5 Two-dimensional single point measurement
5-1
5.2Standard setting
Page 2
3 Set parameters.
INFO. When f11[Image capture] key is pressed, image is captured using camera with camera
number obtained from specified calibration number. Captured image is displayed in image
display portion at top left.
5-2
5.2Standard setting
5-3
5.2Standard setting
4 Set parameters.
In case automatic exposure is “Enable”, since image cannot be captured unless automatic
POINT exposure reference setting is executed, do not forget to execute automatic exposure
reference registration.
When retrial mode of standard setting is “Each” and number of times of retrial is set at 1 or
POINT more, [Next exposure condition] key is displayed in f10 key, and [Previous exposure
condition] key is displayed in [Enable] +f10 key.
By pressing the keys, setting can be switched to each retrial exposure condition.
5-4
5.2Standard setting
When f12[Quit] key or [R] key is pressed, exposure condition setting screen returns. At the time, the exposure
time set in this screen is set as exposure time of exposure condition setting screen.
POINT If camera image cannot be displayed, confirm set calibration number, and confirm existence
or non-existence of calibration data and camera number.
5-5
5.2Standard setting
Area setting is carried out in automatic exposure reference setting screen, and area for brightness value
calculation is determined.
By pressing f12[Register] key, average brightness value of set area is acquired and exposure condition setting
screen returns.
Acquired brightness value is set in “Reference” of automatic exposure parameter.
Brightness value is indicated by values of 0 to 255. 0 represents black and 255 represents
POINT white. Each pixel has the number, and the average of brightness values of pixels in a set
area is the reference value of automatic exposure.
When automatic exposure function is used with registered reference brightness value, set
POINT automatic exposure as valid in exposure condition setting screen.
In case of invalid, image is captured by specified exposure time.
POINT When automatic exposure function is used, image capture time is longer than when fixed
exposure time is used.
5-6
5.3Image processing
5-7
5.3Image processing
New image processing can also be added by inputting unused image processing number
INFO. and pressing [Enter] key instead of using [Add] key in 2. Numbers that can be input are 1 to
16.
By “Addition”, although addition is executed on smallest number available, addition can be
executed in optional number by number input.
Table 5.3.1 Type of image processing that can be registered by two-dimensional single point measurement
Type of image
Explanation
processing
Rotation search Position and angle are detected by extracting portion of image with big difference in
brightness, and executing matching using the feature extracted from model image and
feature of measured image.
Usually the feature is edge information such as contour of measurement object.
Blob Image is binarized with brightness threshold value, and feature portion is extracted.
Position is detected at the barycenter of feature portions.
5-8
5.3Image processing
INFO. Image processing can also be selected by inputting image processing number to be edited in
3.
5-9
5.3Image processing
When already registered image processing number is specified to copy target, following
INFO. message is displayed.
5-10
5.3Image processing
5-11
5.4Image processing – rotation search
Page 2
5-12
5.4Image processing – rotation search
5-13
5.4Image processing – rotation search
Polarity is ○ × △
valid:
Full inversion ○ ○ △
is valid
Partial inversion ○ ○ ○
is valid
○: Recognizable, ×: unrecognizable, △:Loss of point
Search accuracy 0.9 0.0∼1.0 Precision for measurement is set. The smaller the
value, the smaller dispersion is, but processing time
becomes longer.
Usually use initial value.
Angle Maximum 10 0∼180[degree] Maximum and minimum values within recognizable
range Minimum -10 -180∼0[degree] rotation range are set.
The wider the range, the longer recognition time
becomes.
Scale Maximum 1.2 1.0∼2.0[times] Maximum and minimum values within recognizable
range Minimum 0.8 0.5∼1.0[times] scale range are set.
The wider the range, the longer recognition time
becomes.
The number of find 1 1∼16 Maximum number detected by this image processing is
set.
5-14
5.4Image processing – rotation search
Initial
Item Setting range Explanation
value
Detection priority Score: Score: high→low/ When plural recognition results satisfying lower limit
high→low Pos: top→bottom/ value were obtained in the state where number of
Pos: bottom→top/ detections is set to be 2 or more, the detection results
Pos: left→right/ are rearranged according to the set priority order, and
Pos: right→left/ same number as the number of detections of results are
Pos: top left output from the top priority in ascending order.
→bottom right/
Pos: bottom right
→top left/
Pos: bottom left
→top right/
Pos: top right
→bottom left/
Pos: image center/
Pos: model origin/
Angle: model angle/
Scale: model scale/
Size: big→small/
Size: small→big
5-15
5.4Image processing – rotation search
When model is unregistered, all parameters are displayed in gray and setting is not
possible.
3 Press f11[Image Acquire] key while pressing [Enable] key.
≫Image is captured and the captured image is displayed in image display portion.
+
5-16
5.4Image processing – rotation search
5-17
5.4Image processing – rotation search
Use cursor key to adjust position of origin, and press [Return] key to set origin.
Amount of shift of origin by cursor key is adjustable with increase-decrease key.
16 When setting ended, press f12[Complete] key.
≫Setting is stored in file.
In order to cancel content of edit, press [R] key and end recognition setting screen.
5-18
5.4Image processing – rotation search
Be sure to adjust model if parameters related to calculation of model features such as mask
POINT area, contrast and minimum size are adjusted.
When model registration screen is tried to end without model adjustment, following
confirmation message will be displayed.
5-19
5.4Image processing – rotation search
5-20
5.4Image processing – rotation search
POINT Be sure to set positions of workpiece and robot at base position of teaching.
For example, when workpiece is taken out, set worpiece at the same position as the position
of workpiece when operation program of take-out part was created.
5-21
5.5Image processing - blob
In order to change page, press up-down cursor key while pressing [Enable] key.
3 Press f10[Image Acquire] key while pressing [Enable] key.
≫Image is captured, and captured image is displayed in image display portion.
+
5-22
5.5Image processing - blob
5-23
5.5Image processing - blob
5-24
5.5Image processing - blob
5-25
5.5Image processing - blob
5-26
5.5Image processing - blob
POINT Be sure to set positions of workpiece and robot at base position of teaching.
For example, when workpiece is taken out, set worpiece at the same position as the position
of workpiece when operation program of take-out part was created.
5-27
5.6Correction amount calculation
Page 2
3 Set parameters.
5-28
5.6Correction amount calculation
Table 5.6.1 Correction amount calculation parameters for two-dimensional single point measurement
Initial
Item Setting range Explanation
value
Measure base position Each Each/Common Whether the values of measurement base position
set by each image processing are separately used
or one position is commonly used is selected.
