CONTROLLER SETUP

AND OPERATION MANUAL

FOR: DX100 CONTROLLER
DX200 CONTROLLER

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.

YASKAWA INSTRUCTIONS
CONTROLLER INSTRUCTIONS
OPERATOR’S MANUAL
MAINTENANCE MANUAL
The operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.

Part Number: 169390-1CD

Revision: 7

MANUAL NO. 1 of 210

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PalletSolver

Copyright © 2017, 2016, 2015, YASKAWA America, Inc.

Terms of Use and Copyright Notice

All rights reserved. This manual is freely available as a service to
YASKAWA customers to assist in the operation of Motoman robots,
related equipment and software This manual is copyrighted property of
YASKAWA and may not be sold or redistributed in any way. You are
welcome to copy this document to your computer or mobile device for
easy access but you may not copy the PDF files to another website, blog,
cloud storage site or any other means of storing or distributing Online
content.

Printed in the United States of America

First Printing, 2015

YASKAWA America, Inc.

Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200

www.motoman.com

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MANDATORY
• This manual explains the error recovery function. Read this manual
carefully and be sure to understand its contents before operation.
• General items related to safety are listed in Section 1: Safety, in the
Controller Instructions. To ensure correct and safe operation,
carefully read the Controller Instructions before reading this manual.
• For detailed instructions regarding additional equipment including
controller, manipulator, or other components, refer to the specific
equipment manuals included with your documentation package

CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
• Software described in this manual is supplied against licensee only,
with permission to use or copy under the conditions stated in the
license. No part of this manual may be copied or reproduced in any
form without written consent of YASKAWA.

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PalletSolver

We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved YASKAWA training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.

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PalletSolver Notes for Safe Operation

Notes for Safe Operation

Before using this product, read this manual and all the other related
documents carefully to ensure knowledge about the product and safety,
including all the cautions.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

Indicates a potentially hazardous

WARNING situation which, if not avoided, could
result in death or serious injury to
personnel.

Indicates a potentially hazardous

CAUTION situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.

Always be sure to follow explicitly the

MANDATORY items listed under this heading.

PROHIBITED Must never be performed.

Even items described as “CAUTION” may result in a serious accident in

some situations.
At any rate, be sure to follow these important items

To ensure safe and efficient operation at all times, be sure to

NOTE follow all instructions, even if not designated as “CAUTION”
and “WARNING”.

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PalletSolver Notes for Safe Operation

WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the [Emergency Stop] buttons on the front door of the
controller and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the [Emergency Stop] buttons do not function.
Figure 1: Emergency Stop Button

• Once the [Emergency Stop] button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN

• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning on the power for the controller.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an [Emergency Stop]
button immediately if there is a problem.
The [Emergency Stop] buttons are located on the right of front door of
the controller and the programming pendant.

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PalletSolver Notation for Menus and Buttons

CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately,
and be sure that all other necessary processing has been
performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the controller after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
Controller Instructions before operating the manipulator:

Notation for Menus and Buttons

Descriptions of the programming pendant, buttons, and displays are
shown as follows:
Item Manual Designation
Menu The menus displayed on screen are
denoted with { }. ex. {TOOL}.
Button The buttons, check boxes, radio
buttons displayed on screen are
denoted with [ ].
ex. [Close]; [Sync] check box; [Fast]
radio button.

Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • •”
means the following operations:
• To move the cursor to the object item and left-click on it with the mouse.
• To pick out the object item by the tab key and press the Enter key.
(In case of selecting a menu, use arrow keys instead of the tab key to pick
out the object item, then press the Enter key.)

Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.

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PalletSolver Table of Contents

Table of Contents

1 Introduction ..................................................................................................................................... 1-1

1.1 Overview ............................................................................................................................ 1-1

1.1.1 Operation Areas.................................................................................................... 1-2

1.1.2 Modules ................................................................................................................ 1-2

1.2 Features............................................................................................................................. 1-3

1.2.1 PalletSolver- PC Pattern Generation Tool ............................................................ 1-3

1.2.2 PalletSolver-Controller.......................................................................................... 1-3

1.3 System Requirements........................................................................................................ 1-4

1.3.1 PalletSolver PC Minimum Requirements.............................................................. 1-4

1.3.2 Controller Requirements....................................................................................... 1-4

1.4 About this Document.......................................................................................................... 1-5

1.5 Learning PalletSolver......................................................................................................... 1-6

1.6 Reference to Other Documentation ................................................................................... 1-6

1.7 Customer Support Information........................................................................................... 1-7

2 PalletSolver System Definitions ...................................................................................................... 2-1

2.1 Cell Identification................................................................................................................ 2-1

2.2 Station and Gripper Identification....................................................................................... 2-2

2.2.1 Station Definition................................................................................................... 2-3

2.2.1.1 Station Frame .......................................................................................... 2-3
2.2.1.2 Station Interference Boundary................................................................. 2-4

2.3 Forkable Conveyors........................................................................................................... 2-7

2.4 Conveyor End Stops ......................................................................................................... 2-8

2.5 Package Definition ............................................................................................................. 2-9

2.5.1 Package Frame and Dimensions.......................................................................... 2-9

2.5.2 Label Position ....................................................................................................... 2-9

2.5.3 Package Coordinates ........................................................................................... 2-9

2.5.3.1 Package Orientation on the Infeed ........................................................ 2-10
2.5.3.2 Package Orientation on the Build Station.............................................. 2-11

2.6 Gripper Definition ............................................................................................................. 2-12

2.6.1 Vacuum Gripper.................................................................................................. 2-12

2.6.2 Clamp Grippers................................................................................................... 2-12

2.6.2.1 Clamp Fixed Edge ................................................................................. 2-13
2.6.2.2 Clamp Moving Edge .............................................................................. 2-13

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2.6.3 Fork grippers ...................................................................................................... 2-14

2.6.4 Bag Grippers ...................................................................................................... 2-15

2.6.5 Gripper Orientation on Infeed Conveyor............................................................. 2-15

2.6.6 Gripper Orientation on Build Station................................................................... 2-16

2.6.7 Physical Gripping and Sensing Areas ................................................................ 2-17

2.6.8 Virtual Gripper .................................................................................................... 2-18

2.6.9 Gripper I/O Signal Mapping ............................................................................... 2-18

3 Flow of Operations.......................................................................................................................... 3-1

3.1 Setup ................................................................................................................................. 3-2

4 Controller PalletSolver Setup Application ....................................................................................... 4-1

4.1 Cell Setup Operational Sequence ..................................................................................... 4-1

4.1.1 Robot Controller/ Gripper Interfaces..................................................................... 4-3

4.1.1.1 Background ............................................................................................. 4-3
4.1.1.2 Overview ................................................................................................. 4-5
4.1.1.3 Pre-engineered Universal Outputs .......................................................... 4-6
4.1.1.4 Pre-engineered Universal Inputs............................................................. 4-7

4.2 Station Setup ..................................................................................................................... 4-9

4.2.1 User Frames....................................................................................................... 4-10

4.2.1.1 User Frame Locations ........................................................................... 4-10
4.2.1.2 Required User Frames Number ............................................................ 4-10
4.2.1.3 User Frame Offsets ............................................................................... 4-11

4.2.2 Clearance Z ........................................................................................................ 4-12

4.2.3 Dispenser Types................................................................................................. 4-12

4.3 Cell Setup Applications’ Use of External Memory Devices.............................................. 4-13

4.4 PalletSolver Setup Application......................................................................................... 4-16

4.4.1 Start PalletSolver Setup Application................................................................... 4-16

4.4.2 Open an Existing Setup File ............................................................................... 4-17

4.4.3 Defining a New Cell ............................................................................................ 4-18

4.4.4 PalletSolver Editor .............................................................................................. 4-19

4.4.5 Cell Editor ........................................................................................................... 4-19

4.4.5.1 Station Selection ................................................................................... 4-19
4.4.5.2 Add New Stations.................................................................................. 4-20
4.4.5.3 Delete Station........................................................................................ 4-20
4.4.5.4 Edit Station ............................................................................................ 4-22

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4.4.6 Gripper Definition................................................................................................ 4-22

4.4.6.1 Define Gripper Types ............................................................................ 4-22
4.4.6.2 Set Gripper ID ....................................................................................... 4-25
4.4.6.3 Set Tool Center Point Number (TCP).................................................... 4-25
4.4.6.4 Grip Areas ............................................................................................. 4-26
4.4.6.5 Gripper Motion Setup ............................................................................ 4-27
4.4.6.6 Gripper Operation.................................................................................. 4-29

4.4.7 Station Definition................................................................................................. 4-30

4.4.7.1 Dispenser Stations Types...................................................................... 4-31
4.4.7.2 Optional Station Sensors....................................................................... 4-32

4.4.8 Pattern Setup...................................................................................................... 4-35

4.4.9 Network Option ................................................................................................... 4-36

4.4.9.1 Pattern File Naming Convention............................................................ 4-37
4.4.9.2 Network Folder Usage........................................................................... 4-38

4.4.10 System Control ................................................................................................. 4-39

4.4.11 Write Cell Setup Job ......................................................................................... 4-39

4.4.12 Close Button ..................................................................................................... 4-40

5 PalletSolver PC Pattern Generation Tool........................................................................................ 5-1

5.1 Build Pattern Files.............................................................................................................. 5-1

5.1.1 MotoPlus Pattern File Importer Application .......................................................... 5-1

5.1.2 Initiating Build Pattern Conversion........................................................................ 5-1

6 Controller Jobs and Concurrent I/O Program.................................................................................. 6-1

6.1 Structure ........................................................................................................................... 6-1

6.2 Jobs ................................................................................................................................... 6-2

6.2.1 System Jobs ......................................................................................................... 6-2

6.2.1.1 System_PLC_Messaging ........................................................................ 6-2
6.2.1.2 System_Machine_State........................................................................... 6-2

6.2.2 Standard Jobs ...................................................................................................... 6-3

6.2.2.1 PalletSolver_Master_Job......................................................................... 6-3
6.2.2.2 PalletSolver_Planner: .............................................................................. 6-3
6.2.2.3 PalletSolver_Motion................................................................................. 6-4
6.2.2.4 PalletSolver_Cell_Setup.......................................................................... 6-4
6.2.2.5 PATTERN_#............................................................................................ 6-4

6.2.3 User Jobs.............................................................................................................. 6-4

6.2.3.1 USER_ADJUSTMENTS .......................................................................... 6-5
6.2.3.2 USER_CONTROL_TASK...................................................................... 6-13
6.2.3.3 USER_MOVE_REJECT ........................................................................ 6-14
6.2.3.4 USER_GRIPPER_ON ........................................................................... 6-15
6.2.3.5 USER_GRIPPER_OFF ......................................................................... 6-15
6.2.3.6 USER_DISPERSER_GRIPPER_CONTROL ........................................ 6-15

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6.2.3.7 USER_CLEAR_IO................................................................................. 6-16

6.2.3.8 USER AUTO_DISPENSE ..................................................................... 6-16

6.3 Concurrent I/O ................................................................................................................. 6-17

6.3.1 Overview ............................................................................................................ 6-17

6.3.2 Gripper Setup Introduction ................................................................................. 6-17

6.3.2.1 Gripper Setup ........................................................................................ 6-18

6.3.3 Gripper Setup Examples .................................................................................... 6-29

6.3.3.1 Vacuum Gripper .................................................................................... 6-29
6.3.3.2 Zone Clamp Gripper.............................................................................. 6-36
6.3.3.3 Variable Stroke Fork Gripper................................................................. 6-38
6.3.3.4 Gripper Testing ..................................................................................... 6-42

7 DX100 & DX200 Operation Monitor and Control Interface ............................................................. 7-1

7.1 Functions ........................................................................................................................... 7-1

7.2 Interface: Direct I/O Signals............................................................................................... 7-2

7.2.1 System Signals..................................................................................................... 7-2

7.2.1.1 System Start/Stop ................................................................................... 7-2
7.2.1.2 Palletizing Stop/Start ............................................................................... 7-3
7.2.1.3 PLC Controlled System ........................................................................... 7-3
7.2.1.4 Fieldbus Heartbeat .................................................................................. 7-3
7.2.1.5 Set Next Infeed Pick................................................................................ 7-4
7.2.1.6 Safety Speed........................................................................................... 7-4
7.2.1.7 Speed Override ....................................................................................... 7-4
7.2.1.8 Battery Warning ...................................................................................... 7-4
7.2.1.9 Motion Sequence .................................................................................... 7-5

7.2.2 Warning and Error Handling ................................................................................. 7-5

7.2.2.1 PalletSolver Job Warning ........................................................................ 7-6
7.2.2.2 Pick/Place Error....................................................................................... 7-6
7.2.2.3 System Job Running ............................................................................... 7-8

7.2.3 All Stations ........................................................................................................... 7-8

7.2.3.1 Station Exists .......................................................................................... 7-8
7.2.3.2 Station Active .......................................................................................... 7-8
7.2.3.3 Station Lock/Unlock ................................................................................ 7-8
7.2.3.4 Station Pick/Place Error .......................................................................... 7-9

7.2.4 Reject Station ..................................................................................................... 7-10

7.2.4.1 At Reject Drop ....................................................................................... 7-10
7.2.4.2 Reject Full ............................................................................................. 7-10
7.2.4.3 Gripper Package Release ..................................................................... 7-10
7.2.4.4 Goto Reject Station ............................................................................... 7-11

7.2.5 Build Stations ..................................................................................................... 7-11

7.2.5.1 Build Pattern Assigned .......................................................................... 7-11
7.2.5.2 Build Pallet Present ............................................................................... 7-11
7.2.5.3 Normal Build Done and Eject ................................................................ 7-11

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7.2.5.4 Build Station Forced Done and Eject.................................................... 7-12

7.2.5.5 Build Station Lock after Build is Done ................................................... 7-12
7.2.5.6 Build Station Verify Layer ...................................................................... 7-12

7.2.6 Infeed Stations.................................................................................................... 7-13

7.2.6.1 Infeed Package Request ....................................................................... 7-13
7.2.6.2 Purge Infeed .......................................................................................... 7-13

7.2.7 Dispenser Stations.............................................................................................. 7-14

7.2.7.1 Dispenser Reset Search Height ............................................................ 7-14
7.2.7.2 Dispenser Low Stack............................................................................. 7-14
7.2.7.3 Dispenser Empty ................................................................................... 7-14

7.3 Interface: Message Communication ................................................................................ 7-15

7.3.1 PLC to Robot Message Structure ....................................................................... 7-15

7.3.2 Handshaking....................................................................................................... 7-17

7.3.3 Functions ............................................................................................................ 7-19

7.3.3.1 Reset Message Transaction ID ............................................................. 7-19
7.3.3.2 Build Station Assign/Unassign Pattern .................................................. 7-20
7.3.3.3 Station Package Info ............................................................................. 7-21
7.3.3.4 Build Station Request Pattern Info ........................................................ 7-22
7.3.3.5 Build Station Request Build Status........................................................ 7-23
7.3.3.6 Build Station Request Associated Stations ........................................... 7-25
7.3.3.7 Select Sequencing Mode ...................................................................... 7-25
7.3.3.8 Infeed Ratio ........................................................................................... 7-28
7.3.3.9 Infeed Priority ........................................................................................ 7-30
7.3.3.10 Package Height Adjustment ................................................................ 7-32
7.3.3.11 Station Frame Adjustment ................................................................... 7-33
7.3.3.12 Build Station Maximum Layer.............................................................. 7-35
7.3.3.13 Infeed Station Row Data ..................................................................... 7-36

8 Operation Monitor and Control Pendant Application....................................................................... 8-1

8.1 Function ............................................................................................................................. 8-1

8.2 Starting the PalletSolver HMI............................................................................................. 8-1

8.3 Interface ............................................................................................................................. 8-3

8.3.1 System Overview Screen ..................................................................................... 8-3

8.3.2 Monitor Mode Overview........................................................................................ 8-4

8.3.3 Controller Screen.................................................................................................. 8-4

8.3.4 Build Station Screen ............................................................................................. 8-6

8.3.5 Infeed Station Screen ........................................................................................... 8-8

8.3.6 Dispenser Station Screen: .................................................................................. 8-10

8.3.7 Settings and Optimization Screen ...................................................................... 8-12

8.3.8 Sequencing Screen ............................................................................................ 8-13

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8.3.9 Frame and Product Adjustment Screen ............................................................. 8-14

8.3.10 Speed Adjustment Screen................................................................................ 8-15

8.3.10.1 Adjusting the Speed ............................................................................ 8-15

8.3.11 Gripper Testing................................................................................................. 8-16

8.3.11.1 Grip Output Control ............................................................................. 8-16
8.3.11.2 Gripper Part Sensors........................................................................... 8-17
8.3.11.3 Gripper Open and Close Sensors ....................................................... 8-18

8.3.12 Security Check ................................................................................................. 8-19

8.3.13 Reject Station Screen....................................................................................... 8-21

8.3.13.1 Reject Station Controls........................................................................ 8-21
8.3.13.2 Gripper Controls .................................................................................. 8-21
8.3.13.3 Station Lock ........................................................................................ 8-21

Appendix A .......................................................................................................................................A-1

A.1 Monitor and Control Direct I/O Mapping............................................................................A-1

A.1.1 Controller Outputs (PLC Inputs)...........................................................................A-2

A.1.2 Controller Inputs (PLC Outputs)...........................................................................A-9

A.2 Error and Warning Lists...................................................................................................A-16

A.2.1 Messaging Error List ..........................................................................................A-16

A.2.2 Job Warning List ................................................................................................A-18

A.2.3 Controller Error and Warning List.......................................................................A-21

A.3 PLC Messaging Example ................................................................................................A-22

A.3.1 Example: Get Sequencing Mode (Command 5) ...............................................A-22

A.3.2 Example: Request Build Pattern Associated Station Info (Command 3) ...........A-25

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PalletSolver 1 Introduction
1.1 Overview

1 Introduction

1.1 Overview
The PalletSolver Software Suite provides a turn-key, easy to use system
for integrators to develop a palletizing system faster and with ease. This
suite also allows the end user to create new palletizing patterns and add
new products with ease on a PC and then to quickly transfer the
generated pattern to the system controller.
Fig. 1-1: Overview of the Easy Pallet Software Suite

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1.1 Overview

1.1.1 Operation Areas

There are two main operational areas of the PalletSolver Software Suite
and they are:
• PC Windows Application: The PC component consist of a Pattern
Generation tool that will run on a Windows base PC. This
applications purpose is to generate patterns.

Though this application takes into account physical

NOTE restrictions of a system (physical interferences, gripper
dimensions), it is basically independent of the specifics of
the system (robot type, cell layout, I/O configuration.)

• Controller Application: The controller components consist of the

controller jobs, Concurrent I/O program, pendant applications, and
MotoPlus applications which are executing in the controller without
the need of an external PC. An external PLC I/O interface is
available monitor and control the system. The Online components
will provide the following major functions:
– System Initial Setup - cell layout, I/O mapping, user-frame
definition…
– System Monitor and Controller - system status, build status,
pattern selection…
– Pattern File Import - import information from pattern file
generated by the PalletSolver - PC Pattern Generation Tool
– Run Time Execution - job and concurrent jobs executing the
pallet builds)
– PLC Interface - enables an external PLC/HMI to Monitor and
Control the system

1.1.2 Modules
Modules included with the Pallet Software Suite work to together through
interface using the Pattern Files (Pattern XML Files), Controller Variables
and I/O Tables, and Configuration Jobs (Palletizing Cell Project.JBI and
Pattern.JBI). This suite is composed of the following modules:
• PalletSolver - Cell Setup Pendant Application
• PalletSolver - PC Pattern Generation Application
• Pattern File Importer MotoPlus Application
• Controller Job and Concurrent I/O Program
• Operator Monitor and Control Interface
• PalletSolver - HMI Pendant Application

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PalletSolver 1 Introduction
1.2 Features

1.2 Features

1.2.1 PalletSolver- PC Pattern Generation Tool

• Intuitive user interface with guided pallet recipe generation
• Interference constraints per station to ensure quick change over
without halting production
• Import pallet patterns generated by TOPS or CAPE software
• Virtually unlimited SKUs supported
• Support for multiple-cells
• Dynamic gripper zone configuration to suit modular gripper design
• Support for the following grippers:
– Vacuum Grippers
– Clamp Grippers
– Fork Grippers
– Bag Grippers

1.2.2 PalletSolver-Controller
• System Configuration - Maximum: 8 infeed x 8 build stations, 2 pallet
dispensing stations, 2 slipsheet dispensing stations
• Dynamic robot path adjustment to ensure optimum production rate
• Pre-Mapped I/O to communicate with PLC/supervisory control for
status and monitoring
• PLC- Robot Messaging interface for operations control
• Intuitive guided setup and configuration using robot pendant HMI
• PLC-less operation in the case where the robot controller is the only
controller in the system
• Network enabled for importing of Pattern (recipe) files generated by
PalletSolver- PC
• Granular control over Palletizing operations
– Controlling infeed pick sequence (Round robin, priority, relative
ratio, PLC controlled)
• Automatic reject of parts
• Conveyor/Pallet lock-out for maintenance or failures
• End of production handling
• Adjusting pick-place depth as package changes due to
environmental conditions
• Integration Customization Library: customize applications for
unique gripper handling, error handling or customizing pick-
place handling

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1.3 System Requirements

1.3 System Requirements

1.3.1 PalletSolver PC Minimum Requirements

• Compatible with Microsoft Windows XP Service Pack 2.0 and
Microsoft Windows 7
• Microsoft.NET Framework 3.5
• 400 megahertz (MHz), Recommended 1 gigahertz (GHz)
• 128 megabytes (MB), Recommended 256 megabytes (MB)
• 30 MB Hard Disk Space
• Monitor Resolution of 1280 x 1024 dots per inch (dpi)
• Hardware Key provided with the Pallet Software Suite

1.3.2 Controller Requirements

• Controller
– DX100 controller with DS3.91 - 14 or later Controller Software
with MotoPlus support.
– DX200 controller with DN1.54 or later Controller Software.
• Programming Pendant
• Industrial Grade Memory Compact Flash Card (CF Flash) or a USB
Flash Drive with 256 MB of available space or more

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1.4 About this Document

1.4 About this Document

This manual is intended as an introduction and overview for personnel
who are familiar with the operation of their YASKAWA Motoman robot
model and Microsoft® Windows®/PC usage.
This manual provides an overview of the YASKAWA Motoman
PalletSolver system.
This manual contains the following sections:
• Chapter 1 "Introduction"
• Chapter 2 "PalletSolver System Definitions"
• Chapter 3 "Flow of Operations"
• Chapter 4 "Controller PalletSolver Setup Application"
• Chapter 5 "PalletSolver PC Pattern Generation Tool"
• Chapter 6 "Controller Jobs and Concurrent I/O Program"
• Chapter 7 "DX100 & DX200 Operation Monitor and Control
Interface"
• Chapter 8 "Operation Monitor and Control Pendant Application"
• Appendix A

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PalletSolver 1 Introduction
1.5 Learning PalletSolver

1.5 Learning PalletSolver

YASKAWA has created this product with keeping with our proven track
record of delivering industry leading quality, innovation and customer
satisfaction. With that said if training is still needed a variety of options are
available to help you learn the PalletSolver, including training and
technical support. For more information on available training classes for
the PalletSolver Suite, please contact our training department at:
training@motoman.com or visit our website at: www.motoman.com.
Also be sure to try the Online training course at:
http://info.motoman.com/palletsolver-download
This course allows you to download and practice creating pallet patterns
with the PalletSolver - PC Pattern Generation Tool.

1.6 Reference to Other Documentation

For additional information refer to the following:
• YASKAWA Controller Manual
• YASKAWA Maintenance Manual
• YASKAWA Operator's Manual for General
• YASKAWA Operator's Manual for Handling
• YASKAWA Concurrent I/O Parameter Manual
• YASKAWA INFORM User’s Manual
• YASKAWA Inform Extension Function Structured Program Language
Manual
• YASKAWA PalletSolver PC Pattern Generation Tool Manual
• YASKAWA Search Function Manual
• YASKAWA Speed Override Function Manual
• YASKAWA TCP Function Manual
• YASKAWA Standard I/O Signal Assignment Manual
• Vendor manuals for system components not manufactured by
YASKAWA

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PalletSolver 1 Introduction
1.7 Customer Support Information

1.7 Customer Support Information

If you need assistance with any aspect of your PalletSolver system,
please contact YASKAWA Customer Support at our 24-hour telephone
number:

(937) 847-3200

For routine technical inquiries, you can also contact YASKAWA Customer
Support at the following e-mail address:

techsupport@motoman.com

When using e-mail to contact YASKAWA Customer Support, please

provide a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.

Please use e-mail for routine inquiries only. If an urgent or

NOTE emergency need for service, replacement parts, or
information, contact YASKAWA Customer Support at the
telephone number shown above.

Please have the following information ready before calling:

System PalletSolver
Robots
Software Version Access this information on the
Programming Pendant’s LCD display
screen by selecting {MAIN MENU} -
{SYSTEM INFO} - {VERSION}
Robot Serial Number Located on the robot data plate
Robot Sales Order Number Located on the controller data plate

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PalletSolver 2 PalletSolver System Definitions
2.1 Cell Identification

2 PalletSolver System Definitions

The system definition establishes conventions to identify and define
components in both the controller and windows software. These
conventions must be followed on both sides inorder for the system to
operate properly. This definition only needs to be done once during the
initial setup of a new cell.

2.1 Cell Identification

Each cell is identified by a unique user-defined number, the cell ID. This
number is entered in both the PalletSolver PC Pattern Generation Tool
application and the controller PalletSolver Cell Setup pendant application.
During operation, when the XML pattern files generated in the PalletSolver
PC the cell ID of the XML pattern file is checked against the cell ID of the
controller system to confirm the Offline validation (gripper, interference
zone….) of the pattern was done with the data corresponding to the
proper physical cell.

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2.2 Station and Gripper Identification

2.2 Station and Gripper Identification

During the initial definition of the cell, it is important the components
identified in PalletSolver PC application matches the physical
identification of the controller system. Each station within a cell should be
identified by type: infeed (conveyor), build station (outfeed conveyor),
pallet dispenser, slipsheet dispenser; and an ID number starting at 1 to the
number of stations of that type.
Grippers are also have a unique identification number (GripperID)
identifying a physical gripper of a specific type, dimension and
configuration. If multiple cells have identical grippers, they should share
the same GripperID and data.
Fig. 2-2: Station Identification Example

Build
Station 1

Infeed
Station 1
Slipsheet
Dispenser 1

Pallet
Dispenser 1
Infeed
Station 2

Build
Station 2

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PalletSolver 2 PalletSolver System Definitions
2.2 Station and Gripper Identification

2.2.1 Station Definition

2.2.1.1 Station Frame

All frames (coordinate systems) used in the calculations follow the Right-
Hand-Thumb rule for frames.
• Infeed Conveyor Frame: The origin of conveyor frame is at the right
hand corner at the front of the conveyor such that X-axis of the frame
is pointing against the flow of the conveyor. The X-axis is aligned
with the right side of a right justified box and the Y-axis is aligned
with the front the first box.
Fig. 2-3: Infeed Conveyor Frame

X
Y

• Build Station Frame (Pallet/Outfeed Frame): The origin of the pallet

frame is at the right hand bottom corner of the pallet such that the
entire pallet lies in the positive quadrant of X and Y axis. The Z-
location of the origin is at the bottom of the pallet.
Fig. 2-4: Build Station Frame

X
Y

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2.2 Station and Gripper Identification

• Dispenser Frame: The origin of the dispenser frame is at the right

hand bottom corner of the pallet/shipsheet such that the entire pallet/
shipsheet stack lies in the positive quadrant of X and Y axis. The Z-
location of the origin is at the bottom of the pallet/slipsheet stack.
Fig. 2-5: Pallet Dispenser Frame

Z
X
Y

• Reject Station Frame: The origin of the reject frame may vary
depending on the related user job customizing. In general, it should
be at the lowest possible drop point. The only restriction is that the
Z-axis must point upward.

2.2.1.2 Station Interference Boundary

Station interference boundaries are defined around the build station and
infeed station. These interferences add constraints for picking or placing
the products.
These constraints define the area where the robot can pick the product
safely without the gripper interfering with other parts of the cell.

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2.2 Station and Gripper Identification

Fig. 2-6: Station Interference

The interference constraints are defined with respect to the origin of the
infeed or build station and distances in the positive and negative direction
of the frame orientation axes.
Fig. 2-7: Infeed Station Interference Boundary

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2.2 Station and Gripper Identification

Fig. 2-8: Build Station Interference Boundary

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PalletSolver 2 PalletSolver System Definitions
2.3 Forkable Conveyors

2.3 Forkable Conveyors

Fork and bag grippers have to move between the conveyor roller and
beneath the product during the pickup sequence. The PalletSolver - PC
Pattern Generation Tool is responsible for ensuring the conveyor is
forkable with each associated Fork Gripper.
Fig. 2-9(a): Moving Between Rollers and Under Product

Fig. 2-9(b): Balancing Loads on Grippers

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PalletSolver 2 PalletSolver System Definitions
2.4 Conveyor End Stops

2.4 Conveyor End Stops

Infeed Conveyors can be equipped with optional End stops. These stops
are mainly used with Fork style grippers. They are typically used to help
center the products on the fork gripper. Each time the product size
changes this stop might need adjusting. This information is set in
PalletSolver - PC Pattern Generation Tool.
Fig. 2-10: Conveyor End Stops

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PalletSolver 2 PalletSolver System Definitions
2.5 Package Definition

2.5 Package Definition

2.5.1 Package Frame and Dimensions

The package frame is in the middle of the top surface of the package.
Fig. 2-11: Package Frame

X: Length
Y: Width
Z: Height

2.5.2 Label Position

Labels can be defined on one or more sides of a box package relative to
the package frame.

2.5.3 Package Coordinates

The package X and Y coordinates define the position and orientation of
the center in relation to conveyor/pallet frame and are defined in the
pattern files.
The orientation is the Z rotation angle of the box X-axis relative to the
conveyor/pallet frame.

The package coordinates do not directly correspond to the

NOTE robot coordinates. The robot coordinates are based on the
gripper coordinates.

