1506, TFDEN-050-003, 001

FD/CFD CONTROLLER
INSTRUCTION MANUAL
CONVEYOR TRACKING

3rd 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.
 Table of contents

Table of Contents

Chapter 1 Basic settings

1.1 Outline ....................................................................................................................................... 1-1
1.1.1 Principle of conveyor tracking (synchronization)............................................................... 1-1
1.1.2 Terms used with conveyor synchronization....................................................................... 1-1
1.1.3 Conveyor mode ................................................................................................................. 1-2
1.2 Basic conveyor settings............................................................................................................. 1-3
1.2.1 Initialization ........................................................................................................................ 1-3
1.2.2 Conveyor setting................................................................................................................ 1-6
1.2.3 Conveyor compensation of follow ..................................................................................... 1-8
1.2.4 Setting the conveyor error detection ................................................................................. 1-9
1.2.5 Setting the conveyor added function ............................................................................... 1-11
1.3 Allocating the conveyor synchronization input/output signals ................................................. 1-12
1.3.1 Conveyor synchronization input signals.......................................................................... 1-12
1.3.2 Conveyor synchronization output signals........................................................................ 1-13
1.4 Allocating soft keys .................................................................................................................. 1-13

1.5 How to select the conveyor mode ........................................................................................... 1-14

1.5.1 Selection using Teach/Playback Condition ..................................................................... 1-14
1.5.2 Selection using f key........................................................................................................ 1-14
1.5.3 Selection using Shortcut (R code)................................................................................... 1-14
1.5.4 Selection using input signals ........................................................................................... 1-14

Chapter 2 Needed Parts and Connection

2.1 Needed Parts (FD controller)..................................................................................................... 2-1

2.2 Needed Parts (CFD controller) .................................................................................................. 2-6

Chapter3 Teaching
3.1 Teaching Flow............................................................................................................................ 3-1

3.2 Recording conveyor synchronization step................................................................................. 3-2

3.3 Recording function commands .................................................................................................. 3-3

3.3.1 CNVSYNC (FN55:Conveyor counter reset) ...................................................................... 3-3
3.3.2 CNVI (FN550:Conveyor interlock)..................................................................................... 3-3
3.3.3 CNVSYNCI (FN562:Conveyor interlock(sync.))................................................................ 3-3
3.3.4 CNVYSYNCCHG (FN274: Conveyor sync change) ......................................................... 3-4
3.4 Modifying the teaching contents ................................................................................................ 3-5
3.4.1 Modifying using the [EDIT] key.......................................................................................... 3-5
3.4.2 Changing by program conversion (Condition/speed)........................................................ 3-6
3.5 Check Go / Check Back ............................................................................................................ 3-7
3.5.1 Before proceeding to Check go / Check back................................................................... 3-7
3.5.2 Changing point of conveyor synchronizing step................................................................ 3-8
3.5.3 Changing point of recorded conveyor register .................................................................. 3-9

1
Table of contents

Chapter4 Useful Functions

4.1 Conveyor monitor displays ........................................................................................................ 4-1

4.2 Changing the conveyor register values ..................................................................................... 4-2

4.3 Resetting the conveyor counter................................................................................................. 4-3

4.4 Shortcut (R code)....................................................................................................................... 4-4

4.4.1 R40 (Set conveyor register) .............................................................................................. 4-4
4.4.2 R44 (Conveyor counter reset) ........................................................................................... 4-4
4.4.3 R224 (Select conveyor mode)........................................................................................... 4-4
4.4.4 R363 (Set conveyor speed)............................................................................................... 4-4
4.4.5 R364 (Select conveyor No.) .............................................................................................. 4-4

Chapter5 Playback
5.1 Playback .................................................................................................................................... 5-1
5.1.1 Normal ............................................................................................................................... 5-1
5.1.2 Simulation .......................................................................................................................... 5-2
5.1.3 Test .................................................................................................................................... 5-2

Chapter6 Troubleshoot
6.1 List of error codes ...................................................................................................................... 6-1
6.1.1 Error................................................................................................................................... 6-1
6.1.2 Alarm.................................................................................................................................. 6-2
6.1.3 Information......................................................................................................................... 6-2

2
 1.1 Outline

Chapter 1 Basic settings

1.1 Outline

1.1.1 Principle of conveyor tracking (synchronization)

The conveyor synchronization function ensures that the robot tracks the conveyor in synchronization with
the conveyor’s movement. It enables the correlation between the tool positions and postures and the work
position which was established at the teaching stage to be maintained. The teaching is done after the
conveyor has come to a standstill. During playback, the robot calculates the position of the conveyor using
the signals from the pulse generator to track the conveyor.

It is now assumed that the teaching shown in figure (a) below has been performed when the conveyor is
at a standstill. If what has been taught is played back while the conveyor is moving, the robot will move
along the path shown in figure (b) below. When viewed from the perspective of the work personnel, the
movements appear as shown in figure (b) below, but when viewed from a point on the conveyor, they
appear as shown in figure (a).

Principle of conveyor synchronization

1.1.2 Terms used with conveyor synchronization

Terms used with conveyor synchronization
Terms Explanation of terms
This unit is directly coupled to the drive source of the conveyor, and it generates
Pulse generator pulses in order to detect the position of the conveyor.

This refers to the memory in which are stored the values obtained by converting
the pulse values from the pulse generator into distances (measured in
millimeters or degrees). In order for the position of the conveyor at the teaching
Conveyor register
stage to be recorded, the values in this register are recorded as part of the
teaching data.

This is a mechanical limit switch which detects the work on the conveyor and
serves as the conveyor synchronization start reference. When it is actuated, the
Start LS
pulse signals from the pulse generator are counted.

There are 3 conveyor synchronization modes:

- Normal
Conveyor mode - Simulation
- Test
Please refer to the next clause for detail.

1-1
1.1 Outline

1.1.3 Conveyor mode

There are 3 conveyor synchronization modes.

Conveyor synchronization mode

Mode Explanation of terms Conveyor register
In this mode, the conveyor is actually operated and the robot
operates in synchronization with the moving work. The work position
The register is
Normal is calculated by counting the pulse signals from the pulse generator
reset at step 0.
which is mounted on the conveyor.

