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Stations

Machining Center

The Machining Center is a station used to manufacture lids and bases from raw material. First, the articulated robot waits for raw material to be placed at the entry bay. When new material is detected, it is loaded into the CNC machine, which will start manufacturing an item. Each item type takes different time to be produced (lids: 6 seconds; bases: 3 seconds) and once the operation is complete the robot places the item on the exit bay.

machining center

The production operation can be stopped at any time, restarted or reset. You can interact with the Machining Center through the electric switchboard next to the safeguard door:

  • Emergency: triggers an emergency stop, interrupting the articulated robot and the CNC. After an emergency stop, the station can only be reset by disarming the emergency button and pressing the Reset button

  • Start: starts the station

  • Stop: stops the articulated robot and the CNC. To restart press the Start or Reset button

  • Reset: resets the station

Two stack lights placed on top of the safeguard provide information about the current status.

  • Green light: not busy
  • Yellow light: busy
  • Red light: has error (incorrect item detected at entry bay)
Tag Controller I/O Type Description
Machining Center # (Produce Lids) Output Bool Set True to produce lids; False to produce bases.
Machining Center # (Start) Output Bool Start.
Machining Center # (Stop) Output Bool Stop.
Machining Center # (Reset) Output Bool Reset.
Machining Center # (Is Busy) Input Bool Indicates whether an item is being processed.
Machining Center # (Has Error) Input Bool Indicates whether an invalid item was detected on the entry bay.
Machining Center # (Opened) Input Bool True when the door is open.
Machining Center # (Progress) Input Float Machining progress (0-100).

Elevator

Heavy duty chain driven elevator, used for transportation of all sorts of cargo between floors. The elevator is equipped with two retroreflective sensors, placed at each end of the platform. The elevator can be controlled by digital or analog values, according to the selected configuration.

  • Roll radius: 45 mm
  • Platform stroke: 7 m
  • Platform speed: 0.68 m/s
  • Max. conveying speed: 0.45 m/s (digital); 0.8 m/s (analog)
  • Retroreflective sensor LED: green (detecting reflector), yellow (beam not interrupted)

elevator

Configurations

Digital

Tag Controller I/O Type Description
Elevator # (Up) Output Bool Move platform up.
Elevator # (Down) Output Bool Move platform down.
Elevator # (Slow) Output Bool Slow movement (20% of default speed).
Elevator # (+) Output Bool Roll (arrow direction).
Elevator # (-) Output Bool Roll.
Elevator # (Left Limit) Input Bool Item detected.
Elevator # (Right Limit) Input Bool Item detected.

Analog

Tag Controller I/O Type Description
Elevator # Set Point (V) Output Float [0, 10] V: set target position.
Elevator # Position (V) Input Float [0, 10] V: current position.
Elevator # (+) Output Bool Roll (arrow direction).
Elevator # (-) Output Bool Roll.
Elevator # (Left Limit) Input Bool Item detected.
Elevator # (Right Limit) Input Bool Item detected.

Pick & Place

Gantry Pick and Place station with three axes controlled by servomotors. Often used to move light lad cargo (e.g. cardboard boxes) into other conveyors or pallets.

The Pick and Place had four degrees of freedom, three corresponding to the axes linear movement and another to the gripper rotation. The gripper is enabled by suction cups and includes a proximity sensor. The Pick and Place can be controlled by digital and analog values, according to the selected configuration. When controlled with digital I/O, axis movement is performed incrementally (step by step) on each rising edge of the controlling tag value.

  • Y-axis stroke: 1.25 m
  • X-axis stroke: 2.125 m
  • Z-axis stroke: 0.5m
  • Step: 0.125 m
  • Beam speed: 1.5 m/s
  • Gripper angular speed: 4.6 rad/s

pick and place

Configurations

Digital

Tag Controller I/O Type Description
Pick & Place # X(+) Output Bool Take a positive step along X-axis.
Pick & Place # X(-) Output Bool Take a negative step along X-axis.
Pick & Place # Y(+) Output Bool Take a positive step along Y-axis.
Pick & Place # Y(-) Output Bool Take a negative step along Y-axis.
Pick & Place # Z(+) Output Bool Take a positive step along Z-axis.
Pick & Place # Z(-) Output Bool Take a negative step along Z-axis.
Pick & Place # C(+) Output Bool Rotate gripper.
Pick & Place # (Grab) Output Bool Activate suction cups.
Pick & Place # (Moving-Z) Input Bool Moving along Z-axis.
Pick & Place # (Moving-XY) Input Bool Moving along XY-plane.
Pick & Place # (Box Detected) Input Bool Detecting an item.
Pick & Place # (C Limit) Input Bool Gripper at angular limit.