Common Measure cond 1 1∼999 In case a measurement base position is commonly
base pos. No. used, number of commonly used measurement
condition of which base position is set is specified.
Image process 1 1∼16 In case a measurement base position is commonly
No. used, number of image processing with
measurement condition for which commonly used
base position is set is specified.
Z-Shift Disable Disable/Enable Whether or not to execute calculation of correction
value in Z axis direction using scale is specified.
This is usable for rotation search only, but not
usable for blob.
Rot. around Z-axis Enable Disable/Enable Whether or not to output rotation correction amount
around Z axis is selected.
The Number of output 1 1∼32 Maximum number of finally output results is
specified.
Shift limit X,Y,Z 100.0 0.0∼9999.0[mm] Limit of correction amount is set.
[mm] If correction amount exceeding correction limit is
RX,RY,RZ 30.0 0.0∼180.0[deg] detected, robot will stop due to error.
[deg]
POINT
When validity of Z correction and valid or invalid of rotation around Z axis are switched,
execute base position registration of each image processing again.
5-29
5.7Test measurement
5-30
5.7Test measurement
POINT
Measurement is executed following retrial mode of standard setting.
Retrial is executed when retrial is valid and confirmation trouble occurred.
POINT
Test measurement can be executed in individual image processing.
In this case, test measurement is executed for selected image processing only.
5-31
5.7Test measurement
NOTE
5-32
6 Cross laser measurement
6-1
6.2Standard setting
Page 2
3 Set parameters.
INFO. When f11[Image Acquire] key is pressed, image is captured using camera with camera
number obtained from specified calibration number.
Captured image is displayed in image display portion at top left.
6-2
6.2Standard setting
6-3
6.2Standard setting
4 Set parameters.
6-4
6.2Standard setting
In case automatic exposure is “Enable”, since image cannot be captured unless automatic
POINT exposure reference setting is executed, do not forget to execute automatic exposure
reference registration.
When retry mode of standard setting is “Individual” and number of times of retrial is set at 1
POINT or more, [Next exposure condition] key is displayed in f10 key, and [Previous exposure
condition] key is displayed in [Enable] +f10 key.
By pressing the keys, setting can be switched to each retrial exposure condition.
6-5
6.2Standard setting
When f12[Return] key or [R] key is pressed, exposure condition setting screen returns. At the time, the
exposure time set in this screen is set as exposure time of exposure condition setting screen.
POINT If camera image cannot be displayed, confirm set calibration number, and confirm existence
or non-existence of calibration data and camera number.
6-6
6.2Standard setting
Area setting is carried out in automatic exposure reference setting screen, and area for brightness value
calculation is determined.
By pressing f12[Register] key, average brightness value of set area is acquired and exposure condition setting
screen returns.
Acquired brightness value is set in “Reference” of automatic exposure parameter.
Brightness value is indicated by values of 0 to 255. 0 represents black and 255 represents
POINT white. Each pixel has the number, and the average of brightness values of pixels in a set
area is the reference value of automatic exposure.
When automatic exposure function is used with registered reference brightness value, set
POINT automatic exposure as valid in exposure condition setting screen.
In case of invalid, image is captured by specified exposure time.
POINT When automatic exposure function is used, image capture time is longer than when fixed
exposure time is used.
6-7
6.3Image processing
If the "Image process" is only "Cross laser", the measurement only by the cross-laser will be executed. In this
case, Z shift, RX rotation, and RY rotation will be calculated as the correction amount.
(In case of FD controller, the measurement only by the cross-laser can be used in V2.04 or higher)
6-8
6.3Image processing
New image processing can also be added by inputting unused image processing number
INFO. and pressing [Enter] key instead of using [Add] key in 2. Numbers that can be input are 2 to
16.
By “Addition”, although addition is executed on smallest number available, addition can be
executed in optional number by number input.
Table 6.3.1 Type of image processing that can be registered by cross laser measurement
Type of image
Explanation
processing
Rotation search Position and angle are detected by extracting portion of image with big difference in
brightness, and executing matching using the feature extracted from model image and
feature of measured image.
Usually the feature is edge information such as contour of measurement object.
Blob Image is binarized with brightness threshold value, and feature portion is extracted.
Position is detected at the barycenter of feature portions.
6-9
6.3Image processing
INFO. Image processing can also be selected by inputting image processing number to be edited in
3.
6-10
6.3Image processing
When already registered image processing number is specified as copy target, following
INFO. message is displayed.
6-11
6.3Image processing
6-12
6.4Image processing – cross laser
2nd page
In case of FD controller, this page is displayed when the software version is V2.04 or
higher.
6-13
6.4Image processing – cross laser
6-14
6.4Image processing – cross laser
6-15
6.4Image processing – cross laser
Be sure to execute laser slit light irradiation within search area on the same plane. If different
POINT plane is involved, correct measurement result is not obtained but erroneous shift amount
may be obtained.
POINT “Z-Shift Measure point” is applied when only “Cross laser” is registered as the “Image
process”.
6-16
6.4Image processing – cross laser
6-17
6.4Image processing – cross laser
In this case, the position of the work-piece and the robot position must be the original
POINT teaching position. For example, to pickup the work-piece, place the work-piece at the exact
same position where the picking-up program was created.
6-18
6.5Image processing – two-dimensional (rotation search, blob)
6-19
6.6Correction amount calculation
Page 2
In case of FD controller, this page is displayed when the software version is V2.04 or
higher.
3 Set parameters.
6-20
6.6Correction amount calculation
Initial
Item Setting range Explanation
value
Z-shift Disable Disable/Enable Whether or not to execute calculation of correction
value in Z axis direction using scale is specified.
This is usable for rotation search only, but not
usable for blob.
Rot. around Z-axis Enable Disable/Enable Whether or not to output rotation correction amount
around Z axis is selected.
Shift limit X,Y,Z 100.0 0.0∼9999.0[mm] Limit of correction amount is set.
[mm] If correction amount exceeding correction limit is
RX,RY,RZ 30.0 0.0∼180.0[deg] detected, robot will stop due to error.
[deg]
RX,RY Shift (*1) Enable Disable/Enable Enable/Disable the RX and RY Shift.
If “Disable” is set, the RX, RY shift in the vision
sensor coordinates become 0.0.
RZ Shift (*1) Enable Disable/Enable Enable/Disable the RZ Shift.