In this mode, even if the conveyor is not actually operated, the robot
operates in synchronization with the conveyor speed specified in
response to the manual input of the conveyor speed. By using
machine lock as well, the software stroke and cycle time can be The register is
Simulation
checked without operating the reset at step 0.
conveyor and robot. In the Simulation mode, an error results when
the conveyor operation underway signal is input, and the robot stops.

In this mode, the robot operates as recorded regardless of the

position of the conveyor. It enables teaching to be checked while the The register is not
Test
conveyor is at a standstill. reset.

There are 4 ways to select the conveyor synchronization mode. ( “1.5 How to select the conveyor
mode”)

1) Selection using Teach/Playback Condition

2) Selection using f keys
3) Selection using shortcut (R codes)
4) Selection using external signals

1-2
 1.2 Basic conveyor settings

1.2 Basic conveyor settings

The initial conveyor settings are performed in this section.
An operator class of SPECIALIST or above is necessary to change these settings.

1.2.1 Initialization
Prior to use the conveyor tracking utility, conveyor mechanism must be registered.

When mechanism registration or editing is proceeded, all setting parameters are

cleared.
IMPORTANT

1 Select the teach mode.

2 Press <Constant Setting> -> [12 Format and Configuration].

>> Following screen appears.

3 Set the cursor to [2.Register mechanism] and press [ENTER].

>> Following screen appears.

This screen is a sample when SRA166-01 robot was defined as mechanism 1.

1-3
12 Basic conveyor settings

4 Set the cursor on the 2nd mechanism,

Press f9 <Add conveyor> with [Enable] key at the same time.
+F9 >> Following conveyor mechanism selection list appears.

5 Select the conveyor type “LINEAR” or “CIRCLE” according to racking

direction.
・LINEAR (Linear conveyor) -> Standard type belt driven conveyor
・CIRCLE (Circle conveyor) -> Rotating conveyor such as turn table

Example: LINEAR conveyor is selected

Conveyor must be registered at the last mechanism.

IMPORTANT

Example of multi-unit

6 Press F12<Complete>.
>> Following confirmation message appears.

1-4
 1.2 Basic conveyor settings

7 Select <YES> and press [Enter] key.

>> Following screen appears.

- Conveyor mechanism must be fixed on the “GROUND”.

IMPORTANT - When traverse unit is used, traverse unit mechanism must be fixed on the “GROUND”,
and robot mechanism must be fixed on the traverse unit.

Example : “SRA166-01” robot is installed on traverse unit “T35MC160”

8 Select the basic mechanism for each mechanism. and press F12<Complete>.
>> Following confirmation message appears.

9 Select <YES> and press [Enter] key.

>> After application and soft key initialization is completed, following screen appears.

10 Press F12<Complete> to finish the initialization procedure.

1-5
12 Basic conveyor settings

POINT In case of multi unit;

If conveyor is used for each unit, each conveyor registration is needed for each unit

POINT Conveyor mechanism does not need the amplifier allocation.

1.2.2 Conveyor setting

Next, the correlation between the conveyor and the robot must be set. These values are determined by
machine design.
An operator class of EXPERT or above is necessary to change these settings.

1 Select the teach mode.

2 Press <Constant Setting> -> [20 Conveyor Synchronization].

>> Following screen appears.

3 Set the cursor on [1.Conveyor setting] and press [ENABLE].

>> Following screen appears.

When two or more conveyors are to be used, needed conveyor can be selected by
pressing <Page scroll> keys.

4 Align the cursor with the desired position, input the numerical values, and
press the [Enter] key.

5 Upon completion of all the settings, press the f12 <Complete> key.

1-6
 1.2 Basic conveyor settings

Conveyor setting
Factory Input
Parameter Description of function
settings range
Pulse constant 0 -10000 This parameter is used to set the relationship between the
to pulse generator mounted on the conveyor and the machine.
100000 Set the number of conveyor pulses to be output when the
［pulse/m］ conveyor moves by 1 m or 1 inch (depends on defined unit)
in the case of linear conveyor, or by 1 degree in the case of
circular conveyor.
Since the pulses which are output from the pulse generator
are multiplied by 4 inside the control unit, the pulse count is
calculated by multiplying it by 4.
Robot controller can count up to 67,108,860 conveyor pulse
(this value is after multiplied by 4).

Example; When a linear conveyor is used

When 2,000 pulses have been output from the pulse
generator while the conveyor has moved by 2 m.
2000 / 2 x 4 = 4000 The pulse constant is 4000.

Installed angle Directly Directly This parameter is used to define the position of conveyor.
input Input Two ways, inputting direct values or referring user
・ coordinate system, are permitted.
User
Coord. Directly input: Using the world coordinate system as the
reference, the parameter is used to set the home position
and inclination angle of the conveyor as numerical values.
User Cord.: The conveyor coordinate system is registered
as a user coordinate system ahead of time, and the number
of this user coordinate system is used to specify the
parameter.
User coordinate No. 0 1 to The conveyor coordinate system can be defined as the user
100 coordinate system, and its number is registered here.
The installation position of the conveyor is not modified
even if the user coordinate system has been changed after
the conveyor installation has been registered.

X axis rotation 0 -180.0 This parameter is used to specify the inclination as

Y axis rotation to referenced to the world coordinate system.
Z axis rotation 180.0 Register these parameters as followed, in case both set
［deg］ with user coordinate system and set with numeric.
1) In case of LINEAR conveyor; Align the Z axis with the
direction of motion. (X and Y axes do not matter.)
2) In case of CIRCLE conveyor; Align the Z axis with the
direction of the rotary axis. (X and Y axes do not matter.)
Use the world coordinate system for all the angles and
coordinates which are to be set.
When setting the angles, rotate around the Z axis, Y axis
and X axis in this order (ZYX Euler).

X Vector Coordinate 0 -10000 When a circular conveyor is used, this parameter is used to
Y Vector Coordinate to specify the home position of the conveyor as referenced to
Z Vector Coordinate 10000 the world coordinate system. There is no need to set this for
［mm］ linear conveyor. Register the coordinate value based on the
world coordinate system, in case both set with user
coordinate system and set with numeric.

Synchronization Pos.Ang Pos.Ang. This parameter is used to specify the conveyor

type . ・ synchronization type.
Position:
・ Pos.Ang. : Both position and angle (posture) are
Press synchronized with conveyor. Normally select this type.
Position:: Only position is synchronized with conveyor. In
case of circular conveyor, robot posture may change
significantly. When this parameter is set to “Position”, robot
will operate in synchronization with the conveyor while its
tool posture remains fixed.
Press: Used for press brake synchronization system. Not
used for normal conveyor synchronization.

