Integration Guide Yaskawa LS 1.5

Integration guide for Yaskawa Robots with Locator Studio version LS 1.5.

1. Robot Controller Setup

1.1 IP Configuration

Start the Robot Controller in a Maintenance Mode by holding the Main Menu button while turning the main switch on. You should hear a short beep during the boot. The Maintenance Mode screen is shown in the figure below:

Switch the Security Level from Editing to Management Mode. Browse to System Security

And select Management Mode from the list:

The password for accessing Management Mode is 9999 9999 9999 9999 (16 x 9 without spaces):

Note

the three keys in the top status bar - this indicates that - Management Mode is Active.

In order to configure the IP address of the Robot Controller, browse to System ? Setup ? Option Functions

Select LAN Interface Setting to enter the Network Configuration pane:

Select Manual Setting for LAN2 Port and amend the IP Address to meet your network requirements:

Note

It is recommended to plug the Ethernet cable into the LAN2 port.

Note

Subnet Mask 255.255.255.0 equals 24 bit subnet mask representation. See this table for more combinations: https://dnsmadeeasy.com/support/subnet

An example of matching Network configuration on Vision Controller side

• Vision Controller IPv4 Address: 192.168.1.1 / 24

• Robot Controller IPv4 Address: 192.168.1.2 / 24 (as configured in previous step)

1.2 Enabling MotoPlus functionality

If MotoPlus functionality has not been already enabled on Robot Controller, browse to System → Setup → Option Functions

Switch MOTOPLUS Func State from NOT USED to USED.

The MotoPlus APL icon should now become visible on the left pane.

Enter the MotoPlus Func. Settings:

Enable the MotoPlus autostart option:

1.3 Loading of Motoplus Binary (.out)

The Photoneo Yaskawa Interface consists of

• MotoPlus Binary - PhotoneoModule_LS_1.5.0.out

• INFORM files - Request INFORM Jobs + Program INFORM Job Templates

Based on the type of your robot controller, use the .out file from the appropriate folder (DX100, DX200, FS100, YRC1000, YRC1000u) and make sure it is available at the root directory of USB Flash drive.

Load MotoPlus Binary using following steps:

Select MOTOPLUS Apl. Load (User Application)

Select the PhotoneoModule_LS_1.5.0.out file and confirm Load. The Maintenance Mode section of the configuration process is now complete.

Note

Only single .out Photoneo binary can be uploaded at the same time. Check File List to make sure there is no other Photoneo MotoPlus binary uploaded. Restart the Robot Controller back into Normal Mode.

1.4 Loading of INFORM Jobs

Make sure all Inform jobs are available at the root directory of the USB flash drive. Browse to Ex. Memory Load and hit Edit Select all to select available JOBS from INFORM folder:

Hit Enter to start the transfer:

All JOB files should now be available in the Robot Controller.

1.5 Loading of VARNAME.dat

In order to populate names for variables used by Photoneo, VARNAME.dat system file is provided together with INFORM jobs. Loading of this file will erase all existing names and populate the ones used by Photoneo.

Make sure VARNAME.dat is available at the root directory of the USB drive. Go to Ex. Memory Load

Select System Data

Select VARIABLE NAME ? VARNAME.DAT file from the list, hit Enter button and confirm Loading.

After executing this operation, all variable comments will be erased and names of variables used by Photoneo will be populated (BYTE, INTEGER, POSITION, STRING).

1.6 Set IP address of Vision Controller on the Robot Side

As a next step we need to let Yaskawa Robot Controller know what is the IP address of Vision Controller as configured on the Locator Studio Network page. First 4 integer variables are used for this purpose:

IP Address configured in first 4 Integer variables must match Vision Controller IP address as defined on LS Network page:

To confirm that the Robot Controller is physically connected to the Vision Controller and the Network is configured properly use the Ping feature from System Info ? Network Utility:

Type IP address of Vision Controller to Host field and hit Execute button:

If a connection exists, Ping will return a “OK” message on all 4 attempts. You can also use the Test Connection button on the Photoneo Vision Controller Network page to Ping Yaskawa Robot from Photoneo Vision Controller.

