Bin Picking Tutorial: Setting up Photoneo Bin Picking Studio with FANUC robots

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1. Prerequisites

Please make sure that your Fanuc controller meets following criteria:

- System version 8.10 and higher (Versions 6.40 - 7.70 are also supported with certain limitations)

- R632 Karel - Karel option available

- R648 User Socket Msg - Socket Communication option available

Click Menu -> Status -> Version ID -> Next -> F3[ORDER FI] to verify that required options are installed on your robot controller (see figure below):


Fanuc tutorial Step1.png

2. Fanuc Controller Setup

2.1 Set IP Addresses of Ethernet Ports

As a first step, configure IP addresses of robot controller.

On Pendant Press Menu -> Setup -> Host Comm -> TCP/IP:


Fanuc tutorial Step2.png


Two Ethernet ports should be available, it is recommended to configure Port#1 for communication with Vision Controller.

Adapt an IP address of Port#1 to meet you network configuration:


Fanuc tutorial Step2 2.png


If you use ROBOGUIDE for workcell commisioning, configure Port#2 for transferring files between robot controller and your PC.

Adapt an IP address of Port#2 to meet you network configuration:


Fanuc tutorial Step3.png


2.2 Configure TCP/IP Server

Photoneo Fanuc Module requires State Server to run as a background task on the robot controller. Configured TCP/IP server is necessary for this purpose.

Press Menu -> Setup -> Host Comm -> F4[SHOW] and select Servers


Fanuc tutorial Step4.png


Select S3 slot - we keep S1 and S2 slots reserved for user application.


Fanuc tutorial Step5.png


Configure TCP/IP server S3 as shown in the figure below:


Fanuc tutorial Step6.png


2.3 Configure TCP/IP Client

The main Photoneo Bin Picking application works in a client mode. Configure TCP/IP Client for this purpose.

Press Menu -> Setup -> Host Comm -> F4[SHOW] and select Clients


Fanuc tutorial Step4.png


Select C3 slot - we keep C1 and C2 slots reserved for user application.


Fanuc tutorial Step7.png


Configure TCP/IP client C3 as shown in the figure below:

NOTE: Set an IP address of Vision Controller to SERVER IP/HOSTNAME


Fanuc tutorial Step9.png


2.4 Change Cartesian Origin of Robot

The Cartesian origin of Fanuc robots is different than the Cartesian origin of robot models used in the Photoneo Binpicking Studio.

In order to ensure successful calibration, we need to apply predefined offset in Z axis in UFRAME.

Press Menu -> Next -> System -> Variables and scroll down until you find system variable named GROUP. (Use Shift button to speed up scrolling)


Fanuc tutorial Step10.png


Press Enter to open GROUP menu and select UFRAME option as shown in the figure below:


Fanuc tutorial Step11.png


Edit the Z value of UFRAME according to the Offset table below.


Fanuc tutorial Step12.png


A table of Z axis offsets for specific robot models:


Fanuc tutorial Offset table small.png


NOTE: Be careful since this change might affect your previously taught Cartesian positions !!!


2.5 Load Photoneo Fanuc Module Files

The Photoneo Fanuc Interface consists of two Karel binaries and approximately 20 TP programs. All these files needs to be copied to the robot controller in order to get Photoneo Fanuc Module up and running.

Extract Photoneo Fanuc Module archive (.zip file) which you received with Photoneo Bin Picking Studio to the USB stick and plug it to Teach Pendant.

Press Menu -> File -> File -> F5[UTILS] and select Set Device:


Fanuc tutorial Step13.png


Select USB on TP (UT1:) option as shown in the figure below:


Fanuc tutorial Step14.png


Press F2[DIR] to open Photoneo Fanuc Module directory:


Fanuc tutorial Step15.png


Select *.*(all files) and press F3[LOAD] and YES to load all the files from Photoneo Fanuc Module to the robot controller:


Fanuc tutorial Step16.png


Press Select button to verify that all TP and Karel programs were successfully loaded:


Fanuc tutorial Step17.png


2.6 Enable Autostart of State Server

As a next step we need to configure State Server to start automatically after boot.