If “Disable” is set, the RZ shift in the vision sensor
coordinates become 0.0.
POINT When validity of Z correction and valid or invalid of rotation around Z axis are switched,
execute base position registration of each image processing again.
When being sent to the robot controller, the shift value is converted to the designated
POINT coordinate system. Therefore, even if “RX, RY shift” and “RZ shift” are disabled, the value
stored in the Shift register of the robot controller is not 0.0. The RZ, RY, or the RZ shift value
will become as the result of the shift calculation in the robot controller. And, depending on the
calculation result, the value may not become 0.0 completely.
6-21
6.7Test measurement
POINT
Measurement is executed in accordance with retrial mode of standard setting.
Retrial is executed when retrial is valid and confirmation trouble occurred.
POINT
Test measurement can also be executed in individual image processing.
In this case, test measurement is executed for selected image processing only.
6-22
6.8Example of teaching
Camera
Laser unit
Lighting
Hand
Workpiece
take-out
Workpiece transport
Because of protrusion at the bottom, workpiece may be supplied in tilted state in some cases.
Since workpiece is tilted, when workpiece is grasped by hand, attitude of hand needs to be corrected in
accordance with the tilt of workpiece in order to insert claws of hand into workpiece. The correction of tilt is
executed using cross laser measurement.
In take-out operation, cross laser measurement position is corrected by two-dimensional measurement, cross
laser measurement is executed at corrected position, and operation is carried out reflecting the resulting
correction of displacement of workpiece
Two-dimensional measurement
6-23
6.8Example of teaching
Lighting
Hand
Workpiece
reference
position
Workpiece suply
Fig. 6.8.3 Workpiece base position
Camera
Laser unit
Lighting
Hand
Measurement distance
Workpiece = distance between
reference reference plate and
position camera for calibration
Fit measurement distance to the distance between reference plate and camera for calibration.
Utilizing live display in measurement condition screen for vision sensor setting, etc., determine
position of camera so that position of workpiece comes near the center of image captured by
camera.
Placing workpiece at screen center can expand the range in which workpiece can
POINT be measured even if it is decentered.
6-24
6.8Example of teaching
Usually the position is same as two-dimensional record position, since angle of laser unit is so
adjusted that intersection of cross laser is at center of screen in reference plate position for
calibration.
4 Record position which is to be the route for workpiece take-out.
照明 照明
(9) Correction (2) Hand entry position (3) Grasp position (4) Workpiece (5) Correction end position
start position release position
6-25
6.8Example of teaching
Model
Search area
Search area
By setting search area in a ring form, recognition of laser slit light projected in the
POINT hole at the center of workpiece and other laser slit light can be avoided.
In order to allow for a little displacement and tilt, set search area a little outward
and inward from internal circle and external dimension respectively.
6 Add and set rotation search to image processing of cross laser measurement condition.
Model area
Model
Search area
Registration of almost same content as the content of setting for two-dimensional single point
measurement is executed.
Search area shall be smaller than that for two-dimensional single point measurement, since it is
corrected to lie almost at the center for two-dimensional single point measurement.
6-26
6.8Example of teaching
6-27
6.8Example of teaching
1 2 3 4
Two-dimensional single point Cross laser Take-out correction Take-out hand entry position
measurement position measurement position start position
8 7 6 5
Hand
Take-out operation end position Take-out correction end position Workpiece release position Grasp position
Fig. 6.8.5 Cross laser measurement corrective operation
6-28
7 Stereo measurement
Feature point 2
Feature point
Feature point 1 Feature point 3
7-1
7.1Stereo measurement
Output console is displayed on menu by pressing f12[Console On] key. Results of test
INFO. measurement, etc. can be confirmed.
When f12[Console OFF] key is pressed during display of output console, console display
ends.
7-2
7.2Standard setting
Page 2
3 Set parameters.
When f11[Image Acquire] key is pressed, image is captured using camera with camera
INFO. number obtained from specified calibration number.
Captured image is displayed in image display portion at top left. Left side is display for left
camera, and right side is display for right camera.
7-3
7.2Standard setting
7-4
7.2Standard setting
4 Set parameters.
7-5
7.2Standard setting
In case automatic exposure is “Enable”, since image cannot be captured unless automatic
POINT exposure reference setting is executed, do not forget to execute automatic exposure
reference registration.
When retrial mode of standard setting is “Individual” and number of times of retrial is set at 1
POINT or more, [Next exposure condition] key is displayed in f10 key, and [Previous exposure
condition] key is displayed in [Enable] +f10 key.
By pressing the keys, setting can be switched to each retrial exposure condition.
When exposure time is separately set, it is displayed as shown below and can be set
POINT separately for right and left cameras.
7-6
7.2Standard setting
By pressing key, displayed camera images are switched in the order shown below; both cameras →
left camera → right camera → both cameras.
Both cameras display
POINT If camera image cannot be displayed, confirm set calibration number, and confirm existence
or non-existence of calibration data and camera number.
7-7
7.2Standard setting
Screen for setting brightness value that is reference for automatic exposure is displayed.
Area setting is carried out in automatic exposure reference setting screen, and area for brightness value
calculation is determined.
By pressing f12[Register] key, average brightness value of set area is acquired and exposure condition setting
screen returns.
Acquired brightness value is set in “Reference” of automatic exposure parameter.
Brightness value is indicated by values of 0 to 255. 0 represents black and 255 represents
POINT white. Each pixel has the number, and the average of brightness values of pixels in a set
area is the reference value of automatic exposure.
When automatic exposure function is used with registered reference brightness value, set
POINT automatic exposure as valid in exposure condition setting screen.
In case of invalid, image is captured by specified exposure time.
POINT When automatic exposure function is used, image capture time is longer than when fixed
exposure time is used.
7-8
7.3Image processing
7-9
7.3Image processing
New image processing can also be added by inputting unused image processing number
INFO. and pressing [Enter] key instead of using [Add] key in 2. Numbers that can be input are 1 to
16.
By “Addition”, although addition is executed on smallest number available, addition can be
executed in optional number by number input.
7-10
7.3Image processing
When f12[Model display] key is pressed in 2, image of model is displayed at top right as
INFO. shown in the figure below ( in the case of rotation search). What is displayed here is the
model of left camera.
When f12 [Model display] key for the second time, the model of right camera is displayed.
Image of right camera is displayed at top left.
When f12[Model display] key is pressed further, model image disappears, and in turn images
of right and left cameras are displayed at top.