Based on the result of Test Connection (ping command) Robot Available or Robot Unavailable is returned

If the robot is unavailable, please check cabling, network settings on both sides and try again, make sure ethernet cables are connected to proper ports and if there is a switch used, it is not blocking the connection.

1.7 USER COORDINATE setup

For Locator Studio solution types (Localization and Delayering) it is recommended to stick with the original Yaskawa Base frame as origin for both Calibration and Picking. Yaskawa Base frame origin sits at the intersection of J1 axis and J2 axis plane (see image below). In order to guarantee successful calibration and picking, User Coordinate 1 needs to have all values zeroed.

It is recommended to create a PHO_ZERO_OFFSET user coordinate frame to prevent this frame from being used later by robot programmers. In order to do so follow steps below:

Choose user frame - press Robot User Coordinate

Select User Coordinate 1 from the list and name it PHO_ZERO_OFFSET.

In order to see coordinate values, select first frame and press Display Coordinate Data

Make sure all values are zeroed, Robot R1 is selected and the Basic Coordinate frame is set to BASE.

This configuration will make sure that there is a zeroed Yaskawa Base User Coordinate frame which is important for proper calibration and picking.

Note

Integer variable PHO_CALIB_USER_ID is reserved in the variable list but not used in this version of the module. Hardcoded value pointing to User Coordinate 1 is used instead. If this is causing issues in your application, please contact Help Center for a customized module version.

1.8 TOOL Frame

Note

Tools are only visible if Setup ? Teaching Conditions ? Tool No Switch is Set To Permit.

Calibration TOOL - for calibration purposes Photoneo Locator Studio needs zeroed Tool Frame. By default TOOL 63 (the last one) is used under the assumption that it is all zeros. So as long as TOOL 63 is zeroed nothing needs to be changed in terms of coordinate values. It is recommended to give it a name to make sure the tool is not used later by robot programmers.

Picking TOOL - for picking purposes, use properly configured/calibrated Tool ID as you would use in normal robotic applications.

Note

Integer variable PHO_CALIB_TOOL_ID is reserved in the variable list but not used in this version of the module. Hardcoded value pointing to Tool ID 63 is used instead. If this is causing issues in your application, please contact Help Center for a customized module version.

2. Robot Module

2.1 Requests List

This section describes available API calls (Requests) supported by the Robot module. These procedures are intended for high-level control of the Locator Studio application from INFORM program:

INFORM Job	Function	Input	Populates
PHO_CALIB_ADD_POINT	Add Calibration Point Request	None	I007
PHO_CHANGE_SOLUTION	Change Solution Request	I006	I007
PHO_START_SOLUTION	Start Solution Request	I006	I007
PHO_STOP_SOLUTION	Stop Solution Request	None	I007
PHO_GET_RUNNING_SOLUTION	Get Current Running Solution Request	None	I007, I006
PHO_SCAN_REQUEST_LOC	Regular Scan Request	I005	None
PHO_WAIT_FOR_SCAN	Counterpart for Scan and Capture Request	None	I007
PHO_GET_POSES	Request Cartesian Poses of all localized objects	I005	I007, P011-P109
PHO_GET_STATUS	Get Vision System Status - Number of Localized, Pickable objects, Vision System Status - Running/Finished	I005	I007, I016, I017, I018
PHO_CALIB_START	Start Calibration Request	I005, I006	I007
PHO_CALIB_STOP	Stop Calibration Request	None	I007
PHO_CALIB_SAVE	Save Calibration Request at the end of Calibration	None	I007, I015, P010
PHO_CAPTURE_REQUEST_LOC	Capture Scan Request - for meshing, doesn’t initiate localization	I005, I031*	I007
PHO_REUSE_SCAN_REQUEST_LOC	Reuse last captured scan for localization on different Vision System	I005	I007
PHO_CHANGE_BBOX	Request to change bounding box	I005, I032	I007
PHO_COM_CHECK	Request to check communication	None	I007

I005 Vision System ID, I006 Solution ID, I007 Error Data, I015 Calib Accuracy, I016 Num of Localized, I017 Num of Pickable, I018 VS Running/Finished, I031 *Capture Gap Only used in Dynamic Meshing, I033 - Bounding Box ID, P010 Calibration Result Pose, P011-P109 - Cartesian Object Poses

2.2 INFORM Connection Procedures

The following procedure is used for connection and disconnection of the Motoplus backend from Vision Controller.

