ENCODER SETUP SCREEN


ENCODER SETUP SCREEN

An encoder helps the robot track the job on the conveyor correctly. It provides the robot with a number of pulse counts for every millimeter that the conveyor moves. Setting up the encoder establishes the physical relationship between the robot and the conveyor. Encoder setup requires you to set up the items listed and described in Table 1, " Encoder Setup Items " in order to execute rail or line tracking.

Table 1.  Encoder Setup Items

ITEM DESCRIPTION

Encoder Number

This item is the number of the encoder you are setting up. Currently, only one encoder is supported.

Average

This item is a value that will help to smooth robot motion when tracking the conveyor. If you have a conveyor that does not move smoothly, the average should be a larger value to smooth the motion. A typical encoder average value is 25.

Scale

(pulse/mm)

This item is the physical relationship between the robot and the conveyor, measured in encoder pulses per millimeter of conveyor travel. For every millimeter the conveyor moves, the encoder will return a certain number of counts (pulses). The scale value will vary per site.

Pulse Threshold

(mm/sec)

This item represents the actual speed the conveyor will have to reach before the encoder hardware will inform the robot that the conveyor is moving. A typical pulse threshold value is 5 mm/sec.

Minimum Detect Distance

(mm)

This item indicates the minimum distance, in millimeters, that the conveyor must travel before the system will acknowledge a new part detect signal. This prevents the controller from receiving more than one part detect signal for the same part. A typical minimum detect distance is 1000 mm.

Maximum Travel to Start (mm)

Range: 0 - 999 mm

Default: 0

This item indicates a measured distance from the part detect switch. When a part has traveled past this point on the conveyor, the part has traveled too far for the job to be painted. Therefore, a part that has past this point before the job is started will be skipped and an error message will be displayed.

If this value is set to 0, parts will never be skipped. PaintTool will attempt to paint all parts. Otherwise, the value of maximum travel to start is used to determine the distance a part can travel before it is skipped.

Maximum Part Detects

Range: 1 - 20

This item indicates the maximum number of parts that can be tracked between the detect switch and the robot. If more than the maximum number of detects is received, the error message, PAIN-103 "Tracking que exceeded" is displayed. To eliminate this problem, expand the robot boundaries by increasing the number of maximum part detects, or lower the conveyor speed.

Ghost Part Detect

Default: 0

This item has the same meaning as the Part Detect Dist. except that this value is used in place of the Part Detect Distance only when a Ghost job is being executed. During the execution of a normal job, the value from the Part Detect Dist. item above is used.

Complete One Stroke Option

This item is only used with tracking systems. The Complete One Stroke Option provides the ability to affect where the robot will stop and turn off its applicator trigger when the conveyor stops.

If disabled (NO) when the conveyor stops during robot motion the robot will execute all motion segments within the current tracking window.

If enabled (YES) when the conveyor stops during robot motion the robot will complete the current gun stroke and then stop. With rail tracking it is required that the rail position be different to trigger the stop event. Only a small difference is required (<0.1mm).

Applicator off when Waiting

This item will force the Gun Off when waiting for the part to enter window if the conveyor is stopped.

Sim.Conveyor Speed (mm/sec)

This is the conveyor speed that will be used when simulating the conveyor.

Tracking FSSB Location

This field sets the tracking encoder axis being used. Valid options are COP10A-1, COP10A-2, or COP10A-3. These options correlate to the connector that the encoder is connected to on either the main CPU or the auxilliary axis card.

Ethernet Master RIPE Id

This is Ethernet master ROS IP member when using Ethernet Encoder option. ID is the index of member in ROSIPCFG.XML file. Master is controller in zone with actual encoder connected. All controllers in zone that are sharing same master encoder must be set correctly. Refer to Controlled Start Options for PaintTool in System Operations section for information on setting up RIPE members. Encoder number and parameters setup above are used by each controller individually even though encoder may not be physically connected. Setting equal to 0 will allow non tracking motion to be executed.

Increment Travel Dist (mm):

This is the distance at which the conveyor incremental travel pulse transitions. The pulse remains on for half the specified travel distance.

Increment Travel Dist GOUT:

The incremental travel distance will be sent to the group output specified by this setting. You are required to cycle power after changing this parameter.

Increment Travel DOUT:

This is the digital output indicating that the conveyor incremental travel distance has been achieved, see Incremental Travel Distance. This is typically used by PLC to monitor conveyor travel. You are required to cycle power after changing this parameter.

Conv Speed GOUT (mm/sec):

The conveyor speed will be output to the group output specified by this setting. You are required to cycle power after changing this parameter.