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2.5 Package Definition

2.5.3.1 Package Orientation on the Infeed

The package orientation is defined relative to the infeed conveyor frame.
Fig. 2-12: Package Orientation on Infeed

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2.5 Package Definition

2.5.3.2 Package Orientation on the Build Station

The package orientation is defined relative to the build station (outfeed
conveyor) frame.
Fig. 2-13: Package Orientation on Build Station

The pallet itself is considered as a package and has an orientation relative

to the build station frame. The pallet can be defined as “Length on X” or
“Length on Y”.
Fig. 2-14: Pallet Orientation

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2.6 Gripper Definition

2.6 Gripper Definition

The tool control point (TCP) defined on the robot controller must match
the gripper frame that defines the position of the gripper relative to the
station frame in the PalletSolver PC Pattern Generation Tool. To do so,
conventions are based on the gripper type.

2.6.1 Vacuum Gripper

The vacuum gripper or suction cup gripper frame is usually defined in the
center of suction cups at the bottom of the suction cups. There is some
flexibility on the X, and Y positioning of the TCP. For the Z position, it
MUST be at the bottom of the cups where a box would be before applying
vacuum to grip it. The X axis is along the length of the gripper and the
Z axis toward the bottom of the gripper. The Y axis is perpendicular to the
other two axes following the right-hand rule.
The gripper interference (body) constraints are defined with respect to the
frame (TCP) and distances in the positive and negative direction of the
frame orientation axes.
Fig. 2-15: Gripper Tool Definition

2.6.2 Clamp Grippers

Clamp grippers are classified by the number of moving clamps as defined
below:
• Clamp Fixed Edge
• Camp Moving Edge

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2.6 Gripper Definition

2.6.2.1 Clamp Fixed Edge

These grippers have one fixed edge and one moving edge. See the Fixed
Edge Clamp Gripper picture below. The TCP in this type of gripper is
defined at the bottom inside edge of the fixed clamp or paddle with the
(+Y) axis pointing away from the gripper and the (-Y) axis point towards
the movable clamp. The Z axis points down, away from the end of the
paddle.
The X axis origin can be in the center or the end of the fixed clamp edge.
The X axis is pointing along the edge of the clamp.
Fig. 2-16: Fixed Edge Clamp Gripper

2.6.2.2 Clamp Moving Edge

TCPs are similar to the Fixed Edge clamp TCPs but with the Y axis origin
in the middle of the two moving paddles. See the figure below.
Fig. 2-17: Moving Edge Clamp Gripper

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2.6 Gripper Definition

2.6.3 Fork grippers

Fork grippers come in two types called:
• Retractable Fork Grippers
• Variable Stroke Fork Grippers
Retractable Fork Grippers have only two fork positions: fully open and fully
closed.
Fig. 2-18: Retractable Fork Grippers

Variable stroke grippers can close and open a set number of distances
between the fully open and fully closed position.
Fig. 2-19: Variable Stroke Fork Grippers

The TCPs setup is the same for all fork grippers. The origin of the TCP is
usually set at the inside edge of the fixed wall. The (+Y) axis is pointing
towards the retracted fork. The origin of the Z axis is at the top surface of
the fork. The (+Z) axis must be pointing towards the bottom of the gripper
fork. The (-Y) axis is pointing in the direction that the fork moves when it
is closing. The X axis is pointing towards the fork tines, with the origin
usually in the center of the tines or at the edge of the first tine.

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2.6 Gripper Definition

2.6.4 Bag Grippers

The bag gripper frame is defined on the surface formed by the fork tines in
the closed position. The Z axis points down. The X-Y origin is usually at
the center of the gripper. The X axis is pointing to the other fork tines and
the Y axis in the fork open and close motion. Fig.2-20 "Bag Gripper"
shows the frame of a bag gripper.
Fig. 2-20: Bag Gripper

2.6.5 Gripper Orientation on Infeed Conveyor

The gripper orientation is defined relative to the infeed conveyor frame.
Only two orientations are supported:
Fig. 2-21: Gripper Orientation on Infeed Conveyor

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2.6 Gripper Definition

2.6.6 Gripper Orientation on Build Station

The gripper orientation is defined relative to the build station frame.
Fig. 2-22: Gripper Orientation on Build Station

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2.6 Gripper Definition

2.6.7 Physical Gripping and Sensing Areas

The physical gripping and sensing zones define the center location (X, Y)
and dimension (Length_X and Width_Y) of the effective area of each
GripAreaID or SensorID. Each GripAreaID or SensorID should have its
own set of I/O signals on the Online side. There is a maximum of 32
GripAreaID and 32 Sensor ID.
A GripAreaID identify one or more suction cups or actuators that will
always be activated together. For example, there would a single
GripAreaID, if a single vacuum generator is connected to four suction
cups and the effective area would cover all four suction cups. In the case
of vacuum, the effective area should be the minimum area that needs to
be completely covered by the packages in order for the vacuum to be
made.
Fig.2-16 Gripping and Sensing Area Examples shows two examples. In
the first, each suction cup is independently controller and has its own
sensor (vacuum confirmation). In the second, the vacuum gripper has four
gripping areas (composed of four suction cups physically connected
together) and two sensor areas.
Fig. 2-23: Gripping and Sensing Area Examples

A SensorID identifies the sensing area of a single sensor. The effective

area is defined as the area where the sensor will turn on if a package is
partially in the area.

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2.6 Gripper Definition

2.6.8 Virtual Gripper

A physical gripper may have multiple virtual grippers define as needed
based on the package size by the person making the palletizing pattern.
The purpose is to combine gripping areas and sensor areas together into
a logical zone that matches the package size to facilitate the pattern
building process on the PC side. This is particularly useful for flexible
vacuum grippers that can accommodate various box sizes by having
individual control for each suction cup. Using virtual grippers the operator
doesn't have to activate a large number of individual grip area to pick-up a
single large box, he can define virtual zone that groups the smaller
physical areas into larger zones.
For example in the following figure a virtual gripper with two zones is
defined to pick-up larger boxes. Zone 1 is composed of grip area 1 to 4
and 9 to 12 plus the sensor area 1, and Zone 2 of grip area 5 to 8 and 13
to 16 plus the sensor zone 2.
Fig. 2-24: Virtual Zone Definitions

The use of virtual gripper and gripping and sensing areas also allows
abstracting from the PC Pattern Generation Tool application the details of
the I/O signals required to grip or release boxes and detected their
presence.

2.6.9 Gripper I/O Signal Mapping

On the controller side, there is a maximum of 32 GripAreaIDs (grip areas)
and 32 Sensor IDs (sensor areas) available. Each GripAreaID and
SensorID have assigned auxiliary relays that need to be mapped to
external signal. Please refer to Section 6.3 “Concurrent I/O” on page 6-17
for details for mapping the gripper I/Os.

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PalletSolver 3 Flow of Operations

3 Flow of Operations
While installation of the software is performed by a YASKAWA technician,
on the controller there are other procedures that must be complete, before
you can use the palletizing system.

CAUTION
The customer is responsible for providing trained operators to run the
equipment. The customer is also responsible for making sure that all
equipment is operated in accordance with the ANSI/RIA R15.06-2012
Robot Safety standard, as well as any other required standards.

Fig. 3-1: PalletSolver Setup Flow Chart

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PalletSolver 3 Flow of Operations
3.1 Setup

3.1 Setup
The setup process is described in the following paragraphs.
The PalletSolver Cell Setup Pendant Tool is a Wizard type interface to
help guide the user in the initial definition and setup of the system. It will
generate a palletizing cell project file that can be store on the local storage
device (USB Drive or CF Card) of the controller pendant and also
generate a corresponding Cell Configuration Job that sets the appropriate
variables defining the system on the controller. This job file is called before
starting operation to make sure that system is always reset to its proper
definition before starting.
The PalletSolver PC Pattern Generation Application runs on a PC and
generates pattern files in XML format that is stored on a storage device.
The storage device is used to store multiple pattern files for various
products, patterns and build stations. It can be a Network storage location
or a local storage device (USB Drive or CF Card) on the pendant.
When a pattern change command is issued, the Pattern File Importer
MotoPlus Application will retrieve the requested pattern file for a build
station from the network or local storage device and convert it to a job
format.
During operation, the controller's standard software runs a set of standard
palletizing jobs and the Concurrent I/O program written for the
PalletSolver system. A master job calls subroutines take care of resetting
the system, control the sequence, pick and place package, etc. The job
makes reference to various variables and I/O signals to control the various
aspect of the operation. The patterns generated by the PalletSolver PC
and imported in jobs are called at each cycle to populate variables
defining required information for the next pick and place cycle of the
pattern. The monitoring and controller operation can be done by reading
and writing to the various variables and I/O signals.
The monitoring and control of the palletizing operation can be done
through the PalletSolver HMI Application. This application can read
variables and I/O to get the status of the system or write to them to modify
the behavior of the system. It will also enable the operator to assign
pattern to build station.
In a similar fashion as the pendant application, the Monitor and Control
Interface can be used to make a user customized interface with a PLC/
HMI. A set range of I/O is dedicated to allow a PLC/HMI to send
commands and retrieve information.

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PalletSolver 4 Controller PalletSolver Setup Application
4.1 Cell Setup Operational Sequence

4 Controller PalletSolver Setup Application

This application is used to define the robotic palletizing cell. The cell is
defined by setting various gripper parameters and the palletizing station
types and key variables that are used in the robot cell.
The setup definition is stored in a Setup *.xml file and in a robot controller
job called 'PalletSolver_Cell_Setup.JBI. The setup job is called by the
main PalletSolver master job.
The setup job must be created and loaded into the controller before the
cell can properly operate.
PalletSolver Setup allows gripper and station types listed below:
• Gripper 1
• Gripper Types
• Vacuum Gripper
• Clamp Gripper
• Fork Gripper
• Bag Gripper
• Infeed Stations 1 to 8
• Build Station 1 to 8
• Slipsheet Dispenser 0 to 2
• Pallet Dispenser 0 to 2
• Reject Station 0 to 1

4.1 Cell Setup Operational Sequence

PalletSolver cell setup works with and supplements the partial setup
information that is captured in the PC based application. While the PC
information focuses more on general setup data, some information
between the two systems overlaps. The main purpose of this application is
to define the robot specific variables required for the gripper and each
station to operate.
For example, when defining a gripper, the PC system defines the basic
gripper type and functional use (how many boxes will be moved and in
what orientation.) While the gripper type and gripper ID numbers are
defined in both systems, the pendant application is more concerned with
very specific gripper issues such as wiring, number, type of control points
and IO required to make the gripper function.
Additionally, the cell setup can be an iterative process that is performed a
number of times as the system definition is modified and goes from initial
design to actual operation. The Setup application is designed to
accommodate this process and allows stations to be modified, deleted, or
added as needed. Each time the cell changes the user can recreate the
cell setup job.

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4.1 Cell Setup Operational Sequence

Fig. 4-1: Gripper Installation Flow

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PalletSolver 4 Controller PalletSolver Setup Application
4.1 Cell Setup Operational Sequence

4.1.1 Robot Controller/ Gripper Interfaces

4.1.1.1 Background
All Grippers are controlled by a combination of robot variables, universal
inputs and outputs, M Registers, and external Inputs and Outputs. Robot/
Gripper control requires both PalletSolver pre-engineered controller jobs,
customized User modified jobs, pre-engineered CIO ladder and user
customized CIO ladder additions.
Fig.4-2 "Gripper I/O Mapping Flowchart" is a simplified view of this
process. This drawing shows the robot controller as a large green block
and the gripper as a yellow block. In this drawing the objects shown in
brown are pre-engineered and are provided as part of the PalletSolver
system. The objects in light blue are tasks that must be completed by the
user. They include:
• Mapping Auxiliary Relays to External Input and outputs
• Modifying CIO ladder with these custom mappings
• Modifying User jobs
• Wiring the Gripper to the External Inputs and Outputs
• Gripper Testing

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4.1 Cell Setup Operational Sequence

Fig. 4-2: Gripper I/O Mapping Flowchart

Depending upon the gripper type and options, the user may also have to
Map some Universal outputs and inputs into external inputs and outputs.
These modifications are required when a gripper function must be
controlled in the User Jobs.

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4.1 Cell Setup Operational Sequence

4.1.1.2 Overview
This section will trace through the process of picking and placing product
at a very high level.
The process starts off line in the PalletSolver - PC Pattern Generation
Tool. Here a pattern is defined in a robotic cell, with desired product
pattern and gripper models. The PatternX.XML file is read into the robot
controller where it is converted to a job (Pattern_X.JBIs.)
The Pattern_X.JBI defines the virtual gripper states required for each pick
and place operation. (See section 2.6.7 "Physical Gripping and Sensing
Areas” on page 2-17 for an explanation of Virtual Grippers and sensing
areas.)
When the pattern is read into the controller, these states are mapped to a
variables. When the robot is picking and placing the next product set for
that pattern, the appropriate values are past as argument to the gripper
related user jobs.
During box picking, the 32 grippers on/off states are transferred from two
I variables (GripArea1-16 and GripArea17-32) to M registers M110 and
M111. When the Universal output Grip_ON is set to true or “on”, the M110
and M111 are simultaneously transferred to external outputs via the User
defined Auxiliary Relay to External Output Mapping and with the User
modified CIO ladder.
When product is picked up, it may be verified with a number of sensors.
These sensors include part present sensors and gripper state sensors
such as gripper on/fork close/clamp close.
The feedback sensors require the user defined External Inputs to Auxiliary
Relay and user modified CIO ladder functions.
Product placement is similar to product pickups. Here the Grip Off/Clamp
Open/Fork retract and possibly the Blow Off signals are used.
The following figure shows the PalletSolver major motion jobs. The jobs
filled with pink are pre-engineered. The USER_GRIPPER_ON.JBI,
USER_GRIPPER_OFF.JBI and
USER_DISPENSER_GRIPPER_CONTROL.JBI may need to be modified
by the user. These jobs are shown in light blue.
As Fig. 4-3 shows, gripper control for product picking is done in the
USER_GRIPPER_ON.JBI job, and gripper control for product placing is
done in the USER_GRIPPER_OFF.JBI job. However gripper control for
both pallet and slipsheet dispensers and for both picking and placing is
done in one job: USER_DISPENSER_GRIPPER_CONTROL.JBI.

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4.1 Cell Setup Operational Sequence

Fig. 4-3: Pick Place Motion Flowchart

4.1.1.3 Pre-engineered Universal Outputs

The following outputs are ready to use in any User Modified Jobs.
The signal names and definitions are show in the tables below. The
gripper can be controlled with standard inform I/O commands such
as;
• PULSE OT#(Grip_ON)
• DOUT OT#(Grip_ON) OFF
Table 4-1: Pre-engineered Universal Outputs
Universal Output Conc. I/O Address Name Description
OT#(1593) #12000 Griper_HasPart Indicate that the gripper is carrying parts.
NOTE: This signal is based on pick/place sequence
tracking and not on sensor feedback.
OT#(1596) #12003 DispGripSensIgn Temporarily turn ON to disregard (turn ON) the
dispenser part present of the gripper.
OT#(1601) #12010 Grip_ON Turn on the GripOn Relays (and turns off the GripOff
relays) specified by the registers M110 and M111.
OT#(1602) #12011 Grip_OFF Turn off the GripOn Relays (and turns on the GripOff
relays) specified by the registers M112 and M113.
Also, turn on the corresponding BlowOff relays for
the amount of time specified by register M122.
OT#(1605) #12014 PartSensor_ON Add the PartSensor Relays specified by the registers
M114 and M115 to the verification list.
Remove the PartSensor Relays specified by the
OT#(1606) #12015 PartSensor_OFF
registers M116 and M117 to the verification list.

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4.1.1.4 Pre-engineered Universal Inputs

The following inputs are ready to use in any User modified Jobs. The
signal names and definitions are show in the table below. The gripper can
be controlled with standard inform I/O commands such as WAIT
IN#(GripOpened_OK!)=ON.
Table 4-2: Pre-engineered Universal Inputs
Universal Input Conc. I/O Address Name Description
Indicate that the gripper is carrying parts.
IN#(1597) #02004 Pal1_Grip_Sens Note that this signal is based on pick/place
sequence tracking and not on sensor feedback.
Confirms that the gripper sensor(s) detecting a
IN#(1598) #02005 Pal2_Grip_Sens
pallet from dispenser 2 is ON
Confirms that the gripper sensor(s) detecting a
IN#(1599) #02006 Slp1_Grip_Sens
slipsheet from dispenser 1 is ON
Confirms that the gripper sensor(s) detecting a
IN#(1600) #02007 Slp2_Grip_Sens
slipsheet from dispenser 2 is ON
Confirms that the part sensors enabled for part
IN#(1606) #02015 GripSensors_OK!
present verification are all ON
Confirms that the sensors verifying that a grip area
IN#(1607) #02016 GripOpened_OK! is open are ON for all the grip areas that are
currently OFF.
Confirms that the sensors verifying that a grip area
IN#(1608) #02017 GripClosed_OK! is closed are ON for all the grip areas that are
currently ON.
Confirms that the gripper sensor(s) detecting the
IN#(1609) #02020 Pal1_HiSrchSens
top of pallet dispenser 1 stack is ON
Confirms that the gripper sensor(s) detecting the
IN#(1610) #02021 Pal2_HiSrchSens
top of pallet dispenser 2 stack is ON
Confirms that the gripper sensor(s) detecting the
IN#(1611) #02022 Slp1_HiSrchSens
top of slipsheet dispenser 1 stack is ON
Confirms that the gripper sensor(s) detecting the
IN#(1612) #02023 Slp2_HiSrchSens
top of slipsheet dispenser 2 stack is ON
Confirms that the gripper sensor(s) detecting the
IN#(1613) #02024 Pal1_LoSrchSens
top of pallet dispenser 1 stack is ON
Confirms that the gripper sensor(s) detecting the
IN#(1614) #02025 Pal2_LoSrchSens
top of pallet dispenser 2 stack is ON
Confirms that the gripper sensor(s) detecting the
IN#(1615) #02026 Slp1_LoSrchSens
top of slipsheet dispenser 1 stack is ON
Confirms that the gripper sensor(s) detecting the
IN#(1616) #02027 Slp2_LoSrchSens
top of slipsheet dispenser 2 stack is ON

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4.1 Cell Setup Operational Sequence

In the PalletSolver application, control of the gripper is programmed in the

concurrent I/O using Registers and Auxiliary relays. A Double variable is
decomposed into two Integer variables that are then used to set two
Registers. A universal output is then pulsed to apply the change to the
auxiliary relays.
Table 4-3: 4 Sets of Outputs
Output Set Auxiliary Relays Description
GripOn 71030 to 71067 GripOn outputs are the main actuator to grip a
package and should always be used.
GripOff 71070 to 71107 The GripOff outputs are to be used when a
secondary signals is required to ungrip a
package. They are always the opposite of the
GripOn signal.
BlowOff 71110 to 71147 The BlowOff outputs are automatically
triggered to match GripOn signals that are
being turned off. The signal is held for the
amount time set in register M122.
VariableStroke 71310 to 71327 The VariableStroke outputs correspond to the
binary representation of the value set in the
VariableStroke register M109. The combination
the GripOn signals and the VariableStroke
signals can be combined to control the
actuators of a grip area into intermediate
position based on the package width.

Table 4-4: 5 Set of Inputs

Input Set Auxiliary Relays Description

Part Present
71150 to 71187 Signals from the gripper sensors
Sensor
Gripper Open Signals from the gripper actuators confirming
71190 to 71227
Sensor that the grip areas that are OFF are fully open.
Gripper Close Signals from the gripper actuators confirming
71230 to 71267
Sensor that the grip areas that are ON are closed.
Dispenser Part
Signals from the gripper sensor when a pallet
Present 71280 to 71284
or slip-sheet is present in the gripper
Sensor
Signals from the gripper sensor used when
searching for the top pallet or slip-sheet of a
Dispenser Part
71290 to 71297 stack. Each dispenser has a high speed and
Search Sensor
low speed search sensor. (See Gripper
Handling of Dispenser Part for details)

The specific external inputs and outputs of the gripper will need to be
mapped in the concurrent I/O to these auxiliary relays in the Concurrent
I/O for each specific system. The signals are resolved and generated for
all 32 bits of each set but only the required signals need to be mapped to
the external inputs and outputs.

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4.2 Station Setup

4.2 Station Setup

All stations have two variables, User Frame Offset and Clearance Height.
Pallet and Slip-Sheet Dispensers also have Station Types that must be
defined.
Fig. 4-4: Station Setup Flowchart

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4.2 Station Setup

4.2.1 User Frames

The robot knows the location of each station via a user frame. Section 2.2
“Station and Gripper Identification” on page 2-2 defines how the station
numbers are assigned.

4.2.1.1 User Frame Locations

Section 2.2.1 “Station and Gripper Identification” on page 2-3 shows user
frame location for the various station types.

4.2.1.2 Required User Frames Number

PalletSolver User frames numbers are fixed and cannot be changed. The
table below shows the Stations and their required User Frame Numbers.
Table 4-5: User Frame #
Station Required User Frame
Build Station 1 1
Build Station 2 2
Build Station 3 3
Build Station 4 4
Build Station 5 5
Build Station 6 6
Build Station 7 7
Build Station 8 8
Infeed Station 1 11
Infeed Station 2 12
Infeed Station 3 13
Infeed Station 4 14
Infeed Station 5 15
Infeed Station 6 16
Infeed Station 7 17
Infeed Station 8 18
Pallet Dispenser 1 21
Pallet Dispenser 2 22
Slipsheet Dispenser 1 31
Slipsheet Dispenser 2 32
Reject Station 1 41
a)
Pick Station 62
Place Stationa) 63
a) The Pick Station and Place Station user frames are dynamically recalculated
each cycle by combining the currently selected pick and place station user
frame and their associated frame offsets (see Section 4.2.1.3 “User Frame
Offsets”).

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4.2 Station Setup

4.2.1.3 User Frame Offsets

Sometimes the robot cannot reach the required user frame location on all
stations. (See Fig. 4-5) In this figure the robot reach is shown in yellow.
Location (1) is the desired user frame location. However the robot cannot
reach this point.
In these cases, the user can set the station user frame to a known location
such as the front left edge of the outfeed conveyor or position (2). A
measurable offset such as the width of the outfeed conveyor (3) can be
added to position (2).
Position (2) becomes the user frame. Position (3) is the offset from
Position (2).
When possible, the user frame should be set directly on the station,
position (1) and the offset (x,y, and z) should be set to 0.0
Fig. 4-5: Offset Reach

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4.2 Station Setup

4.2.2 Clearance Z
Each Station has a clearance height called Clearance Z. Clearance Z is
the height about the station user frame that will allow the robot to safely
transition over it. Clearance Z does not take into consideration product on
the station.
Some stations, such as Slipsheet stations, have a clearance height that is
larger than the station plus it’s associated product stack height. Other
stations such as some infeed conveyors have a clearance height that is
lower than the conveyor with typical product on it.
Fig. 4-6: Clearance Z
Clearance Z for Roller Conveyor Clearance Z for a Slipsheet Station

4.2.3 Dispenser Types

Dispensers hold a stack of Pallets or Slip-sheets. They can be Fixed Level
(the bottom product is pushed to a set pickup location) or Searchable
(varying stack height whose top of stack is determined by robot gripper).
Optional Station Level sensors can also be set to determine when the
stacks are low or empty.
Fig. 4-7: Pallet Dispensers
Fixed Level Pallet Dispenser Searchable Pallet Dispenser

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4.3 Cell Setup Applications’ Use of External Memory Devices

4.3 Cell Setup Applications’ Use of External Memory Devices

As described earlier in the chapter, the Setup application reads and writes
project files (*.pcs). These files are used for permanent storage of cell
setup information. It also writes a 'PalletSolver_Cell_Setup.JBI that
captures the same setup options in a job or *.jbi format. It is called from
the PalletSolver master job and the system will not run without a valid
setup job loaded on the controller.
The Cell Setup Application uses external memory (CF or USB format) as
described below:
1.0 Open Project File Command -- Reads the *.pcs project file from
CF/USB Memory
2.0 Write Cell Setup Job command
2.1 Writes *.pcs file to external CF/USB memory
2.2 Writes 'PalletSolver_Cell_Setup.JBI to CF/USB memory
2.3 Automatically moves the 'PalletSolver_Cell_Setup.JBI from CF/
USB memory to robot controller memory
The figure below shows this process graphically.
Fig. 4-8: Cell Setup using External Memory Device

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4.3 Cell Setup Applications’ Use of External Memory Devices

1. Failure to have a CF/USB memory device will cause

errors during read and write operations,
2. You can have multiple *.pcs project files
(For example you may create a project file that has only one
infeed and build station during initial setup or testing and then
later create a project with three infeeds and three build
NOTE stations as your system become or complete.)
3. You can only have one setup file named
'PalletSolver_Cell_Setup.JBI. Each time the Write Cell
Setup command is executed, it creates and overwrites
the old one.
4. Both the *.pcs files and the 'PalletSolver_Cell_Setup.JBI
are stored in the base directory of the USB/CF memory
device.

If the application is started without the CF Card or USB Flash Drive that
contains the correct support files, the Setup application will display a
message box, as shown in Fig. 4-9:
Fig. 4-9: No Storage Device Available Message Box

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4.3 Cell Setup Applications’ Use of External Memory Devices

To open an existing project, the user must insert a CF Card or USB Flash
Drive with a valid project file.
Alternatively, create a new project file without an external memory, but a
CF/USB memory is required before saving.
Fig. 4-10: Correcting No Storage Device Available Message Box

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4.4 PalletSolver Setup Application

4.4 PalletSolver Setup Application

4.4.1 Start PalletSolver Setup Application

With the Pendant Key, place the Controller in the Teach Mode. Set the
security level to Management.

NOTE The controller must be in Teach Mode and Management

Mode to display the PalletSolver Setup pendant button.

Below the {Main Menu} (1) press the right [►] button. Press the (2)
[APPLICATION] button and then select the (3) [PalletSolver Setup].
Fig. 4-11: Starting PalletSolver Setup Application Actions

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4.4 PalletSolver Setup Application

The PalletSolver Setup Screen appears see Fig. 4-12

Fig. 4-12: PalletSolver Setup Screen

4.4.2 Open an Existing Setup File

To open an existing Setup File, the user needs to select the desired Setup
File (1) and press the (2) [Open] button. The file will be read in and the
Setup Application will automatically open the Setup Editing form.
Fig. 4-13: Process of Opening an Existing File

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4.4.3 Defining a New Cell

To define a new cell, (1) press the New Button. The screen will be
replaced with a large Keyboard. (2) Type in the desired cell and (3) press
“Enter.”
Fig. 4-14(a): Process of Defining a New Cell

Fig. 4-14(b): Process of Defining a New Cell

When a new cell is created, the application automatically defines a

minimum cell of one gripper, one infeed, and one build station. The three
elements are created with default values. Actual values should be entered
to replace the default data.

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4.4 PalletSolver Setup Application

4.4.4 PalletSolver Editor

This is the page where most work is done. This page:
• Uses the station editor to add, delete and modify gripper and
palletizing stations
• Sets the control mode to PLC or Robot (local control)
• Defines the source of the XML Pattern files
• Writes the robot setup job: PalletSolverCellSetup.JBI
Fig. 4-15: PalletSolver Editor Screen

4.4.5 Cell Editor

The editor allows you to add new stations, and to delete and edit existing
stations and the gripper tool.
The Gripper is shown at the top of the cell editor window and all of the
stations are show below the gripper in the list box named Station List.

4.4.5.1 Station Selection

To select a station highlight the desired station in the Station List using the
mouse and then press the [Done] button.

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4.4.5.2 Add New Stations

To add a new station, the user presses the [Add] button see Fig. 4-15. A
form similar to Fig. 4-16 displays. Chose the type of station (1) by
selecting the Station Type and (2) press the [OK] button.
Fig. 4-16: Adding a New Station

The user will be lead through a series of wizard forms that guide them
through the setup options for each station type. Once all options have
been entered, the Editor form (Fig. 4-15) will reappear with the new station
type selected in the Station List.

4.4.5.3 Delete Station

To delete a station, select the last station of its type and press the [Delete]
button. If the station is deleted successfully a message box displays
(Fig. 4-17).
Fig. 4-17: Delete Message Box

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4.4 PalletSolver Setup Application

If you attempt to delete a station that is not the last of it's type, a delete
error will occur.
In the following example, the user has selected Feed Conveyor 2 to be
deleted.
Fig. 4-18: Example of Selecting Feed Conveyor 2 for Deletion.

When pressing the [Delete] button, the message screen in Fig. 4-19
displays and the last station of it’s type is highlighted.
Fig. 4-19: Delete Station Error

NOTE Do to FeedConv_3 being the last station of a type it is

highlighted automatically and can be deleted successfully.

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4.4.5.4 Edit Station

To edit a station, select it and press the [Edit] button. Each Station Wizard
Page displays and can be edited as explained in the following sections.

4.4.6 Gripper Definition

The major steps, required to define a gripper, are shown below.

4.4.6.1 Define Gripper Types

This release supports the following types of grippers:
• Vacuum
• Clamp
• Fork
• Bag
To select the desired gripper type from the {Gripper Sub Type} Menu
shown below:
Fig. 4-20: Defining Gripper Type

 Vacuum Grippers
Vacuum Grippers use suction to hold the boxes on the robot gripper. They
attach to the product tops and are generally the most flexible grippers to
work with. They are the most flexible and support the most number of
pallet patterns.

 Clamp Grippers
These grippers attach to a product's sides. The carry the product by
closing the paddles until they apply sufficient force to securely hold it.
Clamp Grippers come with a variety of gripper paddles, paddle covering
and paddle lengths.
These grippers are further divided by the number of paddles that move as
explained below:
• Clamp Fixed Edge
This gripper has one fixed paddle and one moving paddle.