INFORM JOB	Description
PHO_CONNECT_TO_VC	INFORM Job used to notify MotoPlus backend to establish connection to Vision Controller

2.3 INFORM Examples List

There are several INFORM Example Templates available in LS 1.5 module that demonstrate how to properly use requests listed in section 2.1 for various use cases:

INFORM Example	Description
PHO_MAIN_CALIBRATION PHO_MAIN_CALIBRATION_HAND_EYE	Template for Calibration procedure, first calibration of Vision System must be started and confirmed manually by the user on the Vision Controller side. Calibration procedure requires proper USER COORDINATE configuration as described in chapter 1.7. Teach all 9 poses required for calibration. If communication with the vision controller is established by PHO_CONNECT_TO_VC then PHO_CALIB_ADD_POINT request calls feed vision controller with current robot pose for each added point. If communication cannot be established, then it is possible to add robot poses manually on the vision side by typing values from the current robot pose from the pendant. General rule of thumb is that Calibration Error should be below 3mm. If it is more, then there is usually some systematic error (Robot not reporting proper pose, or calibration ball moved during transitioning between poses etc). If calibration error is below 3mm, save calibration on the Vision Controller side and quit calibration.
PHO_MAIN_AUTO_RECALIBRATION	After the first calibration is successful and automatic recalibration is allowed in Vision System settings, you can run automatic recalibration from the robot without even touching the vision system. Calibration ball or marker pattern must remain in the same spot as during initial calibration.This example adds PHO_CALIB_START, PHO_CALIB_SAVE and PHO_CALIB_STOP to the original PHO_MAIN_CALIBRATION example.
PHO_MAIN_BASIC_LOC	Very basic example for a statically mounted scanner where the user can see how to initialize a system, send scan request, get poses request, receive targets and execute paths. The provided example also demonstrates error handling - PHO_SCAN_REQUEST and PHO_GET_POSES return error value to I007 - PHO_ERROR_DATA. Make sure you manually set Start and End positions in PHO_PICK_OBJECTS_LOC prior running this INFORM job (Chapter 3.1) and fill out blank gripper commands (Chapter 3.2)
PHO_MAIN_BASIC_LOC_HAND_EYE	Same as PHO_MAIN_BASIC_LOC but for a Hand Eye mounted scanner. The only difference is scanning pose is different than for the static mount and I010 - PHO_HAND_EYE_ENABLE switch is turned ON
PHO_MAIN_BASIC_LOC_MULTI_VS	Same as PHO_MAIN_BASIC_LOC but with switching between two Vision Systems. Integer variable I005 PHO_VS_ID is important in this case. Value in this variable controls which Vision System will be triggered or requested for poses. The first pick in the loop is executed using Vision System 1 and the second pick in the loop is executed using Vision System 2.
PHO_MAIN_BASIC_LOC_SOL_SWITCH	Same as PHO_MAIN_BASIC_LOC but demonstrates use of all Solution Switching related requests. Integer variable I006 PHO_SOL_ID is important here as it defines what solution will be activated with the next PHO_START_SOLUTION or PHO_CHANGE_SOLUTION requests.
PHO_MAIN_BASIC_LOC_CHANGE_BBOX	Same as PHO_MAIN_BASIC_LOC but demonstrates use of Bounding Box switching request. Besides I005 PHO_VS_ID Integer variable I032 PHO_BBOX_ID is important here as it defines what bounding box will be activated with the next PHO_CHANGE_BBOX request
PHO_MAIN_BASIC_LOC_REUSE_SCAN	Same as PHO_MAIN_LOC_MULTI_VS but instead of sending regular scan requests, the new request called PHO_REUSE_SCAN_REQUEST is demonstrated here. This request is useful in situations where the scene hasn’t changed since the last scan was triggered but the user wants to repeat localization with a different configuration (searching for different objects, in different bounding boxes or with different settings). Scan for VS1 is regular and scan for VS2 is then reused from scan for VS1. Integer variable I005 PHO_VS_ID is used for reuse scans in the same fashion as for regular Vision System switching.
PHO_MAIN_LOC_MESHING_STATIC	An example of how to stitch multiple scans before initiating localization. It is useful for more complicated scenes or large objects. This example demonstrates a static approach with a robot stopping in each scanning position and triggering/capturing scan. B004 PHO_MESH_DYNAMIC needs to be set to 0. During the meshing process, each PHO_CAPTURE_REQUEST scan must be followed by PHO_WAIT_FOR_SCAN to finalize the request. When done with capturing, trigger regular PHO_SCAN_REQUEST_LOC to initiate localization - this request doesn’t trigger actual scan, it only initiates localization process. The total number of scans should be less than 10.
PHO_MAIN_LOC_MESHING_DYNAMIC	Similar to PHO_MAIN_LOC_MULTIVIEW_STATIC but in this case capturing happens while the robot is continuously moving. LS integrates Photoneo Instant Meshing technology in combination with Parallel structured light technique provided by Motion Cam 3D. Important Flags and Variables: B004 PHO_MESH_DYNAMIC, B005 PHO_MESH_STARTED, I031 PHO_CAPTURE_GAP. This example demonstrates how to initiate a capturing procedure, allowing Motion Cam to trigger scans with mutual delays set by I031 PHO_CAPTURE_GAP while moving the robot through predefined waypoints. B004 - PHO_MESH_DYNAMIC must be set to TRUE to activate Dynamic Meshing mode, and I031 PHO_CAPTURE_GAP should be set to approximately 100-500 ms to throttle the scanning and not oversaturate system with scans. Robot position during first scan is essential for proper orientation of the final point cloud therefore robot motion is blocked by Photoneo interface until B005 - PHO_MESH_STARTED is set to 1 by Motoplus backend after first scan is received and reset after the last scan is captured. Only the last PHO_CAPTURE_REQUEST in this dynamic case is followed by a PHO_WAIT_FOR_SCAN request. Regular PHO_SCAN_REQUEST_LOC must be sent at the end of capturing to initiate localization. This scan doesn’t flash any light, it only starts the localization process. The scanning trajectory should be smooth without large rotations and the scanned area needs to be in the field of view all the time to avoid losing track. The total number of scans should be less than 60.

