Skip to content

07-calibration.md

Latest commit

 

History

History
323 lines (260 loc) · 8.69 KB

07-calibration.md

File metadata and controls

323 lines (260 loc) · 8.69 KB
Raw

7. Calibration and System Actions

7.1 Calibration Overview

Calibration is the process of adjusting module parameters to compensate for physical changes in the factory hardware. While the PLC handles low-level motor control, the high-level positioning logic for storage and sorting relies on calibrated values stored in the system.

Factors requiring recalibration:

  • Mechanical Drift: Wear and tear on belts, gears, and motors over specific runtime periods.
  • Environmental Impact: Micro-expansions or sensor sensitivity changes due to temperature fluctuations.
  • Maintenance: Any physical intervention (e.g., tightening a screw or moving a module) invalidates previous coordinates.

In the APS MQTT system, only AIQS, HBW and DPS modules support remote calibration commands, as these rely on precise coordinate systems (HBW, DPS axes) and color sensor thresholds (AIQS, DPS sorting) that must be aligned with the physical reality.

Note: Calibration affects the physical coordinate systems of the storage mechanisms (High-Bay Warehouse, Delivery & Pickup Station) and the sorting logic (Quality Control with AI, Delivery & Pickup Station). Incorrect values will lead to mechanical failures (collisions, missed pick-ups).

Prerequisites

Calibration should be performed when:

  1. Setting up a new module.
  2. Mechanical maintenance has altered component positions.
  3. Positioning errors (e.g., missed slots) are observed.

Warning: Never calibrate while a production order is active. Calibration changes the operating mode to TEACHIN, causing any active AUTOMATIC processes to fail.

7.2 Calibration Process

Entering Calibration Mode

Send the startCalibration instant action:

Instant Action:

{
  "serialNumber": "HBW001",
  "timestamp": "2024-12-08T14:00:00.000Z",
  "actions": [
    {
      "actionType": "startCalibration",
      "actionId": "calib-start-123"
    }
  ]
}

Module Response:

{
  "serialNumber": "HBW001",
  "operatingMode": "TEACHIN",
  "actionState": null,
  "information": [
    {
      "infoType": "calibration_status",
      "infoLevel": "INFO",
      "infoReferences": [
        {
          "referenceKey": "POSITIONS.CURRENT",
          "referenceValue": "HOME"
        },
        {
          "referenceKey": "POSITIONS.AVAILABLE",
          "referenceValue": "1-1,1-2,2-1,2-2"
        }
      ]
    }
  ]
}

Exiting Calibration Mode

Send the stopCalibration instant action:

{
  "serialNumber": "HBW001",
  "timestamp": "2024-12-08T14:30:00.000Z",
  "actions": [
    {
      "actionType": "stopCalibration",
      "actionId": "calib-stop-456"
    }
  ]
}

Module Response:

{
  "serialNumber": "HBW001",
  "operatingMode": "AUTOMATIC",
  "actionState": null
}

7.3 Calibration Instant Actions

Available Calibration Actions

Action Type Purpose Metadata
startCalibration Enter calibration mode None
stopCalibration Exit calibration mode None
setCalibrationValues Update calibration parameters references array
selectCalibrationPosition Move to specific position position
testCalibrationPosition Test current position position
storeCalibrationValues Save parameters to persistent storage None
resetCalibration Reset to factory defaults factory: true

Setting Calibration Values

Example: Adjust HBW position parameters

{
  "serialNumber": "HBW001",
  "timestamp": "2024-12-08T14:05:00.000Z",
  "actions": [
    {
      "actionType": "setCalibrationValues",
      "actionId": "set-calib-789",
      "metadata": {
        "references": [
          {
            "referenceKey": "cal__colA",
            "referenceValue": 1500
          },
          {
            "referenceKey": "cal__row1",
            "referenceValue": 2000
          }
        ]
      }
    }
  ]
}

Selecting a Position (HBW/DPS)

For modules with positioning systems:

{
  "serialNumber": "DPS001",
  "timestamp": "2024-12-08T14:10:00.000Z",
  "actions": [
    {
      "actionType": "selectCalibrationPosition",
      "actionId": "select-pos-123",
      "metadata": {
        "position": "HBW"
      }
    }
  ]
}

Available Positions:

  • DPS: HOME, HBW, custom positions
  • HBW: Storage grid positions like 1-1, 2-3

Testing a Position

Test if a position works correctly:

{
  "serialNumber": "HBW001",
  "timestamp": "2024-12-08T14:15:00.000Z",
  "actions": [
    {
      "actionType": "testCalibrationPosition",
      "actionId": "test-pos-456",
      "metadata": {
        "position": "2-2"
      }
    }
  ]
}

The module moves to the position and reports success/failure.