Table 7.3.1 Type of image processing that can be registered by cross laser measurement
Type of image
Explanation
processing
Rotation search Position and angle are detected by extracting portion of image with big difference in
brightness, and executing matching using the feature extracted from model image and
feature of measured image.
Usually the feature is edge information such as contour of measurement object.
Blob Image is binarized with brightness threshold value, and feature portion is extracted.
Position is detected at the barycenter of feature portions.
7-11
7.4Image processing – rotation search
Different from two-dimensional measurement, there are four items; common setting,
left camera processing, right camera processing and base position setting.
2 Select [1 Common setting].
≫Common setting screen is displayed.
3 Input comment.
7-12
7.4Image processing – rotation search
7-13
7.4Image processing – rotation search
(On right side, f keys are shown when [Enable] key is pressed.)
In the case of stereo measurement, base position is acquired using only the result of highest
POINT priority that was set by image processing even when no less than two detections are set in
recognition setting.
7-14
7.5Image processing – blob
Different from two-dimensional measurement, there are four items; common setting,
left camera processing, right camera processing and base position setting.
2 Select [1 Common setting].
≫Common setting screen is displayed.
3 Input comment.
7-15
7.5Image processing – blob
7-16
7.5Image processing – blob
(On right side, f keys are shown when [Enable] key is pressed.)
In the case of stereo measurement, base position is acquired using only the result of highest
POINT priority that was set by image processing even when no less than two detections are set in
recognition setting.
7-17
7.6Correction amount calculation
3 Set parameters.
POINT In the case of plural point measurement, measurement reference planes set for each image
processing are used. The setting executed here is neglected.
7-18
7.7Example of teaching
Measurement condition:1
Hand clamp signal :O1
Hand clamp end signal:I1
Stereo camera
Hand
Workpiece transport
Workpiece take-out
Workpiece supply
Workpiece is supplied by an inclined apparatus. Since position of worpiece is not specified, its position and
attitude varies piece by piece. Attitude of hand is corrected in accordance with the variation when it grasps
workpiece so that pin of hand is inserted in the hole for clamping created on the workpiece.
7-19
7.7Example of teaching
7.7.2 Teaching
Following example is a system that supplied workpiece is taken and transported.
5 Shift robot so that camera is in measurement position, and record the position
(step 4).
7-20
7.7Example of teaching
16 Shift hand to position above workpiece, and record the position in step 12.
7-21
7.7Example of teaching
1 2 3 4
Measurement position Take-out correction start position Clamp position Take-out correction end position
Fig. 7.7.2 Example of workpiece take-out corrective operation
7-22
8 Combined measurement
Combined measurement calculates corrective amount from measurement results of plural measurement
points, by registration of measurement conditions of these measurement points in the measurement condition of
combined measurement.
8-1
8.2 Standard setting
3 Set parameters.
4 Press f12[Complete] key.
≫Setting is stored.
Undetectable
Measurement point 1
8-2
8.3 Measurement points
8-3
8.3 Measurement points
New measurement point can also be added by inputting unused measurement point number
INFO. and pressing [Enter] key instead of using [Add] key in 3. Numbers that can be input are 1 to
16.
By “Addition”, although addition is executed on smallest number available, addition can be
executed in optional number by number input.
Measurement point can also be registered inputting measurement condition number and
INFO. pressing [Enter] key instead of cursor shift + [Register] key. Numbers that can be input are 1
to 999.
However, unregistered measurement conditions and measurement conditions that cannot be
used in combined measurement cannot be registered.
8-4
8.3 Measurement points
When to execute measurement registration of plural points of 4 or more points, register them
POINT so that the registration order goes round the workpiece as shown below.
Measurement point 1: feature A
Measurement point 2: feature B
Measurement point 3: feature C
Measurement point 4: feature D
Feature B
Barycenter of
Feature A four points
Feature C
Feature D
Further, when measurement points are registered in such order that three points, two
measurement points and barycenter, are arranged on a straight line, error occurs due to
measurement point trouble and corrective amount cannot be obtained.
Measurement point 1: feature A
Measurement point 2: feature B
Measurement point 3: feature D
Measurement point 4: feature C
* Corrective amount cannot be obtained because measurement points 2→3 and 4→1 are
arranged on straight lines with barycenter.
POINT Measurement points in measurement order need not be measured from smallest
measurement number in ascending order.
8-5
8.3 Measurement points
INFO. Measurement points can be edited by inputting measurement point numbers in 3 and
pressing [Enter] key.
8-6
8.3 Measurement points
8-7
8.4 Corrective amount calculation
3 Set parameters.
When plural point measurement is executed, corrective amount can be made calculable
INFO. even if there were unrecognizable measurement points at the time of measurement, by
reducing set value for minimum measurement point number to less than the number of
measurement points.
POINT The “Measure Point Check” is available in the vision sensor software version V02.03 or
higher.
8-8
8.4 Corrective amount calculation
In two point measurement, attitude of workpiece for rotational shift amount is represented by two angles of
rotation and tilt. Actual corrective operation is an operation of correcting the two angles of workpiece.
The figure below describes the take-out corrective operation of workpiece when the plane on the board
place on ground is the reference plane. Rotation of workpiece is represented by the angle of workpiece
around the axis perpendicular to the plane on board, and tilt is represented by the angle formed by the plane
on board and the two measurement points of workpiece. For such rotational shift amount of workpiece,
correction of rotation and tilt is executed to robot as shown in figure below.
Rotational
correction
Tilt correction
Measurement
Measurement
point 2
point 1
Rotation Tilt
Measurement reference position
For reference plane setting, reference plane is selected in accordance with corrective operation from
three planes (XY plane, YZ plane and ZX plane) represented by two axes of corrective reference coordinate
system. Therefore, when accompanied by corrective operation shown in the figure above, XY plane is
selected as reference plane since corrective reference coordinate system refers to world coordinate.
Corrective amount cannot be obtained when workpiece is tilted by ± 90° against reference
POINT
plane. Avoid registration with such reference plane. When it is unavoidable, consider
changing to plural point measurement of three or more points by increasing measurement
points.
Note that erroneous setting of two point measurement reference plane may result in
unintended tool attitude in some cases. Also note that when setting is changed, corrective
movement of robot after change is different from that before change even if amount of
CAUTION displacement of workpiece is same.
8-9
8.5 Measurement point exchange
Measurement
point number
Currently selected measurement points can be confirmed with title bar and
f12[measurement point exchange] key.