2.4 INFORM Picking Procedures

The following procedure is used for picking and placing of all objects received from the Vision Controller. This is just an example on how to iterate through received targets and control robot movements. Local Start and End points that need to be touched up in PHO_PICK_OBJECTS_LOC before running the main program. Feel free to copy and modify if needed.

INFORM JOB	Description
PHO_PICK_OBJECTS_LOC	INFORM Job for picking and placing targets received from Vision Controller.

2.5 BYTE Variables

This version of the LS module uses following 6 Byte variables:

BYTE Var	Description	Set by
B000 PHO_CONNECT_VC	This flag is set from INFORM Job to notify MotoPlus backend to establish connection to Vision Controller	user
B001 PHO_CONNECTED	This flag is set internally by MotoPlus backend after connection to action server running on Locator Studio side is established and reset after session is terminated	system
B002 PHO_NEW_REQ	This flag is set by request INFORM Job to notify MotoPlus backend that a new request has been initiated by the user. MotoPlus backend resets this flag after it gets processed on its side	user
B003 PHO_REQ_FINISHED	This flag is set by the MotoPlus backend to notify INFORM that a response for a recently submitted request has been received. The INFORM side resets this flag right after.	system
B004 PHO_MESH_DYNAMIC	This flag activates Dynamic meshing mode. It must be set to TRUE before the first PHO_CAPTURE_REQUEST request and reset to FALSE right after reaching the final meshing waypoint to stop scanning sequence. Set to FALSE is using Capture in Static mode	user
B005 PHO_MESH_STARTED	This flag is set by MotoPlus backend to notify INFORM that first scan of the meshing sequence has arrived and predefined capture trajectory can be started on the INFORM side.	system