1-7
12 Basic conveyor settings

Conveyor type - Circle This parameter is used to specify the conveyor shape.
・ This can be changed from initialized setting. But if this is
Linear changed after teaching is completed, robot locus may
change. This setting must be completed before starting the
teaching procedure.
Circle : Conveyor shape is circle.
Linear : Conveyor shape. Is linear.

Example of rotation angle for LINEAR conveyor

rotation angle
Direction of Z axis
INFO. X axis Y axis Z axis
0.0 0,0 0.0 +Z direction of world coordinate system
0.0 90.0 0.0 +X direction of world coordinate system
90.0 0.0 0.0 -Y direction of world coordinate system

1.2.3 Conveyor compensation of follow

When the robot is tracking the conveyor and moving, there may be a delay in its movement from the
movement of the conveyor. Conveyor tracking compensation is a function used to compensate for delays
like this.

1 Press <Constant Setting> -> [20 Conveyor Synchronization] → [2 Conveyor

compensation of follow].
>> Following screen appears.

When two or more conveyors are to be used, needed conveyor can be selected by
pressing <Page scroll> keys.

2 Align the cursor with the desired position, input the numerical values, and
press the [Enter] key.

3 Upon completion of the settings, press the [Complete] key. The settings are
now saved in the constant file.
>>The operations of the robot can be limited then and there using the setting data.

1-8
 1.2 Basic conveyor settings

Conveyor compensation of follow

Factory Input range Input range
Parameter Description of function
settings (linear) (circle)
Calib. slow speed 0.0 0.0 to 999.999 0.0 to 360.0 The three pairs of conveyor
speeds and compensation
Calib. slow speed shift 0.0 0.0 to 199.999 0.0 to 360.0 amounts are interpolated for
“linear” to calculate the
Calib. middle speed 0.0 0.0 to 999.999 0.0 to 360.0 compensation amounts
corresponding to the current
Calib. middle speed shift 0.0 0.0 to 199.999 0.0 to 360.0 conveyor speeds.
The compensation is provided
Calib. high speed 0.0 0.0 to 999.999 0.0 to 360.0 by adding the requested
compensation amount to the
Calib. high speed shift 0.0 0.0 to 199.999 0.0 to 360.0
value in the conveyor register.

Method used to calculate conveyor compensation amounts

1.2.4 Setting the conveyor error detection

Parameters of error detection level for conveyor synchronization are set here.

1 Press <Constant Setting> -> [20 Conveyor Synchronization] [3 Conveyor error

detection].
>> Following screen appears.

When two or more conveyors are to be used, needed conveyor can be selected by
pressing <Page scroll> keys.

2 Align the cursor with the desired position, input the numerical values, and
press the [Enter] key.

3 Upon completion of all the settings, press the f12 [Complete] key.
>>The operations of the robot can be limited then and there using the setting data.

1-9
12 Basic conveyor settings

Conveyor error detection

Factory Input
Parameter Description of function
settings range
This is used to set the projected maximum speed of the
0.0 to conveyor. It is used to detect trouble. It is set in
Conveyor max speed 0.0 999.9 mm/sec. units for a linear conveyor and in deg/sec.
[mm/s] units for a circular conveyor.

This is used to set the interval at which the conveyor

pulses are checked to apply compensation to the robot.
When the sampling interval is increased: The
vibration of the robot caused by the pulsation of the
conveyor speed decreases. The ability of the robot to
0.02 to 2.0 respond to changes in the conveyor speed deteriorates.
Sampling cycle 0.02
[sec.] When the sampling interval is reduced: The vibration
of the robot caused by the pulsation of the conveyor
speed may increase. The ability of the robot to respond
to changes in the conveyor speed improves.
(At the 0.0 setting, no trouble is detected.)

Error E897 is detected if the conveyor pulse counter

0.0 to 10.0 value does not satisfy the “Pulse check error level”
Pulse check start time 0.0
[sec.] setting in spite of the fact that the time which has been
set for “Pulse check start time” has elapsed after the
start signal was input.
0 to 10000 (If Pulse check start time is set to 0.0, no trouble is
Pulse check error level 0.0
[pulse] detected.)

An error results if the maximum conveyor speed is

continuously exceeded after the conveyor start LS was
0 to 100
Speed check filter 0 input.
[times]
(At the 0 setting, no trouble is detected.)

Error E0704 is detected when the conveyor register

value exceeds this value while steps 1 to 4 are played
0.0 to
Failure detection back. Set a value greater than the conveyor register
0.0 9999.9
just after playback value projected for when steps 1 to 4 are played back.
[mm]
(At the 0 setting, no trouble is detected.)

Error E0704 is detected when the change amount in the

0.0 to conveyor register in each calculation cycle exceeds this
Max change for every
0.0 9999.9 value.
cycle
[mm] (At the 0 setting, no trouble is detected.)

In order to track the conveyor, the robot moves to

positions which are shifted from the recorded ones.
0.0 to Error E0704 is detected when the shift amount exceeds
Max shift amount 0.0 9999.9 this value.
[mm] Set a value greater than the projected shift amount.
(At the 0 setting, no trouble is detected.)

1-10
 1.2 Basic conveyor settings

1.2.5 Setting the conveyor added function

Parameters for some useful functions for conveyor synchronization are set here.

1 Press <Constant Setting> -> [20 Conveyor Synchronization] → [4 Conveyor

added function].
>> Following screen appears.

When two or more conveyors are to be used, needed conveyor can be selected by
pressing <Page scroll> keys.

2 Align the cursor with the desired position, input the numerical values, and
press the [Enter] key.

3 Upon completion of all the settings, press the f12 <Complete> key.
>>The operations of the robot can be limited then and there using the setting data.