2 Press f12[Change point] key.
≫Measurement point exchange screen is displayed.
3 Select measurement point using up-down cursor key, and press [Enter] key.
Measurement
point number
8-10
8.5 Measurement point exchange
When measurement point is not registered, functions shown below cannot be used.
POINT ・Test measurement
・Live display
・Image capture
・Full screen display
When measurement can be executed without shifting robot at all measurement points, test
POINT measurements at all measurement points can be executed collectively in measurement
point exchange screen of 2.
When all measurement points are selected, measurement point number becomes 0, and
following functions cannot be used.
・Live display
・Image capture
・Full screen display
8-11
8.6 Test measurement
2 Press F12[Change point] key, and select measurement points with which test
measurement is executed.
Refer to section for measurement point exchange for measurement point exchange.
3 At measurement points selected in 2, when robot is not at measurement
position, move to steps in which measurement positions are recorded using
[Check go/back].
Result of recognition result is displayed in Image display portion at left top and in
output console at right top.
5 Execute 2∼4 at all measurement points required for corrective amount
calculation.
8-12
8.6 Test measurement
When setting screen for combined measurement is ended, all measurement results obtained
POINT
in test measurement are deleted. When to enter setting screen for combined measurement
and corrective amount measurement again, test measurement at each measurement point
needs to be re-executed.
POINT
When plural measurement condition results of single point measurement registered in
measurement point are obtained, measurement result with highest priority is used.
When measurement can be executed without shifting robot at all measurement points, test
POINT measurements at all measurement points can be executed collectively by selecting F10[All
measurement points] in measurement point selection screen of 2.
POINT
Corrective amount is calculated according to “corrective reference coordinate” set in
corrective amount calculation screen.
8-13
8.7 Example of teaching
Hand
Workpiece
Camera
In this system, workpiece is taken out in accordance with position and attitude of workpiece using hand that
utilizes pin clamp cylinder. Pins at the edge of hand are inserted in the two holes at right and left of workpiece,
and workpiece is secured by clamp signal and handled. In order to improve precision of correction for such a big
workpiece combined measurement is used.
In this example, three holes (features) of workpiece is specified as three measurement points, and registered
in combined measurement condition. In order to measure three dimensional position and attitude of workpiece,
cross laser is used for measurement of each measurement point. Since three points cannot be measured in
one measurement because of measurement range of cross laser, robot shifts to measurement positions of
each camera and execute measurement as shown in the figure below.
Measurement point 2
Measurement point 3
Measurement
position 3
Measurement point 1
Measurement position 2
Measurement posiion 1
8-14
8.7 Example of teaching
What is explained here is a minimal teaching and just an example. In actual teaching,
execute teaching in accordance with specification of the whole system.
IMPORTANT
8-15
8.7 Example of teaching
12 Record position at a small distance from insertion position with attitude of tool
that allows pins to enter holes of workpiece in step 12.
14 Shift hand to position where pins are inserted in holes of workpiece, and
record the position in step 14.
8-16
8.7 Example of teaching
18 Shift workpiece to position where it is taken out, and record the position in step 18.
8-17
8.7 Example of teaching
In this system, corrective operation of workpiece placing in accordance with position and rotation of
workpiece grasped by robot hand is executed. Because workpiece is big in size, combined measurement is
used to measure features of both edges of workpiece.
Fixed camera
Suction hand
Workpiece
Measurement point 1
Measurement point 2
Two holes (features) of workpiece are measurement points. Robot shifts workpiece to positions where fixed
camera can measure holes in measurement points of workpiece and executes measurement. Two-dimensional
single point measurement is used for measurement of holes of workpiece, and the results are registered in
measurement points of combined measurement conditions. Combined measurement of two points is executed
under this measurement condition.
8-18
8.7 Example of teaching
In this system, corrective operation of workpiece take-out is executed in accordance with position and rotation
of workpiece. In order to shorten cycle time, combined measurement using two fixed cameras is executed,
instead of combined measurement using one hand camera to measure measurement points sequentially.
Fixed camera
Fixed camera
Measurement point 2
Workpiece
Measurement point 1
Fig. 8.7.6 Example of correction system of workpiece take-out using plural cameras
Two features at both edges of workpiece are used as measurement points. Two-dimensional single point
measurement is used for measurement of features and registered in measurement points of combined
measurement condition. Combined measurement of the two points is executed under this measurement
condition.
Since measurement is executed at two measurement points with two separate cameras,
POINT measurement at all allowance positions can be executed by one measurement instruction.
In order to do this, record 0 (all measurement positions) as measurement point number
specified in FN331:VSTART. Further, also in test measurement, test measurement of all
measurement points can be executed as a whole by specifying 0 for measurement point
number (all measurement points).
8-19
8.7 Example of teaching
Camera
Hand
Measurement point 1
Measurement point 6
Measurement point 2
Measurement point3
Measurement point 5
Workpiece
Mesurement point 4
Fig. 8.7.8 Example of combined measurement system using minimum measurement point number
In this case, six holes (features) of workpiece are measurement points. Robot moves camera to its measurement
positions for corresponding measurement points to execute measurement. Cross laser measurement is used for
measurement of holes of workpiece, and registration is executed in measurement points of combined measurement
condition. Combined measurement of six points is executed under this measurement condition.
Measurement point 1
Measurement point 6
Measurement point 2
Measurement point 5
Measurement point 3
Measurement point 4
For example, when minimum measurement point number is set to be four, corrective operation
POINT can be executed even if recognition trouble occurred in two measurement points out of six. In
that case, record next step for evacuation step specified by FN331:VSTART . When corrective
amount cannot be obtained because, for example, number of measurement result does not
satisfy minimum measurement point number, error is detected in FN333:VSHIFT. In order to
end operation program as an error, set 10000 in evacuation step. In order to execute retrial,
record desired evacuation step.
8-20
9 Hardware
9-1
9.1System configuration
Function
・Microprocessor and surrounding circuits
・Fixed disk I/F (IDE)
・Ethernet
・PCI bus
・Compact flash card (for storage of systems and operation programs)
・USB interface (for external storage)
9-2
9.1System configuration
About battery:
A battery (CR14250SE-CN16) for built-in clock is mounted on a CPU board. Exchange the
battery periodically once in 5 years.
CAUTION
9-3
9.1System configuration
Functions
・Image input
・Input and output control
9-4
9.2Connection
9.2 Connection
General method of hardware connection for construction of vision systems is explained.