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• Clamp Moving Edge

It has two moving paddles.
• Clamp Tool Parameters
– Max. Insertion - This is the maximum amount that the product
should be inserted into the clamp paddle. This distance must be
less than the gripper clamp paddle length. This parameter is
entered in millimeters.
– Min. Clearance - This defines a minimum distance between the
end of the clamp paddle and the conveyor or pickup surface. It is
entered in millimeters.
– Max. Y Opening - This the size of the clamp gripper when all
clamp paddles are open. The product width must be smaller than
this. It is entered in millimeters.
Fig. 4-21: Determining Clamp Gripper Type
Clamp Fixed Edge

Clamp Moving Edge

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4.4 PalletSolver Setup Application

 Fork Retractable
Fork Grippers carry the product on top of the gripper fork. They pick up the
product by going beneath the product (generally by having the fork tine's
go between the conveyor rollers) and then moving upward. They release
the product by retracting the gripper fork when the product is in the
desired location.
They are very reliable and are able to carry heavy products whose cases
cannot be gripped from the top or sides.
• Fork Gripper Retractable Zones
Fork grippers are further divided by the number of retractable fork
lengths. Fork grippers with more than one retractable length are
called “Fork Variable” grippers while fork grippers with only one
retractable length are called “Fork Retractable”. PalletSolver
supports fork grippers with 1 to 3 retractable lengths or zones.
• Fork Gripper Parameters
– Fork Thickness - User must measure and enter the thickness of
the fork tines.
– Fork Length - Distance from the tip of the fork tine when fully
extended to the side wall against which the box rests. This is the
area that is available for the product to ride on.
Fig. 4-22: Determining Fork Type
Fork Retractable

Fork Variable

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4.4 PalletSolver Setup Application

 Bag Gripper
Bag Grippers are used to move bag products. They operate like a claim
shell, having two closeable forks. The open forks pass between the
conveyor's rollers and go beneath and around the ends of the bag
product. The forks close and the robot moves the gripper up with the
gripper supporting the bag product from underneath.
Bag Grippers generally hold one product at a time. Bag palletizing is
performed very quickly. Many times the grippers forks are opening and
closing during robot motions and gives the appearance that the robot is
tossing the product onto the pallet.
• Z Open Clearance
This is the Z distance between the tip of the open fork and the top of
the closed fork surface where the bag product is held. This value is
required for proper gripper pick and place operation.

The figure below show the Z Open Clearance value that must be
entered.
Fig. 4-23: Bag Gripper Parameters for Z Open Clearance

4.4.6.2 Set Gripper ID

The gripper ID is set in this application and in the PalletSolver PC Pattern
Generation Tool. These IDs are how the system determines the same
gripper is being referenced for both systems.

4.4.6.3 Set Tool Center Point Number (TCP)

This form sets the tool number for use with:
• standard robot box pick and place operations
• empty pallet pick and place operations from a Pallet Dispenser
Station
• slipsheet pick and place operations from a Slip Sheet Dispenser
Station
Each tool number can be set to a value between 0 and 63.

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4.4.6.4 Grip Areas

This section only applies to Clamp, Fork, and Bag grippers. It will not be
visible when vacuum grippers are selected.
For Clamp and Fork Grippers, please check the following boxes if the
clamp/fork devices have sensors that are set when the clamp/fork is set to
the commanded position:
• Grip Areas have Close Sensors
• Grip Areas have Open Sensors
The number of grip areas must also be entered. For example the gripper
below has 3 grip areas.
Fig. 4-24: 3 Grip Area Clamp Gripper

Fig. 4-25: Wizard TCP Screen

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4.4.6.5 Gripper Motion Setup

Some grippers have motion related setup variables. The figures show
these the parameters required for each gripper type. In the figures below,
the relative motion is shown via blue vectors.

 Fork Gripper Motion Parameters

This gripper has three motion related parameters.
• Y Approach
Clears the side of the product as the gripper is moving down into
position. After the gripper is at the correct height, the gripper moves
in the Y direction until the stationary gripper product support moves
so that it touches the product side. The Y approach is typically in the
50 to 100 mm range.
• Z Below Approach
Moves the top of the forks below the box by a small distance
(generally between 10 and 50 mm.) If this value is set too low or too
high, the gripper could collide with parts of the infeed conveyor.
Once reaching this position, the gripper forks extend beneath the
product.
• Z Check Height
Moves the gripper up so that it clears the infeed conveyor surface
and that the gripper top clamp (not shown below) is closed. Gripper
securely holds the product at this point. This parameter is generally
in the 50 to 100 mm range.

 Bag Gripper Motion Parameters

This gripper has two motion related parameters.
• Z Below Approach
Moves the top of the fork below the bag by a small distance
(generally between 10 and 50 mm.) If this value is set too low or too
high, the gripper could collide with parts of the infeed conveyor or the
bag. Once reaching this position, the gripper forks close beneath the
product.
• Z Check Height
Moves the gripper up so that it clears the infeed conveyor surface
and that the gripper top clamp (not shown below) is closed. The
gripper holds the product securely at this point. This parameter is
generally in the 50 to 100 mm range.

 Other Gripper Motion Parameters

Other grippers (Clamp and Vacuum Grippers) do not have any motion
parameters included in the Cell Setup application. When these gripper
types are selected a “No Motion Parameters Required for This Gripper
Type” message displays.

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Fig. 4-26: Gripper Motion Parameters

Fork Gripper Motion
Parameters

Bag Gripper Motion

Parameters

Other Grippers Not

Requiring Motion
Parameters

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4.4.6.6 Gripper Operation

Gripper operation is controlled via CIO Ladder modifications. See section
4.1.1 "Robot Controller/ Gripper Interfaces” on page 4-3 and section 6.3.2
"Gripper Setup Introduction” on page 6-17 for more details.
To setup the Gripper Sensor and to robot input mapping:
(1) Select the starting input number. It is recommended to set it to 73
(see section 4.1.1 "Robot Controller/ Gripper Interfaces” on page
4-3 and section 6.3.2 "Gripper Setup Introduction” on page 6-17.)

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4.4.7 Station Definition

Pallet Solver stations consist of:
• Build Stations
• Infeed Stations
• Reject Station
• Pallet Dispenser
• Slip-Sheet Dispenser
Station Setup consists of defining the following parameters for all stations:
• User Frame Offsets
• Clearance Z Heights
Fig. 4-27: Defining Station Flowchart

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4.4.7.1 Dispenser Stations Types

Dispenser stations also have subtypes as described below.
Two types of dispenser stations are supported. These include stations that
dispense product to a set location and are referred to as “Fixed Level”
dispensers, and searchable dispensers called “Searching Stack”
dispensers. Searching Stack dispensers use the gripper and it's sensors
to define the current stack height. These station types are shown below:
Fig. 4-28: Selecting Type of Dispenser
Fixed Level
Dispenser

Searchable
Dispenser

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4.4.7.2 Optional Station Sensors

Station Sensors may also be added to each dispenser station. These
sensors constantly monitor the height of the dispenser stack and can give
a warning when the stack goes below a desired level (Low Height Sensor)
or an alarm when the stack is empty. These sensors can be used on both
Fixed Level and Searchable Stations as seen below.
Fig. 4-29: Selecting Optional Level Sensors
Fixed Level
Dispenser with
Optional Station
Level Sensors

Searchable
Dispenser with
Optional Station
Level Sensors

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The following forms are the same for each of the station types. The only
thing that changes is the picture of the station type.
Fig. 4-30: Station Wizard

Fig. 4-31: User Frame Wizard

Enter any user frame offsets in the X, Y, and Z boxes below. User Frame Offsets
are defined earlier in this section.

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Fig. 4-32: Clearance Z Wizard

Enter the clearance Z value in the form below. Remember that the Clearance Z is
the safe transition height over the empty station.

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4.4.8 Pattern Setup

The PalletSolver PC creates one pattern file for each pallet solution.
These pattern files can be opened from one of three possible sources:
• Compact Flash Card
• USB Flash Drive
• Via Network (Ethernet)
The Pattern Setup section allows the user to select and store this
information in the Setup files (XML and Job formats.) This source of the
pattern files is chosen from the “Select Pattern File Source” drop down
box.
Fig. 4-33: Pattern Setup from USB or CF Card

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4.4.9 Network Option

The Network option allows the controller to retrieve pattern files by
accessing a FTP Server on an Ethernet network.
As Fig. 4-34 shows, when the “Network” option is chosen, additional
information must be entered. This information includes:
• FTP User Name
• FTP Password
• IP Address and
• Network Directory
The FTP User Name and/or Password may be left bank. These options
maybe required for FTP Anonymous operation.
Fig. 4-34: Setting Network

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4.4.9.1 Pattern File Naming Convention

Pattern files are created with the following naming convention:
<ProductID>,<PatternID>,<CellID>,<StnID>.xml
The following example shows a number of pattern file names and their
meanings:
• 111,1,1,1.xml - Where
• ProductID = 111
• PatternID = 1
• CellID = 1
• StnID (Build Station ID) = 1
• 123,2,2,3.xml = where
• Product ID = 123
• Pattern ID = 2
• Cell ID = 2
• Stn ID (Build Station ID) = 3

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PalletSolver 4 Controller PalletSolver Setup Application
4.4 PalletSolver Setup Application

4.4.9.2 Network Folder Usage

FTP Servers may set their Home directory to essentially any directory they
prefer. All external references refer to subdirectories under the Home
directory. The Network Directory must be setup this way and is further
explained below:
<FTP Server Home Dir.>/<Network_Dir.>/Cell#/filename.xml
At the deepest folder level, the .xml pattern file must be in a subdirectory
titled “Cell#” where # is the Cell ID number. This corresponds to the folder
structure enforced by the PalletSolver - PC Pattern Generation Tool when
creating the pattern files.
The Network_Dir should always be specified with a leading “/” character.
This corresponds to the “Home Directory” or root of the FTP Server.
The following table gives six example pattern files names and directories.
It shows three possible FTP Server Home Dir. Settings and the correct or
required Network Directory settings.

Table 4-6: Pattern File and directory on FTP Server

Pattern File and directory on FTP Server Example FTP Server Home Required Network_Dir
Dir. Setting Setting
C:\Data\PatternLibrary\Cell1\ 111,1,1,1.xm C:\ “/Data/PatternLibrary
C:\Data “/PatternLibrary
C:\Data\PatternLibrary “” or (blank)
C:\Data\PatternLibrary\Cell1\123,2,1,1.xml C:\ “/Data/PatternLibrary
C:\Data “/PatternLibrary
C:\Data\PatternLibrary “” or (blank)
C:\Data\PatternLibrary\Cell1\199,2,1,2.xm C:\ “/Data/PatternLibrary
C:\Data “/PatternLibrary
C:\Data\PatternLibrary “” or (blank)
C:\Data\PatternLibrary\Cell2\ 111,1,2,1.xml C:\ “/Data/PatternLibrary
C:\Data “/PatternLibrary
C:\Data\PatternLibrary “” or (blank)
C:\Data\PatternLibrary\Cell2\ 123,1,2,1.xml C:\ “/Data/PatternLibrary
C:\Data “/PatternLibrary
C:\Data\PatternLibrary “” or (blank)
C:\Data\PatternLibrary\Cell2\ 199,1,2,1.xml C:\ “/Data/PatternLibrary
C:\Data “/PatternLibrary
C:\Data\PatternLibrary “” or (blank)

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PalletSolver 4 Controller PalletSolver Setup Application
4.4 PalletSolver Setup Application

4.4.10 System Control

The PalletSolver can run with or without a PLC. If the Robot is controlling
the system then the user would select Robot option of System Control. If a
PLC is controlling the system simply set the PLC Radio button.

• The PLC control and monitor signals are covered in

Chapter 7 "DX100 & DX200 Operation Monitor and
Control Interface". Appendix A has a list of pre-mapped
robot controller inputs and outputs that can be used by
NOTE the PLC to control the robotic palletizing system.
• During PLC control, the Monitor and Control Pendant
Application is limited to Monitoring only. See section
8.3.1 "System Overview Screen” on page 8-3 for more
details.

4.4.11 Write Cell Setup Job

Pressing this button will attempt to write both the cell setup *.xml project
file and the 'PalletSolver_Cell_Setup.JBI as described in detail in
Section 4.3 “Cell Setup Applications’ Use of External Memory Devices”.
When the tasks are successfully completed, a Message box is displayed
(see Fig. 4-35.)
Fig. 4-35: Setup Job Successfully Written Message Box

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4.4 PalletSolver Setup Application

4.4.12 Close Button

If edits have been made and the user presses the [Close] button, a
Message Box is displayed. It warns the user that the edits made will be
lost if the file is not saved.
Fig. 4-36: Project File Modified Message Box

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PalletSolver 5 PalletSolver PC Pattern Generation Tool
5.1 Build Pattern Files

5 PalletSolver PC Pattern Generation Tool

PalletSolver PC Pattern Generation Tool optimizes the time required to
create pallet build patterns by allowing the user to develop the build
pattern on a PC without requiring the physical system. Each Pallet Build
Pattern is exported from the PC application as a single XML file. See the
PalletSolver PC Pattern Generation Tool Manual for specific information
on the pallet build pattern work flow.

5.1 Build Pattern Files

These XML- formatted build patterns can be imported from one of three
storage devices:
• USB Flash Drive
• CF Card
• Connecting the robot controller to an Ethernet FTP site.
For details on setting the XML Build Pattern source, refer to Section 4.4.8
“PalletSolver Setup Application” on page 4-35 for more details.

5.1.1 MotoPlus Pattern File Importer Application

When changing build patterns, the MotoPlus Pattern File Importer
Application retrieves the XML formatted build pattern file, from the
specified source, and converts the file to a robot controller job or *.jbi.
The MotoPlus application:
• is started automatically when the robot controller is powered up,
• is always running and ready to convert a build pattern into a robot
job,
• has little or no direct user interface,
• can only assign one build pattern to each build station
• can unassign a build pattern and thus make the build station offline
or in a locked state,
• checks the build station's state to ensure that the build pattern can be
changed.

5.1.2 Initiating Build Pattern Conversion

While the MotoPlus application does the actual XML to robot job
conversion, the conversion process can be initiated by using the Build
Station Assign/Unassign command describe in Section 7.3 “Interface:
Message Communication” on page 7-15.
An operator can also assign and unassign patterns using the “Build
Station Screen” of the PalletSolver - HMI pendant application described in
Chapter 8 "Operation Monitor and Control Pendant Application".

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6.1 Structure

6 Controller Jobs and Concurrent I/O Program

During operation, the controller's standard software will playback a set of
standard palletizing jobs and run the Concurrent I/O program written for
this palletizing system. A master job will call subroutines that will take care
of resetting the system, controller the sequence, pick and place package,
etc.

6.1 Structure

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6.2 Jobs

CAUTION
Only use signals and variables for the purpose that they are intended.
The PalletSolver jobs interface is done using fixed assignment of
variables and I/O signals. Those variables and I/O signals are pre-
assigned and labeled in the system.

Modifying the signals and variables to purpose other than they are
intended may cause damage to equipment.

The jobs are the robot controller programs or scripts that run the
palletizing system. In PalletSolver, the jobs are divided into three
categories: System Jobs, Standard Job and User Jobs.

6.2.1 System Jobs

CAUTION
Do not edit these jobs. If modifications are required, contact your
YASKAWA representative for assistance

Editing these jobs can cause damage to equipment.

System jobs are jobs that are automatically started once the controller
completes its boot sequence. They run in the background even when the
controller is not playing back the jobs. They are not accessible to the user
under normal circumstances.

6.2.1.1 System_PLC_Messaging
The system PLC messaging job allows the controller to maintain message
communication with the PLC even if the MasterJob is not running. This
allows the PLC to send command message and get reply back from the
controller as long as the controller is powered up. Note that for some
commands, the data may not be up to date if the Master Job is not
running.

6.2.1.2 System_Machine_State
The system machine state job keeps some of the I/O and variables
representing the state of each station up to date base on changing input or
command received.

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6.2.2 Standard Jobs

CAUTION
Do not edit jobs. If modifications are required, contact your YASKAWA
representative for assistance.

Editing jobs can cause damage to equipment.

The job structure breaks down the job functions into main jobs that run as
separate tasks. Those main jobs may then call on several sub jobs. Some
variables and I/O signals are used to handshake between the tasks
running in parallel and synchronize them when necessary.

6.2.2.1 PalletSolver_Master_Job
Initialize the system and start the other tasks. The main initialization steps
are:
• Call the USER_ADJUSTMENT job
(section 6.2.3.1 “USER_ADJUSTMENTS”)
• Safely move the robot back to the home position
• Clear required I/O signals and variables
• Load the cell setup generated by the PalletSolver-Cell Setup
pendant application
• Set the Gripper mapping
• Calculate the stations position around the robot
• Start task:
• PalletSolver_Planner
(section 6.2.2.2 “PalletSolver_Planner:”)
• PalletSolver_Motion:
(section 6.2.2.3 “PalletSolver_Motion”)
• USER_CONTROL_TASK
(section 6.2.3.2 “USER_CONTROL_TASK”)

6.2.2.2 PalletSolver_Planner:
Based on the sequencing mode and the station current state, this task
selects the next build pattern and then set the required information for its
next pick and place cycle. This task handshakes with the
PalletSolver_Motion task to coordinate the timing at which the planning is
ready for the motion and when the next cycle planning can be started.

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6.2.2.3 PalletSolver_Motion
This is the only task that moves the robot. It moves the robot through the
path determined by the palletizing planner. The product's pick and place
sequence are executed by this standard job. For dispensers and reject
station, customizable user jobs are called so that they can be adapted to
the various devices and setups. See section 6.2.3 “User Jobs” on page 6-
4 for details.

6.2.2.4 PalletSolver_Cell_Setup
The “PalletSolver - Cell Setup” pendant application generates a job that
will set system definition variables when it is executed at the beginning of
the master job. This ensures that the system is reset properly every time
the system restarts.

6.2.2.5 PATTERN_#
The “XML Pattern File Importer” MotoPlus Application also converts the
XML pattern file generated by the “PalletSolver-PC: Pattern Generation
Tool” application to job files that will set pattern definition variables for the
appropriate build station. Note that pattern file information is usually too
large to be completely loaded into variable memory. So, after the initial
load of the general information (used stations, virtual gripper
definitions…), the pattern job is repeatedly called at each pick/place cycle
to set the variables related to the pick/place with the current cycle data.

6.2.3 User Jobs

User jobs are jobs that are intended to be modified as needed to adapt the
PalletSolver system to the user specific needs and devices. The default
template job supplied with the system should provide a good starting point
for most systems. Most of the changes should be minimal for example
setting some I/O points address or adjusting a key position. User jobs
have a capitalized name starting with “USER_”.

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6.2.3.1 USER_ADJUSTMENTS
The “USER_ADJUSTMENTS” job contains variables such as clearance
heights, search heights, timers etc. that can be adjusted by the user to fit
their system specific needs. Please refer to the comments in the job for
details on each adjustment.

 Home Position
The Home_User_Set variable (P700) is the position where the robot
returns to when the system is not palletizing. This position is defined in
pulse coordinates so that it is not affected by tool changes. To prevent an
accidental change of this position, the position is set in the
USER_ADJUSTMENTS job. To set the values, the operator can move the
robot to the desired position and display the robot current position and
write down the values, then enter those values as the last argument of the
SETE instruction.
Fig. 6-1: Setting Home Position in USER-ADJUSTMENTS JOB

Whenever the system is reset the robot will move directly up

to clear all stations, move backward or forward to be on the
NOTE same radius as the Home position, and then swivel around
to the Home position. Pay attention when defining the Home
position so that it is on a radius that allows moving around
the whole cell without hitting any obstacles or fences.

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Once the home position is determined, the Interference Area 64 should be

defined in Axis Interference method (pulses) so the Home Position is
inside the Interference Area 64. Please refer to the Controller Instructions
Manual for further detail on defining the Interference Areas.
Fig. 6-2: Defining Interface Area 64

 Ready Position
The Ready_Position variable (P743) is the position where the robot
returns to when the system is idle because no stations are ready. It is
recommended to place the Ready position close to the infeeds to improve
cycle time.
To use this position, set the output #248 Ready_Exists to ON in the
USER_ADJUSTMENT job. The usrIdleTimeLimit (R756) can be set to
adjust the time in second to wait in idle before sending the robot to the
Ready Position.
In the same way as the Home position, the Ready position is defined in
pulse coordinates so that it is not affected by tool changes. To prevent an
accidental change of this position, the position is set in the
USER_ADJUSTMENTS job. To set the values, the operator can move the
robot to the desired position and display the robot current position and
write down the values, then enter those values as the last argument of the
SETE instruction.
Once the Ready Position is determined, the Interference Area 1 should be
defined in either Cubic or Axis Interference method so that the Ready is
inside the Interference Area 1. Please refer to the Controller Instructions
Manual for further detail on defining Interference Areas.

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 Via-Points
The standard robot motion between stations consist of radial motion. In
some irregular shaped cell layout, this may cause collision with fencing or
some other components in the cell. Via-points can be define to modify the
path of the robot between stations.
Fig. 6-3(a): Via-point Example

When a via-point is define between stations, the robot path will be

modified so that the package Grip TCP of the gripper passes by the
via-point X, Y coordinates with the set Rz rotation. The Z coordinate will
be the same or above the define via-point.
Up to 6 via-points can be defined in the USER_ADJUSTMENT job.
Via-points are considered defined when the X or Y value of a via-point is
non-zero. Via points define the robot base frame (X, Y, Z, Rz) using the
package Grip TCP.
To set the appropriate values, set the current tool to the package grip TCP
and move the robot in the desired position. Display the robot current
position in the Base frame and record the values. Then go to the
USER_ADJUSTMENT job and modify the values set for the via point to
those recorded. All the digits should be entered but without the decimal
points because the values of the SETE instructions are in microns
(0.001 mm) or 0.0001 degrees.
Fig. 6-3(b): Setting Via-point in USER_ADJUSTMENT job

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 T-axis Motion Control (DX100 only)

For the DX100, the T_PulseMax (D757) and T_PulseMin (D758) variables
are used to define the range within which the T-axis can move while
preventing the gripper cables from winding around the T-axis and getting
pulled too tightly. Move the gripper by pressing the T+ key until the desired
maximum (leaving some of play in the cables) is reach. Look at the T-axis
current position in pulses and enter the value on the SET T_PulseMax
instruction. Repeat the same process in pressing the T- key and enter the
value for the SET T_PulseMin instruction.

• If the standard T-axis software limits are made too

restrictive, conversion errors may occur during playback.
In such case, open up the standard software limits. The
T_PulseMax (D757) and T_PulseMin (D758) variables
NOTE will take care of controlling the T-axis proper motion
during normal playback of PalletSolver jobs.
• For the DX200, the T-axis motion is controlled by setting
parameter S2C430 to 4 and adjusting the soft limits to
the desired range of motion.

 Minimum Clearance Height

The All_Clear_By_um variable (D759) is the minimum clearance to have
between the package in the gripper and the stations clearance when
moving above stations. The minimum value is 25 mm. Adjust this value to
take into account motion cornering and to keep a comfortable distance
between the gripper and the top of stations.

 Look Ahead
The LookAheadOn variable (D757) enable the planning of an extra cycle
ahead of time. When set to 1, it will populate extra information about the
infeed next cycle required quantity. This information can be retrieved by
using the “Get Infeed Lookahead Row Data” message (see Table 7-26
"Get Infeed Lookahead Row Data" on page 7-38 for details). Note that
enabling Lookahead variable will slightly increase the cycle planning time.

 Smart Conveyor Mode

The smart conveyor mode can be enable for a single row,
UsrSmartOneRow (B758) or multiple row conveyor configuration,
UsrSmartMultirow (B759). When the Smart Conveyor mode is enable,
orientation of the box on a row is added to the quantity of boxes.
Bits 0-5 contains the quantity 1-63 and bits 6-7 the orientation:
Table 6-1: Byte Locations

Bit 7 6 5 4 3 2 1 0
Usage Orientation Number of boxes 1-63

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Table 6-2: Bits 6 and 7 Sets The Orientation

Orientation Bit 7 Bit 6
0 degrees 0 0
90 degrees 0 1
180 degrees 1 0
270 degrees 1 1

For multiple row conveyor, this information can be retrieved by using the
“Get Infeed Row Data” message (see Table 7-25 "Set Station Maximum
Layer" on page 7-37 for details).

 Approach Vector
The approach vector variables are set globally for all build stations. There
are two options:
• Set vector magnitude as a (%) relative to the height of the box.
• Set an absolute value in mm.

NOTE For absolute values to be considered the relative % value

must be set to 0%.

Table 6-3: Approach Vector Variables

Station Relative % of box height Absolute value in mm
Name Variable Name Variable
XY Approach Usr_XY_vect_% I750 Usr_XY_vect_mm I753
Z-High Approach Usr_Z_Hi_vect_% I751 Usr_Z_Hi_vect_mm I754
Z-Low Approach Usr_Z_Lo_vect_% I752 Usr_Z_Lo_vect_mm I755

Fig. 6-4: Approach Vector Diagram

During the pattern generation on the PC, the pattern is

validated for a Maximum Approach Vector. If the set
NOTE approach vector exceed the pattern Maximum Approach
Vector, the build station will lock and job warning 36 will be
generated.

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 Motion Speed
The motion speed variables set the default speed and acceleration.
Different values can be set when the gripper is empty and when it is
holding boxes (loaded), a pallet or a slipsheet. The Air Motion Velocity %
is the speed value that will be used for MOVJ VJ=<Air Motion Velocity %>.
The Approach Motion Velocity % will be multiplied by the robot maximum
linear velocity (usually 1500 mm/s) and used for MOVL V=<Approach
Motion Velocity %> x <Robot Maximum Linear Velocity>. The acceleration
is used with motion argument ACCEL=<Acceleration %> and
DECEL=<Acceleration %>. All these percentages need to be between 1%
and 100%. Note that the loaded values will also be multiplied by a product
specific speed and acceleration ratio as define in the pattern file
generated by the PalletSolver - PC Pattern Generation Tool.
Table 6-4(a): Motion Speed Variables for Empty Gripper and
Loaded with Boxes
Empty Gripper Loaded with Boxes
Name Variable Name Variable
Air Motion UsrEmptyAirVel% B750 UsrLoadedAirVel% B753
Velocity %
Approach Motion UsrEmptyApprVel% B751 UsrLoadApprVel% B754
Velocity %
Acceleration and UsrEmptyAcc% B752 UsrLoadedAcc% B755
Deceleration %

Table 6-4(b): Motion Speed Variables for Loaded with Pallets and Loaded
with Slipsheet
Loaded with Pallet Loaded with Slipsheet
Name Variable Name Variable
Air Motion UsrPalletAirVel% B774 UsrSlipAirVel% B777
Velocity %
Approach Motion UsrPaletApprVel% B775 UsrSlipApprVel% B778
Velocity %
Acceleration and UsrPalletAcc% B776 UsrSlipAcc% B779
Deceleration %

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• Stack Dispenser Motion

For pallet and slipsheet dispensers where the robot picks from a
stack, the main settings are available through the pendant Cell Setup
application, but extra adjustments are also available as USER
ADJUSTMENT for finer control. The figures below show the various
settings and whether they can be adjusted in the Cell Setup
application or the USER_ADJUSTMENT job.
Fig. 6-5: Stack Dispenser Downward Motion

Fig. 6-6: Stack Dispenser Upward Motion

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After a first search has been done, the starting point of the next
search is set to the position where the last product was found. If
cases where the product is fairly thin (slipsheet), this might take the
robot at fairly high speed to close to the product before the search is
initiated. The Next Search Offset value is added to the last found
position (height) and can be adjusted to start the next search from a
higher point.
Table 6-4(c): Pallet and Slipsheet Next Search Offset Variables
Station Name Variable
Pallet Dispenser 1 pd1NxtSrchOffset I605
Pallet Dispenser 2 pd2NxtSrchOffset I630
Slipsheet Dispenser 1 sd1NxtSrchOffset I655
Slipsheet Dispenser 2 sd2NxtSrchOffset I680

Speed and distance can be specified for the upward motion after
picking from the stack. This is useful to make adjustment to allow
proper separation between stacked slipsheets (or pallets). The
speed value is specified in mm/s. If the speed is not specified (set to
0) then normal approach linear motion is used. The distance is
specified in mm from the pick point. The upward motion is capped
so that it does not exceed the defined stack maximum start search
height.
Table 6-4(d): Pallet and Slipsheet Dispenser Variables For Upward Motion
Station Name Variable
Pallet Dispenser 1 pd1MoveUpDist D607
pd1MovUpSpeed D608
Pallet Dispenser 2 pd2MoveUpDist D632
pd2MovUpSpeed D633
Slipsheet Dispenser 1 sd1MoveUpDist D657
sd1MovUpSpeed D658
Slipsheet Dispenser 2 sd2MoveUpDist D682
sd2MovUpSpeed D683

 Pick/Place Timer
The Pick/Place timer variables are time delay after the gripper I/O has
been signal and before the next motion starts. The value is in units of 0.01
second. So a value of 50 is equivalent to 0.50 second. They are defined
for each station:
Table 6-5: Pick/Place Timer Variables
Station Pick Place
Name Variable Name Variable
Infeed Conveyor 1 fd1Pick_Time I121 fdPlace_Time I122
Infeed Conveyor 2 fd2Pick_Time I146 fd2Place _Time I147
Infeed Conveyor 3 fd3Pick_Time I171 fd3Place _Time I172
Infeed Conveyor 4 fd4Pick_Time I196 fd4Place _Time I197
Infeed Conveyor 5 fd5Pick_Time I221 fd5Place _Time I222
Infeed Conveyor 6 fd6Pick_Time I246 fd6Place _Time I247
Infeed Conveyor 7 fd7Pick_Time I271 fd7Place _Time I272
Infeed Conveyor 8 fd8Pick_Time I296 fd8Place _Time I297
Pallet Dispenser 1 pd1Pick_Time I601 pdPlace_Time I602
Pallet Dispenser 2 pd2Pick_Time I626 pd2Place _Time I627
Slipsheet sd1Pick_Time I651 sdPlace_Time I652
Dispenser 1
Slipsheet sd2Pick_Time I676 sd2Place _Time I677
Dispenser 2

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 Blow Off Timer

The UsrBlowOffTimer (I759) variable is used with vacuum gripper to set
the duration of the blow off. The value is in units of 0.01 second. So a
value of 50 is equivalent to 0.50 second.

 Network Delay
The setting “Network_Delay” is the delay in milliseconds that the robot
controller will wait before retrying to re-read a packet of data when an
error occurs retrieving a pattern file from a network. The default value is
50 milliseconds, but results may be fine-tuned on a particular network. If
there are many errors occurring when trying to retrieve a pattern file
across the network, try increasing this value.

6.2.3.2 USER_CONTROL_TASK
This job runs as an independent task that only starts if the system control
is set as "Robot" in the PalletSolver Setup pendant application and is
mainly for when the robot controller is controlling the number of box on the
infeed conveyor and the removal of the pallet on the build station.
If the infeed conveyors control signals are wired directly to the robot
controller rather than a PLC, then the System Integrator will need to
modify job to evaluate the quantity needed, control the conveyor to obtain
that quantity, and send back a ready signal.
For pallet removal, jobs are customizable by removing a pallet by
interacting with a conveyor or an operator doing a manual removal.
The default “USER_CONTROL_TASK” only contains a loop with a timer
inside. The user code should be inserted inside the loop.