Analog

Tag Controller I/O Type Description
Pick & Place # X Set Point (V) Output Float [0, 10] V: set target position along X-axis.
Pick & Place # Y Set Point (V) Output Float [0, 10] V: set target position along Y-axis.
Pick & Place # Z Set Point (V) Output Float [0, 10] V: set target position along Z-axis.
Pick & Place # C(+) Output Bool Rotate gripper.
Pick & Place # (Grab) Output Bool Activate suction cups.
Pick & Place # X Position (V) Input Float [0, 10] V: current position along X-axis.
Pick & Place # Y Position (V) Input Float [0, 10] V: cuurrent position along Y-axis.
Pick & Place # Z Position (V) Input Float [0, 10] V: current position along Z-axis.
Pick & Place # (Box Detected) Input Bool Detecting an item.
Pick & Place # (C Limit) Input Bool Gripper at angular limit.

Digital & Analog

Tag Controller I/O Type Description
Pick & Place # X Set Point (V) Output Float [0, 10] V: set target position along X-axis.
Pick & Place # Y Set Point (V) Output Float [0, 10] V: set target position along Y-axis.
Pick & Place # Z Set Point (V) Output Float [0, 10] V: set target position along Z-axis.
Pick & Place # C(+) Output Bool Rotate gripper.
Pick & Place # (Grab) Output Bool Activate suction cups.
Pick & Place # X Position (V) Input Float [0, 10] V: current position along X-axis.
Pick & Place # Y Position (V) Input Float [0, 10] V: current position along Y-axis.
Pick & Place # Z Position (V) Input Float [0, 10] V: current position along Z-axis.
Pick & Place # (Moving-Z) Input Bool Moving along Z-axis.
Pick & Place # (Moving-XY) Input Bool Moving along XY-plane.
Pick & Place # (Box Detected) Input Bool Detecting an item.
Pick & Place # (C Limit) Input Bool Gripper at angular limit.

Stacker Crane and Rack

Rail mounted stacker crane used to stock heavy cargo. Includes a cart, a vertical platform and two forks which may slide to both sides.

Two laser rangefinders placed on the cart and the platform measure the horizontal and vertical position of the platform. Racks are upright steel frames connected by horizontal steel beams with the purpose to store loads. The available rack is single-deep rack type, also known as selective rack, which only allows loads to be stored one pallet deep. Loads can be stored from both sides of the rack.

Each rack mus be aligned with one of the rail ends, making the stacker crane stop at the correct position. The stacker crane can be controlled by Digital, Numerical and Analog values, according to the selected configuration.

  • Forks stroke: 1.2 m
  • Cart stroke: 10.5 m
  • Platform stroke: 6.625 m
  • Cart speed: 1.4 m/s
  • Forks speed: 0.5 m/s
  • Platform speed: 1.7 m/s
  • Number of cells: 18

stacker crane and rack

  • Numerical: the target cell can be defined by an integer value between 1 and 54. If this value is set to zero, the stacker crane stops at the current position. However, if it is higher than 54, it will move to the rest position (55).

  • Analog: the target/current position for each axis can be set/measured with analog values.

  • Digital: each cell number is encoded by five digital values (see the following table)

Position Actuators
Bit 0 1 2 3 4 5
Locked 000000
1 100000
2 010000
3 001000
... ...
55 (rest) 111011

Configurations

Numerical

Tag Controller I/O Type Description
Stacker Crane # Target Position Output Integer Move to the desired cell.
Stacker Crane # (Left) Output Bool Move forks left.
Stacker Crane # (Right) Output Bool Move forks right.
Stacker Crane # Lift Output Bool Slightly raises the platform for loading/unloading operations.
Stacker Crane # Moving-X Input Bool Moving along X-axis.
Stacker Crane # Moving-Z Input Bool Moving along Z-axis.
Stacker Crane # Left Limit Input Bool Forks at left limit.
Stacker Crane # Middle Limit Input Bool Forks at middle.
Stacker Crane # Right Limit Input Bool Forks at right limit.

Analog

Tag Controller I/O Type Description
Stacker Crane # X Set Point (V) Output Float [0, 10] V: set target position along X-axis.
Stacker Crane # Z Set Point (V) Output Float [0, 10] V: set target position along Z-axis.
Stacker Crane # (Left) Output Bool Move forks left.
Stacker Crane # (Right) Output Bool Move forks right.
Stacker Crane # X Position (V) Input Float [0, 10] V: current position along X-axis.
Stacker Crane # Z Position (V) Input Float [0, 10] V: current position along Z-axis.
Stacker Crane # Left Limit Input Bool Forks at left limit.
Stacker Crane # Middle Limit Input Bool Forks at middle.
Stacker Crane # Right Limit Input Bool Forks at right limit.

