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System Commissioning

System Installation Checklist​

Before applying power to the system, ensure all the tasks in section 30.1 have been completed

Commissioning Procedure​

28.2.1Floor Scanner​

Configure the floor scanner Trip and Warning Zones using Keyence SZ-V Configurator software. This software is available as a free download from the Keyence Web site.

  1. On the Unit Configuration tab, select the number of scanner heads, typically 2.

  2. On the Operation tab, keep all defaults.

  3. On the Zone tab, use the drawing tools to sketch the Protection (red) and Waning (yellow) Zone boundaries. The Protection Zone trips the robot immediately upon detecting an obstacle. The Warning Zone notifies the control system that an obstacle was detected, but no immediate action is taken.

The Protection Zone should cover the majority of the area inside the robot cell. Make sure to leave margin around the fences, racks, and robot to avoid erroneous trips. The Warning Zone should extend into the hallway.

  1. On the Others tab, keep all defaults.

  2. On the Communication tab, make the following selections:

  3. Use the Transfer tab to download settings to the floor scanner. Scroll to the bottom of each confirmation window to enable the Accept button. The default password is 1111.

Safety System Checkout​

Exercise each safety circuit in sequence to verify that it operates correctly.

  1. Begin from a neutral state: the safety system is not tripped, the robot is active

    • (motors are powered on), and as few personnel as possible are near the robot.

  2. Enter the hallway. Verify that the indicator light on the front of the floor scanner changes from green to yellow.

  3. Enter the robot cell. Verify that the indicator light on the front of the floor scanner changes from yellow to red. Verify that the HMI beeps and that the floor scanner indicator on the HMI is red.

  4. Reset the safety system.

  5. Break the robot curtain without entering the cell. Verify that the robot trips and that the HMI indicates the robot curtain was interrupted.

  6. Reset the safety system.

  7. Press the panel E-Stop button. Verify that the robot trips and that the HMI indicates the E-Stop was pressed.

  8. Reset the safety system.

  9. Press the remote (hallway entry) E-Stop button. Verify that the robot trips and that the HMI indicates the E-Stop was pressed.

  10. Reset the safety system.

  11. While not interrupting either hallway curtain beam, verify that the curtain indicator lights are green. Break each hall curtain in turn, and verify that the indicator lights turn red while the beam is broken.

Load Batteries into Racks​

  1. Ensure the robot is active (system is not tripped and motors are on).

  2. Position one pallet or crate of batteries into the hallway at a time. The pallet or crate should be roughly centered in the robot cell opening. The robot has a minimum operating height which is slightly higher than the battery crate height. Verify that the battery pins which the robot will grab are at least 12 inches above the floor. Stack the battery crate on top of another pallet if required.

  3. Navigate to the Rack Information screens. From the home screen, select System Health and then one of the Rack screens; if more than one rack is installed, it does not matter which one is chosen. If not already logged in, you will be prompted to log in. The default user name and password are both ‘service’.

  4. Place a DM code encoded with “POP,U,LATE” somewhere in the End of Arm camera’s field of vision. During development, good results were obtained by taping the DM code near the center of the field of view. An appropriate DM code is attached here.

  5. Select Populate Rack. The button is not visible unless the robot is at idle position. If the robot is not at idle position, stand on the pressure pad to send it there. When prompted, press the flashing green button to begin the population sequence. The robot scans the destination rack location, if required, to estimate the place location. Next, the robot scans the battery in the hallway, picks it up, and places it in the rack. If required, the robot then grips the battery in the rack position to calibrate that position.

  6. Repeat this process as necessary until all batteries that should be loaded into the rack are loaded.

Rack Position Calibration​

After loading batteries, use the Empty Sleeve button and/or Quarantine button to calibrate the remaining rack positions. This step is optional but highly recommended. If this step is not performed, calibration is performed during the first access of each sleeve location.

Keep track manually of which positions are calibrated during rack population. When population is complete, quarantine all sleeves which have been calibrated. Select each battery in turn, then choose Empty Sleeve on the Rack Information screen to relocate that battery to a different sleeve. Typically, sleeves are not yet calibrated at this point in the commissioning process; therefore, moving a battery into a sleeve causes it to be calibrated.

To manually calibrate sleeve positions (for instance, if batteries are populated using the manual cart), select the relevant battery position on the HMI, then press the Calibrate Sleeve button. As before, the button is only visible if the robot is idle and at home position; if needed, stand on the pressure pad to send the robot home.