Camera 1 Camera 3
Camera 2 Camera 4
Fig. 9.2.2 Camera connection connector (pin arrangement in side view of the controller)
Use cables for camera connection specified by us. Use of unspecified cables will cause
troubles with image input boards.
CAUTION
9-5
9.2Connection
Use cameras specified by us. Use of unspecified cameras will cause troubles with cameras
and image input boards.
CAUTION
Carry out camera switch setting with power turned off. Setting with power turned on will
cause troubles with cameras.
CAUTION
XC-HR50 XC-ES51
Fig. 9.2.3 Rear view of Sony’s cameras
9-6
9.2Connection
9-7
9.2Connection
•Counterpart connector
J21DF-16V-KX(JST)
•When to use external power unit, use one with specification shown below.
External power specification: DC+24V±10%
CNIN A1
B1
Relay contact, etc.
A2
B2
…
…
A8
B8
External power
GND
DC+24V
9-8
9.2Connection
•Counterpart connectors
CNOUT1 J21DF-20V-KX (JST)
CNOUT2 J21DF-20V-KY (JST)
CNP24 J21DF-06V-KX (JST)
•When to use external power unit, use one with specification shown below.
External power specification: DC+24V±10%
•Power specification for one output circuit is shown below. Be sure to use it within rating.
Rated switching capacity: DC24V±3V, 0.1A
• Commons containing 8 output circuit units are independent so that power can also be separated.
(Example)
Output signal Power
OUT1∼OUT8 Power A
OUT9∼OUT16 Power B
9-9
9.2Connection
9-10
9.2Connection
…
…
OUT*
Common
CNP24
External power A3, B3 pins
GND
A1, B1 pins
DC+24 V
9-11
9.3Replacement procedure
Method of installation
1 Fix removed system CF card on card slot (CNCF) of new CPU board.
2 Insert new CPU board in CPU unit, and fix the board with screws at two positions at top and bottom.
3 Connect all connectors.
4 Turn power of controller on, and fully confirm operation.
Screws for
fixing CPU
board
9-12
9.3Replacement procedure
Method of installation
1 Insert new board along board guide rail of board rack, and fix the board with screws at two positions at
top and bottom.
2 Connect all connectors.
3 Turn power of controller on, and fully confirm operation.
9-13
9.3Replacement procedure
Confirm that primary power is turned off, and execute operation after more than 5 minutes have passed.
Electric charge remains in board and electrolytic capacitor.
Method of disinstallation
(1)Take out CPU board following “9.3.1 exchange of CPU board”.
(2) Remove battery (CR14250SE-CN16) of CPU board.
Method of installation
(1) Mount battery (CR14250SE-CN16) on CPU board.
(2) Install CPU board following “9.3.1 exchange of CPU board”.
Battery
CR14250SE-CN16
9-14
9.4Maintenance parts
◆ Maintenance parts A: key maintenance parts to be prepared for daily maintenance and inspection
・A-1 Important backup parts
・A-2 Periodical exchange parts
◆ Maintenance parts B: maintenance parts to be prepared at the time of plural unit purchasing
・B-1 Parts cordially asked to purchase from Fujikoshi
We recommend preparing at least one set of A-1 and A-2 described above, since they are important parts
minimum required for maintaining ordinary operation.
Further, pay attention to following points in maintenance of printed boards, since highly reliable ones are used.
∼85 % RH
◆ Maintenance humidity 20∼
∼65 % is recommended for maintenance of reliability. Further, avoid storage
For long term storage, 45∼
under conditions prone to bedewing and mold growth.
9-15
9.4Maintenance parts
Note1 Regardless of operating time, replace the battery once every 5 years.
Note2 On January 1, 2009, for revision of the UN Recommendations on the Transport of Dangerous Goods, Model
Regulations-15th edition, Transportation regulation of Lithium battery is partially revised.
When you transport the Lithium battery by air, transport it according to providing items of the newest ICAO-TI and IMDG
Code of IMO
9-16
10 System setting
In this chapter, parameter setting of vision sensor system such as camera type
setting is explained.
POINT IP address of vision sensor unit and IP address of CPU unit shall be setting in the same
network.
10-1
10.2License
10.2 License
License is required for using vision sensor functions.
License is controlled by USB dongle for connection to USB port and license file containing dongle information
used. License file is stored in system CF of vision sensor unit. Operation of storing license file in system CF is
called import. Operation of acquisition (backup) of license file from system CF is called export.
License ID
In delivery, license ID is used for license name. Because license ID is pasted in the
dongle used, confirm they are coincident.
10-2
10.2License
2 Turn power for robot control unit OFF, and open door.
Mount the USB memory to the CNUSB2 or CNUSB3 on the CPU board.
The CPU board is mounted in the rack unit of the controller.
Pay attention to the direction of theUSB memory when inserting it. The USB memory
cannot be inserted to the port in wrong direction.
正面図(内部)
Front (Internal) ラックユニット拡大図
Enlarged rack unit diagram
ラックユニット
Rack unit CPU CPU基板
Board CNUSB3
CNUSB2
USBメモリ
USB Memory
There are 2 USB ports in the CPU board. The USB memory will work
irrespective of which USB port it is connected to. However, do not connect 2
IMPORTANT USB memories at the same time.
10-3
10.2License
When communication with vision sensor failed, following message is displayed and import is
POINT not possible.
“Connection to vision sensor failed.”
Confirm communication setting and network and retry.
When USB memory (RC Ex.Mem) is not inserted or license file does not exist in specified
POINT folder, following message is displayed and import is not possible.
“Import is not possible because license file does not exist in external storage media.”
Confirm the USB memory (RC Ex. Mem), and retry.
When correct license file corresponding to vision sensor was not imported, following
POINT message is displayed.
“License trouble of vision sensor was detected. Confirm license file.”
Confirm license file and dongle, and retry.
10-4
10.2License
POINT In order to be prepared to break down of system CF, backup of license file by this operation
is recommended.
1 Turn power for robot control unit OFF, and open door.
Mount the USB memory to the CNUSB2 or CNUSB3 on the CPU board.
The CPU board is mounted in the rack unit of the controller.
Pay attention to the direction of theUSB memory when inserting it. The USB memory
cannot be inserted to the port in wrong direction.
