...
product data
layer types
layers
zones
Project overview
This section of the pattern file includes base data about the product itself, such as
...
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{
"name": "test",
"description": "my first pattern",
"dateModified": "2020-04-29T07:03:20.288Z",
"dimensions": {
"height": 1048,
"length": 1200,
"width": 800,
"palletHeight": 145
},
"productDimensions": {
"width": 365,
"height": 262,
"length": 377,
"weight": 5000
},
"maxGrip": 1,
"maxGripAuto": true,
"labelOrientation": 0, |
Layer types
Layer types define possible layouts of individual layers. Depending on the desired stacking method, the pallet can be built by using the same layer type repeatedly (column stack) or alternating two or more different layouts (flipped, rotated, etc.) in order to create interlocking between the layers for increased stability.
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{
[...]
"layerTypes": [
{
"name": "normal",
"pattern": [
{
"x": 588.5,
"y": 217,
"r": [90, 270]
},
{
"x": 211.5,
"y": 217,
"r": [90, 270],
"g": [0],
"f": 1
},
[...]
],
"altPattern": [
{
"x": 588.5,
"y": 217,
"r": [90, 270]
},
[...]
],
"approach": "inverse"
},
{
"name": "rotated",
"pattern": [
{
[...] |
Box position
Each box has a specific position (the "x" and "y" values) relative to the pallet corner. The edges of the pallet define a Cartesian coordinate-system with the origo in the lower left corner. By default, positions are defined in millimeters.
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Note: The layer type is a 2-dimensional logical model of the layout, thus only the x and y coordinates are defined. The z-coordinate will be calculated from the product height and the actual layer being palletized. The [x, y, z] values point to the center point at the top of the box on the pallet. |
Box rotation
Each product has at least one allowed rotation (the "r" values) on the pallet, which can be 0, 90, 180, or 270 degrees, or the combinations of [0, 180] and [90, 270] respectively.
Box order
Boxes are palletized in the same order as they are defined in the pattern file. All positions of one layer are completed before the robot continues on the next layer. The only exception is the use of zones.
Enforced single/multi-grip
By default, the robot will try to palletize two or more adjacent boxes in one turn, in order to maximize throughput. The number of boxes that the robot can pick at once is limited by the maxGrip parameter in the pattern file as well as the installed product sensors on the production line and the size of the gripper.
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"maxGrip": 3
[...]
"pattern": [
{
"x": 690,
"y": 165,
"r": [0, 180],
"f": 1
},
{
"x": 690,
"y": 455,
"r": [0, 180],
"f": 0
},
{
"x": 690,
"y": 745,
"r": [0, 180],
"f": 0
},
[...]
],
[...] |
Gripper rotation at the conveyor
By default, the robot will choose the best gripper position when picking up the box(es) from the conveyor. The possible options are specified by the gripper optimization settings in the URCap (4-ways, 2-ways, or none).
For specific box positions however, it is possible to enforce a gripper position (the "g" values) or limit the possible gripper positions the robot can choose from. Any combinations of the following values are allowed: 0, 90, 180, and 270, where 0 corresponds to the configured pickup position in the URCap, other values are angles, counterclockwise when seen from above.
Left and right pallet layout
Each layout can be defined separately for the left and right pallet position. Even if the left and right pallets look identical, the order of the boxes can be different.
The default layout (the "pattern" structure) defines the layout for the right pallet. The alternative layout (the "altPattern" structure) defines the layout for the left pallet. By default - if no alternative layout is defined - the robot will generate a mirrored layout for the left pallet, in order to make a symmetric setup.
Inverse approach
For each layer type it is possible to define how the robot should approach the target position (the "approach" value corresponds to the right, and the "altApproach" to the left pallet layout). The approach direction should depend on the box order - palletizing from the furthest side of the pallet and in ("normal") or starting at the nearest side and continuing further out ("inverse"). In special circumstances - especially when the mounting base is wide - the inverse box order and approach produces a better result with less or no collision situations.
Shim paper
Shim papers are considered as special layers without actual products. The shim paper layer has its own height, usually 2-3 mm. The number of shim paper layers is not limited.
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"layerTypes": [
{
"name": "shimPaper",
"class": "separator",
"height": 3
} ...
],
"layers": [
"shimPaper", ... |
Layers
The "layers" structure defines the actual layout of the final pallet. Each layer is built according to one of the layer types as described above.
...
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Note: The first element in the layer list is the first layer on the empty pallet. The last element in the list is the topmost layer. |
Zones
Normally the robot completes a layer before starting the next layer. However, the pallet can be split into different regions (the "zones" and the optional "altZones" structure) which override the regular layer completion rules. In general, a zone cannot be started until the previous zone is finished.
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{ [...]
"zones" : [
{
"z" : { "condition" : "<=", "value" : 730 },
"posData" : [0,0,0]
},
{
"z" : { "condition" : "<=", "value" : 980 },
"posData" : [0,0,466]
},
{
"x" : { "condition" : ">=", "value" : 200 },
"z" : { "condition" : "<=", "value" : 1220 },
"posData" : [0,0,466]
},
{
"x" : { "condition" : ">=", "value" : 500 },
"z" : { "condition" : ">=", "value" : 1220 },
"posData" : [0,0,466]
},
{
"x" : { "condition" : "<=", "value" : 200 },
"z" : { "condition" : "<=", "value" : 1220 },
"posData" : [0,0,466]
},
{
"x" : { "condition" : "<=", "value" : 500 },
"z" : { "condition" : ">=", "value" : 1220 },
"posData" : [0,0,466]
}
],
"altZones" : [
{
[...] |
Conditions
Zones are defined by using relational operators "<", "<=", ">", ">=" on the x, y, and z axis in the Cartesian coordinate-system defined by the pallet edges with the origo in the lower left corner of the pallet. If multiple conditions are used, they have to be enclosed in an array:
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Note: Zones are evaluated in the order they are defined. If two or more zones are overlapping, the program will choose the first one that matches the condition criteria. This might cause some zones to never be activated. |
Position transformations
Each zone can define a position transformation hint, which may be used by the Pally URCap to control a lifting column and/or a base slider. Before the robot starts palletizing the specified zone, the external hardware is controlled by the Pally program to put the robot into the desired mounting position.
The "posData" value has the following format: [x, y, z] in the robot base coordinate system (in millimeters). The default position is [0, 0, 0].
Location of the zone definitions
For compatibility reasons it is possible to define the zones in 3 different locations, which are loaded in the following order:
...