Difference between revisions of "Bin Picking Tutorial: Setting up Photoneo Bin Picking Studio with KAWASAKI robots"
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− | Type IP address of Port 2 as configured in the pendant in previous step: | + | Type IP address of Port 2 as configured in the pendant in previous step and click '''Add''' button: |
Revision as of 14:39, 6 June 2018
NOTE: It is highly recommended to read general introduction to robot interfaces prior to installing specific robot modules.
Contents
1. Prerequisities
Photoneo KAWASAKI Interface is compatible with E series robot controllers.
2. KAWASAKI Controller setup
The following tutorial gives a step by step guide of how to configure your KAWASAKI E-series controller and install all necessary .pg files you will need to get the robot interface for Photoneo Binpicking Studio up and running.
2.1 Network configuration
Turn on the robot controller, wait for the system to boot, open the Menu screen and select the Aux Function option:
In Aux function menu select System and Network Settings:
E-series robot controllers have two Ethernet ports. We will use Port 1 for communication with Photoneo Binpicking Studio, while Port 2 will be utilized for transferring programs between PC and Robot controller using KRTerm.
Configure Port 1 to meet your network requirements and make sure that both robot controller and vision controller running Photoneo Binpicking Studio will be on the same subnet.
Configure Port 2 for transferring programs between PC and robot controller. Click Next Page, configure network settings and confirm by clicking Enter button.
2.2 Enable Autostart
Photoneo KAWASAKI interface consists of two tasks - Binpicking Client task and State server. While Binpicking Client is Cycle Started as a normal robotic program, State server runs in the background from boot.
In order to enable State server to run from the first boot properly, it is necessary to enable AUTOSTART.PC system switch.
On pendant click Menu -> Aux Functions -> Advanced Settings -> System Switch
You should see the list of system switches. AUTOSTART.PC switches are available on the second page so click Next Page to access them. Turning AUTOSTART.PC ON enables State Server to start properly even on the first boot
Restart robot controller to apply network and autostart settings.
3. KRTerm
Photoneo KAWASAKI interface consists of three .pg files
- photoneo_common.pg
- customer_definitions.pg
- main_application.pg
These three files includes approximately 25 programs which compose the Photoneo Kawasaki Interface. All these files need to be transferred to the robot controller to get interface up and running.
3.1 Transfering .pg files to robot controller
You should receive .pg files as an .zip archive together with Photoneo Binpicking Studio. You can copy the .pg files to robot controller directly from the USB stick using Pendant, however the most convenient method is to use the KRTerm tool.
Make sure that Port 2 is configured for communication with your PC and both devices are connected to the same subnet (you must be able to ping robot controller from command line).
Open KRTerm and select COM -> Options to add new robot controller:
Type IP address of Port 2 as configured in the pendant in previous step and click Add button:
Click File -> Set Current Folder and set path to the folder where you store extracted .pg files
You are now ready to connect to the robot. Make sure that you are able to ping robot controller from your PC and click on Connect button. If connection was established properly you should see login prompt as shown in the figure below:
Login name is as . If login succeeded you should be able to issue commands directly to robot controller. In order to load .pg files to robot controller type LOAD command as shown in the figure below:
Use LOAD command to upload all three .pg files of Photoneo KAWASAKI interface.
At this point your Robot Controller is configured to work with Photoneo Binpicking Studio. However your AS code must be adopted to meet your application requirements - you need to reteach HOME, START and END poses, update part placing, application logic, etc. The following section of the tutorial provides basic examples of how this can be programmed as well as a detailed explanation of Photoneo AS API.
4. AS Language
Photoneo KAWASAKI interface was designed to be easily integrated into existing application written in AS code. It provides two means which influence the final robot behavior:
- AS API - set of AS requests (or procedures) used to control the binpicking sequence. Requests are defined in photoneo_common.pg module and used within main_application.pg
- AS CONFIG - customer_definitions.pg holds an application specific settings such as gripper commands, motion execution settings and object placing definitions.
4.1 AS API
The following API describes the functionality of requests provided by Photoneo KAWASAKI Interface. These requests are intended for high level control of binpicking sequences and are usually called in main_application.pg
- connect_to_vc(.ret_val_conn) - function to establish a connection to the Vision Controller. Blocking function; suspends the program until a proper connection is established.
- scan_req(.ret_val_scan) - request to trigger the next scan and localization. Non-blocking request; the AS program continues immediately at the next line.