正面図(内部)
Front (Internal) ラックユニット拡大図
Enlarged rack unit diagram
ラックユニット
Rack unit CPU CPU基板
Board CNUSB3
CNUSB2
USBメモリ
USB Memory
There are 2 USB ports in the CPU board. The USB memory will work
irrespective of which USB port it is connected to. However, do not connect 2
IMPORTANT USB memories at the same time.
10-5
10.2License
When communication with vision sensor failed, following message is displayed and export is
POINT not possible.
“Connection to vision sensor failed.”
Confirm communication setting and network and retry.
When the USB memory (RC Ex. Mem) is not inserted, following message is displayed and
POINT export is not possible.
“RC Ex. Mem is not inserted.”
Confirm if the USB memory (RC EX. Mem) is correctly inserted, and retry.
10-6
10.3Setting of vision sensor unit
When camera setting is changed, already registered calibration and measurement condition
may not function correctly.
IMPORTANT Pay full attention, since erroneous action is possible as the result.
10-7
10.3Setting of vision sensor unit
7 Set signal logics, delay times and whether or not to use strobe of output ports
1∼8.
When there is delay time after signal is turned on until lighting or laser is actually lit,
larger value than the delay time is set as delay time. Delay time is set in msec unit.
When strobe is set as “use”, signal turns on synchronized with trigger signal of
camera. Output ports 1∼8 correspond to trigger signals of cameras 1∼8 respectively.
10-8
10.3Setting of vision sensor unit
9 Set signal logics and delay times of output ports 9∼16 are set.
ON/OFF test of lighting and laser can be carried out in signal setting screen.
INFO. Move cursor to portion allocated to tested lighting or laser in page 1 of allocation screen.
, the signal turns off. Since the operation is executed using the data stored in file,
operation reflecting conditions during editing before input cannot be executed.
10-9
10.3Setting of vision sensor unit
4 [Select [3 Communication].
≫Communication setting screen is displayed.
Set subnet mask and default gateway in accordance with setting of <Constant Setting> - [8
POINT Communication] [2 Ethernet] [TCP/IP].
Set IP addresses and IP port numbers so that their numbers are in accordance with IP port
numbers of <Constant Setting> - [31 Vision sensor].
10-10
10.3Setting of vision sensor unit
Make the setting so that the robot controller and the vision sensor belong to the identical
network. But, IP addresses with same numbers cannot be set on the same network. Be sure
IMPORTANT to use different numbers for all.
Setting example
Communication port IP address Subnet mask Default gateway
Robot controller 10.34.1.2 255.255.255.0 10.34.1.255
Vision sensor 10.34.1.1 255.255.255.0 10.34.1.255
communication
setting
GigEGigE カメラポート1
camera port1
GigE camera
GigE port2
カメラポート2
10-11
10.3Setting of vision sensor unit
10-12
11 Troubleshooting
In this chapter, method of handling troubles that occur in using vision sensor
functions is explained.
11.1 Robot controller error codes................................................................... 11-1
11.2 Vision sensor error ................................................................................. 11-2
11.3 Troubleshooting...................................................................................... 11-6
11.3.1 Connection failure with vision sensor ......................................... 11-6
11.3.2 Communication setting of vision sensor alone ........................... 11-7
11.3.3 License trouble........................................................................... 11-9
11.3.4 Camera mounting position was changed ................................. 11-10
11.3.5 Hardware-related troubles........................................................ 11-10
11.1Robot controller error codes
11-1
11.2Vision sensor error
11-2
11.2Vision sensor error
11-3
11.2Vision sensor error
11-4
11.2Vision sensor error
The license has not License trouble was Refer to “11.3.3 License trouble”.
E5000
been inserted. detected.
Because the license Menu cannot be displayed
has not been due to license trouble.
E5001
inserted, the menu
cannot be displayed.
Fail to save error log. Storing of error log failed. Confirm that there is room in drive
capacity of storage target.
E5002
If there is no room, clean drive to
save capacity.
Fail to remove error Deletion of error log failed. Deletion is not possible when
log. attribute of data is changed or data
E5003 are damaged. Confirm attributes of
data folder and file and restore
them.
Fail to update vision System renewal of vision Re-apply main power, and renew
E5004
sensor system. sensor failed. system again.
Fail to back up of Backup of vision sensor Confirm free space of external CF of
E5005
vision sensor data. failed. robot side.
Fail to restore of Backup of vision sensor Confirm backup data for restoration
E5006
vision sensor data. failed. in external CF of robot side.
Fail to export of Export of license file failed. Confirm free space of external CF of
E5007
license file." robot side.
Fail to import of Import of license file failed. Confirm license file for import in
E5008
license file. external CF of robot side.
11-5
11.3Troubleshooting
11.3 Troubleshooting
Cause, investigation and method of solution of various troubles are explained.
11-6
11.3Troubleshooting
2 Mount key board and display on CPU board of vision sensor unit.
Connect key board to CN11, and display to CN7.
CN7 Display
CPU board
It may take more than one minute after turning power on until screen is displayed.
11-7
11.3Troubleshooting
4 Select [3 System setting] using key board, and press [Enter] key.
≫Following screen is displayed.
9 Remove key board and display from CPU board of vision sensor unit.
Never execute operation using key board and display other than explained in this section, or
vision sensor may become to function in correctly.
CAUTION
11-8
11.3Troubleshooting
Dongle
License file
FLEXnet ID-X-
license_X-XXXXXXXX.dat
XXXXXXXX
License ID:X-XXXXXXXX
Never change file name and data of license file. Although file name of license file is added for
confirmation of ID stored in file data, actual ID information is encrypted and stored in file.
Therefore, even if license file name is changed to fit dongle, license ID is not changed and
CAUTION authentication cannot be executed.
11-9
11.3Troubleshooting
11-10
12 In case of CFD Controller
In this chapter, the supplemental explanations for CFD controller are described.
If not described in this chapter, the operation is the same with the FD controller
(See other chapters).
In the rack of the vision sensor unit, there is the CPU board (R04601) and the image input board (UM345).
12-1
12.1Outline of this system
Function
- Microprocessor and its peripheral circuit
- Fixed disk I/F (IDE)
- Ethernet (For communication with the control CPU of the robot)
- PCI bus I/F
- Compact flash card I/F (for image processing system and measurement condition memory)
- USB port for USB dongle
- GigE camera communication port * 2
CN2
CNCF
CN7
GigE1
GigE2
CN12
CNUSB2
CNUSB3
CN11
CN4
12-2
12.1Outline of this system
About battery:
On this CPU board, a battery (CR14250SE-CN16) for the internal clock is installed. This
battery must be replaced every 5 years.