Storing Calibration Values

Save current calibration to persistent storage (EEPROM/file):

{
  "serialNumber": "HBW001",
  "timestamp": "2024-12-08T14:25:00.000Z",
  "actions": [
    {
      "actionType": "storeCalibrationValues",
      "actionId": "store-calib-789"
    }
  ]
}

⚠️ Important: Values are typically stored in volatile memory until explicitly saved with this command.

Reset to Factory Defaults

Reset all calibration parameters to factory defaults:

{
  "serialNumber": "DPS001",
  "timestamp": "2024-12-08T14:28:00.000Z",
  "actions": [
    {
      "actionType": "resetCalibration",
      "actionId": "reset-calib-123",
      "metadata": {
        "factory": true
      }
    }
  ]
}

7.4 Module-Specific Calibration

DPS Module

Calibratable Parameters:

  • Camera position coordinates (X/Y encoder values)
  • Color sensor thresholds
  • NFC reader positioning

Calibration Procedure:

  1. Enter calibration mode
  2. Use selectCalibrationPosition to move camera
  3. Visually verify correct position
  4. Use setCalibrationValues to store coordinates
  5. Use storeCalibrationValues to save permanently

HBW Module

Calibratable Parameters:

  • Storage grid position coordinates (X/Y encoder values for each slot)
  • Gripper extend/retract positions
  • Movement speeds

Critical for HBW: Incorrect position calibration leads to:

  • Failed storage/retrieval
  • Mechanical collisions
  • Dropped workpieces

Calibration Procedure:

  1. Home all axes (move to reference positions)
  2. Use selectCalibrationPosition to jog to each storage position
  3. Use setCalibrationValues to record encoder values for that slot
  4. Use testCalibrationPosition to verify each position
  5. Use storeCalibrationValues to save permanently

Other Modules

MILL, DRILL, OVEN, AIQS: Calibration is handled via PLC configuration, not through MQTT. Use the PLC programming interface or manufacturer tools to adjust timing and sensor parameters for these modules.

7.5 Calibration Best Practices

Do's ✅

  1. Document Original Values: Record default values before changing
  2. Change One Parameter at a Time: Isolate effects
  3. Test Thoroughly: Run multiple cycles after calibration
  4. Store Values: Use storeCalibrationValues to persist changes
  5. Calibrate When Idle: No active production during calibration
  6. Use Small Increments: Adjust gradually, not drastically

Don'ts ❌

  1. Don't Calibrate Blindly: Understand parameter effects
  2. Don't Skip Testing: Always verify after changes
  3. Don't Forget to Store: Values may be lost on restart
  4. Don't Calibrate During Production: Causes module unavailability
  5. Don't Use Extreme Values: Can damage hardware
  6. Don't Mix Manual and MQTT Calibration: Choose one method

Troubleshooting Calibration Issues

Symptom Possible Cause Solution
Changes don't persist Not stored Send storeCalibrationValues
Can't enter calibration mode Module busy Cancel active orders first
Position test fails Wrong coordinates Re-measure encoder values
Sensor readings unstable Environmental factors Shield sensors, adjust thresholds
Module crashes Invalid parameter value Reset to factory defaults

7.6 Calibration Data Topics

Publishing Calibration Data

The CCU can publish calibration data during calibration:

Topic: ccu/state/calibration/<serial>

Example:

{
  "timestamp": "2024-12-08T14:20:00.000Z",
  "serialNumber": "HBW001",
  "parameters": {
    "cal__colA": 1250,
    "cal__colB": 2500,
    "cal__colC": 3750,
    "cal__row1": 500,
    "cal__row2": 1500,
    "cal__row3": 2500
  }
}

This allows external tools to monitor and log calibration activities.

Next Steps

  • See Manual Intervention for warnings about manual control
  • Review Module Documentation for module-specific calibration details
  • Consult module-specific source documentation for advanced calibration