Conveyor added function

Factory Input
Parameter Description of function
settings range
This is used only in the Simulation mode.
This function performs playback while simultaneously
reducing the simulated speed of the conveyor as well when
the robot speed is controlled to low speed by the speed
override.
Conveyor Enabled
Enabled: If the speed override has been set to a value other
simulation Enabled ・
than 100%, the conveyor operates at a
variable speed Disabled speed which is changed by an amount equivalent to the
override setting.
Disabled: Even when the speed override has been set to a
value other than 100%, the conveyor moves at the speed
which was set.
Enabled: At this setting, it is considered that the start signal
and start LS signal have been input simultaneously, and the
Count up Enabled count-up is started when the start signal is input.
synchronized Enabled ・ Disabled: At this setting, the conveyor register is reset when
start signal Disabled the start signal has been input and, after awaiting the input of
the start LS signal, the count-up of the conveyor pulses is
started.
This is used only in the Simulation mode.
When “Normal” has been selected as the conveyor
0 to 10000
synchronization mode, this parameter starts the conveyor
Conveyor [mm]
counter after the start signal has been input and the start LS
simulation offset 0 or
signal is awaited. At this time, the timing of the start LS signal
distance 0 to 360
and start signal may not necessarily be the same. In the
[deg]
“Simulation” mode, the offset distance is input for this
parameter since the start LS signal plays no role.
This parameter sets how the robot is to operate in the
conveyor operation underway signal status when the start
signal has been input.
Pause: When the conveyor operation underway signal has
Pause not been input, the start lamp remains lighted, and the hold
When turning off ・ status is established. When the conveyor operation underway
conveyor running Pause Alarm signal is subsequently input, playback is continued.
signal. ・ Alarm: When the conveyor operation underway signal has
Ignore not been input, the robot is stopped unconditionally.
Ignore: Playback continues even if the conveyor operation
underway signal is not input.
( Table of “Relation between conveyor mode and
conveyor running signal”)

1-11
1.3 Allocating the conveyor synchronization input/output signals

1.3 Allocating the conveyor synchronization input/output signals

This section provides a description of the input/output signals which are used to implement the conveyor
synchronization function.
Please refer to “Instruction Manual SETUP”, ”Chapter 4 Setup” for the detail operation.

1.3.1 Conveyor synchronization input signals

Conveyor synchronization input signals are allocated in <Constant Setting> -> [6 Signals] -> [2 input
Signal Assignment] -> [1 Standard Inputs]

Conveyor synchronization input signals

Basic input signal Factory set
Description of function
designation input signal
If playback is being performed with conveyor synchronization
enabled, it is necessary for the “Conveyor running” signal to
have been input.
This signal indicates that the conveyor operation is underway,
and the auxiliary contacts of the magnet switch supplying the
power to the motor that normally drives the conveyor are used.
Conveyor running 0
If the signal is not input, the conveyor is judged to be stopped,
and the playback is stopped with the start status still
established. When it is input again, playback is started. An
error results when it is not input before start. When the
“Simulation” or “Test” mode is established, an error results if
the signal is not input.
Conv.normal 0
Conv.simulation 0 This signal selects the conveyor synchronization mode.
Conv.test 0
These signals connect the signal from the start LS of the
conveyor. It uses the start LS to start counting the conveyor
Conv.start LS 0 pulses. It is received only once after step 0 has been
executed.

Table 1.8 Relation between conveyor mode and conveyor running signal
Mode
Conv.normal Conv.test Conv.simulation
setting
ON: running
Pause ON ON
OFF : hold/stop
ON: running
Alarm ON ON
OFF : stop
Ignore ON/OFF ON/OFF ON/OFF

1-12
 1.3 Allocating the conveyor synchronization input/output signals

1.3.2 Conveyor synchronization output signals

Conveyor synchronization output signals are allocated in <Constant Setting> -> [6 Signals] -> [3 Output
Signal Assignment] -> [1 Standard Outputs]

Conveyor synchronization output signals

Basic input signal Factory set
Description of function
designation output signal
In the following cases, this signal is output as a 100 msec.
pulse signal.
(1) When the counter is reset using the conveyor monitor
Conv.count reset 0 (2) When FN55 has been executed
(3) At step 0 which is not a program call step
(4) When shortcut R44 has been executed

Conv.normal 0
These signals output the playback mode status of conveyor
Conv.simulation 0
synchronization.
Conv.test 0

1.4 Allocating soft keys

Following soft keys are necessary for conveyor synchronization.

2016 : Conveyor status ON/OFF

2017 : Conveyor mode change

These soft keys are needed to be allocated by customer. Please refer to “Instruction Manual Basic
Operation”, ”Chapter 7 Useful functions” “7.8.1 Changing the soft key allocation” for the detail operation.

1-13
1.5 How to select the conveyor mode

1.5 How to select the conveyor mode

1.5.1 Selection using Teach/Playback Condition

1 Press <Teach/Playback Condition>.
Scroll page until the screen in which [22 Conveyor mode] menu is included.

2 Align cursor with [22 Conveyor mode] menu and press [Enter] key.

2 Pres [↑] [↓] keys to choose the desired mode and press [Enter] key.

3 Upon completion of settings, press the f12 <Complete> key.

1.5.2 Selection using f key

The conveyor synchronization modes can be selected by allocating them to the f keys and then pressing
these f keys. ( “1.4 Allocating soft keys”)

1.5.3 Selection using Shortcut (R code)

1 At the mode screen, press [Reset/R] key and [2] [2] [4] [Enter] keys.
>> Following screen appears.

2 Select the mode using the number key (0 to 3), and press [Enter].

Numeric

1.5.4 Selection using input signals

The modes can be selected from an external source by allocating “Normal”, “Simulation” and “Test” to
external input signals.

1-14
 2.1 Needed Parts (FD controller)

Chapter 2 Needed Parts and Connection

2.1 Needed Parts (FD controller)
To implement the conveyor synchronization system, following equipments are necessary.

Contained parts of this option FD11-OP47-A

equipment Manufacturer Type or so
Conveyor synchronization NACHI This is a unit to read conveyor pulse sent from PTU
Receiving unit (Conveyor Sync. Transmission Unit).
This is installed inside robot controller cabinet.

Other equipments and works needed for conveyor tracking system (Prepared by customer)
Equipment pr Work Manufacturer Type or so
I/O board NACHI This is DC24V I/O board to connect Start LS and or
so. This is installed inside robot controller cabinet.
FD11-OP125-#
(#=A : 32 points, B :64 points )

Conveyor Sync. Transmission Unit NACHI This is a unit to read conveyor pulse sent from Pulse
(PTU) Generator (prepared by customer) and send it to
robot controller.
Type; AW10-OP47-A

Pulse Generator (any) Recommended;

OMRON E6C2-CWZ3E
or OMRON E6C2-CWZ1X

Start LS (any) When this limit switch is activated, robot starts

counting of conveyor pulse and initiates conveyor
tracking motion.