CAUTION
The timer inside the loop of the “USER_CONTROL_TASK” must not be
removed otherwise this task will use too much system resources and
affect the system overall performance.

The job programming can be done to complete handshake that would

normally be done by a PLC. To this end, the outputs and inputs intended
for the PLC have been also been mapped to a block of user I/O that can
be used by user job to emulate PLC logic in a job. To emulate the inputs
that would normally be coming from a PLC, the output signals starting at
993 have been combined with an OR instruction with the PLC and
Network signals to trigger input starting at IN#193. So any input from
IN#193 to IN#480 can be triggered by changing the state of the output
corresponding to the input number plus 800. For example, to turn ON
input #254, turn ON output #1054 (254 + 800). In a similar way, controller
output signals intended for the PLC which start at OT#193 can be checked
by looking at signals starting at input IN#993.

To avoid conflicts between multiple points of control, the

user job outputs and Pendant HMI Network signals are only
NOTE considered when the system is defined as ROBOT
controlled. The PLC outputs are only considered when the
system is defined as PLC controlled.

Refer to Chapter 7 "DX100 & DX200 Operation Monitor and Control

Interface" for details about the various I/O handshake.

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6.2.3.3 USER_MOVE_REJECT
This job is called whenever the system aborted a sequence and needs to
safely drop off any package held by the gripper before continuing with the
next cycle. The user should program a path clear of any potential collision
from the “Home” position to the reject position and then back to the home
position. Interaction can be programmed at the drop position using the
reject station I/O signals: “Force Gripper Release”, “At Reject Drop”,
“Reject Drop Acknowledge”.
For more elaborate reject sequence where the exact product in the gripper
need to be considered, the package in the gripper can be identified by
looking up the source if the package which is stored in variables
Grip_PickStnType (B840) and Grip_PickStnID (B841). User should
consider if the system can reject pallet or slipsheet. For example the
following code segment would enable the user to get the package height
to adjust the drop height:
…
Get the package height
and handling speed for
package in gripper
IFTHEN Grip_PickStnType=2
Infeed Conveyor
SET Variable_Offset EXPRESS ( Grip_PickStnID - 1 ) * 25
SET PackHeight_adr EXPRESS 123 + Variable_Offset
SET GripPackHeight D[PackHeight_adr]
ELSEIF Grip_PickStnType=3 ORIF Grip_PickStnType=4
Pallet or Slipsheet Dispenser
SET Variable_Offset EXPRESS ( Grip_PickStnType - 3 ) * 50 + (
Grip_PickStnID - 1 ) * 25
SET PackHeight_adr EXPRESS 603 + Variable_Offset
SET GripPackHeight D[PackHeight_adr]
ELSE
SETUALM 8007 “INVALID PICK STATION TYPE” Grip_PickStnType
Unknown source of package
currently in gripper
PAUSE
ENDIF
…
Please refer to comments in the template job and Chapter 7 "DX100 &
DX200 Operation Monitor and Control Interface" for details about the
reject station signals.

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6.2.3.4 USER_GRIPPER_ON
The “USER_GRIPPER_ON” job is called to grab boxes on one of the
infeed by turning on vacuum, closing clamps, extending forks. There four
arguments passed to this job: Grip 1 to 16, Grip17 to 32, Sensor 1 to 16
and Sensor 17 to 32, which are the values defined by the Pattern file to
grab the boxes in the required gripper zone.
The default “USER_GRIPPER_ON” job assigns those values to the
proper registers and pulses the corresponding output to apply the
command to the gripper. Modification of the job should only be required if
secondary actuators need to be activated after the primary actuator is
turned on. For example on a fork gripper, if clamp down mechanism needs
to be activated after the forks are extended.
For further details on gripper operation and examples, please refer to the
Gripper Control section.

6.2.3.5 USER_GRIPPER_OFF
The “USER_GRIPPER_OFF” job is called to release boxes by turning off
vacuum, opening clamps, retracting forks. There four arguments passed
to this job: Grip 1 to 16, Grip 17 to 32, Sensor 1 to 16 and Sensor 17 to 32,
which are the values defined by the Pattern file to release the boxes in the
required gripper zone.
The default “USER_GRIPPER_OFF” job assigns those values to the
proper registers and pulses the corresponding output to apply the
command to the gripper. Modification of the job should only be required if
secondary actuators need to be activated after the primary actuator is
turned on. For example on a fork gripper, if clamp down mechanism needs
to be raised before the forks are retracted.
For further details on gripper operation and examples, please refer to the
Gripper Control section.

6.2.3.6 USER_DISPERSER_GRIPPER_CONTROL
This jobs is used to control the robot gripper during the handling of pallets
and slip-sheets.
It is called from the following jobs:
• Motion_Pick_Dispenser_Fix.JBI,
• Motion_Pick_Dispenser_Stack.JBI, and the
• Motion_Place_Dispenser.JBIs
The jobs is supplied with 3 major inputs which are:
• Station Type (Pallet or Slipsheet Dispenser)
• Station ID and
• Action
– PREPICK
– ON or CLOSE
– OFF or OPEN
– POSTPLACE

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The PREPICK and POSTPLACE commands are optional. They can be

used to prepare the gripper for picking pallets and/ or slip-sheets or for
restoring the gripper after the product has been placed. One example of
how a PREPICK command could be used would be to lower vacuum cups
on a fork or clamp gripper. The POSTPLACE would then be used to
restore the vacuum cups to their normal location after the placement is
complete.
The Following example shows how the user would turn on the first 3 grip
areas and the first 3 sensor areas during a pallet or slip-sheet Pick up
operation.

IF Action=”ON” ORIF Action=”CLOSE”

' Turn on grip area 1,2,3
' Binairy value of 7
SETREG MREG#(110) 7
‘zones 17 to 32 not used
SETREG MREG#(111) 0
PULSE OT#(Grip_ON)
' turn on Sensors
' Set sensor feedback
SETREG MREG#(114) 7
SETREG MREG#(115) 0
PULSE OT#(Sensor_ON)
ENDIF
For further details on gripper operation and examples, please refer to
the Gripper Control section.
It is also possible to include checks in this routine to confirm proper
grasping of pallet or slipsheet. Error handling routine can be
customized and calls to the MOTION_PICK_PLACE_ERROR routine
made to generate Job Warning and get recovery response such as
ignore/retry/abort. On a successful dispenser operation, the
USER_DISPERSER_GRIPPER_CONTROL job should return 0, on a
failure returning a value of -1 will cause the calling routine to abort the
sequence.

6.2.3.7 USER_CLEAR_IO
This job is call whenever the system is restarted from the Top of the
Master Job. It allows the user to reset the user control output (OG#125 to
160 or OT#993 to 1280). The default “USER_CLEAR_IO” resets all the
user control output back to the OFF state except for the “Speed Override”
output group (OG#132).

6.2.3.8 USER AUTO_DISPENSE

This job signals an external device to dispense a product to a build station
and wait until completion to increment the next layer.
It is used to complete signaling when control mode is robot and when the
robot is not handling the empty pallets from the pallet dispenser.

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6.3 Concurrent I/O

6.3.1 Overview

CAUTION
PalletSolver concurrent I/O program modifications may cause damage
to equipment.
Only make gripper control modifications to the concurrent I/O.

The PalletSolver Interface between the operator/PLC is done through I/O

signals. The controller concurrent I/O program maps the jobs universal I/O
and other system I/O to external and network I/O that can be accessed by
PLC and Pendant Applications to monitor and control the system. The
concurrent I/O also controls the gripper operation.
PalletSolver uses a modified concurrent I/O program in the controller.
There modifications are essential for proper and safe operation of the
system.
Only Concurrent I/O changes to allow for gripper control are allowed.
Making other changes to the concurrent I/O ladder are not allowed and
could cause unpredictable behavior of the system.

6.3.2 Gripper Setup Introduction

Section 4.2.2 “Robot Controller/ Gripper Interfaces” on page 4-3 gives a
general overview of the communications between the robot controller and
the Gripper. Please see this section for background information.
This section gives detailed instructions for the users on how to setup
various types of grippers to work in the PalletSolver system. In general,
the vast majority of gripper setup work is generic and does not have to be
changed.
The following functions must be completed by the user:
• Mapping External Outputs - Mapping concurrent I/O auxiliary
relays outputs to robot controller external outputs (mappings go into
the concurrent IO file) for:
– Grip On/ Clamp Close/ Fork Close
– Grip Off/ Clamp Open / Fork Open
– Blow Off
– Variable Stroke
• Mapping External Inputs - Mapping concurrent I/O auxiliary relay
inputs to robot controller external inputs for:
– Gripper Part Present Sensor Inputs
– Gripper Open Sensor Inputs
– Gripper Closed Sensor Inputs
– Gripper Pallet part present (from Pallet dispenser #1 and #2)
– Gripper Slipsheet part present (from Slipsheet dispenser #1 and
#2)

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• Mapping Universal Outputs to User External Outputs

– This mapping only applies in the case that the user has extra
signals that are not covered by the PalletSolver pre-engineered
signals.
– These are outputs that are controlled in jobs via DOUT
instructions
– Requires both CIO edits and User Job modification to turn the
signals on and off
• Mapping User External Inputs to Universal Inputs
– This mapping only applies in the case that the user has extra
signals that are not covered by the PalletSolver pre-engineered
signals.
– These are inputs that can be used in jobs via WAIT, IF
instructions.
– Requires both CIO edits and User Job modification to check the
signals on and off state
• Update Concurrent IO (CIO.LST)
• Update User Jobs as required

6.3.2.1 Gripper Setup

 Available Robot Outputs and Inputs

CAUTION
Modifications of Universal Inputs or Outputs and External Inputs or
Outputs used by PalletSolver may cause unpredictable behavior and
damage to the equipment!

Please use the recommended I/O range listed below for user needs.
Do not modify the I/O range listed below.

Recommended PalletSolver Range

Robot Controller
Range for User (Do Not Use)

Universal Input 0010 to 00237 00250 to 00787

01250 to 01607

01990 to 02207

Universal Output 10010 to 10237 10250 to 10787

11250 to 11607

11990 to 12207

External Input 20030 to 20257 20270 to 20807

External Output 30030 to 30257 30270 to 30807

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 Robot Controller Auxiliary Relay Output to External Output Mapping

PalletSolver supports 32 outputs for each of the following gripper valve (or
control) types listed below.
• Vacuum On or Clamp Close
– Auxiliary Relay to External Output Mapping
– Maximum of 32 outputs
– Vacuum Grippers have control valves that turn on vacuum to an
area of the gripper.
– Clamp Grippers use this digital control to close the clamp until it
squeezes the product with sufficient force that it may be moved
by the robot and gripper system.
– Simple Fork grippers (Fork Retractable system grippers) have a
close command that causes the fork to be completely extended.
– More complicated fork grippers (Fork Variable style grippers)
have the ability to close to a number of different distances.
Generally one to three distances are defined. These are used for
narrow, medium and wide boxes.
• Vacuum Off or Clamp Open
– Auxiliary Relay to External Output Mapping
– Maximum of 32 outputs
– Required if a separate valve is required to un-grip (vacuum off,
clamp open or fork retract) and release the product.
• Blow Off
– Auxiliary Relay to External Output Mapping
– Maximum of 32 outputs
– Used by Vacuum Grippers to help blow off or brake the seal
between the vacuum cups and the product.
• Variable Stroke
– Auxiliary Relay to External Output Mapping
– Maximum of 16 outputs
– Used by Fork Grippers to move the fork in or out.
Table 6-6 "Auxiliary Relay to External Outputs Mapping Work Sheet" can
be copied and used when wiring in your gripper to the PalletSolver
system.
The concurrent I/O already has auxiliary relays assigned to each of the
defined control above. These auxiliary relays should not be used for any
other purpose. Do not modify existing rungs that uses these auxiliary
relays.

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Robot Controller Aux. Relay to External Output

Mapping Procedure
1. Determine the number of Gripper On or Gripper Close Valves
a) # of Gripper On/Close Valves = ____________
2. Determine if separate grip Off Valves are required by the Gripper
a) If Yes then number of grip off valves = number of grip On
Valves
b) If No, then number of grip off valves = 0
c) # of Grip Off Valves = _____________
3. Determine if the gripper has Blow Off Valves
a) If Yes then number of Blow off valves = number of grip On
Valves
b) If No, then number of Blow off valves = 0
c) # of Blow Off Valves = _____________
4. Complete Table 6-6 "Auxiliary Relay to External Outputs Mapping
Work Sheet"
• This step is used to determine how to wire up the robot controller
outputs to the gripper inputs for the Grip On/ Grip Close, Grip Off/
Grip Open and Blow Off control signals.
a) Assign a CIO Auxiliary relay output to each of the grip On,
grip Off and Blow off valves
• Example CIO instructions
i) Example - Assign 1 bit
• STR #71030
• OUT #30030
ii) Example - Assign 8 consecutive bits to 8 consecutive
outputs
• GSTR #71030
• GOUT #30030
b) Record each gripper Aux. Relay to robot External Output
assignment in the worksheet
c) Wire each gripper valve to the robot External Output in the
worksheet
d) Use available outputs between 30030 and 30257
e) Any wiring order is okay as long as it matches the physical
gripper wiring

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Table 6-6: Auxiliary Relay to External Outputs Mapping Work Sheet

Gripper On Gripper Off Blow Off Variable Stroke

Control
Auxiliary External Auxiliary External Auxiliary External Auxiliary External
Valve # Relay # Output # Relay # Output # Relay # Output # Relay # Output #

1 71030 71070 71110 71310

2 71031 71071 71111 71311
3 71032 71072 71112 71312
4 71033 71073 71113 71313
5 71034 71074 71114 71314
6 71035 71075 71115 71315
7 71036 71076 71116 71316
8 71037 71077 71117 71317
9 71040 71080 71120 71320
10 71040 71081 71121 71321
11 71041 71082 71122 71322
12 71042 71083 71123 71323
13 71043 71084 71124 71324
14 71044 71085 71125 71325
15 71046 71086 71126 71326
16 71047 71087 71127 71327
17 71050 71090 71130
18 71049 71091 71131
19 71050 71092 71132
20 71052 71093 71133
21 71053 71094 71134
22 71054 71095 71135
23 71055 71096 71136
24 71056 71097 71137
25 71057 71100 71140
26 71060 71101 71141
27 71061 71102 71142
28 71062 71103 71143
29 71063 71104 71144
30 71064 71105 71145
31 71066 71106 71146
32 71067 71107 71147

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5. If you need signals that must be controlled in a user job, then map it to
an available Universal Output.
a) Complete Table 6-7 "Universal Outputs to External Outputs
Work Sheet"
b) Assign a Universal output to each required External Output
• Example CIO instructions
i) Example - Assign 1 bit
• STR #10010
• OUT #30030
c) Record each Universal output to robot External Output
assignment in the worksheet
d) Wire each gripper valve to the robot External Output in the
worksheet
e) Use available outputs between 30030 and 30257
f) Any wiring order is okay as long as it matches the physical
gripper wiring
g) Modify the required USER Job
i) Add DOUT instructions as required
Table 6-7: Universal Outputs to External Outputs Work Sheet
Universal Output # External Name Job Usage Example
Output #
JBI # Internal
Controller #
1 10010 DOUT OT#(1) ON
2 10011 DOUT OT#(2) ON
3 10012 DOUT OT#(3) ON
4 10013 DOUT OT#(4) ON
5 10014 DOUT OT#(5) ON
6 10015 DOUT OT#(6) ON
7 10016 DOUT OT#(7) ON
8 10017 DOUT OT#(8) ON

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 Robot Controller External Input Overview

PalletSolver supports the following types of external inputs from the
gripper:
• Part Present Sensors (maximum of 32 Inputs)
– Part Present Sensors, generally one per grip area or zone
– Used to confirm that a product is held in the associated sensor
area
• Dispenser Part Present Sensors (1 for each dispenser station to -
4 maximum)
– Used to determine if a dispenser pallet or slipsheet is held by the
gripper
– May have up to one Dispenser Part Present Sensor for each
dispenser station
– Generally the same sensor will be used for all dispenser stations
or for dispensers of the same type (Pallet or Slipsheet)
– May use one of the 32 standard product part sensors listed
above
• Dispenser Part Search - High Speed (1 per dispenser station -4
maximum)
– Used when the gripper is performing a high speed search for the
top of the dispenser stack and rapid input are not used.
– Generally the same sensor will be used for all dispenser stations
or for dispensers of the same type (Pallet or Slipsheet)
– If the same external sensor is used for multiple stations or for
both low and high speed searches, map each one of the
auxiliary input with the same external input.
– Required setup for Normal IO Searches only - Rapid Input setup
is performed in Cell Setup, see section 4.4.7 “Station Definition”
on page 4-30
• Dispenser Part Search - Low Speed (1 per dispenser station -
4 maximum)
– Used when the gripper is performing a low speed search for the
top of the dispenser stack and rapid input are not used.
– Generally the same sensor will be used for all dispenser stations
or for dispensers of the same type (Pallet or Slip-Sheet)
– If the same external sensor is used for multiple stations or for
both low and high speed searches, map each one of the
auxiliary input with the same external input.
– Required setup for Normal IO Search only - Rapid Input setup is
performed in Cell Setup, see section 4.4.7 “Station Definition” on
page 4-30
• Gripper Open Sensors (maximum of 32 inputs)
– Signals form the gripper confirming that the associated grip area
that have been turned OFF, are either OFF (vacuum gripper) or
are fully open (clamp and fork gripper)
– Used as feedback to determine that the gripper is in the
commanded state

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• Gripper Closed Sensors (maximum of 32 robot inputs)

– Signals form the gripper confirming that the associated grip area
that have been turned ON, are either ON (vacuum gripper) or
are fully closed (clamp and fork gripper)
– Used as feedback to determine that the gripper is in the
commanded state
The concurrent I/O already has auxiliary relays assigned to each of the
defined control above. These auxiliary relays should not be used for any
other purpose. Do not modify existing rungs that uses these auxiliary
relays.
Table 6-8 "Robot Controller External Input Mapping Worksheet" can be
copied and used when wiring in your gripper to the PalletSolver system.

Robot Controller External Inputs (From Gripper) Mapping

Procedure
1. Determine the number of part present sensors.
a) # of part present sensors= _______________
2. Determine the number of Gripper Open External Inputs
a) # of Gripper Open Inputs= ____________
3. Determine the number of Gripper Closed External Inputs
a) # of Gripper Closed External Inputs= ____________
4. Complete Table 6-8 "Robot Controller External Input Mapping
Worksheet".
• This step is used to determine how to wire up the robot controller
external inputs to the gripper outputs of part present, gripper open
and gripper close signals.
a) Assign a CIO Auxiliary relay input to each of the of the
controls
b) Record each gripper CIO valve to robot external input
assignment in the worksheet
c) Wire each gripper sensor to the robot External Input in the
worksheet
d) Use available external inputs between 20030 to 20257
e) Any wiring order is okay as long as it matches the physical
gripper wiring

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Table 6-8: Robot Controller External Input Mapping Worksheet

Part Present Gripper Open Gripper Closed

Inputs Inputs Inputs
Control External Auxiliary External Auxiliary External Auxiliary
Valve # Input # Input # Input # Input # Input # Input #
1 71150 71190 71230
2 71151 71191 71231
3 71152 71192 71232
4 71153 71193 71233
5 71154 71194 71234
6 71155 71195 71235
7 71156 71196 71236
8 71157 71197 71237
9 71160 71200 71240
10 71161 71201 71241
11 71162 71202 71242
12 71163 71203 71243
13 71164 71204 71244
14 71165 71205 71245
15 71166 71206 71246
16 71167 71207 71247
17 71170 71210 71250
18 71171 71211 71251
19 71172 71212 71252
20 71173 71213 71253
21 71174 71214 71254
22 71175 71215 71255
23 71176 71216 71256
24 71177 71217 71257
25 71180 71220 71260
26 71181 71221 71261
27 71182 71222 71262
28 71183 71223 71263
29 71184 71224 71264
30 71185 71225 71265
31 71186 71226 71266
32 71187 71227 71267

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5. Dispenser Part Present Mapping

In this procedure we will determine how to wire the robot controller to
gripper dispenser part present sensors. The following flowchart and
table serves as guides during this process.

The light blue boxes, in the flow chart shows the 4 different choices for
wiring the Pallet Present Sensors and the Slipsheet present sensors.
These choices are:
a) No mapping required - no dispenser part present sensors
are being used

This is usually the case when the pallets or slipsheets are

not being handled by the robot.
b) Map both slipsheet/pallet dispenser part present sensors to
one standard part present sensor. One that is tied to part
present sensor # X where X is 1 to 32.

This is the most likely scenario since the gripper cannot

simultaneously hold product, pallets and slip sheets. Here a
standard part present sensor is used for dispenser and part
presence.

In this case use the same external input # for all four table
entries.
c) Map both slipsheet/pallet dispenser part present sensors to
the same external input

In this case one or more new (do not use a part present
sensor) external Inputs must be used.
• Use the same input # if all dispenser stations are
using the same dispenser part present
• Use a different input number for pallet and slipsheet
dispenser stations when the two types of dispensers
require a different part present sensors

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Fig. 6-7: Dispensing Part Present Flowchart

Table 6-9: Dispenser Part Present - External Inputs Mapping Work Sheet
Dispenser Type Dispenser Index External Input # Auxiliary Relay
Input #
Pallet 1 71280
Pallet 2 71281
Slipsheet 1 71282
Slipsheet 2 71283

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6. Dispenser Stack Search Mapping

The gripper is used to search to find the current dispenser stack height
or top of stack. PalletSolver supports both a low speed and a high
speed sensor for each dispenser station or a total of eight dispenser
search sensors are shown in the table below.

In cases where there are no dispenser stations or where the dispenser

types are fixed height, no dispenser search sensors are required and
no wiring is required.

In most cases only one high speed and one low speed search sensor
is required since the same sensors can be used on all dispenser
stations. In this case the high speed sensor would be mapped to all
four high speed external inputs in the table. Similarly, one low speed
search sensor (one external input) is mapped to all four low speed
sensor entries in the table.

Sometimes users may want to use a different high speed and low
speed sensor for slipsheet dispensers and pallet dispensers. When
this is the case the table would have a unique input for all eight search
sensors.
Table 6-10: Gripper Search for Dispenser Top of Stack - External Inputs to
Auxiliary Relay Mapping Worksheet
Dispenser Dispenser Sensor Type External Input Auxiliary
Type Index # Relay Input #
Pallet 1 High Speed 71290
Pallet 2 High Speed 71291
Slipsheet 1 High Speed 71292
Slipsheet 2 High Speed 71293
Pallet 1 Low Speed 71294
Pallet 2 Low Speed 71295
Slipsheet 1 Low Speed 71296
Slipsheet 2 Low Speed 71297

• CIO Editing
Each external input or output that is mapped into CIO auxiliary
relays, must be identified in the CIO.LST file.
– Adding an External Output to the CIO Ladder

STR 7XXXX
OUT 30YYY where 7XXXX is the auxiliary relay #
30YYY is the external output
– Adding an External Input to the CIO Ladder

STR 20XXX
OUT 7YYYY where 20XXX is the external Input #
7YYYYY is the auxiliary relay #

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6.3.3 Gripper Setup Examples

6.3.3.1 Vacuum Gripper

Fig.6-7 "Dispensing Part Present Flowchart" is an example of the vacuum
gripper is composed of eight suction cups controlled individually with
vacuum. This gripper uses eight blow off valves but does not use a
separate gripper off signals.
All eight vacuum cups have sensor feedbacks to determine if a part is
present.
The gripper has a set of mechanical jaws to grip and convey the empty
pallets among stations. These jaws are controlled in the PalletSolver User
modified jobs with a Universal Output.
The pallet dispenser is a searchable stack height type of dispenser. The
gripper will use both a high and low speed sensor when finding the stack
top.
Fig. 6-8: Example Vacuum Gripper with Pallet Clamp

1. Map Grip On and BlowOff Signals

• The first step is to assign external outputs to the Gripper On and
BlowOff On signals. The tables below shows these assignments.
Table 6-11: External Output Assignments
Gripper On Blow Off
Control
Valve # Auxiliary External Name Name
Valve # Auxiliary External
Relay # Output # Relay # Output #
1 71030 30010 Vacuum 1 On 1 71110 30020 BlowOff 1 On
2 71031 30011 Vacuum 2 On 2 71111 30021 BlowOff 2 On
3 71032 30012 Vacuum 3 On 3 71112 30022 BlowOff 3 On
4 71033 30013 Vacuum 4 On 4 71113 30023 BlowOff 4 On
5 71034 30014 Vacuum 5 On 5 71114 30024 BlowOff 5 On
6 71035 30015 Vacuum 6 On 6 71115 30025 BlowOff 6 On
7 71036 30016 Vacuum 7 On 7 71116 30026 BlowOff 7 On
8 71037 30017 Vacuum 8 On 8 71117 30027 BlowOff 8 On

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2. Add Grip ON and BlowOff Signals to CIO

• The next two lines connect the Auxiliary relay 71030 to 70137 to the
group of external outputs 30010 to 30017 (Vacuum on signals.)
Lines three and four do the same functions for the BlowOff signals.

GSTR #71030 // Auxiliary Relay Grip On

GOUT #30010 // to External Grip On outputs
GSTR #71110 // Auxiliary Relay Blow Off On to
GOUT #30020 // to External BlowOff On outputs
3. Map Clamp Open and Clamp Close Signals
• The pallet clamps are independently controlled by two valves (Clamp
Open and Clamp Close). These controls must be accessed in the
USER_DISPENSER_GRIPPER_CONTROL job. Therefore we need
to assign the Clamp Open and Clamp Close to External Outputs and
then to Universal outputs. In the following table Clamp Open is
assigned to external output 30030. It is also mapped to universal
output 10010 (or OT#(1)). It can be set and cleared in PalletSolver
jobs by the DOUT Inform instruction.
Table 6-12: Universal to External Output Mapping

Externa
Universal Example Use in
l Output Name CIO Modification
Output Job
#
Clamp STR #10010 // Univ. output 1 DOUT OT#(1) ON
1 10010 30030
Open OUT #30030 // Open Clamp DOUT OT#(1) OFF

Clamp STR #10011 // Univ. output 1 DOUT OT#(2) ON

2 10011 30031
Close OUT #30031 // Clamp Close DOUT OT#(2) OFF
3 10012
4 10013
5 10014
6 10015
7 10016
8 10017

4. Add Clamp Open and Clamp Close Signals to CIO

STR #10010 // Universal output 1

OUT #30030 // Open Clamp
STR #10011 // Universal output 2
OUT #30031 // Close Clamp

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5. Map Part Present Inputs to External Inputs

Table 6-13: Robot Controller External Input Mapping
Control Part Present Inputs
Valve #
Name External Auxiliary Input #
1 Vacuum 1 Sensor 20010 71150
2 Vacuum 2 Sensor 20011 71151
3 Vacuum 3 Sensor 20012 71152
4 Vacuum 4 Sensor 20013 71153
5 Vacuum 5 Sensor 20014 71154
6 Vacuum 6 Sensor 20015 71155
7 Vacuum 7 Sensor 20016 71156
8 Vacuum 8 Sensor 20017 71157

6. Add Part Present Inputs to CIO

• GSTR and GOUT store 8 bits in one operation

GSTR #20010 // External Vacuum Sensor

GOUT #71150 // Auxiliary Part Present Sensor

7. Map Gripper High and Low speed External Inputs

Table 6-14: Dispenser Search Sensor Inputs
Dispenser Dispenser Sensor External Auxiliary
Type Index Type Input # Relay #
Pallet 1 High Speed 20032 71290
Pallet 1 Low Speed 20033 71294

8. Add Gripper Search Inputs to CIO

STR #20032 // Long Range Sensor

OUT #71290 // Pallet 1 High Speed Search Sensor
STR #20033 // Short Range Sensor
OUT #71294 // Pallet 1 Low Speed Search Sensor

9. Modification for picking boxes:

The vacuum sensors are used to detect the part present. Each suction
cup has a signal to turn on the vacuum and one to control blow off.

Job Modification:
In “USER_ADJUSTMENT.JBI”
Timer for the duration of the
blowoff (0.01s)
SET UsrBlowOffTimer 50

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10. Modification for picking a pallet with independent clamp mechanism:

• The pallet presence is confirmed when the clamp is closed but the
actuator close sensor is not reached (because the pallet is blocking
the way). The pallet search is done using two sensors: a long range
sensor for faster search and a short range sensor for slower search.

STR-NOT #30030 // Signal to Open Clamp is Off

AND #30031 // Signal to Close Clamp is On
AND-NOT #20030 // Clamp Open Sensor Off
AND-NOT #20031 // Clamp Close Sensor Off
11. Job Modification For pallet picking with independent clamp
mechanism:

In “USER_DISPENSER_GRIPPER_CONTROL.JBI”
…
-----------------
Pallet Handling
-----------------
IFTHEN StationType=3
IFTHEN Action=”PREPICK”
Called before going down
for the pallet pick.
Open the gripper
DOUT OT#(1) ON
DOUT OT#(2) OFF
WAIT IN#(1)=ON
ELSEIF Action=”ON” ORIF Action=”CLOSE”
Called to grap pallet
Close the gripper
output #30030
DOUT OT#(1) OFF

DOUT OT#(2) ON
WAIT IN#(1)=OFF
TIMER T=1.0
ELSEIF Action=”OFF” ORIF Action=”OPEN”
Called to release pallet
Open the gripper
DOUT OT#(1) ON
DOUT OT#(2) OFF
WAIT IN#(1)=ON
ELSEIF Action=”POSTPLACE”
Called after releasing
pallet and moving up
No Action

ELSE
SETUALM 8005 “UNHANDLED GRIPPER ACTION TYPE” 0
PAUSE
RET -1
ENDIF

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12. In “USER_ADJUSTMENT.JBI”
…
and Place timers
for handling the products
of each dispenser.
unit of 0.01 s
SET pd1Place_Time 25
SET pd1Pick_Time 25

Search speed for dispenser

stack search in 0.1 mm/s
SET pd1Srch_HiSpeed 500
SET pd1Srch_LoSpeed 500
…
The modification is done for Pallet Dispenser 1 and should be repeated if
a second pallet dispenser is available.