2.6 INTEGER Variables

This version of the LS module uses following Numeric Variables:

Variable	Description	Set by
I000 PHO_VC_IP_ADDR_1	First octet of IP address of Vision Controller	user
I001 PHO_VC_IP_ADDR_2	Second octet of IP address of Vision Controller	user
I002 PHO_VC_IP_ADDR_3	Third octet of IP address of Vision Controller	user
I003 PHO_VC_IP_ADDR_4	Fourth octet of IP address of Vision Controller	user
I004 PHO_REQ_TYPE_ID	Set by every request INFORM job to notify MotoPlus which request to process	system
I005 PHO_VS_ID	Variable to control which Vision system ID is going to be used for next request	user
I006 PHO_SOL_ID	Variable to control which Solution ID is going to be used for next request	user
I007 PHO_ERROR_DATA	Populated as a result of request handling. See error table for error code descriptions	system
I008 PHO_NUM_POS_REQ	Number of targets requested by PHO_REQ_GET_POSES request	user
I009 PHO_NUM_POS_RCVD	Number of received targets populated by PHO_REQ_GET_POSES request	system
I010 PHO_HAND_EYE_ENB	Switch between Static (0) and Hand Eye mode (1)	system
I011 PHO_USER_COOR_ID	Register controlling which USER Frame is used for TCP reporting	user
I012 PHO_TOOL_ID	Register controlling TOOL frame used for TCP reporting	user
I013 PHO_CAL_USER_FRM	Register controlling which USER Frame is used for calibration	user
I014 PHO_CAL_TOOL_FRM	Register controlling UTOOL is used for TCP reporting (Not used if Hand Eye is disabled)	user
I015 PHO_CALIB_ERROR	Calibration error from automatic recalibration in milliradians	system
I016 PHO_NUM_OF_LOC	Number of already localized objects - gets populated by Get Status response	system
I017 PHO_NUM_PICKABLE	Number of pickable objects - gets populated by PHO_REQ_GET_STATUS request	system
I018 PHO_VS_CUR_STAT	Current Vision system status - gets populated by PHO_REQ_GET_STATUS request	system
I019 PHO_RESERVED	Reserved for internal iteration variable	system
I020 PHO_RESERVED	Reserved for internal iteration variable	system
I021 PHO_RESERVED	Reserved - aligns with BPS PHO_TOOL_INV (not used in LS)	system
I022 PHO_RESERVED	Reserved - aligns with BPS PHO_GRIPPING_PT_ID (not used in LS)	system
I023 PHO_RESERVED	Reserved - aligns with BPS PHO_GRIPPING_PT_INV (not used in LS)	system
I024 PHO_DIMENSIONING_X	Dimensioning X of current localized object (AI-based solutions, same as Info Data op 4)	system
I025 PHO_DIMENSIONING_Y	Dimensioning Y of current localized object (AI-based solutions, same as Info Data op 5)	system
I026 PHO_DIMENSIONING_ROT_Z	Dimensioning Rot Z of current localized object in degrees (AI-based solutions, same as Info Data op 6)	system
I027 PHO_NN_LABEL	NN Label (Neural Network object class label, AI-based solutions, same as Info Data op 7)	system
I028 PHO_MAX_Z_HEIGHT	Max Z Height of current localized object (same as Info Data op 8)	system
I029 PHO_TILT	Tilt angle of current localized object in milliradians (same as Info Data op 9)	system
I030 PHO_INFO_DATA_10	Reserved - not populated by current info operations (Info Data op 10 dispatches to PHO_CALIB_ERROR I015)	system
I031 PHO_CAPTURE_GAP	Controls delay in milliseconds between consecutive scans in Instant Meshing mode	user
I032 PHO_BBOX_ID	Controls which Bounding box ID will be used for next request	user
I034 PHO_RUNNING_SOLUTION	Currently running Solution ID (populated by Get Running Solution request)	system

2.7 POSITION Variables

P000 - P007 are free for customers.