Connecting cables between (any) Connecting cables between all above equipments
equipments and those work and those work

Power
source AC100V/200V

CFD controller
Twisted pair Accessory cable
shield wire of pulse generator
Conveyor
Tracking PTU
Receiving Unit
To
Pulse generator conveyor
Conveyor Sync.
Transmission Unit

Start LS
I/O board
Conveyor motor
controller or
Conveyor magnet switch
running signal
Prepared by customer

System diagram

2-1
2.1 Needed Parts (FD controller)

260
244
Conveyor Tracking Transmission Unit 8 8
(PTU) 220
220
120 4-φ5.2 Thru hole

20
230

230

190
1-φ16 Thru hole
2-φ22 Thru hole

20
Conveyor Tracking Transmission Unit PTU (Type AW10-OP47-A)

2-2
 Conveyor Conveyor
synchronization synchronization
receive board receive board
Terminal block Terminal block
Accessory cable of
pulse generator

Connected
inside terminal

Power unit

Piping prepared by

Circuit Diagram (Pulse generator : E6C2-CWZ3E)

customer
DC24V I/O board

Conveyor start LS
Start trigger
input signal

↑
Conveyor running
FD11-OP47-A input signal
Conveyor motor
Prepared by customer controller or
magnet switch

2-3
2.1 Needed Parts (FD controller)
2-4
Conveyor Conveyor
synchronization synchronization
receive board receive board
2.1 Needed Parts (FD controller)

Terminal block Terminal block

Connected
inside terminal

Power unit

DC24V I/O board

Circuit Diagram (Pulse generator : E6C2-CWZ1X)

Start trigger Conveyor start LS
input signal

↑ Conveyor motor
controller or
FD11-OP47-A Conveyor running magnet switch
input signal

Prepared by customer
 2.1 Needed Parts (FD controller)

■ “Pulse generator” -> “Transmission unit (PTU)”

Wires (Accessory cable of pulse generator) from the pulse generator mounted on the conveyor must be
connected to the terminals of the Transmission unit (PTU).

■ “Transmission unit (PTU)” -> “Robot controller (Terminal block TBCV)”

Wires (twisted pair shield cable) from the Transmission unit (PTU) must be connected to the terminals
(TBCV) of controller.

Do not bind the power and signal cables together, and run through separate tubes
(such as steel or flexible tubes).
IMPORTANT

■ “Start LS” and “Conveyor running” input signal -> “Robot controller DC24V I/O board”

Connect the signal from the start LS mounted on the conveyor unit to the pin allocated to “start LS” on the
input signal connector in robot controller.
Connect the signal from conveyor motor control panel or electromagnetic switch to the pin allocated to
“conveyor running” on the input signal connector in robot controller.
Please refer to “Instruction Manual SETUP”, ”Chapter 3 Connection” for the electric specification of DC24V
input circuit.

■ Jumper setting of Print Circuit Board in Receiving Unit

Purpose Explanation Factory setting

SW1 Board ID In case that one robot synchronizes with two
conveyors, this setting is necessary to identify
the receiving unit in robot controller.
First conveyor : Board ID = 0
Second conveyor : Board ID = 1
Robot controller
First conveyor
Board ID = 0
Conveyor Conveyor
synchronization synchronization
receiving unit transmission unit
(Board ID=0) Pulse generator

Second conveyor
Added
Conveyor
synchronization Conveyor
receiving unit synchronization
transmission unit
(Board ID=1)
Pulse generator

SW2 One shot pulse Not used

output

All ON (fixed)
SW3 Channel 3 Not used
Termination
resistor

All ON (fixed)
SW4 Channel 2 Not used
Termination
resistor

All ON (fixed)

2-5
2.1 Needed Parts (FD controller)

Purpose Explanation Factory setting

SW5 Channel 1 This is used to select existence / no-existence of
Termination termination resister in conveyor pulse line.
resistor Pay attention to this setting when one conveyor
is connected with plural robot.

With termination resister ; All ON

In case that only one robot is used or in (with Termination
case that this robot is at the last of chain register )
connection in plural robot, turn all of 4
switches to ON.
No termination resister ;
In case that this robot is not at the last of
chain connection in plural robot, turn all of 4
switches to OFF.

In case of one robot

Robot controller

Conveyor Conveyor
synchronization synchronization
SW6 Channel 0 With termination
register
receiving unit transmission unit

Termination (switch ON) (Board ID=0) Pulse generator

resistor

In case of two robots Robot controller

All ON
Conveyor Conveyor
No termination
synchronization
receiving unit
synchronization (with Termination
register transmission unit
(switch OFF) (Board ID=0) Pulse generator
register )

Robot controller

Conveyor
With termination
synchronization
register receiving unit
(switch ON)
(Board ID=0)

4 : General termination resistor

3 : Phase Z termination resistor
2 : Phase B termination resistor
1 : Phase A termination resistor

2.2 Needed Parts (CFD controller)

Please refer to “CFD controller Technical Document 1”, “Chapter 18 Conveyor Tracking” for detail

2-6
 3.1 Teaching Flow

Chapter3 Teaching
3.1 Teaching Flow
Proceed with teaching by following the steps below.

1 Select the teach mode.

Teaching is performed in the teach mode.

Preparations prior to
teaching
2 Input the number of the work program.

Input the number of the work program to be prepared.

Any number from 0 to 9999 can be input.

3 Decide on the position of the work on the conveyor.

• Place the work on the conveyor.

• After resetting the conveyor counter, move the work
along using the conveyor.
• Ensure that the start LS signal is input correctly.
Stop the conveyor where the work enters the movable
area of the robot.
Record the conveyor synchronization step (operation position and
4 posture).
• Move the robot to the recorded position and posture by
manual operation.
• Press [O.WRITE/REC] to record the step (move
command).
• Record the steps (move commands) in sequence by
Teaching
repeating this process.

5 Record the function commands.

Record the function commands in the appropriate steps.

If function commands are recorded, signals can be output
to an external device or the robot can be made to stand
by.

Checking of 6 In the Simulation mode, check what has been taught.

taught program
Move in numerical order through the recorded steps and
check the recorded positions and postures.