13. Modification for picking a slipsheet with vacuum:

• Since the vacuum control is already maps for the box handling, we
can map the pick box signals back to the slipsheet signals and
manually control the vacuum through the
USER_DISPENSER_GRIPPER_CONTROL.JBI.

– Concurrent I/O Modification:

STR #02015 // Grip Sensor OK

OUT #02006 // SlipSheet 1 Presence in Gripper
STR #02015 // Grip Sensor OK
OUT #02022 // SlipSheet 1 High Speed Search Sensor
STR #02015 // Grip Sensor OK
OUT #02026 // SlipSheet 1 Low Speed Search Sensor

– Job Modification:

In “USER_DISPENSER_GRIPPER_CONTROL.JBI”
…
--------------------
Handling
--------------------
ELSEIF StationType=4

If different I/O control

is required between stations
use StationID to create
separate cases

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IFTHEN Action=”PREPICK”
Called before going down
for the slipsheet pick.
Set Gripper I/O

Example Vacuum on to Search

turn on vacuum before starting
search.
Turn on grip area 1,2,3,4
Binairy value of 15
SETREG MREG#(110) 15
SETREG MREG#(111) 0
PULSE OT#(Grip_ON)

Set sensor feedback

SETREG MREG#(114) 15
SETREG MREG#(115) 0
PULSE OT#(Sensor_ON)

ELSEIF Action=”ON” ORIF Action=”CLOSE”

Called to grap slipsheet

Example Turn On
Turn on grip area 1,2,3,4
Binairy value of 15
SETREG MREG#(110) 15
SETREG MREG#(111) 0
PULSE OT#(Grip_ON)

Set sensor feedback

SETREG MREG#(114) 15
SETREG MREG#(115) 0
PULSE OT#(Sensor_ON)

ELSEIF Action=”OFF” ORIF Action=”OPEN”

Called to release slipsheet

Example turn off vacuum

Turn off grip and sensor
area 1,2,3,4 equivalant to
binairy value of 15
Disable sensor check
SETREG MREG#(116) 15
SETREG MREG#(117) 0
PULSE OT#(Sensor_OFF)

Release vacuum
SETREG MREG#(112) 15
SETREG MREG#(113) 0
PULSE OT#(Grip_OFF)

Timer
TIMER T=0.1

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ELSEIF Action=”POSTPLACE”
' Called after releasing
' slipsheet and moving up
'
' Example: No Action
'
ELSE
SETUALM 8005 “UNHANDLED GRIPPER ACTION TYPE” 0
PAUSE
RET -1
ENDIF
'--------------------
…

In “USER_ADJUSTMENT.JBI”
…
' Set Pick and Place timers
' for handling the products
' of each dispenser.
' unit of 0.01 s
SET sd1Place_Time 25
SET sd1Pick_Time 25

' Search speed for dispenser

' stack search in 0.1 mm/s
SET sd1Srch_HiSpeed 500
SET sd1Srch_LoSpeed 500

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6.3.3.2 Zone Clamp Gripper

Fig.6-8 "Example Vacuum Gripper with Pallet Clamp" is a standard three
zone clamp gripper. The open and close signals can be mapped directly to
the corresponding Clamp Close and Clamp Open signals.
If there are no separate part present sensors, the open and close signals
can be used instead. The part is considered present when the clamp is
closed but the actuator close sensor is not reached (because the box is
preventing reaching the end of the stroke).
Fig. 6-9: Zone Clamp Gripper

1. Map Clamp Close and Clamp Open Signals

Table 6-15: Gripper On / Clamp Close / Fork Close
Valve # Auxiliary Relay # External Output # Name
1 71030 30011 Clamp 1 Close
2 71031 30013 Clamp 2 Close
3 71032 30015 Clamp 3 Close

Table 6-16: Gripper Off / Clamp Open / Fork Retract

Control Auxiliary Relay # External Output # Name
Valve #
1 71070 30010 Clamp 1 Open
2 71071 30012 Clamp 2 Open
3 71072 30014 Clamp 3 Open

2. Map Clamp Close and Clamp Open Signals to the CIO file

STR #71030 // GripOn1

OUT#30011 // Close Clamp 1
STR #71031 // GripOn2
OUT#30013 // Close Clamp 2
STR #71032 // GripOn3
OUT#30015 // Close Clamp 3

STR #71070 // GripOff1

OUT#30010 // Open Clamp 1
STR #71071 // GripOff2
OUT#30012 // Open Clamp 2
STR #71072 // GripOff3
OUT#30014 // Close Clamp 3

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3. Map Part Present Inputs to External Inputs

Table 6-17: Robot Controller External Input Mapping
Control Gripper/Clamp Open Inputs Gripper/Clamp Close Inputs
Valve #
Name External Auxiliary Name External Auxiliary
Input # Input # Input # Input #
1 Clamp Open Sensor 20010 71190 Clamp 1 Close Sensor 20011 71230
2 Clamp Open Sensor 20012 71791 Clamp 2 Close Sensor 20013 71231
3 Clamp Close Sensor 20014 71792 Clamp 3 Close Sensor 20015 71232

4. Add Part Present Inputs to CIO

STR #20010 // Clamp 1 Open Sensor

OUT #71190 // OpenSensor1 Auxiliary Relay
STR #20012 // Clamp 2 Open Sensor
OUT #71191 // OpenSensor2 Auxiliary Relay
STR #20014 // Clamp 3 Open Sensor
OUT #71192 // OpenSensor3 Auxiliary Relay
STR #20011 // Clamp 1 Close Sensor
OUT #71230 // CloseSensor1 Auxiliary Relay
STR #20013 // Clamp 2 Close Sensor
OUT #71231 // CloseSensor2 Auxiliary Relay
STR #20015 // Clamp 3 Close Sensor
OUT #71232 // CloseSensor3 Auxiliary Relay

The following is special CIO logic to allow the clamp open and close
feedback to also be used as part present feedback.

STR-NOT #30010 // Signal to Open Clamp 1 is off

AND #30031 // Signal to Close Clamp 1 is on
AND-NOT #20010 // Clamp 1 Open Sensor Off
AND-NOT #20011 // Clamp 1 Close Sensor Off
OUT #71150 // Clamp 1 Part Presence Auxiliary Relay
STR-NOT #30012 // Signal to Open Clamp 2 is off
AND #30033 // Signal to Close Clamp 2 is on
AND-NOT #20012 // Clamp 2 Open Sensor Off
AND-NOT #20013 // Clamp 2 Close Sensor Off
OUT #71151 // Clamp 2 Part Presence Auxiliary Relay
STR-NOT #30014 // Signal to Open Clamp 3 is off
AND #30035 // Signal to Close Clamp 3 is on
AND-NOT #20014 // Clamp 3 Open Sensor Off
AND-NOT #20015 // Clamp 3 Close Sensor Off
OUT #71152 // Clamp 3 Part Presence Auxiliary Relay

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6.3.3.3 Variable Stroke Fork Gripper

Fig.6-10 "Example with Variable Stroke Fork Gripper" is an example for a
variable stroke fork gripper with a single grip area and a top clamp that
can move down to hold the part while moving.
The forks are moved by a short and a long actuator placed in series so
that four positions (retracted, short, medium and long) can be obtained.
This is required so that the fork gripper can be used to move products of
different widths. The variable closing distances allows the fork tip to stay
under the product and keeps if from damaging products that are already
on the pallet.
There are sensors mounted on the fork slide to confirm each position.
This gripper does not have any dispenser search sensors and will not be
used to carry empty pallet or slipsheets between stations.
Fig. 6-10: Example with Variable Stroke Fork Gripper

1. Map Output Signals

Table 6-18: Gripper Output Signals
Valve # Auxiliary Relay # External Name
Output #
1 71070 (GripOff1) OR NOT 30010 Short Actuator Retract
71310 (VarStroke1)
2 71030 (GripOn1) AND 30011 Short Actuator Extend
71310 (VarStroke1)
3 71070 (GripOff1) OR NOT 30012 Long Actuator Retract
71311 (VarStroke2)
4 71030 (GripOn1) AND 30013 Long Actuator Extend
71311 (VarStroke2)
5 71090 (GripOffAux1) 30014 Clamp Actuator
Retract
6 71050 (GripOnAux1) 30015 Clamp Acturator
Extend

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2. Gripper CIO modifications for Fork and Clamp open and close signals

STR #71070 // GripOff1

OR-NOT #71310 // Variable Stroke 1
OUT #30010 // Short Actuator Retract

STR #71030 // GripOn1

AND #71310 // Variable Stroke 1
OUT#30011 // Short Actuator Extend

STR #71070 // GripOff1

OR-NOT #71311 // Variable Stroke 2
OUT #30012 // Long Actuator Retract

STR #71030 // GripOn1

AND #71311 // Variable Stroke 2
OUT#30013 // Long Actuator Extend

STR #71090 // GripOffAux1 (GripOff17)

OUT#30014 // Clamp Retract (Up)

STR #71050 // GripOnAux1 (GripOn17)

OUT#30015 // Clamp Extend (Down)
3. Map Sensors
In this example, sensors mount directly on the fork rail to confirm the fork
position. The variable stroke outputs combined with the fork position
sensors confirm the “close” position. For the clamp sensor, the “close”
position does not have a sensor because in most cases, the close position
will vary based on the product height therefore we simply check that the
“open” sensor turns off.
Table 6-19: Gripper Inputs

Signal # Name External Ouput # Auxiliary Relay #

1 Fork Retracted Sensor 20010 71190

(Open Sensor 1)
2 Fork Short Stroke Sensor 20011 71230
3 Fork Medium Stroke Sensor 20012 (Close Sensor)
4 Fork Long Stroke Sensor 20013
5 Clamp Up Sensor 20014 71210
(Open Aux1 Sensor)

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4. Add Part Present Inputs to CIO

STR #20010 // Fork Retracted Sensor

OUT #71190 // Fork Open Sensor

STR #20011 // Fork Short Stroke Sensor

AND #71310 // Variable Stroke 1 ON
AND-NOT #71311 // Variable Stroke 2 OFF
STR #20012 // Fork Medium Stroke Sensor
AND-NOT #71310 // Variable Stroke 1 OFF
AND #71311 // Variable Stroke 2 ON
STR #20013 // Fork Long Stroke Sensor
AND #71310 // Variable Stroke 1 ON
AND #71311 // Variable Stroke 2 ON
OR-STR
OUT #71230 // Close Sensor

STR #20014 // Clamp Open Sensor

OUT #71210 // Open Sensor 17
STR-NOT #20014 // Clamp Close Sensor
OUT #71250 // Close Sensor 17

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Modify User Job

In the case of the fork gripper, the “USER_GRIPPER_ON” job is called

twice. The first time, the Grip1to16 argument is set and should be used to
extend the forks. Based in the product width, the M109 register is set to
set the variable stroke value.

The second time, the Grip17to32 and the Sensor1to16 is set and should
be used to activate the clamp down of the product and enable the part
present sensor.

By default the CellSetup application doesn't account for grip area 17 to 32

being used for auxiliary actuators. So the use of open and close sensors
for auxiliary actuators need to be manually set. Those sensors check can
be added by setting the registers M119: Open Sensor Used and M121
Close Sensor User for grip areas 17 to 32. These values are bitwise
values, bit 1 being for grip area 17 (auxiliary actuator 1), bit 2 for grip area
18 (auxiliary actuator 2) and so forth. So in our particular example, we
should set M119 and M121 to 1 in the
USER_GRIPPER jobs.

In “USER_GRIPPER_ON.JBI”:
NOP
GETARG Grip1to16 IARG#(1)
GETARG Grip17to32 IARG#(2)
GETARG Sensor1to16 IARG#(3)
GETARG Sensor17to32 IARG#(4)
'
' Set use of open/close sensor
' for GripArea17 (Aux Actuator 1)
SETREG MREG#(119) 1
SETREG MREG#(121) 1
'
' Set Fork Variable Stroke
' based on product width ' in microns.
SET ProdWidth_adr EXPRESS 120 + ( Pik_PickStnID - 1 ) * 25
IFTHEN D[ProdWidth_adr]>450000
SETREG MREG#(109) 3
ELSEIF D[ProdWidth_adr]>300000
SETREG MREG#(109) 2
ELSE
SETREG MREG#(109) 1
ENDIF
'
' Extend forks
' Set grip area to turn ON
SETREG MREG#(110) Grip1to16
SETREG MREG#(111) Grip17to32
PULSE OT#(Grip_ON)
'
' Set part present feedback
' based on clamp down feedback
SETREG MREG#(114) Sensor1to16
SETREG MREG#(115) 0
'
PULSE OT#(Sensor_ON)
'
DOUT OT#(Griper_HasParts) ON
END

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In "USER_GRIPPER_OFF.JBI":
NOP
GETARG Grip1to16 IARG#(1)
GETARG Grip17to32 IARG#(2)
GETARG Sensor1to16 IARG#(3)
GETARG Sensor17to32 IARG#(4)
'
' Set use of open/close sensor
' for GripArea17 (Aux Actuator 1)
SETREG MREG#(119) 1
SETREG MREG#(121) 1
'
' Set Grip Area
SETREG MREG#(112) Grip1to16
SETREG MREG#(113) Grip17to32
'
' Set Sensor Area
SETREG MREG#(116) Sensor1to16
SETREG MREG#(117) Sensor17to32
'
' Apply new settings
PULSE OT#(Sensor_OFF)
PULSE OT#(Grip_OFF)
'
END

6.3.3.4 Gripper Testing

After the gripper integration with the robot controller is complete, the basic
gripper functionality can be tested with the Gripper HMI application. See
section 6.3.2.1 “Gripper Setup” for details on gripper test capabilities in the
PalletSolver HMI application.

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7.1 Functions

7 DX100 & DX200 Operation Monitor and Control Interface

7.1 Functions
The PalletSolver system is design to offer a flexible user interface to
monitor and control the system. All the functions describes in this section
are I/O based and can be access through various user interface such as a
pendant application, a PLC with an HMI, a PC-HMI… It is up to the
integrator or end-user to define the desired user interface and required
functionality.
The functionality is accessible through a 54 byte I/O block. The block is
split in two sections. The bytes 0 through 35 are direct I/O signals which
are explicitly mapped to specific signals. The bytes 36 through 53 are I/O
used to implement Message Communication which allows reusing the
same block of I/O to exchange various information through messages.
This will allow to expand functionality as needed in the future.
For a PLC, an I/O block is mapped between the controller and the PLC
through a standard communication board such as: DeviceNet, EtherNet/
IP, Profibus… On the controller side, the PLC I/O block is 54 bytes long. It
is mapped to the external I/O signal starting the address 20270 for inputs
and 30270 for outputs.
For Pendant Application or other applications using standard YASKAWA
protocol such as Motocom or High-Speed Ethernet Server, Network
addresses can be used to write Inputs. Outputs can be accessed directly.
The ladder has Network address 25270 (DX100 Controller) or 27270
(DX200 Controller) combined with 20270 by an OR operation to generate
the Universal Input.
It is also possible to control some of the peripheral devices such as
infeeds and outfeeds through user defined jobs when a PLC is not
included in the system. In such case, User Control Job signals are
mapped between the controller job input and output. (Refer to
Section 6.2.3 “User Jobs” on page 6-4 for more details.)
Refer to Chapter 8 "Operation Monitor and Control Pendant Application"
for an example of the Monitor and Control interface usage.

To avoid conflicts between multiple points of control, the

user job outputs and Pendant HMI Network signals are only
NOTE considered when the system is defined as ROBOT
controlled. The PLC outputs are only considered when the
system is defined as PLC controlled.

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7.2 Interface: Direct I/O Signals

7.2 Interface: Direct I/O Signals

The Direct I/O signals are the first 36 bytes of the Monitor and Control I/O
block. They are signals that are explicitly mapped in the controller.
For the complete listing of the direct I/O mapping and their corresponding
PLC, Network, and User signals, refer to Appendix A.

7.2.1 System Signals

7.2.1.1 System Start/Stop

Start and stop controller playback using standard signals such as: Select
MasterJob, Ext. Servo On, Ext. Start, Ext. Hold, etc. For further details on
the standard signal, please refer to the Controller Concurrent I/O manual.

 The pre-start sequence:

• Check that “Operating” is OFF; if ON abort the sequence the system
is already started.
• Check that “Remote Selected” is ON; if OFF, display message to
user.
• Check that “In Hold” is OFF; if ON, you may attempt to turn it off by
turning OFF the “External Hold” signal. If it doesn't turn OFF, the hold
is from another source, display message to user.
• Check that “E-Stop External”, “E-Stop Pendant”, and Safety Gate”
are ON; if OFF, display message to user.
• Check that “In Warning” is OFF; if ON, you may attempt to reset it by
turning ON the “Warning Reset” signal until the “In Warning” signal
turns OFF. If it doesn't turn OFF, display message to user.
• Check that “Play Selected” is ON; if OFF, you may attempt to select it
by turning ON the “Play Mode Select” signal until the “Play Selected”
is ON. If it doesn't turn ON, display message to user.
• Check that “Servo On” is ON; if OFF, you may attempt to turn them
on by turning ON the “Servo On Request” signal until the “Servo On”
signal turns ON. If it doesn't turn ON, display message to user.
• Turn ON either the “Home Request”, if the system is to return (or stay
at) “Home” or the “Build Request” signal to start palletizing.

 Start-Resume sequence:
• Check that the “Resume Allowed” signal is ON. If OFF, it isn't safe to
resume, the system should be restarted from the top of the Master
Job (see the following sequence).
• Turn ON the “External Start” signal until the “Operating” signal turns
ON to confirm that the system started.

 Start-Master Job sequence:

• Turn ON the “Call Master Job” signal until the “Top of Master Job”
signal turns ON.
• Turn ON the “External Start” signal until the “Operating” signal turns
“ON” to confirm that the system started.

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 Stop sequence:
• Turn ON the “External Hold” signal until the “Operating” signal turns
OFF. Note that for a normal stop of the system, it is recommended
to stop palletizing before stopping the system (see Section 7.2.1.2
“Palletizing Stop/Start” on page 7-3).

7.2.1.2 Palletizing Stop/Start

Signal to stop/start palletizing. On a stop, the robot completes the current
pick/place cycle and then the robot returns back to home position and
waits. This shouldn't stop the execution of other tasks that handles
concurrent I/O and PLC communication. On a start, the robot resumes
palletizing with the next pick/place cycle.

 Handshaking:
• Signal “Home_Request” should be held ON until acknowledged by
signal “At_Home”. Signal “In_Home_Cube” should also be checked
to verify the robot is at the home position.
• Signal “Build_Request” must be held ON to enable any motion cycle
other than going home. If the job is running properly, even if not
actively moving, “Build_Request” will be acknowledged by “Building”.

7.2.1.3 PLC Controlled System

The “PLC Controlled System” signal indicates if the system was setup by
the “PalletSolver Cell Setup” pendant application to operate with the PLC.
Slight modifications on the system behavior are based on this signal. For
example, the “Fieldbus Heartbeat” check is only enabled when the system
is “PLC Controlled”. So if a PLC is used, the PLC should check that this
signal is ON.

7.2.1.4 Fieldbus Heartbeat

The “Fieldbus Heartbeat” signal is used to determined health of the
network from the controller perspective. The controller will shut down via a
user Warning, if the robot is operating and does not see a transition of this
signal. The following PLC modification is required for functionality:

 Sequence:
The PLC input must turn on the PLC output.
If this rung is not created the controller will cause a warning and not run in
play mode.

The “Fieldbus Heartbeat” is only enabled when the system

NOTE is setup for “PLC Controlled” in the “PalletSolver Cell Setup”
pendant application.

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7.2 Interface: Direct I/O Signals

7.2.1.5 Set Next Infeed Pick

The “Next Infeed (bit 0 to 3)” signals represent a bitwise value that
indicates the infeed station ID that should be picked from on the next
cycle. The controller will go to that station regardless of the station “Pick
Ready” signal, but will wait for the check for “Infeed# Pick Ready” over the
infeed and initiate a “Infeed# Pick Error” event if not ON.

This setting is only valid when the sequencing mode is set to

NOTE “PLC Mode”. (Refer to Section 7.3.3.7 “Select Sequencing
Mode” on page 7-25 for details.)

 Handshake:
• The “Next Infeed (bit 0 to 3)” value must be held ON until
acknowledged by the signals “Next Infeed Echo (bit 0 to 3)” value
matches the requested value.

The system is capable of planning one cycle ahead, so as

NOTE soon as a pick cycle is initiated the next infeed can be set.
So if the current cycle is aborted, both the current cycle and
the next planned one are canceled.

7.2.1.6 Safety Speed

When the “Safety Speed Select” signal is on, the playback operating
speed is limited by in-guard safe operation speed.

 Handshake:
• The “Safety Speed Select” is turned ON and HELD to limit the
maximum speed of the system.
• The “Safety Speed” signal can be monitored to confirm that the
safety speed is enabled.

7.2.1.7 Speed Override

The “Speed Override % (bit 0 to 7)” signals represent a bitwise value that
indicates a global speed override applied to all programmed speeds. The
value must be set between 1 and 100%. A value of 0% disables the
function and the system will run at a 100% of the programmed speeds.

7.2.1.8 Battery Warning

The “Battery Warning” signal is turned ON to indicate that batteries need
replacement when voltage drops in the memory protection battery and the
absolute encoder memory retention battery. Loss of data in memory due
to a weak battery can cause significant damage.

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7.2.1.9 Motion Sequence

The “Picking Sequence” signal turns ON to indicate that the robot is
currently in the motion sequence to pick a package. This included moving
from the current position to the pick station.
The “Placing Sequence” signal turns ON to indicate that the robot is
currently in the motion sequence to place a package. This includes
moving from the infeed or dispenser station to the build station.
The “Placing Boxes Sequence” signal turns ON to indicate that the robot
started placing the boxes on the build station. The “Placing Sequence”
signal remains ON while this signal is ON.

7.2.2 Warning and Error Handling

There are various types of Warning and errors that can be generated by
the system.
• Controller Errors and Warnings are generated by the controller and
are not specific to the PalletSolver system. When occurring, the
system “In Warning” signal will turn ON and the Warning or error
information will display on the controller pendant. Further details
about those Warnings and errors can be found in the Controller
Maintenance Manual.
• PalletSolver Job Warnings are generated by the PalletSolver jobs.
These alarm details are in Section 7.2.2.1 “PalletSolver Job
Warning” on page 7-6 and in Appendix A.2.2 “Job Warning List” on
page A-18.
• PalletSolver Controller Alarms - Controller alarms in the 8000 range
are generated in the jobs with the instruction SETUALM. They are
mostly introduced to detect job program errors such as trying to
address a Pallet Build Station that does not exist.

Controller Alarms in the 9000 range are generated in the concurrent

I/O ladder.

See Appendix A.2.3 “Controller Error and Warning List” on page A-

21 for a complete list of 8000 and 9000 errors.
• Pick/Place Errors are generated when there is a mismatch between
the expected packages on the gripper and the gripper part present
sensor feedback. Details are in Section 7.2.2.2 “Pick/Place Error”
below and in Section 7.2.3.4 “Station Pick/Place Error” on page 7-9.
• Message Communication Errors are part of the reply message to a
command send by the PLC. Details are in Section 7.3 “Interface:
Message Communication” on page 7-15 and in the Appendix A.2.1
“Messaging Error List” on page A-16.

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7.2.2.1 PalletSolver Job Warning

The “Job Warning” signals are warnings generated when the PalletSolver
job detects an unusual condition in the state of the system. In general,
when such condition is detected, the related station will be locked and a
Job Warning message is issued. Operation will continue for other stations.
The condition should then be resolved before unlocking the station. The
nature of the warning is indicated by a “Job Warning Code (bit 0 to 7)” and
the “Job Warning Parameter (bit 0 to 7)”. For details on the Job Warning
codes, please refer to Appendix A.2.2 “Job Warning List” on page A-18.
The “Job Warning Param” meaning may vary based on the nature of the
warning code but in most cases it should indicate the ID of the station on
which the condition occurred.

 Handshake:
• The signals “Job Warning Code (bit 0 to 7)” and “Job Warning
Parameter (bit 0 to 7)” will be set.
• The “Job Warning” signal will be maintained until acknowledge by a
matching “Job Warning Reset”.
• The PLC would then need to unlock the station after taking any
corrective action needed to correct the condition causing the
warning.

If a warning has already been issued and the PLC or HMI

does not acknowledge and reset the warning within
reasonable time, any new warning will be discarded. If a
NOTE station is locked and the warning for it is has been
discarded, unlocking the station should cause the sequence
to repeat. The station will re-lock and the warning will be
reissued.

7.2.2.2 Pick/Place Error

The Pick/Place Error signal indicates that an error was detected while
picking (on infeed or dispenser) or placing (on a build station). The error is
usually related to the gripper part present sensors not returning the
expected signal. The system will signal the fault and then wait on an
“Ignore”, “Retry” or “Abort” signal.
The same signal is also available on a per station base. See Section
7.2.3.4 “Station Pick/Place Error” on page 7-9 for details.

 Error Response Signals

The “Error Responses” signals work in conjunction with the stations “Pick/
Place” errors.

NOTE Error Response signals can only be used when there is an

active Pick/Place Error

• “Error Response Ignore” signal is used to ignore an error and

proceed as if the error hadn't occurred. This might be used in the
case where a pick error occurs because the part present sensor isn't
detecting the package but the package was in fact pick-up and the
operator want to proceed with the normal cycle.

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• “Error Response Retry” signal is used to repeat a sequence that

caused an error. This might be used in the case where the slipsheet
wasn't picked up and the operator wants the system to retry picking it
again.
• “Error Response Abort” signal is used to cancel a sequence. This
might be used in the case where a box is drop between the pick and
place sequence, so the place sequence should be canceled.

• When aborting, the station involved will automatically be

locked. Proper verification that the station is in working
order should be done before unlocking the station.
• In the case of a build station (place error), the “Verify
Layer Request” signal will also be turned on. This signal
NOTE will prevent accidentally unlocking the station until the
“Layer Verified” signal has been sent.
• When aborting a sequence, if there are any chances of
package being on the gripper, the robot will be sent to
the reject station where the package can be drop or
removed by the operator before resuming normal
operation.

• When the abort is done during the Placing sequence, the abort
mode can be specified by turning on one of the following signal
before sending the “Error Response Abort” signal:
–Abort and Repeat Cycle: The cycle that was aborted will be
repeated.
–Abort and Go to Next Cycle: The cycle that was aborted is
considered completed and the build will continue with the next
cycle.
–Abort and Clear Layer: The current layer is considered to have
been cleared and the build will restart at the first cycle of the
current layer.
–Abort and Go to Next Layer: The current layer is considered to
have been completed and the build will restart at the first cycle
of the next layer.
• If no mode is selected, the default abort mode are:
–To repeat the cycle, if the place error occurred before starting
to place boxes on the build station.
–To clear the layer, if the place error occurred after starting to
place boxes on the build station.

 Handshaking:
The “Error Response” signal should be maintained until the corresponding
“Error Response Acknowledge” comes on. The original Pick/Place Error
signal to the PLC will be cleared after the “Error Response”/“Error
Response Acknowledge” handshake is complete.

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7.2.2.3 System Job Running

The “System Job Running” signal should always be ON. It confirms that
system jobs that handle the PLC messaging and control the system state
are actively running. If the “System Job Running” signal is OFF, the
system should be stopped and the controller power should be cycled.
System Jobs could stop running following some controller alarm or if they
were not setup properly to automatically start when the controller is
powered on.

 Handshaking:
If the “System Job Running” signal is OFF, stop operations and instruct
operator to cycle power on the controller.

7.2.3 All Stations

7.2.3.1 Station Exists

The “Station Exists” signals to indicate that the station is defined in the
cell. This can be useful to create a user interface that can be used on
multiple cells and adapt itself to represent the proper number stations in
the cell.

 Available “Station Exists” signals:

Build# Exists, Infeed# Exists, Pallet Disp# Exists, Slipsheet Disp# Exists,
Reject Exists (where the symbol # represents the station ID).

 Handshake:
“Station Exists” is set from the Cell Setup Pendant application, and must
be ON to use the station.

7.2.3.2 Station Active

The “Station Active” signal indicates that a station is currently being used
in the current pick/place cycle. The build station active signal will be ON
for the full duration of the Pick/Place cycle. For the other station, the active
signal is ON only for the duration of the pick cycle.

 Available Station Active Signals

Available “Station Active” signals: Build# Active, Infeed# Active, Pallet
Disp# Active, Slipsheet Disp# Active, Reject Active (where the symbol #
represents the station ID).

 Handshake:
“Station Active” is ON if the current pick / place cycle is for the station.

7.2.3.3 Station Lock/Unlock

The station lock prevents any further pick or place to the station.

 Station Lock/Unlock Signals

• “Station Lock Request” signal enables the operator/PLC to lock a
station. If the station is currently active, the station will only be locked
once the current pick/place cycle is completed.
• “Station Unlock Request” signal enables the operator/PLC to unlock
a station.

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• “Station Locked” signal reflects the current lock state of the station.

• When a build station is locked, it should prevent any pick to

an associated station feeding it package.
NOTE
• Palletizing job may also lock a station because of a pick or
place error.

 Available Station signals

• “Station Lock Request” signals: Build# Lock Request, Infeed# Lock
Request, Pallet Disp# Lock Request, Slipsheet Disp# Lock Request,
Reject Lock Request (where the symbol # represents the station ID).
• “Station Unlock Request” signals: Build# Unlock Request, Infeed#
Unlock Request, Pallet Disp# Unlock Request, Slipsheet Disp#
Unlock Request, Reject Unlock Request (where the symbol #
represents the station ID).
• “Station Locked” signals: Build# Locked Request, Infeed# Locked
Request, Pallet Disp# Locked Request, Slipsheet Disp# Locked
Request, Reject Locked Request (where the symbol # represents
the station ID).

 Handshake:
The “Station Lock Request” or “Station Unlock Request” signals should be
held ON until acknowledged by the state change of the corresponding
“Station Locked” signal.

7.2.3.4 Station Pick/Place Error

The “Station Pick/Place Error” signal indicates that an error was detected
while picking (on infeed or dispenser) or placing (on a build station). The
error is usually related to the gripper part present sensors not returning the
expected signal. The system will signal the fault and then wait on an
“Ignore”, “Retry” or “Abort” signal (Refer to Section 7.2.2 “Warning and
Error Handling” on page 7-5 for details).
The “Error Response” signal should help ON until the signal “Station Pick/
Place Error” turns is OFF.