CAUTION
12-3
12.1Outline of this system
Functions
- Image input
- Input and output control
12-4
12.2Connection
12.2 Connection
In case of the vision sensor of the CFD controller, only GigE camera is supported.
The GigE cameras can be connected to the CFD controller up to 2.
The connection ports are shown as below.
CAMERA1
CAMERA2
Use cables for camera connection specified by us. Use of unspecified cables will cause
troubles with image input boards or cameras.
CAUTION
Use cameras specified by us. Use of unspecified cameras will cause troubles with cameras
and image input boards.
CAUTION
12-5
12.2Connection
CNIO1
CNIO2
12-6
12.3Setup of the vision sensor unit
To use the GigE camera, please make the communication settings for the GigE camera port
in advance.
IMPORTANT
If the settings for the camera are changed after setting the calibration or the measurement
IMPORTANT condition, those calibrations and measurement conditions may not work correctly. As a
result, the system may work incorrectly. Be careful.
12-7
12.3Setup of the vision sensor unit
Example
12-8
12.3Setup of the vision sensor unit
1 10.34.2.1 10.34.2.*
255.255.255.0 255.255.255.0
10.34.2.255 ----
2 10.34.3.1 10.34.3.*
255.255.255.0 255.255.255.0
10.34.3.255 ----
(* is 2 to 255)
Concerning to the setting for GigE camera port, see “10.3.3 Communication setting”.
9 Press <Complete>.
>>The screen returns to the camera setting screen.
When changing the IP address etc. of the GigE camera that has been connected already, the
POINT following message will be displayed when pressing [R] key. To connect the GigE camera,
press <Complete>.
12-9
12.3Setup of the vision sensor unit
7 Set signal logics, delay times and whether or not to use strobe of output ports
1∼8.
When there is delay time after signal is turned on until lighting or laser is actually lit,
larger value than the delay time is set as delay time. Delay time is set in msec unit.
When strobe is set as “use”, signal turns on synchronized with trigger signal of
camera. Output ports 1∼8 correspond to trigger signals of cameras 1∼8 respectively.
12-10
12.3Setup of the vision sensor unit
9 Set signal logics and delay times of output ports 9∼16 are set.
ON/OFF test of lighting and laser can be carried out in signal setting screen.
INFO. Move cursor to portion allocated to tested lighting or laser in page 1 of allocation screen.
, the signal turns off. Since the operation is executed using the data stored in file,
operation reflecting conditions during editing before input cannot be executed.
12-11
12.3Setup of the vision sensor unit
4 [Select [3 Communication].
≫Communication setting screen is displayed.
Set subnet mask and default gateway in accordance with setting of <Constant Setting> - [8
POINT Communication] [2 Ethernet] [TCP/IP].
Set IP addresses and IP port numbers so that their numbers are in accordance with IP port
numbers of <Constant Setting> - [31 Vision sensor].
12-12
12.3Setup of the vision sensor unit
Setting example
Communication port IP address SUBNET Default gateway
Robot controller 10.34.1.2 255.255.255.0 10.34.1.255
Vision sensor 10.34.1.1 255.255.255.0 10.34.1.255
communication
setting
On the other hand, the “Vision sensor communication setting”, the “GigE camera port1”, and
the “GigE camera port 2” must belong to the different networks respectively.
Setting example
Communication port IP address SUBNET Default gateway
Vision sensor 10.34.1.1 255.255.255.0 10.34.1.255
communication
setting
GigE camera port 1 10.34.2.1 255.255.255.0 10.34.2.255
GigE camera port 2 10.34.3.1 255.255.255.0 10.34.3.255
12-13
12.3Setup of the vision sensor unit
12-14
12.4How to replace the vision sensor unit
How to dismount
(1) Make the user data backup of the vision sensor unit referring to the following sections.
- “2.8.3 Backup”
- “12.6 USB port”
(2) Turn OFF the power of the CFD controller and the vision sensor unit. And, turn OFF the breaker switch of
the power distributer also.
(3) Disconnect the all connectors and cables that connect the CFD controller and the vision sensor unit. And
then remove the CFD controller.
(4) Remove the screws in the following picture to remove the vision sensor unit box cover.
(5) Now it is possible to access the vision sensor unit from the right side of the box.
12-15
12.4How to replace the vision sensor unit
(6) Dismount the USB dongle from the “Vision sensor unit CPU board”.
(7) Open the cover of the new Vision sensor unit box in the same way and mount the USB dongle to the
“Vision sensor unit CPU board” in the new Vision sensor unit box.
How to mount
(1) In the opposite order, connect the “Vision sensor unit box” and the “CFD controller”.
(2) Restore the backup data to the new vision sensor unit. (See the following sections for details.)
12-16
12.5Maintenance parts
◆ Maintenance parts A: key maintenance parts to be prepared for daily maintenance and inspection
・A-1 Important backup parts
◆ Maintenance parts B: maintenance parts to be prepared at the time of plural unit purchasing
・B-1 Parts cordially asked to purchase from Fujikoshi
We recommend preparing at least one set of A-1 described above, since they are important parts minimum
required for maintaining ordinary operation.
Further, pay attention to following points in maintenance of printed boards, since highly reliable ones are used.
∼85 % RH
◆ Maintenance humidity 20∼
∼65 % is recommended for maintenance of reliability. Further, avoid storage
For long term storage, 45∼
under conditions prone to bedewing and mold growth.
12-17
12.5Maintenance parts
(Note1) The necessary cables differ from each other depending on the system configuration. For details, see
“TCFEN-155-### CFD CONTROLLER TECHNICAL DOCUMENT 1”
12-18
12.6USB port
12.6.1 USB port of the CFD controller (for backup and license check)
The position of the USB port of the CFD controller is shown in the following picture. This USB port can be
used for the import/export operation of the license file and the backup/restore operation. The CFD controller
itself has only 1 USB port and the USB memory inserted here is recognized as “RC Ex. Mem 1” (=Robot
controller external memory number 1).
The operation for the data backup/restore, the mechanism of the license check, and the import/export
operation for license file are the same with FD controller. For details, refer to the following sections.
12.6.2 USB port of the vision sensor unit (for dongle installation)
Because the vision sensor unit of the CFD controller is installed in the vision sensor unit box, it is necessary to
remove the cover of the vision sensor unit box when changing the USB dongle. For details, refer to the following
section.
12-19
12.6 USB port
NOTE
12-20
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