Press Menu -> Next -> System -> Variables and scroll down to find SHELL_CFG variable


Fanuc tutorial Step18.png


Edit SHELL_NAME and SHELL_EXT to the state as shown in the figure below:


Fanuc tutorial Step19.png


Cycle power to apply all changes. Press FCTN -> NEXT -> CYCLE POWER and confirm YES.


Fanuc tutorial Step20.png


If everything was set correctly you should see PHOSTATE: Waiting for connection... on the User screen immediately after the boot:


Fanuc tutorial Step21.png


2.7 Teach Home, Start and End positions

A crucial step of bin picking configuration is related to teaching home, start, and end poses. Home position of robot should be taught in a way that robot is outside of the scanning area. Start position should be taught in a way in which robot gripper is approximately above the center of the bin. End position can be similar to start position or slightly shifted towards placing area. Do not place end pose far away from bin since it might significantly affect dynamic trajectory planning, increase total planning time and cause planning errors.

Press Data to visualize Data Registers screen. As you can see in the figure below, Photoneo Fanuc Module has automatically added comments to Data Registers R[1] - R[24] that are utilized for bin picking application.

NOTE: Prevent using registers R[1]-R[24] in your application!!!


Fanuc tutorial Step22.png


In order to switch from Standard Registers to Position Registers press F1[TYPE] -> Position Registers

NOTE: The default range of position registers is usually PR[1] - PR[100]. For proper functionality of Photoneo Fanuc Module it is highly recommended to increase the range up to 120 position registers or more. Since this is a maintenance operation, please contact your local Fanuc support to help you with this step. Be careful since you might loose your previously taught positions and other register data during this operation!

Fanuc tutorial Step23.png


Similarly to Standard Registers, Photoneo Fanuc Module has automatically added comments to Position Registers utilized for bin picking application. As you can see in the figure below - Photoneo Fanuc Module utilize PR[1]-PR[9] for Home, Start, End + calibration positions PR[4]-PR[9] for calibration positions and PR[20]-PR[120] for trajectory transfers. PR[10]-PR[19] are free for user application.

In order to teach Home position jog robot to required Home position, select register PR[1] and press Shift + F3[RECORD] to record position.

You should see that asterisk has changed to R sign after successful operation.


Fanuc tutorial Step24.png


For proper operation of binpicking, internal representation of Home, Start and End needs to be switched from Cartesian to Joint. In order to achieve that press F4[Position] ->F5[REPRE] -> Joint


Fanuc tutorial Step26.png


Confirm switching representation by pressing Continue. Repeat the same procedure also for Start and End poses.

NOTE: If you utilize Calibration poses in your application, these don't need to be switched to Joint representation.


Fanuc tutorial Step27.png


At this point your Robot Controller is configured to work with Photoneo Binpicking Studio. However you should adapt the TP code to meet the precise requirements of your application. This may involve updating part placing, gripper commands or application logic. The following section of the tutorial provides some basic examples of how this can be programmed as well as a detailed explanation of the Photoneo TP API.

3. TP LANGUAGE

The Photoneo Fanuc Module was designed to be easily integrated into existing applications written as TP programs.

3.1 TP API

The following list of programs comprises Photoneo Fanuc TP API. These requests are intended for high level control of binpicking sequences and are usually called in PHO_MAIN program.

PHO_REQ_SCAN - request to trigger the next scan and localization. Non-blocking request; the TP program continues immediately at the next line.

PHO_WAIT_SCAN - function to wait for scan to be finished. This should be called after triggering the scan, but not doesn't have to be called immediately. Blocking function, waits for response from Vision Controller.

PHO_TRAJ_REQ - request to start trajectory planning for current goal. Non-blocking function; the TP program continues immediately at the next line.

PHO_TRAJ_RECV - function to receive requested bin picking trajectories (consisting of a sequence of trajectory and gripper operations). Blocking function; waits for motion data to be received.

PHO_INIT - request to initialize bin picking application from the Vision Controller side. Start and End Poses defined by the operator from Teach Pendant are transferred to the Vision Controller and used in the trajectory planning pipeline as start and terminus points.

PHO_CALIB_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.