 Available Station signals

“Station Pick/Place Error” signals: Build# Place Error, Infeed# Pick Error,
Pallet Disp# Pick Error, Slipsheet Disp# Pick Error (where the symbol #
represents the station ID).

 Handshake:
The “Station Pick/Place Error” indicates that an error occurred during the
pick/place cycle for this station and will suspend palletizing until it receives
an “Ignore, Retry or Abort Error Response” signal.

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7.2.4 Reject Station

The reject station is a defined location in the system where the robot
should go to when it detects that packages are in the gripper when it
shouldn't. This usually occurs following when a pick/place cycle is
aborted. The reject station could take various shapes, from a simple
maintenance location that give the operator easy access to the gripper to
an outfeed conveyor. The exact sequence can be customized through a
user job.

7.2.4.1 At Reject Drop

The “At Reject Drop” indicates that the robot has stopped at the reject
drop point. Depending on the reject user job structure, this could be before
or after the gripper releases the package. The reject sequence will resume
when the “Reject Drop Acknowledge” signal turns ON.

 Handshake:
• “At Reject Drop” indicates that the robot has reached the product
drop position and must be acknowledged by “Reject Drop
Acknowledge” before the robot will continue.
• “Reject Drop Acknowledge” should be turned OFF once the “At
Reject Drop” signal turns OFF.

7.2.4.2 Reject Full

The “Reject Full” signal is intended to relay a sensor signal that would
indicate that packages are already present at the reject station.
• “Reject_Full” indicates that the Reject station is full and cannot be
used at this time.

 Handshake:
• If “Reject Full” is ON, the robot should stop and wait for the signal to
turn OFF before going to the final drop position.

7.2.4.3 Gripper Package Release

The “Need Gripper Clear” signal indicates that the robot is in a position
where packages on the gripper can be release safely. When ON, it
enables the “Force Gripper Release” function that allows the release of all
the package on the gripper when the “Force Gripper Release” signal is
turned ON.

 Handshake:
• “Need Gripper Clear” indicates that the packages a ready to be
released at reject station.
• Turn ON the “Force Gripper Release” to release the packages until
the “Need Gripper Clear” signal turns OFF.

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7.2.4.4 Goto Reject Station

The “Reject Goto Request” signal indicates that the operator is requesting
for the robot to go to the reject station. This signal essentially calls the
“USER_MOVE_REJECT” job where the use can program custom path to
send to the robot to reject or maintenance position.

 Handshake:
• Pulse the “Goto Reject Request” to latch the signal and send the
robot to the reject sequence after completing the next cycle.
• The “Goto Reject Request” turns OFF when the “Reject Active”
signal turns ON.

7.2.5 Build Stations

The following functions are specific to the build station. The corresponding
I/O signals are repeated for each station.

7.2.5.1 Build Pattern Assigned

The “Build# Pattern Assigned” signal indicates that a valid pattern is
assigned to the build station. To assign or unassign patterns the Message
Communication is used, refer to section “Build Station Assign/Unassign
Pattern”.

 Handshaking:
“Build# Pattern Assigned” indicates that the build station has a Pattern
assigned to it. This signal must be ON in order to use the station.

7.2.5.2 Build Pallet Present

The “Build# Pallet Present” is a signal to send a Pallet Present sensor to
the robot. For any cycle other than the robot placing the first layer pallet,
this signal must be ON to initiate the cycle.

 Handshaking:
“Build# Pallet Present” must be ON to initiate any cycle other than the
robot placing the first layer pallet.

7.2.5.3 Normal Build Done and Eject

The “Build# Done” signal is turn on when the pattern was completed
normally by reaching the total number of layer and place. At this point the
PLC should eject the pallet and respond with “Build# Cleared” signal.
Counters are reset and the build station is ready to start a new build using
the same pattern. If the pallet removal is manual, the operator would
generate the “Build# Cleared” input by pressing a button after removing
the pallet.
If the pallet is automatically removed by conveyors controlled by a PLC,
the PLC would generate the “Build# Cleared” input once the pallet is
cleared of the build station.
If the pallet is automatically removed by conveyors controlled by a robot
controller, the robot controller would turn on the “UserRdyNxt_Bld_#”
output in the job once the pallet is cleared of the build station. That signal
is internally then feedback to the “Build# Cleared” input.

 Handshake:
The “Build# Done” signal is held ON until acknowledged by signal “Build#
Cleared”.

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7.2.5.4 Build Station Forced Done and Eject

The “Build# Done Request” signal is used when the operator/PLC wants
to stop the current build and eject the pallet before the build is completed.
If a pick/place cycle is currently active on the station, the cycle completes
normally before the build is stop and ejected. No further pick/place cycle
will be performed on this build station until the pallet is removed and the
build station is reset.

 Handshake:
“The “Build# Done Request” signal should be held ON until acknowledged
by signal “Build#_ Done”.

7.2.5.5 Build Station Lock after Build is Done

The “Build# Lock After Done” signal requests that the specified station be
locked after the current pallet build on the station is completed. This allows
an operator/PLC to lock a build station after the build is complete so that
he may for example change the pattern before resuming operation.
Refer to the Section 7.2.3.3 “Station Lock/Unlock” on page 7-8 for further
details.

 Handshake:
The “Build# Lock After Done” signal should be held ON until
acknowledged by signals “Build# Done” and “Build# Locked”.

7.2.5.6 Build Station Verify Layer

The “Build# Verify Layer Request” signal indicates that before continuing
the build, the packages on the current layer need to be verified and if
necessary manually adjusted to match the current layer package count
and positions defined by the completed cycles. This Verify Layer Request
usually occurs when the number of boxes on the layer is unclear following
a place error occurrence.
The “Build# Layer Verified Confirm” signal is used to confirm to the system
that the packages of the current layer are matching the current build state
and that the build can be resumed. The station still needs to be unlocked
before the build actually continues.

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7.2.6 Infeed Stations

The following functions are specific to the infeed conveyor station. The
corresponding I/O signals are repeated for each station.

7.2.6.1 Infeed Package Request

The “Infeed#_BoxNeed” signals represent a bitwise value of the number
of packages required on the infeed for the next pick cycle.

 Sequence:
• Normal: The robot controller sets “Infeed# BoxNeeded” value to the
quantity of boxes needed for the next pick, then turns ON “Infeed#
Pick Request”. The signals will be held ON until the packages have
been successfully picked from the conveyor. The robot will not plan a
cycle to pick from the conveyor until the PLC (or User Job) sets the
“Infeed# Pick Ready” to ON.
• The “Infeed# Pick Ready” should be held ON until the corresponding
“Infeed# Pick Request” turns OFF.
• Abnormal: Certain conditions (aborted picks, ending a build early,
cycle power, etc…) may cause the quantity requested value to be
recalculated. In such condition, the “Infeed# Pick Request” will turn
OFF. A new request will not be made until PLC turns off the “Infeed#
Pick Ready” signal. It is possible that the new requested quantity
differ from previous one, it is up to the user to program the logic to
make sure that the quantity on the infeed matched the new “Infeed#
BoxNeeded” value before turning ON the “Infeed# Pick Ready”.

7.2.6.2 Purge Infeed

The “Infeed# Purge” signal indicates that an infeed line is done receiving
more product and that the robot should run one last pick-place cycle to
this infeed even if the expected number of packages hasn't been reached.
Package present sensors will be ignored during the cycle in order to
complete the pick/place cycle without errors. Once the last cycle is
complete, the associated build station pallet is mark as complete.

 Handshake:
The “Infeed# Purge” signal should be held ON until acknowledged by
signal “Infeed# Purge Request Acknowledge”.

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7.2.7 Dispenser Stations

The following functions are specific to the both pallet and dispenser
station. The pallet dispenser signals have the prefix “Pdisp” and the
slipsheet dispensers “Sdisp”. The corresponding I/O signals are repeated
for each station.

7.2.7.1 Dispenser Reset Search Height

The “Dispenser# Reset Search” signal of a dispenser invalidates this
dispenser (pallet or slipsheet) previous search result. This forces the
system to initiate a search from the top of the dispenser on the next pick
cycle on this dispenser.

• This signal should be automatically set whenever a

possible access to the dispenser to reload it is detected.
NOTE
• This signal will reset the “Dispenser# Low Stack” and
“Dispenser#_Empty” signals.

 Handshake:
The “Dispenser# Reset Search” should be held ON until acknowledged by
signal “Dispenser# Reset Search Acknowledge”.

7.2.7.2 Dispenser Low Stack

The “Dispenser# Low Stack” signal indicates that a comparison of the
height the last search end point and a variable setting in job
“USER_ADJUSTMENTS” shows that the dispenser is low in pallets or
slipsheets.

 Handshake:
The “Dispenser# Low Stack” will be held ON until reset by signal
“Dispenser# Search Reset Acknowledge”.

 Alternatives:
A sensor may be used in place of the search height evaluation. In this
case, copy the sensor signal to the robot at “Dispenser# Low Stack
Sensor”. To eliminate the robot signal “Dispenser# Low Stack”, set the
variable to a value below what would ever be reached.

7.2.7.3 Dispenser Empty

The “Dispenser#_Empty” or “Dispenser#_Empty” signal indicates that a
comparison of the height the last search end point and a variable setting in
job “USER_ADJUSTMENTS” shows that the dispenser is out of pallets or
slipsheets. When this signal is on, the station will automatically be locked
and prevent further pick from it. Once the station is refilled, the operator/
PLC must unlock the station, and Reset the Search Height.

 Handshake:
The “Dispenser#_Empty” will be held ON until reset by signal “Dispenser#
Search Reset Acknowledge”.

 Alternatives:
A sensor may be used in addition to the search height evaluation. In this
case, copy the sensor signal to the robot at “Dispenser# Empty Sensor”.
To eliminate the robot signal “Dispenser# Empty”, set the variable to a
value below what would ever be reached. Either “Dispenser#_Empty” or
“Dispenser# Empty Sensor” will keep the robot from attempting to pick at
the station.

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7.3 Interface: Message Communication

The other mode of communication is through a block of I/O signals that
are reserved to send command with arguments and receive information in
a reply block. The same I/O block can then be reused to send and
retrieved various information between the PLC and controller.
Proper code must be developed on both side to implement the protocol
and process the command and reply. On the controller side, a PLC
dedicated system job handles the PLC communication.

Some of the PLC/Controller communication requires the

NOTE controller to be running the master job in order to update the
system variables and return the proper values.

7.3.1 PLC to Robot Message Structure

Fig. 7-1: PLC and Controller Data Flow Diagram

When the PLC wants to command to robot to perform a task, the PLC
generates a message to the robot through direct access of its memory.
The memory locations (registers) vary by specific PLC manufacturer, but
the communication structure remains the same.
The following table defines of all I/O locations of a message and their
functions. Note that the PLC byte number identification is relative to the
starting position of the I/O block.

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Table 7-1: Command (PLC to Controller):

PLC DX Name Value Description

Output Input
Byte 36 IG#61 TransactionID / Byte Cycles 1-99 to indicate a new command
Handshaking (bit 1 to 7)
Handshaking (bit 8)
Byte 37 IG#62 CommandID Byte See sections below for specific Command IDs
and layouts
Byte 38 IG#63 Param1 Integer Varies based on Command ID
Byte 39 IG#64
Byte 40 IG#65 Param2 Integer Varies based on Command ID
Byte 41 IG#66
Byte 42 IG#67 Param3 Integer Varies based on Command ID
Byte 43 IG#68
Byte 44 IG#69 Param4 Integer Varies based on Command ID
Byte 45 IG#70

Table 7-2: Reply (Controller to PLC)

PLC DX Name Value Description

Input Output
Byte 36 OG#61 Reply Byte Cycles 1-99 to indicate the reply id which
TransactionID / should match the command ID (bit 1 to 7).
Handshaking Handshaking (bit 8)
Byte 37 OG#62 CommandID (Echo) Byte See sections below for specific Command IDs
and layouts
Byte 38 OG#63 Param1 Integer Varies based on Command ID
Byte 39 OG#64 (Echo)
Byte 40 OG#65 Param2 Integer Varies based on Command ID
Byte 41 OG#66 (Echo)
Byte 42 OG#67 Param3 Integer Varies based on Command ID
Byte 43 OG#68 (Echo)
Byte 44 OG#69 Param4 Integer Varies based on Command ID
Byte 45 OG#70 (Echo)
Byte 46 OG#71 Data1 Integer Varies based on Command ID
Byte 47 OG#72
Byte 48 OG#73 Data2 Integer Varies based on Command ID
Byte 49 OG#74
Byte 50 OG#75 Data3 Integer Varies based on Command ID
Byte 51 OG#76
Byte 52 OG#77 ErrorCode Integer 0: Success; >0 Failure (see error code list)
Byte 53 OG#78

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7.3.2 Handshaking
The handshaking will be done through the Transaction ID group. The
transaction ID is a number between 1 and 99 that is used to confirm that
the commands and reply don't get out of sync. For each transaction the
transaction ID is incremented by 1 until it reaches 99 and then it is reset to
1. The transaction ID uses the first 7 bits of the Transaction ID byte. This
leaves the 8th bit as an independent signal to indicate that a new
transaction is ready. The sequence is as follows:
Table 7-3: PLC and Robot Controller Handshake

PLC (or PP App) Robot Controller (JOB)

Increments the command transaction ID (first

7 bit of byte 36) leaving the handshaking bit
(8th bit of output byte 36). If the transaction
ID reaches 100, reset to 1.
Wait for the command handshaking bit (8th
bit IG#61) to turn on.
Sets the command ID and parameters (1-4).

Turn on the command handshaking bit (8th

bit of output byte 36)

Increments the reply transaction ID (first 7 bit

of OG#61) leaving the handshaking bit (8th
bit of OG#61). If the transaction ID reaches
100, reset to 1. Check that it matches the
command transaction ID.
Wait for the reply handshaking bit (8th bit
input byte 36) to turn on. Process the command and set command
echo and the reply data (1-3) and error
blocks.

Turn on the reply handshaking bit (8th bit of

OG#61)

Check that the reply transaction ID (first 7 bit

of input byte 36) matches the command
transaction ID

Check the echo fields matches the command

Wait for the command handshaking bit (8th
fields (optional)
bit IG#61) to turn off.
Process the reply

Turn off the command handshaking bit (8th

bit of output byte 36)

Wait for the reply handshaking bit (8th bit Turn off the reply handshaking bit (8th bit of
input byte 36) to turn off. OG#61)

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In the case the transaction ID between the command and the reply
transaction ID are out of sync. The robot controller returns the appropriate
error code and doesn't process the command.
To reset the transaction ID and resync the PLC and controller transaction
ID together, the transaction ID should be set to 0 and the command ID to 0
for no command. If a valid command ID is send with a Transaction ID set
to 0, it will processed normally. So if an integrator doesn't want to
implement transaction ID verification, the transaction ID could always be
kept at zero.
An example of the PLC program for the messaging handling can be found
in the appendix.

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7.3.3 Functions
The functions described in this section are predefined functions included
in the standard system. However the objective of the message
communication is to allow the capability to expanded functionality as
needed. So it is possible to add functions based on the customer
requests.

7.3.3.1 Reset Message Transaction ID

The “Reset Message Transaction ID” is used to initialize the message
communication or to reset a Transaction ID mismatch error.
Table 7-4: Reset Message Transaction ID

Signal Name Values Purpose

Send Command: PLC --> Controller

CommandTransactionID 0 Cycles 1-99 to indicate a new command
CommandID 0 Assign Build Pattern
Parameter 1 0 Unused
Parameter 2 0 Unused
Parameter 3 0 Unused

Parameter 4 0 Unused

Command Reply: Controller --> PLC

Send Command See above Echo of the SendCommand
Data 1 0 Unused
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte 0 0: Success; >0 Failure (see error code list)
Error Code – High byte 0 SubCode (see error code list)

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7.3.3.2 Build Station Assign/Unassign Pattern

The “Assign Pallet Pattern” command is used to assign a new
combination of ProductID and PatternID to the specified build station. This
command may only be executed if the robot is at the Home Position
(In_Home_Cube: PLC Input byte 2 bit 1 is ON) and not palletizing (Home
Request: PLC Output byte 1 bit 0 is ON; or Build Request: PLC Output
byte 2 bit 2 is OFF). To “Unassign Pallet Pattern” the same command is
used but both ProductID and PatternID need to be set to 0. So a 0 value
cannot be used has a valid ProductID or PatternID. It is not required to
“Unassign” before making a new “Assignment”. If the station has either a
partial build or a completed pallet when it is assigned or unassigned it will
flag the station with “Bld#_Build_Done”, and force the clearing of the
station.

Each build station has a signal “Bld#Patrn_Asignd” which

NOTE indicates whether it has a pattern set (refer to Section 7.2
“Interface: Direct I/O Signals” on page 7-2 for details).

Table 7-5: Build Station Command

Signal Name Values Purpose

Send Command: PLC --> Controller

CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 1 Assign Build Pattern
Parameter 1 – Low byte 1 Station Type: 1-Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 INT16 Product ID > 0
Parameter 3 INT16 Pattern ID > 0

Parameter 4 0 Unused

Command Reply: Controller --> PLC

Send Command See above Echo of the SendCommand
Data 1 0 Unused
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.3 Station Package Info

The “Request Station Package Info” command retrieves the package ID
associated with the specified station. This can be used to confirm that the
selection on the controller matches the one on the PLC.
In the case of a build station, the ProductID and PatternID are returned.
The product ID is the ID of the product (box) being palletized.
Table 7-6: Station Package Information

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 4 Request Station PackageID
Parameter 1 – Low byte Station Type: 1:Build, 2:Infeed 3:Pallet Dispenser, 4:SlipSheet
1-4
Dispenser
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 INT16 Package ID >= 0
Data 2 INT16 Pattern ID >= 0 (Build Station Only)
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.4 Build Station Request Pattern Info

The “Request Build Pattern Info” command request the ProductID,
PatternID and Maximum Number of Layer currently assigned to the
specified build station. This is to enable the PLC/HMI to confirm the
current pattern selection and ProductID is assigned.
Table 7-7: Build Station Pattern Information

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 2 Request Build Pattern Info
Parameter 1 – Low byte 1 Station Type: 1-Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 INT16 Product ID >= 0
Data 2 INT16 Pattern ID >= 0
Data 3 1-100 Maximum Number of Layers > 0
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.5 Build Station Request Build Status

The “Request Build Status” command retrieves information about the
progress of the pattern being build at the specified station.
The “Request Build Status1” command retrieves the current layer, current
pick/place cycle and maximum number of cycle on that layer.
The “Request Build Status 2” command retrieves the current box layer
(excludes pallet and slipsheet layer), number of placed package and
maximum number of package on the current layer.
Table 7-8: Build Station Build Status 1 (Layer and Cycles)

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 13 Request Build Status 1
Parameter 1 – Low byte 1 Station Type: 1-Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 >=0 Current Layer
Data 2 >=0 Current Cycle
Data 3 >=0 Maximum number of cycle on current layer.
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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Table 7-9: Build Station Build Status 2 (Box Layer and Packages)

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 14 Request Build Status 2
Parameter 1 – Low byte 1 Station Type: 1-Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 >=0 Current layer of boxes
Data 2 >=0 Current number of package placed
Data 3 >=0 Maximum number of package on current layer.
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.6 Build Station Request Associated Stations

The “Request Build Pattern Associated Station Info” command is used to
retrieve the station ID of the infeed and dispenser stations associated with
a specific build station current pattern.
Table 7-10: Build Station Associated Stations

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 3 Request Build Pattern Associated Station Info
Parameter 1 – Low byte 1 Station Type: 1-Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 – Low byte Associated Station Type: 2:Infeed, 3:Pallet Dispenser,
2, 3, 4
4:SlipSheet Dispenser
Parameter 2 – High byte 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 – Low byte 0, 2, 3, 4 Specified Station Type
Data 1 – High byte 0-8 Station ID
Data 2 – Low byte 0, 2, 3, 4 Specified Station Type
Data 2 – High byte 0-8 Station ID
Data 3 – Low byte 0, 2, 3, 4 Specified Station Type
Data 3 – High byte 0-8 Station ID
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

7.3.3.7 Select Sequencing Mode

The “Get/Set Sequencing Mode” command allows to monitor and control
the algorithm to select which infeed/build station should be selected for
the next pick/place cycle.
The possible modes are:
• Round Robin: Sequentially check which infeed is ready. When a
ready infeed is found, the robot picks and place from it and then the
search resumes with the following infeed.

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• Ratio: A ratio is given to each infeed and the system will select pick
to try to maintain that ratio. The system will only pick from infeed that
have a ready signal, so the ratio are only met as long as the infeeds
ready signal keep pace. The ratio represents the number of pick to
that infeed relative to the overall number of pick. For example, if a 3
infeeds system has ratios set to 1, 2, 1 this gives an overall number
of 4 picks (1+2+1), so infeed 1 and 3 will each be picked 25% (1/4) of
the time and infeed 2 will be picked 50% (2/4) of the time.

Actual infeed ratios are calculated overtime and the

algorithm tries to make them converge toward the set
(desired) ratios. The actual ratios will be reset every time the
NOTE sequencing mode or infeed ratio is set. So if an infeed is
stopped for a long time, it might be necessary to reset the
actual ratios, otherwise, once the infeed is back, the system
will favor it in order to catch-up to the set ratio.

• Priority (Highest Priority First): At each cycle, the search starts with
the infeed with the highest priority setting (1 being the highest). If it is
not ready, then it goes to the next highest priority and so on until a
ready infeed is found.
• PLC Control: PLC explicitly tells the robot to which infeed to go next,
regardless if the infeed is ready or not. For details on selecting the
next infeed pick please refer to Section 7.2.1.5 “Set Next Infeed
Pick” on page 7-4.
Table 7-11: Get Sequencing Mode

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 5 Get Sequencing Mode
Parameter 1 0 Unused
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 1-4 Current Mode: 1-RoundRobin, 2-Ratio, 3-Priority, 4-PLC
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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Table 7-12: Set Sequencing Mode

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 6 Set Sequencing Mode
Parameter 1 1-4 Current Mode: 1-RoundRobin, 2-Ratio, 3-Priority, 4-PLC
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 1-4 Current Mode: 1-RoundRobin, 2-Ratio, 3-Priority, 4-PLC
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.8 Infeed Ratio

The “Set Infeed Ratio” command enables to set a picking ratio between
the infeeds when multiple infeeds are ready for picking.
The “Get Infeed Ratio” command returns the priority level currently set for
the specified infeed.
The ratio represents the number of pick to that infeed relative to the
overall number of pick. For example, if a 3 infeeds system has ratios set to
1, 2, 1 this give an overall number of 4 picks (1+2+1), so infeed 1 and 3
will each be pick 25% (1/4) of the time and infeed 2 will be pick 50% (2/4)
of the time.

NOTE This setting is only valid when the sequencing mode is set to
“Ratio Mode”.

Table 7-13: Get Infeed Ratio:

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 15 Get Infeed Ratio
Parameter 1 – Low byte 2 Station Type: 2:Infeed
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 INT16 Current Ratio > 0
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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Table 7-14: Set Infeed Ratio

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 16 Set Infeed Ratio
Parameter 1 – Low byte 1 Station Type: 1:Infeed
Parameter 1 – High byte 1-8 Station ID
Parameter 2 INT16 Requested Ratio > 0
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 INT16 Current Ratio > 0
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.9 Infeed Priority

The “Set Infeed Priority” command enables to set a higher priority on
picking certain infeeds over other ones when multiple infeeds are ready
for picking.
The “Get Infeed Priority” command returns the priority level currently set
for the specified infeed.
The highest priority is 1. The lowest priority is 8. The higher the number is,
the lower the priority. In the event of multiple stations having the same
priority, a round robin approach will be used to schedule the stations with
identical priorities.

NOTE This setting is only valid when the sequencing mode is set to
“Priority Mode”.

Table 7-15: Get Infeed Priority:

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 7 Get Infeed Priority
Parameter 1 – Low byte 2 Station Type: 2:Infeed
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 INT16 Current Priority > 0
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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Table 7-16: Set Infeed Priority

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 8 Set Infeed Priority
Parameter 1 – Low byte 1 Station Type: 1:Infeed
Parameter 1 – High byte 1-8 Station ID
Parameter 2 INT16 Requested Priority > 0
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 INT16 Current Priority > 0
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.10 Package Height Adjustment

The “Get/Set Package Height” allows the operator to make a small
temporary adjustment to the height of a package associated on an infeed
line to adjust the pick and place position for each infeed line and its
associated build station. The adjustment is automatically reset after a
pattern change.
Table 7-17: Get Package Height Adjustment:

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 9 Get Package Height Adjustment
Parameter 1 – Low byte Station Type: 2:Infeed, 3:Pallet Dispenser, 4:SlipSheet
2, 3, 4
Dispenser
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 Current Height Adjustment in 0.1 mm; Range -250 to +250
INT16
(-25.0 to 25.0 mm)
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

Table 7-18: Set Package Height Adjustment

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 10 Set Package Height Adjustment
Parameter 1 – Low byte Station Type: 2:Infeed, 3:Pallet Dispenser, 4:SlipSheet
2, 3, 4
Dispenser
Parameter 1 – High byte 1-8 Station ID
Parameter 2 Requested Height Adjustment in 0.1 mm; Range -250 to +250
INT16
(-25.0 to 25.0 mm)
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 Current Height Adjustment in 0.1 mm; Range -250 to +250
INT16
(-25.0 to 25.0 mm)
Data 2 0 Unused
Data 3 0 Unused
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.11 Station Frame Adjustment

The “Get/Set Station Frame Adjustment” allows the operator to make
small adjustments to the station reference frame. The adjustment only
affects the specified station and is not reset after a pattern change.
Table 7-19: Get Station Frame Adjustment:

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 11 Get Station Frame Adjustment
Parameter 1 – Low byte Station Type: 1:Build, 2:Infeed 3:Pallet Dispenser,
1-4
4:SlipSheet Dispenser
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 Current X Adjustment in 0.1 mm; Range -250 to +250
INT16
(-25.0 to 25.0 mm)
Data 2 Current Y Adjustment in 0.1 mm; Range -250 to +250
INT16
(-25.0 to 25.0 mm)
Data 3 Current Z Adjustment in 0.1 mm; Range -250 to +250
INT16
(-25.0 to 25.0 mm)
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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Table 7-20: Set Station Frame Adjustment

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 12 Set Station Maximum Layer
Parameter 1 – Low byte 1-4 Station Type: 1:Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 Requested X Adjustment in 0.1 mm; Range -250 to
INT16
+250 (-25.0 to 25.0 mm)
Parameter 3 Requested Y Adjustment in 0.1 mm; Range -250 to
INT16
+250 (-25.0 to 25.0 mm)
Parameter 4 Requested Z Adjustment in 0.1 mm; Range -250 to
INT16
+250 (-25.0 to 25.0 mm)
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 Current X Adjustment in 0.1 mm; Range -250 to
INT16
+250 (-25.0 to 25.0 mm)
Data 2 Current Y Adjustment in 0.1 mm; Range -250 to
INT16
+250 (-25.0 to 25.0 mm)
Data 3 Current Z Adjustment in 0.1 mm; Range -250 to
INT16
+250 (-25.0 to 25.0 mm)
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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7.3.3.12 Build Station Maximum Layer

The “Get/Set Station Maximum Layer” allows the operator to adjustments

the number of box layers on a build station. For example a pattern with 6
layers of boxes could be temporarily reduce to 3 layers without having to
use a different patterns. The maximum number of layers is automatically
reset to the pattern maximum whenever a pattern is assigned to the
station.

Table 7-21: Get Station Maximum Layer

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 19 Set Station Maximum Layer
Parameter 1 – Low byte 1 Station Type: 1:Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 >0 Maximum number of box layers
Data 2 >0 Pattern Number of box layer
Data 3 >0 Pattern number of layer (including pallet and slipsheets.)
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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Table 7-22: Set Station Maximum Layer

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 20 Set Station Maximum Layer
Parameter 1 – Low byte 1 Station Type: 1:Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 >0 Maximum number of box layers
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 >0 Maximum number of box layers
Data 2 >0 Pattern number of box layer
Data 3 >0 Pattern number of layer (including pallet and slipsheets.)
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

7.3.3.13 Infeed Station Row Data

The “Get Infeed Row Data” and “Get Infeed Lookahead Row Data”
messages allow to retrieve the row information for the specified infeed
station. The smart conveyor mode (B758 or B759) must be enabled for
the data to be valid. In the case of the “Get Infeed Lookahead Row Data”,
the lookahead mode (B757) must also be enabled. Row data is encoded in
a byte, so the information for two row is encoded in each word, one in the
lower byte and one in the higher byte. Each byte contains the quantity of
boxes in bit 0-5 (0 to 63 boxes) and the boxes orientation in bit 6-7.

Table 7-23: Byte Locations

Bit 7 6 5 4 3 2 1 0
Usage Orientation Number of boxes 1-63

Table 7-24: Bits 6 and 7 Sets The Orientation

Orientation Bit 7 Bit 6
0 degrees 0 0
90 degrees 0 1
180 degrees 1 0
270 degrees 1 1

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Table 7-25: Set Station Maximum Layer

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 21 Set Station Maximum Layer
Parameter 1 – Low byte 2 Station Type: 1:Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 – Low Byte >0 Row1 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 1 – High Byte >=0 Row2 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 2 – Low Byte >=0 Row3 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 2 – High Byte >=0 Row4 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 3 – Low Byte >=0 Row5 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 3 – High Byte >=0 Row6 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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Table 7-26: Get Infeed Lookahead Row Data

Signal Name Values Purpose

Send Command:
PLC --> Controller
CommandTransactionID 1-99 Cycles 1-99 to indicate a new command
CommandID 22 Get Infeed Lookahead Row Data
Parameter 1 – Low byte 2 Station Type: 1:Build
Parameter 1 – High byte 1-8 Station ID
Parameter 2 0 Unused
Parameter 3 0 Unused
Parameter 4 0 Unused
Command Reply:
Controller --> PLC
Send Command See above Echo of the SendCommand
Data 1 – Low Byte >0 Row1 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 1 – High Byte >=0 Row2 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 2 – Low Byte >=0 Row3 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 2 – High Byte >=0 Row4 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 3 – Low Byte >=0 Row5 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Data 3 – High Byte >=0 Row6 Data: Bit 0-5 = Qty; Bit 6-7 = Orientation
Error Code – Low byte Varies 0: Success; >0 Failure (see error code list)
Error Code – High byte Varies SubCode (see error code list)

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PalletSolver 8 Operation Monitor and Control Pendant Application
8.1 Function

8 Operation Monitor and Control Pendant Application

8.1 Function
The monitoring and control of the palletizing operation can be done
through the Operator Monitor and Control Pendant Application. This
application can read variables and I/O to get the status of the system or
write to them to modify the behavior the system. It will also enable the
operator to assign a pattern to a build station.
This pendant application accesses the data in a fashion similar to a PLC
or HMI. It is intended as an HMI example of Operator Monitor and Control
Interface and could potentially be used on a system that doesn't have a
PLC/HMI interface.