7 Modify the teaching contents if necessary.

Modifying
Change the recorded points, add or delete steps, etc.

3-1
3.2 Recording conveyor synchronization step

3.2 Recording conveyor synchronization step

Conveyor synchronization step recording method.
The “conveyor synchronization step” is the step where the robot moves as it tracks the conveyor.

1 Use the [Axis operation keys] to move the robot to the recorded step.

2 Press <Conveyor ON/OFF> key to turn the conveyor synchronization step to ON.
>>Now “C*” mark is displayed on the record status area. * is conveyor number.

3 Press [O.WRITE/REC].
>>The conveyor synchronization step is now recorded.
When this step is recorded, the current conveyor position is recorded in the conveyor
register, and the conveyor register value at that time appears inside the square brackets
([ ]).

4 To release the conveyor synchronization step, press <Conveyor ON/OFF> key

again.
>>“C*” mark on the record status area is disappeared.
From now on, new recorded is normal (no conveyor synchronize )step.

3-2
 3.3 Recording function commands

3.3 Recording function commands

This section provides a description of functions for conveyor synchronization.
Please refer to “Instruction Manual Basic Operation” for the operation of recording function.

Bear in mind that conveyor register is used incremental direction.

IMPORTANT

3.3.1 CNVSYNC (FN55:Conveyor counter reset)

Although the conveyor counter is reset at step 0, it can be reset at any step when this function is used.

Command name Description

CNVSYNC Conveyer counter reset

Parameter Description, setting range

This is used to specify the number of the conveyor whose counter is to be
Conveyor No.
reset.(1 to * )

3.3.2 CNVI (FN550:Conveyor interlock)

When this function is executed, the robot stands by until the conveyor moves as far as the distance
specified by the conveyor register value. The robot stops and stands by.
When conveyor register reaches up to the interlock length, robot proceeds to the next step. If conveyor
register has reached up to the interlock length before robot starts waiting, robot never stand by .

Command name Description

CNVI Conveyer interlock

Parameter Description, setting range

Interlock length This is used to input the interlock length. (0 to 30000)

3.3.3 CNVSYNCI (FN562:Conveyor interlock(sync.))

When this function is executed, the robot stands by while synchronizing with the conveyor until the
conveyor moves as far as the distance specified by the conveyor register value.
When conveyor register reaches up to the interlock length, robot proceeds to the next step. If conveyor
register has reached up to the interlock length before robot starts waiting, robot never stand by.

Command name Description

CNVYSYNCI Conveyer interlock(sync.)

Parameter Description, setting range

Interlock length This is used to input the interlock length. (0 to 30000)

3-3
3.3 Recording function commands

3.3.4 CNVYSYNCCHG (FN274: Conveyor sync change)

When this function command is used, it is possible to designate a mechanism to follow the conveyor in
the conveyor synchronization function.
When this function command is not used, synchronization mechanism is determined in the order of the
slider, and manipulator included in the objective unit. Automatic change is made so that the manipulator
synchronizes after the slider moves to motion range in synchronization.

Command name Description

CNVYSYNCCHG Conveyer sync change

Parameter Description, setting range

Mechanism number This designates a mechanism for synchronization. (0-9)

3-4
 3.4 Modifying the teaching contents

3.4 Modifying the teaching contents

This section provides a description of how to change what has been taught in the conveyor synchronization step.

3.4.1 Modifying using the [EDIT] key

Use the [EDIT] key to change the conveyor register value recorded in the conveyor synchronization step.

POINT In the step, conveyor register is recorded as the position data of conveyor mechanism.

1 Press the [EDIT] key to display the editing screen.

2 To change whether the robot is to be synchronized or not at the desired step,

align the cursor to the step “C*” position, and input the conveyor number (1 to *)
in the “Input” field and press [Enter].
Numeric -> >>If “0” is input, the step becomes one in which the robot is not synchronized with the
conveyor, and the “C*” display is cleared. The number of the conveyor to be
synchronized can be specified by inputting any number from 1 to *.

3 To change the value in the recorded conveyor register at the desired step,
align the cursor with the conveyor register, and input the conveyor register in
the “Input” field and press [Enter].
Numeric ->

4 To reflect the changes, press [Complete] or press the [EDIT] key again.
(To exit without reflecting the change, press the [Reset/R] key or [Cancel] key.)
or

3-5
3.4 Modifying the teaching contents

3.4.2 Changing by program conversion (Condition/speed)

In this procedure, the program conversion function is used to change the number of the synchronized
conveyor recorded in the conveyor synchronization step. Programs cannot be changed during playback.

1 Press <Service Utilities> - [9 Program Conversion] - [1 Condition/ speed].

>>A setting screen such as the one shown below appears.

2 Input the numbers of the program and step to be changed.

＋ Move the cursor to “Conveyor sync.”, and make the selection using the
[ENABLE] and [Cursor] keys.
>>If OFF is selected, conveyor synchronization is released in the step concerned, and
if a number from 1 to * is selected, the number of the conveyor to be synchronized is
selected. The program contents have not been rewritten at this stage. What has been
changed is not yet reflected. The number of the conveyor to be synchronized is
selected by selecting a number from 1 to *.

3 To reflect the changes, press [Execute] key.

>>When a program already exists, a confirmation message asking whether it is OK to
overwrite it appears, and the change is reflected when OK is selected in response to
the message, and [Enter] is pressed.

3-6
 3.5 Check Go / Check Back

3.5 Check Go / Check Back

This section provides a description of how to proceed the check go and check back.

In order to check the conveyor synchronization program by check go / check back, conveyor
mode must be set to the “Simulation”.
IMPORTANT Correct motion can not be performed under “Normal” and “Test” mode.

Under the “Simulation” mode,

when proceeding check go / check back the conveyor synchronization step, robot moves
according to the current conveyor register value. Therefore current conveyor register value
CAUTION must be checked strictly before proceeding check go / check back.

Under the “Simulation” mode,

IMPORTANT conveyor register value never increases when check go / check back.

3.5.1 Before proceeding to Check go / Check back

When proceeding check go / check back the conveyor synchronization step, robot moves according to
the current conveyor register value. Therefore if conveyor register value was not correct when check go /
check back, robot never moves to the correct position.
But in check go / check back, conveyor register value never increases in all conveyor mode. This means
that robot never moves to the correct position in check go / check back.
Accordingly,
when proceeding check go / check back under “Simulation” mode, conveyor register value can be
changed by replying the confirmation message in the following case.