PHO_CALIB_SET - request to set current calibration result to the PhoXi Scanner

PHO_CALIB_RESET - request to reset current calibration and remove all previously added points

3.2 TP CONFIG

Following programs enable the user to configure several bin picking settings, to implement gripper commands and to adapt placing of the attached object.

PHO_GRIP_ATT - implement function for attaching object to gripper here

PHO_GRIP_DEATT - implement function for deattaching object from gripper here

PHO_GRIP_USER1 - implement function for custom gripper command (reserved for future use)

PHO_GRIP_USER2 - implement function for custom gripper command (reserved for future use)

PHO_GRIP_USER3 - implement function for custom gripper command (reserved for future use)

PHO_GRIP_USER4 - implement function for custom gripper command (reserved for future use)

PHO_GRIP_USER5 - implement function for custom gripper command (reserved for future use)

PHO_GRIP_USER6 - implement function for custom gripper command (reserved for future use)

PHO_PICK_PART - standard bin picking sequence. This flexible, operation-based implementation allows performing bin picking sequences, which consist of various numbers of operations.

PHO_PICK_PART - implement function for placing attached object here

3.3 TP ERROR HANDLING

The Photoneo FANUC interface provides basic error handling. If an error occurs during bin picking operations, an error code is returned in Register R[19] - PHO ERROR DATA.

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

Photoneo Fanuc Interface by default performs basic error handling right after TRAJ_RECV program call.

If NOT_INIT or SERVICE_ERR occurs, the whole bin picking is reinitialized.

If PLANNING_FAILED or NO_PART_FOUND occurs, scanning is repeated.

It is up to user to decide if existing error handling is sufficient for particular application or it needs to be expanded.

3.4 MAIN APPLICATION

PHO_MAIN program can be considered as a basic bin picking template. The main program loop with basic error handling is implemented here. Adapt to meet your application requirements.

  1:  !Start Phoclient  
  2:  RUN PHOCLIENT 
  3:  !Initialize Binpicking 
  4:  LBL[1] 
  5:  CALL PHO_INIT    
  6:  !Clear REINIT flag 
  7:  F[8]=(OFF) 
  8:  WAIT   1.00(sec) 
  9:  LBL[2] 
 10:  !Move to Home Position 
 11:J PR[1] 100% FINE    
 12:  !Request First Scan 
 13:  CALL PHO_REQ_SCAN    
 14:  !Clear REPLAN flag 
 15:  F[9]=(OFF) 
 16:  !Main Loop 
 17:  LBL[3] 
 18:  !Wait For Scan 
 19:  CALL PHO_WAIT_SCAN    
 20:  !Request Trajectory 
 21:  CALL PHO_REQ_TRAJ    
 22:  !Receive Trajectory 
 23:  CALL PHO_TRAJ_RECV    
 24:  !Check Reinit Flag 
 25:  IF (F[8]=ON),JMP LBL[1] 
 26:  !Check Replan Flag 
 27:  IF (F[9]=ON),JMP LBL[2] 
 28:  !Pick Part 
 29:  CALL PHO_PICK_PART    
 30:  !Request Next Scan 
 31:  CALL PHO_REQ_SCAN   
 32:  !Place Part To Defined Spot 
 33:  CALL PHO_PLACE_PART    
 34:  JMP LBL[3] 
 /POS
 /END


4. Runtime

Now you are ready to start the bin picking application. Press Select button and choose PHO_MAIN program:


Fanuc tutorial Step28.png


Make sure that the Bin Picking application on the Vision Controller side is running and waiting for a connection:


Fanuc tutorial Step waiting.png


Start the PHO_MAIN program in Manual or Auto mode and if everything was configured properly you should see that PHOCLIENT has established connection with Vision Controller:


Fanuc tutorial Step29.png


If the connection between the robot controller and the vision controller has been established properly, the robot should move to the Home position and the Bin picking status should show: Connected


Fanuc tutorial Step connected.png


As soon as the trajectory to the first localized object is calculated, the robot should start executing motion.

NOTE: Ensure that you are ready to halt motion execution immediately. It is strongly recommended to reduce the speed to 10% of maximum during initial bin picking tests.