8.2 Starting the PalletSolver HMI

To open the pendant application, either select the [PalletSolver HMI]
button from the Application button on the left menu of the pendant display
(Fig.8-1 "[PalletSolver HMI] button"), or press the [PalletSolver] button in
the lower right corner of the display (Fig.8-2 "[PalletSolver] button").
Fig. 8-1: [PalletSolver HMI] button

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8.2 Starting the PalletSolver HMI

Fig. 8-2: [PalletSolver] button

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8.3 Interface

8.3.1 System Overview Screen

Fig. 8-3: System Overview Screen of the System

The System Overview screen is the entry screen into the PalletSolver
Monitor & Control application. Each station in the cell is represented with a
button that shows the basic status of that station via its color, and when
the button is pressed, it will open a more detailed monitor and control
screen dedicated to that station.
One status indicator shows if the system is Running (jobs running). The
other status indicator shows if the system is at Home, or actively
Palletizing.
The [Controller] button will lead to a screen with a more detailed controller
monitor and control functionality.
The [Settings] button will lead to other settings that may be user adjusted.
• Monitor System
– Running
– Palletizing
• Control System
– Start/Stop System
– Start/Stop Palletizing
• Palletizing Overview
– Button for each station: Displays station details when pressed.
– Station Status: Changes button background color: gray = ready;
blue = active; yellow = requires attention.
• [Controller] button: Displays the Controller screen.
• [Settings] button: Displays the system settings and optimization
screens.
• [Exit] button: Exits the application.

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8.3.2 Monitor Mode Overview

When the palletizing cell is in the PLC control Mode, the HMI will morph
into a Monitor only interface so that the PLC can be the single point of
control.
When the cell is controlled by the robot the HMI has both monitoring and
control capabilities.
The following sections will presents all the screen and controls when
operation in normal mode. In the Monitor mode, some of the controls will
not be available and will be either disabled or hidden.

8.3.3 Controller Screen

Fig. 8-4: Controller Screen

The Controller screen allows for a more detailed display of indicators

describing the state of the system, including the status indicators listed
below.
Additionally, the system may be Started or Stopped from this screen.
• Monitor System Indicators
– Running: If green, indicates the system is running.
– Remote Mode: If green, indicates the controller pendant key
switch is in Remote mode, which is required.
– Servo On: If green, indicates the controller servo is on.
– Allow Resume: If green, indicates that the robot was not
manipulated since it was stopped so that the system may
resume from its present position without a requirement to move
home first.
– Robot at Home: This indicator is green when the robot is at the
home position.

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– Home Requested: When green, indicates that there is a request

for the robot to be at home. This also means the robot is not
actively palletizing at this time. If the system is palletizing (i.e. if
the Palletizing indicator on the System Overview screen is
green), the Home Requested indicator will be off.
– Safety Gate Open: This indicator will turn red when the safety
gate is open.
– Hold: The Hold indicator will turn red when the system is in an
active Hold state (while the physical [HOLD] button on the
pendant is depressed).
– E-Stop: The E-Stop indicator will turn red when the system is
E-Stopped.
– Alarm: The Alarm indicator will turn red when the system has an
alarm
• [Start] button
– Press the Start button to begin operation. Decide if to “Resume
Build” or merely Home the robot.
Fig. 8-5: Resume Build Screen

• [Stop] button
– Stops execution of all jobs
• [Clear Msg] button
– Clears any messages that may remain in the message area at
the bottom of the Controller screen.
• [Return] button: Return to the “System Overview” screen.

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8.3.4 Build Station Screen

Fig. 8-6: Build Station Screen

Each Build Station will have a screen dedicated to it to provide detailed

monitoring information and user interaction. The Build Station screen may
be reached by pressing the related [Build Station] button on the main
System Overview screen. The various indicators and controls are
described below:
• Active indicator: Turns blue when the build station is targeted for a
placement
• Associated Stations buttons:
– These serve as both indicators (that may turn yellow, indicating
the associated station needs attention), and as links. Pushing a
button will open the screen dedicated to that station, the same
as it would if pressed from the main overview screen.
• Build Pattern:
– Product ID: Desired or current build pattern
– Pattern ID: Desired or current build pattern
– Assigned indicator: Green if pattern is currently assigned
– [Assign/Unassign] button: Used to change the pattern. If there is
a pattern assigned the Product ID and Pattern ID fields will be
disabled and display the IDs of the currently assigned pattern.
• To Change Pattern:
– The station must be locked using the [Lock] button to enable the
[Assign/Unassign] button will be enabled.
– To Unassign the pattern, click the [Unassign] button. This will
enable and blank the Product ID and Pattern ID fields.
– To assign a pattern, enter the desired Product and Pattern IDs
by typing in numeric value from keypad, or by pressing the [Edit]
button to display the alphanumeric keyboard. When pattern files
are stored on CF Card or USB drive, selection can be made
from the drop-down list. After entering the desired IDs, click the
[Assign] button to assign the pattern to the build station.

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• Current Build Status:

– Build: Number of builds complete since the last counter reset.
– Layer: Current Layer number and maximum number of layers.
– Package: Number of placed package and maximum number of
package on the current layer
– Complete indicator: When a build pattern completes, this
indicator will turn yellow.
– [Force Complete] button: Provides a way to force the station to a
complete state prior to placing all layers and packages specified
by the current pattern.
– [Build Clear] button: Is enabled when a build is completed (and
the complete indicator is yellow). The user should press this
button after the completed build is physically removed from the
cell to tell the system that the build area is clear and ready for
the next build to proceed.
– Pallet Present indicator: Turns green when the pallet present
signal is on.
• Station Lock:
– Lock indicator: Turns red when the station becomes locked
(unavailable for building) either due to a place error, or through
the user manually locking the station by pressing the [Lock]
button.
– [Lock/Unlock] button: When the station is locked press this
button to unlock the station and make it available for building.
Conversely, if the station is building and it is desired to stop or
pause the build process, the station may be locked by pressing
this button.
– [Lock After Done] button: Pressing this button will force the
station to become locked when the build completes.
• Place Error:
– Place Error indicator: Turns red if there is an error when the
robot attempts a placement. (The lock indicator will also turn
red)
– [Ignore] button: Press the [Ignore] button following a place error
if it is determined it is safe and desirable to continue the build as
if there were no error.
– [Abort] button: Following a place error, press this button if it is
determined the placement should not continue. When pressed,
the robot will assume there are unplaced packages on the
gripper, and will move safely to home, and then to the Reject
Station where the packages will be dropped off.
– Clear Layer Requested indicator: Following an aborted
placement, the system will turn this indicator red, indicating that
the current layer should be physically cleared by the user so that
the robot can start the layer from the beginning.
– [Layer Clear] button: Press this button following a Clear Layer
Request to tell the system the layer has been physically cleared
and it is safe to continue from the beginning of the layer.

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8.3.5 Infeed Station Screen

Fig. 8-7: Infeed Station Screen

Each Conveyor Infeed Station has a screen dedicated to it to provide

detailed monitoring information and user interaction. The Infeed Station
screen may be reached by pressing the related [Infeed Station] button on
either the main System Overview screen, or on the associated Build
Station screen. The various indicators and controls are described below:
• Active indicator: turns blue when the infeed station is targeted for a
pick
• Pick Request:
– Requested indicator: Turns green when a pick is requested by
the system.
– Package Requested numeric indicator: Displays the number of
packages requested when a pick is requested.
– Ready indicator: Turns green when the infeed package
sensor(s) is/are made and the requested number of packages
are present.
– [Purge] button: Press the [Purge] button to purge the remaining
packages on the infeed conveyor... even if there are a different
number of packages available on the conveyor than requested.
• Station Lock:
– Lock indicator: Turns red when the station becomes locked
(unavailable for building) either due to a pick error, or through
the user manually locking the station by pressing the [Lock]
button.
– [Lock/Unlock] button: When the station is locked press this
button to unlock the station and make it available for infeed.
Conversely, if the station is in use and it is desired to stop or
pause the pick process, the station may be locked by pressing
this button.

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• Pick Error:
– Pick Error indicator: Turns red if there is an error when the robot
attempts to pick. (The lock indicator will also turn red)
– [Ignore] button: Press following a pick error if it is determined it is
safe and desirable to continue the build as if there were no error.
– [Retry] button Press this button following a pick error to allow the
system to retry the pick.
– [Abort] button: Following a pick error, press this button if it is
determined the placement should not continue. When pressed,
the robot will assume there are unplaced packages on the
gripper, and will move safely to home, and then to the Reject
Station where the packages will be dropped off.

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8.3.6 Dispenser Station Screen:

Fig. 8-8: Dispenser Station Screen

Each Dispenser station (both Pallet and Slipsheet dispenser(s)) will have
a screen dedicated to it to provide detailed monitoring information and
user interaction. The Dispenser screen may be reached by pressing the
related [Dispenser Station] button on either the main System Overview
screen, or on the associated Build Station screen. The various indicators
and controls are described below:
• Active indicator turns blue when the dispenser station is targeted for
a pick
• Dispenser Status:
– Low or Empty indicators: Turns red when a dispenser is
determined to be low or empty due to either a sensor indication,
or a search height limit.
– [Ht Reset] button: Press to reset the low or empty indicators after
the dispenser has been refilled
• Station Lock:
– Lock indicator: Turns red when the station becomes locked
(unavailable for building) either due to a pick error, or through
the user manually locking the station by pressing the [Lock]
button.
– [Lock/Unlock] button: When the station is locked press this
button to unlock the station and make it available for dispensing.
Conversely, if the station is in use and it is desired to stop or
pause the pick process, the station may be locked by pressing
this button.

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• Pick Error:
– Pick Error indicator: Turns red if there is an error when the robot
attempts to pick. (The lock indicator will also turn red)
– [Ignore] button: Press following a pick error if it is determined it is
safe and desirable to continue the build as if there were no error.
– [Retry] button: Press following a pick error to allow the system to
retry the pick.
– [Abort] button: Following a pick error, press this button if it is
determined the pick should not continue. The system will lock
the station.

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8.3.7 Settings and Optimization Screen

Fig. 8-9: Settings and Optimization Screen

The Settings and Optimization Screen serves as a gateway to various

other settings and optimization screens. Press the appropriate button as
described here:
• [Test Gripper] button: Displays the Test Gripper screen.
• [Speed Adj] button: Displays the Speed Adjustment screen.
• [Password] button: Displays the Security Check screen
• [Sequencing] button: Displays the Sequencing screen
• [Frame Adj] button: Displays the Frame and Product Adjustment
screen.

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8.3.8 Sequencing Screen

Fig. 8-10: Sequencing Screen

The Sequencing screen is dedicated to displaying the current sequencing

mode and allowing it to be changed as described below:
• {Sequencing Mode} section:
– Radio: Displays current setting as starting value
• RoundRobin: Specifies that infeed stations are picked
sequentially in order if they are ready. If not ready, they are
skipped until next time around.
• Ratio: Specifies that infeed stations will be picked according to
the specified ratios. If a station is not ready, the system will skip to
the station that is furthest behind its desired ratio.
• Priority: Specifies that the system will pick from the highest
priority (lowest priority numbered) station that is ready. If there are
two or more highest priority stations ready with the same priority,
the system will alternate between the two.
• PLC: Specifies that the PLC will determine which infeed is the
next to be picked from.
• [Apply] button:
– If mode is Ratio, applies the selected ratios for each infeed.
– If mode is Priority, applies the selected priority for each infeed.
– Sets Round Robin or PLC as the sequencing mode if indicated.
• [Return] button: Go back to the Settings and Optimization screen.

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8.3.9 Frame and Product Adjustment Screen

Fig. 8-11: Frame and Product Adjustment Screen

The Frame & Product Adjustment screen displays and allows changing
the Package Height Adjustment (in Z) and Frame Adjustments (in X, Y, Z)
for all stations:
• Package Height Adjustment section:
a) Select desired Station Type and Station ID from the
respective droplists. (It is not possible to adjust package
height for Build Stations).
b) Set Height Adjustment spin button to desired value and click
Apply.
• Frame Adjustment section:
a) Select desired Station Type and Station ID from the
respective droplists.
b) Set X, Y, and/or Z Frame Adjustment spin button(s) to
desired value(s) and click Apply.
• [Return] button: Go back to the Settings and Optimization screen

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8.3.10 Speed Adjustment Screen

Fig. 8-12: Speed Adjustment Screen

This screen will come up showing the current speed control. The default is
100% speed.

8.3.10.1 Adjusting the Speed

1. Check the Speed Control% check box.
2. Change the speed control value by increasing or decreasing the speed
percentage.
3. Press the [Apply] button to apply the change, or press the [Return]
button to leave the screen without saving any change.

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8.3.11 Gripper Testing

Gripper testing maybe preformed the pressing the [Gripper Test] button on
the Settings and Optimization screen.
The Test Gripper Signals screen is shown below: This screen can be used
for testing the initial gripper operation and wiring. Additionally it can be
used during crash recovery and during system resets to allow the user to
manually grip or un-grip products.

8.3.11.1 Grip Output Control

These signals control the Vacuum On/Off, Clamp in and out and Fork
open and close signals. See Chapter 6 "Controller Jobs and Concurrent I/
O Program" for details on wiring a gripper.
To turn the gripper on or off, select the “Grip” radio button and press the
associated [All On] or [All Off] buttons.
To turn on or off individual gripper valves, select the “Grip” radio button
followed by the valve number. It will toggle between the on (green) or off
(red) states.
Fig. 8-13: Test Gripper Signal Screen

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8.3.11.2 Gripper Part Sensors

Gripper Part Sensors inputs can be checked by pressing the Part Sensor
radio button and the All On button.
If a part is on the gripper that input will be green. Sensors that have no
parts will be red.
Fig. 8-14: Sensor Signal ON with a Sensor Error

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8.3.11.3 Gripper Open and Close Sensors

For Gripper controls that have open and close states, such as Clamp or
Fork Grippers, Open and Closed state Sensors can be wired into the
controller and monitored.
The following screen captures show the open and closed state of each
clamp or fork gripper. Closed Sensors are shown in green and open
senors are shown in red.
Also note that Closed and Open Sensors are complimentary.
Fig. 8-15(a): Test Gripper Open States

Fig. 8-15(b): Test Gripper Close Sensors

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8.3.12 Security Check

The Security Check screen allows to limit access to certain screens by
requiring a password to be entered.
Fig. 8-16: Password Management

• “Enabled Password Check” checkbox: The password check

functionality is enable when checked. Other controls will be disabled
if the unchecked.
• Password textbox: Displays the current password and allows to
change the password. The Keyboard button next to the textbox can
be press to display a keyboard and enter an alphanumeric
password.
• Password required to access area: List all the buttons/screens that
can be protected by the password. When pressed, checked buttons
will be required the user to enter the password before being allowed
to access the corresponding screen.
– The "Exit PalletSolver" checkbox will require the user to enter
the password in order to get out of PalletSolver and have access
to the normal pendant interface.
– Checking the "Settings" checkbox will automatically disable all
the individual checkbox for the buttons underneath the
"Settings" screen.
• [Apply] button: Save the password setting changes and return to the
"Settings" screen.
• [Return] button: Cancel all changes and return the to "Settings"
screen.

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When the user is required to enter the Password, the follow screen
appears.
Fig. 8-17: Password Screen

The operator can enter a numeric password on the pendant keypad and
press [ENTER] or press the {Keyboard} button to display the on-screen
keyboard to enter an alphanumeric password.
• [Return] button: Return the to previous screen
• [Continue] button: Continue to next screen if the valid password was
entered.

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8.3.13 Reject Station Screen

Fig. 8-18: Reject Station Screen

The Reject Station has a screen dedicated to it that provides basic

feedback and control:
• Active indicator: Turns blue when the reject station is targeted for a
place
• [Return] button: Go back to the previous screen

8.3.13.1 Reject Station Controls

• [Goto] button: Request the robot to goto to the reject station after
completing the next cycle.
• [Reject Clr] indicator: The reject area is cleared of packages.
• [At Rej Drop] indicator: The robot is in position to drop packages.
• [Continue] button: Resumes the palletizing after being at drop
position.

8.3.13.2 Gripper Controls

• [Clr Gripper] indicator: The gripper has packages that need to be
removed.
• [Release] button: Release all packages from the gripper.

8.3.13.3 Station Lock

• [Lock/Unlock] indicator: Will turn red when the station becomes
locked (unavailable for drop) through the user manually locking the
station by pressing the [Lock] button.
• [Lock/Unlock] button: When the station is locked press this button to
unlock the station and make it available for dropping package at
reject station. Conversely, if the station is in use and it is desired to
prevent going to the reject station, the station may be locked by
pressing this button.

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A.1 Monitor and Control Direct I/O Mapping

Appendix A

A.1 Monitor and Control Direct I/O Mapping

The following tables present the direct I/O mapping of the controller. The
controller signals used in the jobs are identified above each signal (OUT#
or IN#). The corresponding PLC signals are identified by combining the
byte number of the row with the bit number of the column.
Network Signals are addresses that can be accessed by a Pendant
Application or other application using standard YASKAWA protocol such
as MotoCom or High-Speed Ethernet Server. The network address value
is found be taking the address of the row and replacing the “x” of that
address with the bit of the column.

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Table A-1: Controller Outputs (PLC Inputs)
PLC Network Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Section
PalletSolver

Input Byte Signal

Address

0 #3027x OUT#200 OUT#199 OUT#198 OUT#197 OUT#196 OUT#195 OUT#194 OUT#193 System
Teach Play Selected Remote In Warning Top of Master Servo Off Servo On Operating
Selected Selected Job
A.1

1 #3028x OUT#208 OUT#207 OUT#206 OUT#205 OUT#204 OUT#203 OUT#202 OUT#201 System
Fieldbus Battery E-Stop E-Stop Safety Gate Safety Speed In Hold At Home
Heartbeat Warning Pendant External Open
Appendix A

2 #3029x OUT#216 OUT#215 OUT#214 OUT#213 OUT#212 OUT#211 OUT#210 OUT#209 System
Next Infeed Next Infeed Next Infeed Next Infeed PLC Controlled Building In Home Cube Resume

A-2
Echo Echo Echo Echo System Allowed
(bit 3) (bit 2) (bit 1) (bit 0)
3 #3030x OUT#224 OUT#223 OUT#222 OUT#221 OUT#220 OUT#219 OUT#218 OUT#217 Error
Error Error Error System Job MotoPlus App Pick/Place JobComLock Job Warning Handling
Response Response Response Running Running Error
Abort Retry Ignore
Acknowlege Acknowlege Acknowlege

4 #3031x OUT#232 OUT#231 OUT#230 OUT#229 OUT#228 OUT#227 OUT#226 OUT#225 Error
Monitor and Control Direct I/O Mapping

Job Warning Job Warning Job Warning Job Warning Job Warning Job Warning Job Warning Job Warning Handling
Code Code Code Code Code Code Code Code
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)
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Address
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5 #3032x OUT#240 OUT#239 OUT#238 OUT#237 OUT#236 OUT#235 OUT#234 OUT#233 Error
Job Warning Job Warning Job Warning Job Warning Job Warning Job Warning Job Warning Job Warning Handling
Param Param Param Param Param Param Param Param
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

6 #3033x OUT#248 OUT#247 OUT#246 OUT#245 OUT#244 OUT#243 OUT#242 OUT#241 Other
Ready Exists In Ready Cube Placing Boxes Placing Picking
Sequence Sequence Sequence
Appendix A

7 #3034x OUT#256 OUT#255 OUT#254 OUT#253 OUT#252 OUT#251 OUT#250 OUT#249 Reject
Reject Exists Reject Active Reject Locked At Reject Drop Need Gripper
Clear

A-3
8 #3035x OUT#264 OUT#263 OUT#262 OUT#261 OUT#260 OUT#259 OUT#258 OUT#257 Build
Build1 Exists Build1 Verify Build1 Place Build1 Place Build1 Locked Build1 Build1 Done
Layer Request Error Active Pattern
Assigned

9 #3036x OUT#272 OUT#271 OUT#270 OUT#269 OUT#268 OUT#267 OUT#266 OUT#265 Build
A.1 Monitor and Control Direct I/O Mapping

Build2 Exists Build2 Verify Build2 Place Build2 Place Build2 Locked Build2 Pattern Build2 Done
Layer Request Error Active Assigned

10 #3037x OUT#280 OUT#279 OUT#278 OUT#277 OUT#276 OUT#275 OUT#274 OUT#273 Build
Build3 Exists Build3 Verify Build3 Place Build3 Place Build3 Locked Build3 Pattern Build3 Done
Layer Request Error Active Assigned

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11 #3038x OUT#288 OUT#287 OUT#286 OUT#285 OUT#284 OUT#283 OUT#282 OUT#281 Build
Build4 Exists Build4 Verify Build4 Place Build4 Place Build4 Locked Build4 Pattern Build4 Done
Layer Request Error Active Assigned

12 #3039x OUT#296 OUT#295 OUT#294 OUT#293 OUT#292 OUT#291 OUT#290 OUT#289 Build
Build5 Exists Build5 Verify Build5 Place Build5 Place Build5 Locked Build5 Pattern Build5 Done
Layer Request Error Active Assigned

13 #3040x OUT#304 OUT#303 OUT#302 OUT#301 OUT#300 OUT#299 OUT#298 OUT#297 Build
Appendix A

Build6 Exists Build6 Verify Build6 Place Build6 Place Build6 Locked Build6 Pattern Build6 Done
Layer Request Error Active Assigned

A-4
14 #3041x OUT#312 OUT#311 OUT#310 OUT#309 OUT#308 OUT#307 OUT#306 OUT#305 Build
Build7 Exists Build7 Verify Build7 Place Build7 Place Build7 Locked Build7 Pattern Build7 Done
Layer Request Error Active Assigned

15 #3042x OUT#320 OUT#319 OUT#318 OUT#317 OUT#316 OUT#315 OUT#314 OUT#313 Build
Build8 Exists Build8 Verify Build8 Place Build8 Place Build8 Locked Build8 Pattern Build8 Done
A.1 Monitor and Control Direct I/O Mapping

Layer Request Error Active Assigned

16 #3043x OUT#328 OUT#327 OUT#326 OUT#325 OUT#324 OUT#323 OUT#322 OUT#321 Infeed
Infeed1 Exists Infeed1 Purge Infeed1 Pick Infeed1 Infeed1 Pick Infeed1 Pick
Request Active Locked Error Request
Acknowled

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17 #3044x OUT#336 OUT#335 OUT#334 OUT#333 OUT#332 OUT#331 OUT#330 OUT#329 Infeed
Infeed1 Infeed1 Infeed1 Infeed1 Infeed1 Infeed1 Infeed1 Infeed1
Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

18 #3045x OUT#344 OUT#343 OUT#342 OUT#341 OUT#340 OUT#339 OUT#338 OUT#337 Infeed
Infeed2 Exists Infeed2 Purge Infeed2 Pick Infeed2 Infeed2 Pick Infeed2 Pick
Request Active Locked Error Request
Acknowled
Appendix A

19 #3046x OUT#352 OUT#351 OUT#350 OUT#349 OUT#348 OUT#347 OUT#346 OUT#345 Infeed
Infeed2 Infeed2 Infeed2 Infeed2 Infeed2 Infeed2 Infeed2 Infeed2
Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

A-5
20 #3047x OUT#360 OUT#359 OUT#358 OUT#357 OUT#356 OUT#355 OUT#354 OUT#353 Infeed
Infeed3 Exists Infeed3 Purge Infeed3 Pick Infeed3 Infeed3 Pick Infeed3 Pick
Request Active Locked Error Request
Acknowled

21 #3048x OUT#368 OUT#367 OUT#366 OUT#365 OUT#364 OUT#363 OUT#362 OUT#361 Infeed
A.1 Monitor and Control Direct I/O Mapping

Infeed3 Infeed3 Infeed3 Infeed3 Infeed3 Infeed3 Infeed3 Infeed3

Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

22 #3049 OUT#376 OUT#375 OUT#374 OUT#373 OUT#372 OUT#371 OUT#370 OUT#369 Infeed
Infeed4 Exists Infeed4 Purge Infeed4 Pick Infeed4 Infeed4 Pick Infeed4 Pick
Request Active Locked Error Request
Acknowled

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Address
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23 #3050x OUT#384 OUT#383 OUT#382 OUT#381 OUT#380 OUT#379 OUT#378 OUT#377 Infeed
Infeed4 Infeed4 Infeed4 Infeed4 Infeed4 Infeed4 Infeed4 Infeed4
Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

24 #3051x OUT#392 OUT#391 OUT#390 OUT#389 OUT#388 OUT#387 OUT#386 OUT#385 Infeed
Infeed5 Exists Infeed5 Purge Infeed5 Pick Infeed5 Infeed5 Pick Infeed5 Pick
Request Active Locked Error Request
Acknowled
Appendix A

25 #3052x OUT#400 OUT#399 OUT#398 OUT#397 OUT#396 OUT#395 OUT#394 OUT#393 Infeed
Infeed5 Infeed5 Infeed5 Infeed5 Infeed5 Infeed5 Infeed5 Infeed5
Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

A-6
26 #3053x OUT#408 OUT#407 OUT#406 OUT#405 OUT#404 OUT#403 OUT#402 OUT#401 Infeed
Infeed6 Exists Infeed6 Purge Infeed6 Pick Infeed6 Infeed6 Pick Infeed6 Pick
Request Active Locked Error Request
Acknowled

27 #3054x OUT#416 OUT#415 OUT#414 OUT#413 OUT#412 OUT#411 OUT#410 OUT#409 Infeed
A.1 Monitor and Control Direct I/O Mapping

Infeed6 Infeed6 Infeed6 Infeed6 Infeed6 Infeed6 Infeed6 Infeed6

Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

28 #3055x OUT#424 OUT#423 OUT#422 OUT#421 OUT#420 OUT#419 OUT#418 OUT#417 Infeed
Infeed7 Exists Infeed7 Purge Infeed7 Pick Infeed7 Infeed7 Pick Infeed7 Pick
Request Active Locked Error Request
Acknowled

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Input Byte Signal
Address
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PalletSolver

29 #3056x OUT#432 OUT#431 OUT#430 OUT#429 OUT#428 OUT#427 OUT#426 OUT#425 Infeed
Infeed7 Infeed7 Infeed7 Infeed7 Infeed7 Infeed7 Infeed7 Infeed7
Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

30 #3057x OUT#440 OUT#439 OUT#438 OUT#437 OUT#436 OUT#435 OUT#434 OUT#433 Infeed
Infeed8 Exists Infeed8 Purge Infeed8 Pick Infeed8 Infeed8 Pick Infeed8 Pick
Request Active Locked Error Request
Acknowled
Appendix A

31 #3058x OUT#448 OUT#447 OUT#446 OUT#445 OUT#444 OUT#443 OUT#442 OUT#441 Infeed
Infeed8 Infeed8 Infeed8 Infeed8 Infeed8 Infeed8 Infeed8 Infeed8
Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed Box Needed
(bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)

A-7
32 #3059x OUT#456 OUT#455 OUT#454 OUT#453 OUT#452 OUT#451 OUT#450 OUT#449 Pallet
Pallet Disp1 Pallet Disp1 Pallet Disp1 Pallet Disp1 Pallet Disp1 Pallet Disp1 Pallet Disp1 Dispenser
Exists Pick Error Empty Low Stack Pick Active Locked Search Reset
Ack

33 #3060x OUT#464 OUT#463 OUT#462 OUT#461 OUT#460 OUT#459 OUT#458 OUT#457 Pallet
A.1 Monitor and Control Direct I/O Mapping

Pallet Disp2 Pallet Disp2 Pallet Disp2 Pallet Disp2 Pallet Disp2 Pallet Disp2 Pallet Disp2 Dispenser
Exists Pick Error Empty Low Stack Pick Active Locked Search Reset
Ack

34 #3061x OUT#472 OUT#471 OUT#470 OUT#469 OUT#468 OUT#467 OUT#466 OUT#465 Slipsheet
Slipsheet Slipsheet Slipsheet Slipsheet Slipsheet Slipsheet Slipsheet Dispenser
Disp1 Exists Disp1 Pick Disp1 Empty Disp1 Low Disp1 Pick Disp1 Locked Disp1 Search
Error Stack Active Reset Ack

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Input Byte Signal
Address
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PalletSolver

35 #3062x OUT#480 OUT#479 OUT#478 OUT#477 OUT#476 OUT#475 OUT#474 OUT#473 Slipsheet
Slipsheet Slipsheet Slipsheet Slipsheet Slipsheet Slipsheet Slipsheet Dispenser
Disp2 Exists Disp2 Pick Disp2 Empty Disp2 Low Disp2 Pick Disp2 Locked Disp2 Search
Error Stack Active Reset Ack
Appendix A

A-8
A.1 Monitor and Control Direct I/O Mapping

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 A.1.2 Controller Inputs (PLC Outputs)
Table A-2: Controller Inputs (PLC Outputs)
169390-1CD

PLC Network Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Section
PalletSolver

Output Signal
Byte Address

0 DX100: IN#200 IN#199 IN#198 IN#197 IN#196 IN#195 IN#194 IN#193 System
#2527x Teach Mode Play Mode Warning Reset Call Master Request Servo Request Servo External Start
DX200: Select Select Job Off On
#2727x

1 DX100: IN#208 IN#207 IN#206 IN#205 IN#204 IN#203 IN#202 IN#201 System
#2528x Fieldbus Heart Safe Speed External Hold Home Request
DX200: Select
Appendix A

#2728x

2 DX100: IN#216 IN#215 IN#214 IN#213 IN#212 IN#211 IN#210 IN#209 System
#2529x Next Infeed Next Infeed Next Infeed Next Infeed Build Request