(1) at the point when changing from the no-synchronization step to the synchronization step
(2) at the point when previous conveyor register value and next conveyor register value is different

3-7
3.5 Check Go / Check Back

3.5.2 Changing point of conveyor synchronizing step

When proceeding check go / check back the conveyor synchronization step under “Simulation” mode,
confirmation message is displayed at the point changing from the no-synchronization step to the
synchronization step.
Refer to the following description about how to change the conveyor register value replaying the
confirmation message.

Conveyor register changing and confirmation message is displayed only when conveyor
mode is “Simulation”. Therefore before proceeding check go / check back, please never
IMPORTANT forget to confirm that conveyor mode is “Simulation”.

1 At the point when changing from the no-synchronization step to the

＋ synchronization step, following confirmation message appears to change the
conveyor register value.

or

2 To change the conveyor register value, select “yes” with right/left key and
press [Enter].
>> Following screen appears to entry the conveyor register value.
>> If “no” is selected, conveyor register value does not change.

3 Input the desired conveyor register value and press [Enter].

>> Conveyor register value changes.
Numeric ->

4 Proceed the check go and check back, then robot moves to point according to
＋ the new conveyor register value.
>> If “no” is selected, conveyor register value does not change. So robot moves to the
point according to the previous conveyor register value.

or

3-8
 3.5 Check Go / Check Back

3.5.3 Changing point of recorded conveyor register

When proceeding check go / check back the conveyor synchronization step under “Simulation” mode,
confirmation message is displayed at the point when previous conveyor register value and next conveyor
register value is different.
Refer to the following description about how to change the conveyor register value replaying the
confirmation message.

1 At the point when previous conveyor register value of the conveyor

＋ synchronization step and next conveyor register value of the conveyor
synchronization step is different, following confirmation message appears to
change the conveyor register value.

or

2 To change the conveyor register value, select “yes” with right/left key and
press [Enter].
>> Following screen appears to entry the conveyor register value.
>> If “no” is selected, conveyor register value does not change.

3 Input the desired conveyor register value and press [Enter].

>> Conveyor register value changes.
Numeric ->

4 Proceed the check go and check back, then robot moves to point according to
＋ the new conveyor register value.
>> If “no” is selected, conveyor register value does not change. So robot moves to the
point according to the previous conveyor register value.

or

3-9
3.5 Check Go / Check Back

NOTE

3-10
 4.1 Conveyor monitor displays

Chapter4 Useful Functions

4.1 Conveyor monitor displays
The conveyor counter statuses and conveyor speeds can be monitored on the conveyor monitor displays.

Among the 4 monitor displays available, the example below uses the second monitor screen (monitor 2).

1 Press f３ <Monitor 2> key.

2 Align the cursor with “40 Conveyor Monitor”, and press [Enter].
>>The conveyor monitor data is displayed on monitor 2.

4-1
4.2 Changing the conveyor register values

4.2 Changing the conveyor register values

In the conveyor simulation mode, the conveyor monitor screens can be used to change conveyor register
values and conveyor speeds.

POINT Numerical values can be input only in the conveyor simulation mode.

1 Press [CLOSE] key to make this monitor screen be active.

>>The title bar turns blue. This is the sign of active screen.

2 Press the [Edit].

>>>The title bar turns red, and the current screen is switched to the editing screen.

2 Move the cursor to the desired edit box, input the data, and press the [Enter]
key.
>>The display changes, but the data has not been updated at this point in time.
Numeric→
3 Upon completion of the editing, press the f12 <Complete> key.
>>The data is updated, and the original display screen is restored.

4-2
 4.3 Resetting the conveyor counter

4.3 Resetting the conveyor counter

The conveyor counter can be reset using the conveyor monitor screen.

1 Press [CLOSE] key to make this monitor screen be active.

>>The title bar turns blue. This is the sign of active screen.

2 Press the [Edit].

>>The title bar turns red, and the current screen is switched to the editing screen.

3 Press f10 key <Reset Counter>.

>>A confirmation message appears so select OK to initiate counter resetting.

Select “yes” to reset the conveyor register.

If plural conveyor is used, all conveyor is reset.

POINT When the conveyor counter is reset, the “Conveyor counter reset” signal is output.

4-3
4.4 Shortcut (R code)

4.4 Shortcut (R code)

4.4.1 R40 (Set conveyor register)

This shortcut changes the conveyor register value when the conveyor simulation mode is selected. Only
allowed at the conveyor simulation mode. Not permitted during playback.

Shortcut Description
R40 Set conveyor register

Parameter Description, setting range

Conveyor register Value whose setting is to be changed (0 to 100000 mm, or 0 to 3937 inches)

4.4.2 R44 (Conveyor counter reset)

This shortcut clears the conveyor register during conveyor synchronization. Not permitted during
playback.

Shortcut Description
R44 Conveyor counter reset

4.4.3 R224 (Select conveyor mode)

This shortcut enables the conveyor synchronization playback mode. Not permitted during playback.

Shortcut Description
R224 Select conveyor mode
r
Parameter Description, setting range
Conveyor mode 0: Normal 1: Simulation 2: Test

4.4.4 R363 (Set conveyor speed)

This enables the conveyor speed to be changed when the conveyor simulation mode is selected during
conveyor synchronization.
Only allowed at the conveyor simulation mode. Not permitted during playback.

Shortcut Description
R363 Set conveyor speed

Parameter Description, setting range

Conveyor speed Conveyor speed (0 to 2000 mm, or 0 to 4724 inches)

4.4.5 R364 (Select conveyor No.)

This shortcut selects the conveyor number to be recorded.

Shortcut Description
R364 Select conveyor No.

Parameter Description, setting range

Conveyor No. Conveyor No. (1 to * )

4-4
 5.1 Playback

Chapter5 Playback
5.1 Playback

If robot detects some error and stops, the system logic has to be made to stop the
conveyor also.
CAUTION

Do not turn off the primary power while the playback of conveyor synchronization.
If primary power is turned off while the playback of conveyor synchronization program,
position relationship of the conveyor and the robot becomes wrong because pulse can
CAUTION not been counted from the pulse generator.
Bear in mind that check the absolute position of both conveyor and robot.