- wait_for_scan(.ret_val_wait) - function to wait for scan to be finished. This should be called after triggering the scan, but not immediately. Blocking function, waits for response from Vision Controller.
- traj_req(.ret_val_traj) - request to start trajectory planning for current goal. Non-blocking function; the AS program continues immediately at the next line.
- traj_recv(.ret_val_traj) - function to receive requested binpicking trajectories (consisting of a sequence of trajectory and gripper operations). Blocking function; waits for motion data to be received.
- init_req(.ret_val_init) - request to initialize binpicking application from the Vision Controller side. Start and End Poses defined by the operator from the AS side are transferred to the Vision Controller and used in the trajectory planning pipeline as start and terminus points.
- calib_add_req(.ret_val_add) - request to add calibration point - a scan is triggered and the calibration is recalculated. Blocking request; the program will not continue until the calibration result is recalculated and has been received by the Robot Controller.
- calib_set_req(.ret_val_set) - request to set current calibration result to the PhoXi Scanner
- calib_reset_req(.ret_val_reset) - request to reset current calibration and remove all previously added points
4.2 AS CONFIG
customer_definitions.pg enables the user to configure several binpicking settings, define home, start end binpicking positions, gripper command implementations, trajectory speed and precision adjustments.
4.2.1 ROUTINES
- pick_part() - standard binpicking sequence. This flexible, operation-based implementation allows performing binpicking sequences, which consist of various numbers of operations to be performed. Do not edit !!!
- place_part() - placing operation. Adapt placing sequence and poses to meet your application requirements.
- grip_attach() - implement function for opening your gripper here
- grip_deattach() - implement function for closing your gripper here
- gripper_user_1() - implement custom user gripper command (reserved for future use)
- gripper_user_2() - implement custom user gripper command (reserved for future use)
- gripper_user_3() - implement custom user gripper command (reserved for future use)
- gripper_user_4() - implement custom user gripper command (reserved for future use)
- gripper_user_5() - implement custom user gripper command (reserved for future use)
- gripper_user_6() - implement custom user gripper command (reserved for future use)
4.2.2 VARIABLES
- #pho_home - homing position for a robot - robot moves to this position immediately after connection to Vision Controller is established. This position should not collide with scanner space.
- #pho_start - start binpicking position - this position should be defined right above the bin. Robot moves to this position when trajectory is received successfully
- #pho_end - end binpicking position - this position should be defined not very far from the bin. Robot finishes binpicking movement in this position.
- #pho_place_up - upper placing position - this is only for demonstration purposes here, in real application it is up to user to define own placing positions and routines.
- #pho_place_down - position for part placing - this is only for demonstration purposes here, in real application it is up to user to define own placing positions and routines.
- pho_base - Translation variable which define origin offset in Z axis. See section 4.4 for further details.
4.3 AS ERROR HANDLING
Photoneo KAWASAKI interface provides basic error handling. If an error occurs during binpicking operations, error code is returned to main_application via ret_val variable.
Following is the list of potential binpicking error codes:
OK := 0 - Service response from Vision Controller is valid
SERVICE_ERR := 1 - Service response from Vision Controller is invalid.
UNKNOWN_REQ := 2 - The Vision Controller received an unknown request.
COMM_FAILURE := 3 - Communication failure due to socket closure.
BAD_DATA := 4 - Data validation check has failed.
TIMEOUT := 5 - Communication failure due to socket timeout.
PLANNING_FAILED := 201 - Trajectory planning has failed
NO_PART_FOUND := 202 - No part has been localized
NOT_INIT := 203 - Binpicking application has not been properly initialized on Vision Controller
UNKNOWN_ERR := 299 - Unspecified internal error
The main_application.pg already includes basic error_handling which is implemented through labels and GOTO commands, but it can be adapted to more complex scenarios if needed.
4.4 AS & ROBOT ORIGIN
Photoneo Binpicking Studio requires origin of the robot to be defined at the very bottom of the robot. Since Kawasaki origin is by default defined in the axis of second joint, we need to redefine its position and shift it vertically down in Z-axis.
BASE command with pho_base translation variable argument are used for this purpose. Translation variable pho_base consists of 6 values. Set the third value of pho_base according to used robot and offset list shown below:
RS010N Offset = -430
RS020N Offset = -465
Be careful if you are integrating Photoneo Binpicking into existing application, since origin change might affect your previously taught positions.