A-9
DX200: (bit 3) (bit 2) (bit 1) (bit 0)
#2729x

3 DX100: IN#224 IN#223 IN#222 IN#221 IN#220 IN#219 IN#218 IN#217 Error
#2530x Error Error Error Job Warning Handling
DX200: Response Response Response Reset
#2730x Abort Retry Ignore
A.1 Monitor and Control Direct I/O Mapping

4 DX100: IN#232 IN#231 IN#230 IN#229 IN#228 IN#227 IN#226 IN#225 Error
#2531x Abort Next Abort Clear Abort Next Abort Repeat Handling
DX200: Layer Cycle Cycle Cycle
#2731x

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Byte Address
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5 DX100: IN#240 IN#239 IN#238 IN#237 IN#236 IN#235 IN#234 IN#233 Not Used
#2532x
DX200:
#2732x

6 DX100: IN#248 IN#247 IN#246 IN#245 IN#244 IN#243 IN#242 IN#241 System
#2533x Speed Speed Speed Speed Speed Speed Speed Speed
DX200: Override% Override% Override% Override% Override% Override% Override% Override%
#2733x (bit 7) (bit 6) (bit 5) (bit 4) (bit 3) (bit 2) (bit 1) (bit 0)
Appendix A

7 DX100: IN#256 IN#255 IN#254 IN#253 IN#252 IN#251 IN#250 IN#249 Reject
#2534x Reject Goto Reject Full Reject Unlock Reject Lock Reject Drop Force Gripper
DX200: Request Request Request Acknowledge Release
#2734x

A-10
8 DX100: IN#264 IN#263 IN#262 IN#261 IN#260 IN#259 IN#258 IN#257 Build
#2535x Build1 Layer Build1 Pallet Build1 Cleared Build1 Unlock Build1 Lock Build1 Lock Build1 Done
DX200: Verified Present Request Request After Done Request
#2735x Confirm
A.1 Monitor and Control Direct I/O Mapping

9 DX100: IN#272 IN#271 IN#270 IN#269 IN#268 IN#267 IN#266 IN#265 Build
#2536x Build2 Layer Build2 Pallet Build2 Cleared Build2 Unlock Build2 Lock Build2 Lock Build2 Done
DX200: Verified Present Request Request After Done Request
#2736x Confirm

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Output Signal
Byte Address
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PalletSolver

10 DX100: IN#280 IN#279 IN#278 IN#277 IN#276 IN#275 IN#274 IN#273 Build
#2537x Build3 Layer Build3 Pallet Build3 Cleared Build3 Unlock Build3 Lock Build3 Lock Build3 Done
DX200: Verified Present Request Request After Done Request
#2737x Confirm

11 DX100: IN#288 IN#287 IN#286 IN#285 IN#284 IN#283 IN#282 IN#281 Build
#2538x Build4 Layer Build4 Pallet Build4 Cleared Build4 Unlock Build4 Lock Build4 Lock Build4 Done
DX200: Verified Present Request Request After Done Request
#2738x Confirm
Appendix A

12 DX100: IN#296 IN#295 IN#294 IN#293 IN#292 IN#291 IN#290 IN#289 Build
#2539x Build5 Layer Build5 Pallet Build5 Cleared Build5 Unlock Build5 Lock Build5 Lock Build5 Done
DX200: Verified Present Request Request After Done Request

A-11
#2739x Confirm

13 DX100: IN#304 IN#303 IN#302 IN#301 IN#300 IN#299 IN#298 IN#297 Build
#2540x Build6 Layer Build6 Pallet Build6 Cleared Build6 Unlock Build6 Lock Build6 Lock Build6 Done
DX200: Verified Present Request Request After Done Request
#2740x Confirm
A.1 Monitor and Control Direct I/O Mapping

14 DX100: IN#312 IN#311 IN#310 IN#309 IN#308 IN#307 IN#306 IN#305 Build
#2541x Build7 Layer Build7 Pallet Build7 Cleared Build7 Unlock Build7 Lock Build7 Lock Build7 Done
DX200: Verified Present Request Request After Done Request
#2741x Confirm

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Output Signal
Byte Address
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PalletSolver

15 DX100: IN#320 IN#319 IN#318 IN#317 IN#316 IN#315 IN#314 IN#313 Build
#2542x Build8 Layer Build8 Pallet Build8 Cleared Build8 Unlock Build8 Lock Build8 Lock Build8 Done
DX200: Verified Present Request Request After Done Request
#2742x Confirm

16 DX100: IN#328 IN#327 IN#326 IN#325 IN#324 IN#323 IN#322 IN#321 Infeed
#2543x Infeed1 Unlock Infeed1 Lock Infeed1 Purge Infeed1 Pick
DX200: Request Request Ready
#2743x
Appendix A

17 DX100: IN#336 IN#335 IN#334 IN#333 IN#332 IN#331 IN#330 IN#329 Infeed
#2544x
DX200:
#2744x

A-12
18 DX100: IN#344 IN#343 IN#342 IN#341 IN#340 IN#339 IN#338 IN#337 Infeed
#2545x Infeed2 Unlock Infeed2 Lock Infeed2 Purge Infeed2 Pick
DX200: Request Request Ready
#2745x
A.1 Monitor and Control Direct I/O Mapping

19 DX100: IN#352 IN#351 IN#350 IN#349 IN#348 IN#347 IN#346 IN#345 Infeed
#2546x
DX200:
#2746x

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Output Signal
Byte Address
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PalletSolver

20 DX100: IN#360 IN#359 IN#358 IN#357 IN#356 IN#355 IN#354 IN#353 Infeed
#2547x Infeed3 Unlock Infeed3 Lock Infeed3 Purge Infeed3 Pick
DX200: Request Request Ready
#2747x

21 DX100: IN#368 IN#367 IN#366 IN#365 IN#364 IN#363 IN#362 IN#361 Infeed
#2548x
DX200:
#2748x
Appendix A

22 DX100: IN#376 IN#375 IN#374 IN#373 IN#372 IN#371 IN#370 IN#369 Infeed
#2549 Infeed4 Unlock Infeed4 Lock Infeed4 Purge Infeed4 Pick
DX200: Request Request Ready
#2749x

A-13
23 DX100: IN#384 IN#383 IN#382 IN#381 IN#380 IN#379 IN#378 IN#377 Infeed
#2550x
DX200:
#2750x
A.1 Monitor and Control Direct I/O Mapping

24 DX100: IN#392 IN#391 IN#390 IN#389 IN#388 IN#387 IN#386 IN#385 Infeed
#2551x Infeed5 Unlock Infeed5 Lock Infeed5 Purge Infeed5 Pick
DX200: Request Request Ready
#2751x

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Output Signal
Byte Address
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25 DX100: IN#400 IN#399 IN#398 IN#397 IN#396 IN#395 IN#394 IN#393 Infeed
#2552x
DX200:
#2752x

26 DX100: IN#408 IN#407 IN#406 IN#405 IN#404 IN#403 IN#402 IN#401 Infeed
#2553x Infeed6 Unlock Infeed6 Lock Infeed6 Purge Infeed6 Pick
DX200: Request Request Ready
#2753x
Appendix A

27 DX100: IN#416 IN#415 IN#414 IN#413 IN#412 IN#411 IN#410 IN#409 Infeed
#2554x
DX200:
#2754x

A-14
28 DX100: IN#424 IN#423 IN#422 IN#421 IN#420 IN#419 IN#418 IN#417 Infeed
#2555x Infeed7 Unlock Infeed7 Lock Infeed7 Purge Infeed7 Pick
DX200: Request Request Ready
#2755x
A.1 Monitor and Control Direct I/O Mapping

29 DX100: IN#432 IN#431 IN#430 IN#429 IN#428 IN#427 IN#426 IN#425 Infeed
#2556x
DX200:
#2756x

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Output Signal
Byte Address
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PalletSolver

30 DX100: IN#440 IN#439 IN#438 IN#437 IN#436 IN#435 IN#434 IN#433 Infeed
#2557x Infeed8 Unlock Infeed8 Lock Infeed8 Purge Infeed8 Pick
DX200: Request Request Ready
#2757x

31 DX100: IN#448 IN#447 IN#446 IN#445 IN#444 IN#443 IN#442 IN#441 Infeed
#2558x
DX200:
#2758x
Appendix A

32 DX100: IN#456 IN#455 IN#454 IN#453 IN#452 IN#451 IN#450 IN#449 Pallet
#2559x Dispenser
Pallet Disp1 Pallet Disp1 Pallet Disp1 Pallet Disp1 Pallet Disp1
DX200: Empty Sensor Low Stack Unlock Lock Request Search Reset
#2759x Sensor Request

A-15
33 DX100: IN#464 IN#463 IN#462 IN#461 IN#460 IN#459 IN#458 IN#457 Pallet
#2560x Pallet Disp2 Pallet Disp2 Pallet Disp2 Pallet Disp2 Pallet Disp2 Dispenser
DX200: Empty Sensor Low Stack Unlock Lock Request Search Reset
#2760x Sensor Request
A.1 Monitor and Control Direct I/O Mapping

34 DX100: IN#472 IN#471 IN#470 IN#469 IN#468 IN#467 IN#466 IN#465 Slipsheet
#2561x Slipsheet Slipsheet Slipsheet Slipsheet Slipsheet Dispenser
DX200: Disp1 Empty Disp1 Low Disp1 Unlock Disp1 Lock Disp1 Search
#2761x Sensor Stack Sensor Request Request Reset

35 DX100: IN#480 IN#479 IN#478 IN#477 IN#476 IN#475 IN#474 IN#473 Slipsheet
#2562x Slipsheet Slipsheet Slipsheet Slipsheet Slipsheet Dispenser
DX200: Disp2 Empty Disp2 Low Disp2 Unlock Disp2 Lock Disp2 Search
#2762x Sensor Stack Sensor Request Request Reset

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PalletSolver Appendix A
A.2 Error and Warning Lists

A.2 Error and Warning Lists

A.2.1 Messaging Error List

Table A-3: Main Code
Error Code Meaning
0 Successful
1 Transaction ID out of sync.
2 Command ID unknown
3 Command Parameter Invalid
Subcode: Parameter #
4 Value Out-Of-Range
Subcode: Parameter #
5 Pattern Assign Error
Subcode: MotoPlus Application Error Code

Table A-4: Error 5: Pattern Assign Error Subcodes

Subcode Meaning
1 ROBOT_NOT_IN_ASSIGNMENT_STATE
10 NO_PATTERN_INFORMATION_ELEMENT
11 CELLID_IN_PATTERNFILE_DOES_NOT_MATCH_CELL
12 PATTERNFILE_DOES_NOT_HAVE_ONE_STATIONS_INFORMATION
13 PATTERNFILE_NO_NUMBEROFSTATIONS
14 PATTERNFILE_INVALID_NUMBEROFSTATIONS
15 INFEED_IN_PATTERNFILE_DOES_NOT_MATCH_CELL
16 BUILDSTATION_IN_PATTERNFILE_DOES_NOT_MATCH_CELL
17 NO_INFEED_IN_PATTERNFILE
18 NO_BUILDSTATION_IN_PATTERNFILE
19 PALLETDISPENSER_IN_PATTERNFILE_DOES_NOT_MATCH_CELL
20 SLIPSHEETDISPENSER_IN_PATTERNFILE_DOES_NOT_MATCH_CELL
21 PATTERNFILE_CONTAINS_STATION_WITH_UNDEFINED_TYPE
22 ILLEGAL_PALLETDISPENSER_ID_IN_PATTERNFILE
23 ILLEGAL_SLIPSHEETDISPENSER_ID_IN_PATTERNFILE
24 INVALID_CELLID_IN_PATTERNFILE
25 PATTERNFILE_INVALID_GRIPPER
26 GRIPPERID_IN_PATTERNFILE_DOES_NOT_MATCH_CELL
27 PATTERNFILE_NOT_FOUND_OR_ILLEGAL_FORMAT
28 PATTERNFILE_HAS_ILLEGAL_FORMAT
29 PATTERNFILE_CANNOT_FIND_NUMBEROFVIRTUALGRIPPERS
30 PATTERNFILE_NUMBEROFVIRTUALGRIPPERS_IS_WRONG
31 NOT_ENOUGH_MEMORY_FOR_VGRIPPERS
32 PATTERNFILE_HAS_BAD_VIRTUALGRIPPER
33 PATTERNFILE_CONTAINS_NON_ZONE_SUBELEMENT_OF_ZONES
34 PATTERNFILE_BAD_NUMBER_OF_ZONES
35 PATTERNFILE_BAD_NUMBER_OF_GRIPAREA_IDS
36 PATTERNFILE_CONTAINS_NON_ID_SUBELEMENT_OF_GRIPAREAS

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A.2 Error and Warning Lists

Subcode Meaning
37 PATTERNFILE_CONTAINS_NON_ID_SUBELEMENT_OF_PARTPRESENTSENORS
38 NUMBEROFLAYERS_NOT_FOUND
39 INCORRECT_NUMBER_OF_LAYER_ELEMENTS
40 PATTERNFILE_CONTAINS_NON_LAYER_SUBELEMENT_OF_LAYERS
41 PATTERNFILE_LAYER_MUST_HAVE_TWO_SUBELEMENTS
42 PATTERNFILE_BAD_SUBELEMENT_OF_LAYER
43 NUMBEROFLAYERSTYLES_NOT_FOUND
44 INCORRECT_NUMBER_OF_LAYERSTYLE_ELEMENTS
45 PATTERNFILE_CONTAINS_NON_LAYERSTYLE_SUBELEMENT_OF_LAYERSTYLES
46 PATTERNFILE_LAYERSTYLE_MUST_HAVE_FIVE_SUBELEMENTS
47 PATTERNFILE_BAD_SUBELEMENT_OF_LAYERSTYLE
48 PATTERNFILE_CYCLE_MUST_HAVE_FOUR_SUBELEMENTS
49 PATTERNFILE_BAD_NUMBER_OF_CYCLE_ELEMENTS
50 PATTERNFILE_BAD_NUMBEROFCYCLES_ELEMENT
51 MEMORY_ALLOCATION_FAILED
52 PATTERNFILE_PICKINFORMATION_BAD_NUMBER_OF_SUBELEMENTS
53 PATTERNFILE_BAD_NUMBER_OF_PACKAGES
54 PATTERNFILE_PICKCOORDS_BAD_NUMBER_OF_SUBELEMENTS
55 PATTERNFILE_PACKAGES_BAD_NUMBER_OF_SUBELEMENTS
56 PATTERNFILE_PACKAGES_CONTAINS_NON_PACKAGE_SUBELEMENT
57 PATTERNFILE_PACKAGE_BAD_NUMBER_OF_SUBELEMENTS
58 PATTERNFILE_PACKAGECOORDS_BAD_NUMBER_OF_SUBELEMENTS
59 PATTERNFILE_PLACEMENTINFO_MUST_HAVE_TWO_SUBELEMENTS
60 PATTERNFILE_INVALID_NUMBEROFPLACEMENTS
61 PATTERNFILE_PLACEMENTS_BAD_NUMBER_OF_SUBELEMENTS
62 PATTERNFILE_NONPLACEMENT_SUBELEMENT_OF_PLACEMENTS
63 PATTERNFILE_PLACEMENT_MUST_HAVE_FIVE_SUBELEMENTS
64 PATTERNFILE_PLACEMENTCOORDS_BAD_NUMBER_OF_SUBELEMENTS
65 PATTERNFILE_APPROACHVECTOR_BAD_NUMBER_OF_SUBELEMENTS
66 PATTERNFILE_BAD_BUILDSTATIONID_VALUE
67 INCORRECT_NUMBER_OF_PACKAGESINFORMATION_ELEMENTS
68 PATTERNFILE_NO_NUMBEROFPACKAGES
69 PATTERNFILE_INVALID_NUMBEROFPACKAGES
70 PATTERNFILE_CANT_FIND_VGRIPPER
71 PROBLEM_WRITING_TO_JBI_FILE
72 BAD_SYSTEM_TIME
73 UNABLE_TO_GET_MAXLINEARSPEED
74 UNABLE_TO_GET_XMLFILE_INFO
75 UNABLE_TO_DELETE_JBI_FILE
76 UNABLE_TO_WRITE_STATIC_PART_OF_JBI_FILE
77 UNABLE_TO_WRITE_1ST_PART_OF_JBI_FILE
78 UNABLE_TO_WRITE_2ND_PART_OF_JBI_FILE
79 UNABLE_TO_WRITE_3RD_PART_OF_JBI_FILE
80 UNABLE_TO_WRITE_4TH_PART_OF_JBI_FILE
81 UNABLE_TO_WRITE_5TH_PART_OF_JBI_FILE
82 UNABLE_TO_WRITE_END_PART_OF_JBI_FILE

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 169390-1CD
PalletSolver Appendix A
A.2 Error and Warning Lists

Subcode Meaning
83 UNABLE_TO_READ_PATTERNFILE
84 UNABLE_TO_GET_REMOTE_PATTERNFILE_SIZE
85 PATTERNFILE_NOT_ENOUGH_MEMORY
86 BUILD_NOT_DONE
87 BUILD_NOT_LOCKED
88 NON_ORTHOGONAL_PACKAGE_ORIENTATION
89 PATTERNFILE_CANT_FIND_PACKAGE_LAYERSTYLE
90 UNABLE_TO_CREATE_JOB_FILE
91 INFEEDSTATIONID_IS_ALREADY_IN_USE
92 UNABLE_TO_LOAD_JOB_FILE
93 PATTERNFILE_BAD_NUMBER_OF_ROWS
94 PATTERNFILE_ROWS_CONTAINS_NON_ROW_SUBELEMENT
95 PATTERNFILE_ROW_BAD_NUMBER_OF_SUBELEMENTS
96 PATTERNFILE_BAD_ROWPACKAGEINDEX
100 UNABLE_TO_READ_VARIABLE_FROM_CONTROLLER
101 UNABLE_TO_READ_IO_FROM_CONTROLLER

A.2.2 Job Warning List

Table A-5: Job Warning List
Warning Warning Meaning Remedy
Code Parameter
0 0 No Warning
1 Infeed Requested Pick Quantity Mismatch: The - Remove the boxes from the infeed and
Station ID number of boxes set on the infeed doesn't then clear the box count echo.
match the number of boxes requested by the - Unlock the station after correcting the
system. issue.
2 Build Pallet Present signal is missing: The system - Check that a pallet is on the build station.
Station ID is attempting to place packages on a build - Check that the pallet present sensor is
station that doesn't have a pallet in place. operating properly.
- Unlock the station after correcting the
issue.
3 Build Pallet is already present: The system is -Removethepalletonthebuildstation.
Station ID attempting to place the bottom pallet on a - Check that the pallet present sensor is
build station but the pallet present signal is operating properly.
indicating that a pallet is already present. - Unlock the station after correcting the
issue.
4 Infeed Infeed Station Not Ready: The planner sent - Set the Pick Ready signal for the Infeed.
Station ID the robot at the infeed but once the robot got - Select to Ignore (Error Response Ignore),
to the infeed the station is not ready for the Retry (Error Response Retry) or Abort (Error
pick. Response Abort).
5 0 Home Position Is Not In Home Cube: The - Verify Home Position
robot moved to the home position but the I/O - Verify Home Cube (64) Definition
signal indicating that the robot is in the Home
Cube didn't turn on.
6 Build Motion vs Planning Mismatch: The planned - This situation will automatically be
Station ID pick cycle doesn't match the build station recovered by resetting the motion and
current state. planner.
- This warning should not occur under
normal operations. If it does, please report it
to YASKAWA technical support.

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PalletSolver Appendix A
A.2 Error and Warning Lists

Warning Warning Meaning Remedy

Code Parameter
7 Build Motion vs Planning Mismatch: The planned - This situation will automatically be
Station ID place cycle doesn't match the build station recovered by resetting the motion and
current state. planner.
- This warning should not occur under
normal operations. If it does, please report it
to YASKAWA technical support.
8 Build Zero Height Layer: The pattern is adding a - If the system is not using pallets and a
Station ID layer that no handled by the robot and has a virtual pallet of height 0 is used only to define
height of zero. the palletizing area, then remove this check
from the USER_AUTO_DISPENSER job.
- Check the product definition in the
PalletSolver - PC Pattern Generation Tool
and make sure that the proper height has
been entered.
9 Build “Layer Verified Confirmed” Signal is already Turn off the “Layer Verified Confirmed” signal
Station ID ON before the “Verify Layer Request” has of the specified build station.
been set.
10 0 Ready Position Is Not In Ready Cube: The - Verify Ready Position
robot moved to the ready position but the I/O - Verify Ready Cube (1) Definition
signal indicating that the robot is in the
Ready Cube didn't turn on.
11 0 No Schedule Mode Selected: A valid Select a valid schedule mode.
schedule mode hasn't been assigned.
12 Infeed No Ratio Set: In Ratio sequencing mode, Assign a ratio to at least one of the station.
Station ID none of the station have a ratio assigned to
it.
13 Infeed PLC Selected Station Doesn't Exist: In PLC - Verify PLC sequencing program.
Station ID sequencing mode, the PLC is requesting a - Verify PLC sequence handshaking I/O
station that doesn't exist for the next pick signals.
cycle. - Verify cell setup station configuration.
14 Infeed PLC Selected Station is Locked: In PLC - Unlock the requested station if conditions
Station ID sequencing mode, the PLC is requesting a permit.
station that is currently locked for the next - Have the PLC select a different station
pick cycle. - Verify PLC sequencing program.
15 Infeed PLC Selected Station is Not Ready: In PLC - Check infeed associated build station
Station ID sequencing mode, the PLC is requesting an status.
infeed station associated with a build station - Have the PLC select a different station
that isn't ready. - Verify PLC sequencing program.
16 Infeed PLC Selected Station is Invalid: In PLC - Verify PLC sequencing program.
Station ID sequencing mode, the PLC is requesting a - Verify PLC sequence handshaking I/O
station number that isn't valid. Station signals.
number should be between 0 and 8.
17 Infeed Can't set PLC Selected Station because next - Verify that the Pick Ready signal when the
Station ID box request is not set. Pick Request turns off.
- Verify PLC sequencing program.
- Verify PLC sequence handshaking I/O
signals
20 Build PatternFile Build Station ID Mismatch: The Use the PalletSolver - PC Pattern
Station ID build station ID in the pattern file doesn't Generation Tool to generate the Pattern for
match assigned build station ID. the correct build station.
21 Build Pattern File Infeed Station Already Assigned: Use the PalletSolver - PC Pattern
Station ID The pattern file is defining two infeeds for the Generation Tool to generate the Pattern
same build station. using a single infeed station.
22 Build Pattern File Infeed Station Already In Use: - Unassign the other build station currently
Station ID The infeed station identified in the pattern file using the desired infeed.
is already being used by another build - Assign a different pattern file that uses an
station. infeed currently available.

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PalletSolver Appendix A
A.2 Error and Warning Lists

Warning Warning Meaning Remedy

Code Parameter
23 Build Pattern File Too Many Dispenser: The Use the PalletSolver - PC Pattern
Station ID pattern file is defining more than two pallet Generation Tool to generate the Pattern
dispensers or two slipsheet dispensers. using a maximum of two dispensers of each
type.
24 Build Pattern File Invalid Station Type: The pattern Use the PalletSolver - PC Pattern
Station ID file is defining a station type that is not Generation Tool to generate the Pattern
supported by this system. using supported station types.
25 Build Pattern File Undefined Infeed Station: The Use the PalletSolver - PC Pattern
Station ID pattern file is not defining the infeed station. Generation Tool to generate the Pattern
using one infeed station.
26 Build Invalid Pallet Height: The define pallet height - Verify the Pallet height defined in the
Station ID for the auto dispensing has a height of 0 or PalletSolver - PC application.
smaller.
30 Sensor ID Pick/Place Error: The specified sensor ID did - Confirm product present or put product in
not detect the package presence. position.
- Select to Ignore (Error Response Ignore),
Retry (Error Response Retry) or Abort (Error
Response Abort).
31 Infeed Package Too Larger for Clamp Gripper: The - Verify product selection.
Station ID package width on the infeed is larger than - Verify gripper definition in Setup
the clamp gripper maximum opening. application.
- Change product.
32 Infeed Pick/Place Error: Waiting for gripper open - Check the gripper open sensor signal
Station ID confirmation - Verify gripper mapping in Concurrent I/O
program.
33 Infeed Pick/Place Error: Waiting for gripper close - Check the gripper close sensor signal
Station ID confirmation - Verify gripper mapping in Concurrent I/O
program.
34 Pallet Pick/Place Error: The pallet present sensor - Confirm product present or put product in
Dispenser on the gripper did not detect the pallet position.
Station ID presence. - Select to Ignore (Error Response Ignore,
Retry (Error Response Retry) or Abort (Error
Response Abort).
35 Slipsheet Pick/Place Error: The slipsheet present - Confirm product present or put product in
Dispenser sensor on the gripper didn't detect the position.
Station ID slipsheet presence. - Select to Ignore (Error Response Ignore),
Retry (Error Response Retry) or Abort (Error
Response Abort).
36 Build XY Approach Above Maximum: XY - Reduce approach vector setting in the
Station ID Approach Vector is larger than the validated USER_ADJUSTMENT job.
maximum approach vector defined by the - Increase the maximum approach vector of
pattern file. the pattern using the PalletSolver-PC
Pattern Generation Tool software.
37 0 Gripper has packages that need to be - Unlock the reject station
removed but the reject station is locked. - Manually remove the package from the
gripper
38 Build Pick/Place Error: Place cycle was interrupted Send Abort signal for the specified build
Station ID before completing. station.
39 Build Pick/Place Error: Error cannot be ignored or Send Abort signal for the specified build
Station ID retried. station.

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PalletSolver Appendix A
A.2 Error and Warning Lists

A.2.3 Controller Error and Warning List

Table A-6: Controller User Warning List
Job Warning Meaning
Code
9064 FIELDBUS HEARTBEAT FAILURE: Communication between the
controller and the PLC was lost.
9065 SYSTEM STATE JOB HEARTBEAT FAILURE: The PalletSolver
SYSTEM_STATE_MACHINE system jobs is either not set to run
automatically on start-up or an alarm caused it to stop. Check
proper setting and cycle power to restart the system jobs.
NOTE: Setting the job cycle mode to “STEP” will stop the
continuous execution of the system jobs. To resume execution,
return to normal “CYCLE” mode and restart the system job
manually or by cycling power to the controller.
9066 MOTOPLUS IMPORT APP. FAILURE: The MotoPlus application
that is used to import and assign pattern files is either not
installed or has stopped running. Check proper setting and cycle
power to restart the application.
9067 SYSTEM PLC JOB HEARTBEAT FAIL: The PalletSolver
SYSTEM_PLC_MESSAGING system job is either not set to run
automatically on start-up or an alarm caused it to stop. Check
proper setting and cycle power to restart the system jobs.
NOTE: Setting the job cycle mode to “STEP” will stop the
continuous execution of the system jobs. To resume execution,
return to normal “CYCLE” mode and restart the system job
manually or by cycling power to the controller.

For the complete list of the controller standard error and Job
NOTE Warning lists please refer to the appropriate Controller
Maintenance Manual.

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PalletSolver Appendix A
A.3 PLC Messaging Example

A.3 PLC Messaging Example

There are various message communication formats described earlier in
section 7.3 of this manual. This section shows two examples of how to
create or implement the ladder logic within the Rockwell software
environment. The approach can easily be ported to other PLC
manufacturers. The two examples below is not intended to capture all
available messaging formats.

A.3.1 Example: Get Sequencing Mode (Command 5)

This approach uses four 16-bit data types to hold the data, prior to
sending it to the robot controller over EtherNet/IP. The data received from
the robot controller is also stored in three, 16-bit data types.

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A.3 PLC Messaging Example

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A.3 PLC Messaging Example

Table A-7: Variable / Type Definition for Ladder Segment Above

Variable Name Data Type Bit
Transaction_ID SINT (8 bit)
Command_ID SINT (8 bit)
Parameter1_Value INT (16 bit)
Parameter2_Value INT (16 bit)
Parameter3_Value INT (16 bit)
Parameter4_Value INT (16 bit)
Data1_from_DX100 INT (16 bit)
Data2_from_DX100 INT (16 bit)
Data3_from_DX100 INT (16 bit)
ErrorCode INT (16 bit)

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A.3 PLC Messaging Example

A.3.2 Example: Request Build Pattern Associated Station Info

(Command 3)
This approach uses eight 8-bit data types to hold the data, prior to sending
it to the robot controller over EtherNet/IP. The data received from the
robot controller is also stored in six, 8-bit data types. In this approach, the
Error Code data is also broken up into 2 variables for easier analysis.

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A.3 PLC Messaging Example

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A.3 PLC Messaging Example

Table A-8: Variable / Type Definition for Ladder Segment

Variable Name Data Type Bit
Transaction_ID SINT (8 bit)
Command_ID SINT (8 bit)
Parameter1_Low_Value SINT (8 bit)
Parameter1_High_Value SINT (8 bit)
Parameter2_Low_Value SINT (8 bit)
Parameter2_High_Value SINT (8 bit)
Parameter3_Low_Value SINT (8 bit)
Parameter3_High_Value SINT (8 bit)
Parameter4_Low_Value SINT (8 bit)
Parameter4_High_Value SINT (8 bit)
Data1_from_DX100_LowByte SINT (8 bit)
Data1_from_DX100_HighByte SINT (8 bit)
Data2_from_DX100_LowByte SINT (8 bit)
Data2_from_DX100_HighByte SINT (8 bit)
Data3_from_DX100_LowByte SINT (8 bit)
Data3_from_DX100_HighByte SINT (8 bit)
ErrorCode_Low SINT (8 bit)
ErrorCode_High SINT (8 bit)

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CONTROLLER SETUP
AND OPERATION MANUAL
FOR: DX100 CONTROLLER
DX200 CONTROLLER

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802

YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Europe GmbH

Robotics Divsion )
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Nordic AB
Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800 Fax +46-480-417-999

YASKAWA Electric (China) Co., Ltd.

22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㧗86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542

YASKAWA Electric Korea Co., Ltd

9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek Road㧘Huaykwang, Bangkok 10320, Thailand
Phone +66-2693-2200 Fax +66-2693-4200

PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741

Specifications are subject to change without notice

for ongoing product modifications and improvements.

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