Digital

Tag Controller I/O Type Description
Stacker Crane # Target Position Bit0 Output Bool Target position encoding bit (least significant).
Stacker Crane # Target Position Bit1 Output Bool Target position encoding bit.
Stacker Crane # Target Position Bit2 Output Bool Target position encoding bit.
Stacker Crane # Target Position Bit3 Output Bool Target position encoding bit.
Stacker Crane # Target Position Bit4 Output Bool Target position encoding bit.
Stacker Crane # Target Position Bit5 Output Bool Target position encoding bit.
Stacker Crane # (Left) Output Bool Move forks left.
Stacker Crane # (Right) Output Bool Move forks right.
Stacker Crane # Lift Output Bool Slightly raises the platform for loading/unloading operations.
Stacker Crane # Moving-X Input Bool Moving along X-axis.
Stacker Crane # Moving-Z Input Bool Moving along Z-axis.
Stacker Crane # Left Limit Input Bool Forks at left limit.
Stacker Crane # Middle Limit Input Bool Forks at middle.
Stacker Crane # Right Limit Input Bool Forks at right limit.

Digital & Analog

Tag Controller I/O Type Description
Stacker Crane # X Set Point (V) Output Float [0, 10] V: set target position along X-axis.
Stacker Crane # Z Set Point (V) Output Float [0, 10] V: set target position along Z-axis.
Stacker Crane # (Left) Output Bool Move forks left.
Stacker Crane # (Right) Output Bool Move forks right.
Stacker Crane # X Position (V) Input Float [0, 10] V: current position along X-axis.
Stacker Crane # Z Position (V) Input Float [0, 10] V: current position along Z-axis.
Stacker Crane # Moving-X Input Bool Moving along X-axis.
Stacker Crane # Moving-Z Input Bool Moving along Z-axis.
Stacker Crane # Left Limit Input Bool Forks at left limit.
Stacker Crane # Middle Limit Input Bool Forks at middle.
Stacker Crane # Right Limit Input Bool Forks at right limit.

Palletizer

High-level palletizer used to stack cardboard boxes (Palletizing Box) on pallets.

  • Pusher stroke: 0.88 m
  • Elevator stroke: 1.75 m
  • Elevator speed: 2 m/s

palletizer

Tag Controller I/O Type Description
Palletizer # (Push) Output Bool Move pusher.
Palletizer # (Turn) Output Bool Turn flipper (used to rotate boxes by 90º).
Palletizer # (Clamp) Output Bool Move clamper.
Palletizer # Belt (+) Output Bool Rotate (input direction).
Palletizer # Belt (-) Output Bool Rotate (output direction).
Palletizer # Chain (+) Output Bool Rotate (input direction).
Palletizer # Chain (-) Output Bool Rotate (output direction).
Palletizer # (Open Plate) Output Bool Opens the plate.
Palletizer # Elevator + Output Bool Moves the elevator up.
Palletizer # Elevator - Output Bool Moves the elevator down.
Palletizer # Elevator (Move to Limit) Output Bool Indicates that the elevator should move to the limit (up/down) and not by steps.
Palletizer # (Clamped) Input Bool Clamper reached the front limit.
Palletizer # (Plate Limit) Input Bool Plate is closed.
Palletizer # (Pusher Limit) Input Bool Pusher is at front/back limit.
Palletizer # (Elevator Moving) Input Bool Indicates the elevator is moving.
Palletizer # Elevator (Back Limit) Input Bool Elevator back sensor.
Palletizer # Elevator (Front Limit) Input Bool Elevator front sensor.

Two-Axis Pick & Place

This part can be used to assemble Lids on Bases or pick and place items from one place to another. To guarantee a correct fit, bases and lids should be properly aligned by Positioning Bars.

