Overview

Station 2 handles the cone tray and the Pick & Place Robot responsible for transferring cones into the PR200.

This procedure explains how to remove and load the tray, reinstall it in the correct orientation, verify that the tray sensors detect it properly, and teach the Pick & Place Robot its tray position.

The robot position normally does not need to be taught every time the tray is refilled. Re-teaching is mainly required when changing to a different cone or tray configuration, or when the robot position needs to be corrected.

Remove the Tray

Before loading cones, remove the tray from Station 2.

Release the two tray levers and lower them out of the locked position.

Support the tray from underneath, lift it out of its mounting position, and remove it from the machine.

Place the tray on a stable surface before filling it.

Different trays may be used depending on the cone configuration, including different cone sizes and tip formats.

Prepare and Load the Cones

Remove the cones from their packaging and prepare them for loading.

Begin filling the tray from the right side.

Place the cones into the tray openings row by row until the required section of the tray is filled.

The technician also demonstrates using tape as a practical way to help remove packaging material from groups of new cones before loading them.

For the formats demonstrated in the video, approximately eight cones can be stacked vertically in each tray position. The exact loading configuration may vary depending on the cone and tray being used.

Check the Tray Orientation

Correct tray orientation is important because Station 2 uses sensors to confirm that the tray is installed and ready.

Before inserting the tray, identify the yellow reference dots and the adjustment screw side.

The yellow reference dots should face toward the operator when the tray is inserted.

The adjustment screws should also be facing toward the operator. This positions the tray correctly in relation to the proximity switches used for tray detection.

Reinstall the Tray

Insert the filled tray into Station 2 while maintaining the correct orientation.

Place the tray back into its support and lock it into position.

When the tray is installed correctly, the tray detection indicators should change from yellow to orange.

This indicates that the sensors recognize the tray and that it is properly positioned.

If the indicators do not change as expected, check the tray orientation and seating before operating the machine.

Once the tray is detected correctly, raise it into position and secure the tray using the two locking levers.

When to Re-Teach the Pick & Place Robot

The robot does not normally need to be re-taught after every tray refill.

Re-teaching may be required when changing to a different cone format, installing a different tray, changing the product configuration, or correcting an inaccurate Pick & Place position.

If none of these conditions apply and the existing robot position is correct, the previous taught position can normally remain in use.

Prepare the Machine for Robot Teaching

From the HMI, prepare the Paper Feed system so the robot can be positioned for teaching.

Activate Paper Feed, then stop the machine as soon as the Pick & Place Robot reaches the appropriate working area.

The objective is to stop the machine before the robot closes on the cones.

Opening the machine door releases the robot so that it can be moved manually into the required position.

Open the Tray Position Set Page

From the HMI, open the Paper Feed page and select Tray Position Set.

Make sure Paper Infeed and Product Infeed are disabled while positioning the robot.

The Teach control may not appear while the robot is outside its valid working position.

As the robot is manually moved into the correct area, the HMI will recognize its position and make the Teach function available.

Position the Pick & Place Robot

Move the robot manually toward the first rows of cones.

The Pick & Place Robot should be positioned between the first and second stack of cones.

Use the visible laser as an alignment reference.

The laser should be centered correctly between the cone positions before teaching the new robot position.

Check the robot gripper alignment carefully before saving the position.

Teach the New Position

Once the Pick & Place Robot is correctly aligned and the HMI displays the Teach control, press and hold Teach for approximately two seconds.

This stores the new tray pickup position for the robot.

The taught position becomes the reference position used by the Pick & Place Robot when collecting cones from the tray.