4.4 MAIN APPLICATION
This is a basic binpicking template. The main program loop is defined here and main application utilizes variables defined in customer_definitions.pg
User is expected to set an IP Address and Port of Vision Controller and adapt operation logic here.
; Copyright (c) 2018 Photoneo s.r.o. ; All rights reserved ; Description: Photoneo Kawasaki Module v.1.2.0 Main Application ;//------------------------------------------------------------------------- .PROGRAM main() ;// Enable State Server to start on boot AUTOSTART.PC ON ;// Changing Base Frame to pho_base - see customer definitions for more details BASE pho_base ;// Adopt Network settings to your meet your configuration BP_PORT = 11003 VC_IP[1] = 192 VC_IP[2] = 168 VC_IP[3] = 100 VC_IP[4] = 12 ;// Connect to Vision Controller CALL connect_to_vc(ret_val) IF ret_val == COMM_FAILURE THEN GOTO quit END reinit: ;// Initialize binpicking CALL init_req(ret_val) IF ret_val <> OK THEN GOTO quit END ;// Deattach gripper and move to Home Position - away from scanning area CALL grip_deattach SPEED 10 ALWAYS JMOVE #pho_home BREAK ;// Request first scan CALL scan_req(ret_val) IF ret_val == COMM_FAILURE THEN GOTO quit END ;// Initial wait TWAIT 10 ;// MAIN LOOP WHILE (TRUE) DO main_start: ;// Wait for scan completition CALL wait_for_scan(ret_val) ;// Check COMM_FAILURE error IF (ret_val == COMM_FAILURE) THEN GOTO quit END ;// Check NOT_INIT or SERVICE_ERR state IF (ret_val == NOT_INIT) OR (ret_val == SERVICE_ERR) THEN GOTO reinit END ;// SCAN was received successfully IF (ret_val == OK) THEN ;// Request trajectory CALL traj_req(ret_val) IF ret_val == COMM_FAILURE THEN GOTO quit END ;// Receive trajectory CALL traj_recv(ret_val) ;// Check COMM_FAILURE error IF ret_val == COMM_FAILURE THEN GOTO quit END ;// Check NOT_INIT or SERVICE_ERR state IF (ret_val == NOT_INIT) OR (ret_val == SERVICE_ERR) THEN GOTO reinit END ;// Check PLANNING FAILED or NO_PART_FOUND state IF (ret_val == PLANNING_FAILED) OR (ret_val == NO_PART_FOUND) THEN ;// Move back to home position JMOVE #pho_home BREAK ;// Request new scan CALL scan_req(ret_val) IF ret_val == COMM_FAILURE THEN GOTO quit END GOTO main_start END ;// TRAJECTORY was calculated successfully IF (ret_val == OK) THEN ;// Move robot to binpicking start position JMOVE #pho_start ;// Pick part and wait for movement completition CALL pick_part BREAK ;// Trig new scan CALL scan_req(ret_val) IF ret_val == COMM_FAILURE THEN GOTO quit END ;// Place part CALL place_part END END END ;//End of MAIN LOOP quit: CALL close_socket .END
5. RUNTIME
Upload all changes to the robot controller using USB Stick or KRTerm and you are ready to start binpicking application.
The first step is to select a program which will be run. Click on the yellow program rectangle on the pendant touch screen:
Select Directory to enter the program list:
Find and select the main program:
When main program is prepared for launch, hold A key + press RUN/HOLD key on the pendant. RUN status should appear in the upper right corner:
Now turn motor power on. Hold A key + MOTOR_ON/JOG key. You should hear that motors brakes have been released and MOTOR status should appear right next to the RUN status in the upper right corner.
NOTE: In current implementation, A + MOTOR_ON key starts state server. In the future state server should run directly from the boot
Kawasaki robot is now ready for connection to Vision Controller. Start binpicking in Deployment tab of Photoneo Binpicking Studio and wait until Robot Status and Scanner Status signalize: Connected
Start main program on the robot controller. Hold A key + press CYCLE START/CONT key. Green CYCLE status should appear in the upper right corner:
If connection between robot controller and vision controller is established properly, robot should move to home position and you should see Binpicking status signalize: Connected
As soon as the trajectory to first localized object is calculated, robot should start executing motion.
NOTE: Make sure that you are ready to halt motion execution immediately. It is highly recommended to decrease the speed to 10% of maximum during initial binpicking tests.