  • X-axis stroke: 1.125 m
  • Z-axis stroke: 0.625 m
  • Arm and picker speed: 2 m/s
  • Z-axis rotation in 90° increments (arm and gripper)

two-axis pick and place

Configurations

Digital

Tag Controller I/O Type Description
Two-Axis Pick & Place # Z Output Bool Move along Z-axis.
Two-Axis Pick & Place # X Output Bool Move along X-axis.
Two-Axis Pick & Place # Rotate CW Output Bool Rotate clockwise.
Two-Axis Pick & Place # Rotate CCW Output Bool Rotate counterclockwise.
Two-Axis Pick & Place # Gripper CW Output Bool Rotate gripper clockwise.
Two-Axis Pick & Place # Gripper CCW Output Bool Rotate gripper counterclockwise.
Two-Axis Pick & Place # (Grab) Output Bool Activate suction cup.
Two-Axis Pick & Place # (Moving X) Input Bool Moving along X-axis.
Two-Axis Pick & Place # (Moving Z) Input Bool Moving along Z-axis.
Two-Axis Pick & Place # (Rotating) Input Bool Rotating.
Two-Axis Pick & Place # (Gripper rotating) Input Bool Gripper rotating.
Two-Axis Pick & Place # (Detected) Input Bool Detecting an item.

Analog

Tag Controller I/O Type Description
Two-Axis Pick & Place # X Set Point (V) Output Float [0, 10] V: set target position along X-axis.
Two-Axis Pick & Place # Z Set Point (V) Output Float [0, 10] V: set target position along Z-axis.
Two-Axis Pick & Place # Rotate CW Output Bool Rotate clockwise.
Two-Axis Pick & Place # Rotate CCW Output Bool Rotate counterclockwise.
Two-Axis Pick & Place # Gripper CW Output Bool Rotate gripper clockwise.
Two-Axis Pick & Place # Gripper CCW Output Bool Rotate gripper counterclockwise.
Two-Axis Pick & Place # (Grab) Output Bool Activate suction cup.
Two-Axis Pick & Place # X Position (V) Input Float [0, 10] V: current position along X-axis.
Two-Axis Pick & Place # Z Position (V) Input Float [0, 10] V: current position along Z-axis.
Two-Axis Pick & Place # (Rotating) Input Bool Rotating.
Two-Axis Pick & Place # (Gripper rotating) Input Bool Gripper rotating.
Two-Axis Pick & Place # (Detected) Input Bool Detecting an item.

Digital & Analog

Tag Controller I/O Type Description
Two-Axis Pick & Place # X Set Point (V) Output Float [0, 10] V: set target position along X-axis.
Two-Axis Pick & Place # Z Set Point (V) Output Float [0, 10] V: set target position along Z-axis.
Two-Axis Pick & Place # Rotate CW Output Bool Rotate clockwise.
Two-Axis Pick & Place # Rotate CCW Output Bool Rotate counterclockwise.
Two-Axis Pick & Place # Gripper CW Output Bool Rotate gripper clockwise.
Two-Axis Pick & Place # Gripper CCW Output Bool Rotate gripper counterclockwise.
Two-Axis Pick & Place # (Grab) Output Bool Activate suction cup.
Two-Axis Pick & Place # X Position (V) Input Float [0, 10] V: current position along X-axis.
Two-Axis Pick & Place # Z Position (V) Input Float [0, 10] V: current position along Z-axis.
Two-Axis Pick & Place # (Moving X) Input Bool Moving along X-axis.
Two-Axis Pick & Place # (Moving Z) Input Bool Moving along Z-axis.
Two-Axis Pick & Place # (Rotating) Input Bool Rotating.
Two-Axis Pick & Place # (Gripper rotating) Input Bool Gripper rotating.
Two-Axis Pick & Place # (Detected) Input Bool Detecting an item.

Tank

Liquid tank including two control valves and a capacitive level sensor which can be used to control the flow of liquid in and out of the tank. Control valves are controlled by pneumatic actuators that can be positioned with signals between 0 and 10 V. Note that capacitive sensors can also be used to detect liquid levels. The liquid tank is primarily intended to be used for level and flow control using a PID.

  • Height: 3 m
  • Diameter: 2 m
  • Discharge pipe radius: 0.125 m
  • Max. input flow: 0.25 m³/s
  • Max. output flow: 0.3543 m³/s
  • Capacitive sensors can detect liquid

tank

Configurations

Analog

Tag Controller I/O Type Description
Tank # (Fill Valve) Output Float [0, 10] V: fill valve positioning.
Tank # (Discharge Valve) Output Float [0, 10] V: discharge valve positioning.
Tank # (Level Meter) Input Float [0, 10] V: level meter value.
Tank # (Flow Meter) Input Float [0, 10] V: flow meter value (10 V = 0.3543 m³/s).

Digital

Tag Controller I/O Type Description
Tank (Fill Valve) Output Bool Open fill valve.
Tank (Discharge Valve) Output Bool Open discharge valve.