While the playback of conveyor synchronization, do not stop the robot, select the step
and turn off the power of the controller with no reason.
When restarting the robot, robot may not follow the conveyor because of the safety
CAUTION slow speed playback.

There are three conveyor synchronization modes. Each of these synchronization modes is described below.

5.1.1 Normal
In the “Normal” mode, the conveyor is actually operated, and the robot performs the playback while
tracking the movements of the work.

1 Place the work at a position before the position where the start LS is set to ON.

2 Select the playback mode, and change the conveyor mode to “Normal”.

3 Select the number of the program to be played back, and select step 0.

4 Select 1-cycle or continuous playback.

5 Press the Start button. Operate the conveyor.

Take care to ensure that the start LS will not be set to ON by the next work before the
robot completes the 1-cycle operation. Once the start LS is set to ON, any further
IMPORTANT setting to ON will be ignored during the cycle concerned.

• Since the operation of the conveyor is not subject to control by robot controller, the
synchronization between the robot and conveyor operations will be lost if the speed
IMPORTANT of the robot is changed by the speed override function.
• After the conveyor register value has been reset in step 0, count-up commences
when the start LS signal is input. However, it is not reset at step 0 if that step has
been specified by a program call.

5-1
5.1 Playback

5.1.2 Simulation
In the “Simulation” mode, the robot operates in synchronization with the conveyor by simulating the
setting of the conveyor speed even when the actual conveyor does not move. This mode makes it possible
to check the robot operations during playback, the movable area of the robot or the extent of the cycle
time.

1 Select the playback mode, and change the conveyor mode to “Simulation”.

2 Set the conveyor speed.

3 Select the number of the program to be played back, and select step 0.

4 Select 1-cycle or continuous playback.

5 Press the Start button. Operate the conveyor.

Beware in mind that robot moves without concerning with the actual conveyor
position in simulation mode..
IMPORTANT

5.1.3 Test
In the “Test” mode, it is possible to check the movements of the robot vis-à-vis the work without operating
the conveyor.

1 Select the playback mode, and change the conveyor mode to “Test”.

2 Select the number of the program to be played back, and select step 0.

3 Select 1-cycle or continuous playback.

4 Press the Start button. Operate the conveyor.

The conveyor register value is not reset when operation is started. Therefore, the robot
operates independently of the conveyor position.
IMPORTANT

Bear in mind that robot moves suddenly to the unexpected position depending on the
conveyor register value.
CAUTION

5-2
 6.1 List of error codes

Chapter6 Troubleshoot
6.1 List of error codes
Listed in the table below are the errors relating to conveyor synchronization.

6.1.1 Error

Number 59
Message Tracking is not possible because the conveyor speed is too high.
When error
During playback
occurred
The robot cannot track the conveyor because the maximum speed set for the conveyor
Cause
speed has been exceeded by a wide margin.
Countermeasure Reduce the conveyor speed. Alternatively, check the conveyor pulse detection system.

Number 270
Message The conveyor moved.
When error
During playback
occurred
This error results when “Test” is established as the conveyor synchronization mode
Cause
and the conveyor pulse value has changed by more than 2 pulses/msec.
Stop the conveyor, set the conveyor synchronization mode again, and repeat the the
Countermeasure
conveyor pulse value has changed significantly.execution.

Number 271
Message The conveyor pulse value has changed significantly.
When error
During playback
occurred
Cause This error results if the pulse frequency exceeds 10 kHz.
Countermeasure Check the pulse generator for trouble.

Number 704
Message Illegal conveyor register value
When error
During playback
occurred
This error results when the conveyor register value has exceeded the “Failure detection
Cause
just after playback” level.
Countermeasure Check the conveyor pulse input circuit.

Number 895
Message The conveyor has not moved.
When error
After start LS input
occurred
This error results when “Normal” is established as the conveyor synchronization mode,
Cause
and the conveyor pulses fail to change for 1 or more seconds after the start LS input.
Check whether the conveyor is operating. Check the connecting cable from the pulse
Countermeasure
generator.

Number 897
Message The change in the conveyor pulses is too low.
When error
After start LS input
occurred
This error results if the conveyor pulse value does not satisfy the “Pulse check error
Cause level” value even though the “Pulse check start time” has elapsed after the conveyor
start LS signal was input.
Increase the difference between the input timing of the conveyor start LS signal and of
Countermeasure
the start command.

6-1
6.1 List of error codes

Number 1140
Message The conveyor mode cannot be changed during playback.
When error This error results when an attempt has been made to change the conveyor mode during
occurred playback.
Cause An attempt has been made to change the conveyor mode during playback.
Countermeasure To change the conveyor mode, first stop the robot and then proceed.

Number 1181
Message The conveyor operation underway signal has been turned OFF.
When error
During normal playback
occurred
This warning is given when the conveyor operation underway signal turns OFF or when
Cause
it fails to turn ON during normal playback.
Countermeasure Turn the conveyor operation underway signal ON for normal playback.

Number 2272
Message The conveyor operation underway signal has been input.
When error
During Simulation, Test playback
occurred
This error results when the conveyor operation underway signal has been input while
Cause
“Simulation” or “Test” is established as the conveyor synchronization mode.
Countermeasure Turn the conveyor operation underway input signal to OFF.

6.1.2 Alarm

Number 2174
Message This function cannot be used during conveyor synchronization.
When error
During normal playback
occurred
Cause A function which cannot be used during conveyor synchronization has been used.
Countermeasure Record this function command in a step which is not a conveyor synchronization step.

Number 2230
Message Conveyor synchronization is invalid.
When error
During function command playback.
occurred
This alarm results when a conveyor-related function has been executed even though
Cause
the conveyor was not registered at the formatting stage.
Countermeasure Check whether the conveyor has been registered.

Number 2805
Message Mechanism number is wrong.
Timing of
When executing FN274.
occurrence
Cause This error results when the mechanism, specified in FN274, is mechanism number that
cannot be switched.
Countermeasure Check the number.

6.1.3 Information

Number 3181
Message The conveyor operation underway signal has been turned OFF.
When error
During normal playback
occurred
This information results when the conveyor operation underway signal turns OFF or
Cause
when it fails to turn ON during normal playback.
Countermeasure Turn the conveyor operation underway signal ON for normal playback.

6-2
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Original manual is written in Japanese.