P008 and P009 are CART poses used in the PHO_PICK_OBJECTS_LOC routine for Approach and Deapproach offsets. These variables should only have Z value set in order to achieve proper behaviour using SFTON shift operation. For example Approach pose shown below will set approach point 100mm above target pose if used within SFTON- SFTOF.

P010 is reserved for Calibration Save request and holds Calibration pose after automatic recalibration.

P011 - P100 are reserved for Cartesian Poses received from the Vision Controller.

This version of the LS module uses following 120 Position Variables:

Variable	Repre	Description	Set by
P000		Free for customer	user
…		Free for customer	user
P007		Free for customer	user
P008	CART	Approach pose for PHO_PICK_OBJECTS_LOC (feel free to change code and use)	user
P009	CART	Deapproach pose for PHO_PICK_OBJECTS_LOC (feel free to change code and use)	user
P010	CART	Variable to store Calibration Pose from automatic recalibration invoked by PHO_CALIB_SAVE request. This pose can be useful for various checks or point reteaching especially in hand eye applications	system
P011	CART	Variable to store Cartesian Results received from Vision Controller	system
…	CART	Variable to store Cartesian Results received from Vision Controller	system
P100	CART	Variable to store Cartesian Results received from Vision Controller	system

3. Runtime

If the solution is configured, all Vision Systems are calibrated and all previous steps have been carried out, it is time to complete the final steps on the robot side and finally run the MAIN program on the robot.

3.1 Teaching Start and End Poses in PHO_PICK_OBJECTS_LOC

Start and End poses in PHO_PICK_OBJECTS_LOC define the first and last bin waypoints for pick and must be touched up before running the main picking procedure.

In order to touch up the point, move the program pointer to the MOVJ line, hit start Servo On Ready, jog robot to start position and hit Modify followed by Enter button to confirm new pose value.

Repeat the same for End Pose.

3.2 Gripper commands

Locator Studio Solution doesn’t control gripper commands so use regular DOUT or other IO related commands to control gripper actions in Grasp and Drop points.

3.3 Touch up local MOVJ positions

If you are going to use existing PHO_MAIN templates, scroll through the program and check for existing MOVJ commands and make sure the robot is in proper position during scanning (Out of scanning volume for statically mounted sensors or above the bin with hand eye carried).

3.4 Runtime Prerequisites

Final pre deployment check before running picking interface from the robot side

Make sure that:

• Solution is properly configured on the Vision Controller side

• Network Setup on Robot Side is completed and ping works in both directions

• All Vision Systems defined in solution are calibrated

• Start and End Pose in PHO_PICK_OBJECTS_LOC touched up

• All local poses in MAIN Job you are about to run have been touched up properly

• Gripper procedures are prepared and working

3.5 Running MAIN INFORM Job

Deploy your solution. The Action Request Client (Robot) status on the Deployment page should be DISCONNECTED – from the Action Request Server, if the communication hasn’t been established yet.

Note

. It is strongly recommended to TEST START the application first before deploying to Auto.

Using Select button navigate to program you want to run, in this case PHO_MAIN_BASIC_LOC.JBI template:

Hold Interlock and Test Start keys to test start the program. If connection has been established properly you will see Action Request Client turn to CONNECTED. At this point the sensor should capture the first scan and localization should start localizing objects.

If there is a pickable object in the scene and the trajectory for the first object has been received by the robot controller, the robot should start moving towards the first object. You can check P011 and higher to see if these Position variables have been populated with joint data.

If everything looks fine, keep moving the robot towards the first target and check if the path is correct. At this point if the robot is too far from the object or pushes the object too deep, then make modifications on Picked object page by adjusting origin offset or change TCP configuration on the robot side

4. Error handling

If an error occurs during the execution of a request, the error value is stored in the variable I007 PHO_ERROR_DATA. All PHO_MAIN templates demonstrate basic error handling after PHO_SCAN_REQUEST and PHO_GET_POSES but if more specific handling is needed, it can be implemented additionally. Error codes with their description and troubleshooting can be found here.

An example of Error Handling in TP after PHO_GET_POSES request: