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The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Overview of this manual Overview of this manual About this manual FlexLoader SC 6000 is a standard cell used for machine tool tending. This manual describes how to install, operate, maintain, service and troubleshoot the FlexLoader SC 6000. Usage This manual should be used during: •...
Follow the steps below for getting started with a FlexLoader SC 6000 system. Action Become familiar with this manual. Transport the FlexLoader SC 6000 to its intended location and integrate it with machine tool(s) and other equipment. Installation on page Pay special attention to safety and functional interface.
Equipment that is part of a fully- or semi-automatic system must always be treated with care regarding safety. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed, and that the safety devices necessary to protect people working with the robot system are designed and installed correctly.
CAUTION It is forbidden to step on the illumination roof, the outer walls of the FlexLoader SC 6000 and on any FlexLoader SC 6000 option. Product manual - FlexLoader SC 6000 3HAC051768-001 Revision: D...
2.3 Safety during setup, maintenance, service and repair 2.3 Safety during setup, maintenance, service and repair Always ensure that FlexLoader SC 6000 cannot be started when working on the cell. The installed protection that belongs to the equipment must always remain installed during automatic operation.
2.4 SafeMove 2.4 SafeMove Standard operation The robot working space in the FlexLoader SC 6000 is restricted by the use of SafeMove. Due to space requirements, the SafeMove outer boundaries of restricted space are close to the FlexLoader SC 6000 enclosure.
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Standard mounting position Alternative mounting position The SafeMove configuration must be changed accordingly to the new work space. The standard ABB guidelines for configuration and validation of SafeMove configurations shall be followed. DANGER It is the integrators responsibility to modify and validate the SafeMove configuration for the alternate mounting position in a suitable way.
2.5 Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the FlexLoader SC 6000 will not cause injury or damage even if all safety instructions are complied with.
To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where FlexLoader SC 6000 is installed. Within the EU, refer to the Machinery Directive 2006/42/EC with addendum.
The FlexLoader SC 6000 used with Eden door switches does not evaluate door locking in its safety function. This has to be considered in the risk assessment.
Read the safety precautions and other instructions carefully before unpacking and installing the equipment. This section describes the installation of FlexLoader SC 6000. If the installation contains further parts, safety instructions may also be found in other documentation. Unpack the equipment and look for any signs of damage.
Never walk or stand beneath a suspended load. The FlexLoader SC 6000 weight is ~2300 kg and shall be lifted off the transporter with a forklift from the side. On the wooden pallet there are signs where to lift. The...
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3 Installation 3.2 Mechanical installation Continued FlexLoader SC 6000 can be transported on the workshop floor with a forklift from the side, with 3 handheld lifts as the pictures show, or on appropriate skates. xx1900000186 xx1900000187 Initial transport of the unit using handheld lifts (1). Look for fork lift signs...
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(A). Note Check all delivered parts for damage. If necessary, take appropriate actions. The FlexLoader SC 6000 can be lifted using a fork lift with the provided fork lift slots, placed on the bottom of the machine. xx1900000189...
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3 Installation 3.2 Mechanical installation Continued The FlexLoader SC 6000 can also be positioned by using skates. xx1900000190 xx1900000191 Transport of the FlexLoader SC 6000 using skates (1) xx1900000192 Transport of the FlexLoader SC 6000 using skates (2) Continues on next page...
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3.2 Mechanical installation Continued CAUTION Do not lift the FlexLoader SC 6000 to high in the back only. It will damage the plates on the front door. xx1900000193 Pay attention on inclination in order to avoid damages to front plates.
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Example of absorption bags - in the electrical cabinet - that must be removed. Assemble the vision tower If the FlexLoader SC 6000 was shipped in a container, the vision tower has to be assembled. Use straps to lift the vision tower. The straps shall be fastened around the beams inside the tower.
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The width of the opening towards the machine tool can be adjusted according to the actual needs. By selecting a suitable amount of the flexible panels on the back side of the FlexLoader SC 6000, various opening widths can be achieved (850 mm, 1300 mm, 1500 mm):...
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A ready made corridor part can be mounted on the side of the FlexLoader SC 6000, according to the image below. The extension panels consist of two parts, the extension panel door, and the extension panel back.
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The extension panel back has to be mounted on the FlexLoader SC 6000: Select a suitable position along the rim and secure the extension panel back by mounting it to the FlexLoader SC 6000 outer shell (screws on upper and lower rim of the FlexLoader SC 6000).
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3 Installation 3.2 Mechanical installation Continued If the wholes are drilled prior to putting the FlexLoader SC 6000 into position use the following drilling plan. Pay attention to distances implied by extension panel options.: xx1900000362 FlexLoader SC 6000 drilling template (in mm), seen from above (1)
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Detail A from previous drawing, seen from above (2) Put the FlexLoader SC 6000 at the intended position. Level the FlexLoader SC 6000 with regard to the inconveyor, by using the adjustable machine feet (see picture below). The conveyor must be levelled both in the direction of movement and across it, within <...
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The gap between the swing door upper edge and the upper rim of the FlexLoader SC 6000 shall be checked after tightening the FlexLoader SC 6000 to the floor. If swing door and FlexLoader SC 6000 upper rim do not align, the height of the floor wheel shall be adjusted.
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If risk assessment indicates a risk, e.g. due to elongated or bulky parts, an extra vertical plate of suitable size needs to be mounted close to the turn station on the FlexLoader SC 6000 upper rim to avoid that the risk area can be reached from the outside.
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[mm] Belt adjustment The belt is adjusted when FlexLoader SC 6000 is tested at manufacturing, but it may need to be readjusted after transportation or after repair. • Check that the support rollers are installed at exactly 90° in relation to the frame extension.
Within countries applying US regulations, grounding and bonding equipment shall be performed according to the national electrical code, NFPA 70. CAUTION The FlexLoader SC 6000 is designed for use with the TNS earthing scheme. Product manual - FlexLoader SC 6000 3HAC051768-001 Revision: D...
3.4 Pneumatic installation Connection point Connect the incoming air connection to the FlexLoader SC 6000 at the indicated connection point at the FlexLoader SC 6000 upper rim. The incoming air must be 6 bar / 87 psi. Dry air, no oil. xx1900000364...
3.5 Robot gripper connections 3.5 Robot gripper connections General FlexLoader SC 6000 with base configuration has a number of predefined gripper signals that are routed to the robots Customer Signals/Customer Power (CS/CP) connector. If the standard gripping option is chosen, these signals are already connected to the valve package.
3.6 Machine tool installation 3.6 Machine tool installation General FlexLoader SC 6000 connects to the machine tool by means of a safety interface and a functional interface. The machine tool interface is normally prepared by the integrator and needs almost always customization.
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Other physical interfaces are available by using optional robot field bus or interface options (to be ordered with robot). • ABB DC500 series I/O node connected to the robot PROFINET network. The functional interface must be configured and commissioned prior to use of the FlexLoader SC 6000.
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IP addresses that are pre-configured in the controller. ABB CI502 I/O nodes will get its name depending on the switches/knobs on the module, e.g. ci502-pn-01 if knobs are put in positions 0 (x10H) and 1 (x01H). A cold start is needed to read new name.
ABB Ltd and its entities are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
Mechanically stabilize the FlexLoader SC 6000 prior to transporting it again. The stabilizing support close to the FlexLoader SC 6000:s machine opening has to be fitted to the FlexLoader SC 6000 prior to any transport. This support was delivered and fitted to the FlexLoader SC 6000 for original delivery.
4.1 User accounts General Note There are several default user accounts used in FlexLoader SC 6000. It is strongly recommended to change the default passwords to reduce the risk of unauthorized access to important system parameters. Follow ABB’s advice for administration of user permissions.
• Reset the emergency stop. • Open and close at least one internal FlexLoader SC 6000 cell door. • Reset the door status by shortly turning the reset key. Optionally, if a light curtain is present, a long light curtain reset may be needed (0.5 s) first, followed by a second reset for the whole cell.
Adjust focus: Place a sheet of paper with text or information below the camera on the belt. If you intend to run FlexLoader SC 6000 with tall details, put the sheet on an appropriate height. Adjust the lens focus ring and lock it.
General FlexLoader SC 6000 is delivered with a pre-installed and pre-configured robot gripper system (option) and robot program. For details on the structure of the FlexLoader SC 6000 robot software see RAPID program on page Commissioning includes the following main steps: •...
4.4.2 Calibration of the coordinate systems 4.4.2 Calibration of the coordinate systems Robot coordinate systems that are used in the FlexLoader SC 6000 are pre-defined from factory, but they must be redefined to compensate for possible changes due to transportation and setup.
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General work object considerations Some standard work objects in the FlexLoader SC 6000 actively use both user frame and object frame. When doing standard 3-point calibration, the operator must calibrate by means of the user method. The object frame is used internally in order to move work objects to specific points of interest.
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The following coordinate systems shall be redefined (if the corresponding option is present on the FlexLoader SC 6000). The position of the calibration points can be found in the images below.
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4 Commissioning 4.4.2 Calibration of the coordinate systems Continued Approximate positioning of wCamera1 in the FlexLoader SC 6000. xx1900000366 Finally, check the calibration by the following simple test. Move the robot calibration tool tip to point x=0, y=0, z=0 in wCamera1. Use the mouse curser coordinate display in FlexLoader Vision and point at the image of the calibration tool tip.
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Note that orientation of the tool is used in pre-configured movements. xx1900000370 Approximate positioning of wAirClean in the FlexLoader SC 6000 Deburring tools wDeburr The grinding and deburring tools are accessed from their own coordinate system wDeburr.
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Approximate positioning of wMarker in the FlexLoader SC 6000 Afterwards, call the calibration routine CalibMarker. The point-of-interest is where the calibration tool touches the marking needle, with the marking needle at a suitable marking distance.
4 Commissioning 4.4.3 Further integration steps 4.4.3 Further integration steps The pre-configured robot software for FlexLoader SC 6000 contains suggestions for a working application skeleton. Please follow the suggestions in the section about robot program for building your own applications, see RAPID program on page 91.
4 Commissioning 4.5 Machine tool 4.5 Machine tool The FlexLoader SC 6000 system provides a framework for handling the most common machine tool interface types. Interaction with the machine tool is handled by a machine tool specific module (TemplateMachine.sys). This module translates the actual machine tool communication signals into a standardized set of commands to be understood by FlexLoader SC 6000.
4 Commissioning 4.6 SafeMove 4.6 SafeMove The FlexLoader SC 6000 comes with a standardized setup for the SafeMove system. The delivery setup is as follows: xx1900000414 Schematic positions of SafeMove zones within the FlexLoader SC 6000. The marked areas are forbidden zones.
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Follow standard SafeMove configuration routines as described in the robot manual. DANGER If the intended use of the FlexLoader SC 6000 is changed, a new risk assessment with regard to SafeMove configuration must be done. DANGER SafeToolZones defined within the FlexLoader SC 6000 (STZ4, STZ5, STZ6, STZ7, SST1) shall not be modified more than described above.
4.7 Marking unit General The marking unit is a standard FlexLoader SC 6000 option. The hardware consists of a SIC marking equipment, i.e. an i53 marking head with an E10 controller unit. During operation, the robot communicates by means of serial communication with the controller unit.
4 Commissioning 4.8 Deburring/grinding unit 4.8 Deburring/grinding unit The deburring/grinding unit is a standard FlexLoader SC 6000 option. The hardware consists of an Atlas Copco pneumatic die grinder LSF28 ST030E and a Nitto pneumatic filer ASH-900. These units can be equipped by any suitable tools according to the customer needs.
5 Interface 5.1 Safety interface Introduction The FlexLoader SC 6000 is equipped with a well proven multi-purpose safety center that covers a large variety of standard uses. The safety center is normally connected directly to the machine tool(s). The safety center handles all necessary connections to the door system and the robot safety.
5.2 Function interface 5.2 Function interface General FlexLoader SC 6000 has a function interface that is used to communicate with the robot and the rest of the robot cell. The internal interface between robot and FlexLoader SC 6000 is described below.
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During normal operation, signal exchange to robot occurs according to the following handshaking sequence: xx1800000185 Machine tool interface As standard, the FlexLoader SC 6000 is delivered with the following functional interface capability: • ABB CI502 series I/O node connected to the robot PROFINET bus.
The system can easily be adapted to the requirements of the customer. In a typical application FlexLoader SC 6000 is integrated with a machine tool. The operator places parts on a conveyor belt that acts as a buffer. The robot picks the parts from the conveyor belt.
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6 Function description 6.1 Overview Continued Sensors The main sensors the FlexLoader SC 6000 can be equipped with are: xx1900000377 Pos. Component Pos. Component Sensor that detects if a part has Inconveyor TooFar-sensor, de- been placed on the statistical tects if parts on the inconveyor outlet.
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Operator panels The main operator panels of FlexLoader SC 6000 are situated at the start of the inconveyor, below the vision system screen, and at the sliding door towards the machine tool.
6.2 General function description 6.2 General function description The purpose of FlexLoader SC 6000 is to feed parts to the cameras field of view where they are to be identified by a camera and picked by a robot. The inconveyor is filled with parts manually.
Before programming the FlexLoader SC 6000, it is your responsibility to carefully read the chapter on safety, to become familiar with the FlexLoader SC 6000 and its options, and to become familiar with the safety devices.
7.2 FlexLoader application functionality 7.2 FlexLoader application functionality Overview The FlexLoader SC 6000 application code handles the complete workflow of parts in the cell (e.g. unloading and loading of parts, option handling, picking from inconveyor and leaving on outconveyor). The application code consists of a basic executable skeleton, which must be modified by the integrator in order to match the actual application.
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7.2 FlexLoader application functionality Continued RAPID example MT_MoveRobotTo The principal motion in the FlexLoader SC 6000 is controlled by the MT_MoveRobotTo routine, which moves the robot from known zone positions to a target zone position. From these zone positions (via positions), movement within certain areas of the FlexLoader SC 6000 can be initiated.
Machine1Action CLOSE_DOOR; Machine1Action CYCLE_START; Different machine tools have different behavior. As described in the previous section, FlexLoader SC 6000 supplies a comprehensive set of tools and adjustment possibilities to handle these behaviors. CAUTION All predefined states and actions that are used in the template module shall be implemented or deleted.
FlexLoader SC 6000 offers predefined WorldZone handling in the module Common.sys. The FlexLoader SC 6000 defined WorldZones are active in both jogging mode and automatic mode. The following zone is predefined and must be configured during commissioning.
During teachin, the operator workstation is located at the FlexLoader Vision monitor. WARNING FlexLoader SC 6000 may only be operated by trained operators with the required knowledge of the functions and risks related to FlexLoader SC 6000. DANGER Before FlexLoader SC 6000 is started or restarted, always check that all safety devices are working properly and that no damage can be caused at startup.
• Reset the emergency stop. • Open and close at least one internal FlexLoader SC 6000 cell door. • Reset the door status by shortly turning the reset key. Optionally, if a light curtain is present, a long light curtain reset may be needed (0.5 s) first, followed by a second reset for the whole cell.
8 Operation 8.3 Shutting down the FlexLoader SC 6000 8.3 Shutting down the FlexLoader SC 6000 1 Stop FlexLoader SC 6000 and await a complete cycle stop. 2 Exit the FlexLoader Vision application. 3 Turn off the computer. 4 Turn off the main switch.
FlexPendant. Starting with the robot in manual mode DANGER Running FlexLoader SC 6000 in manual mode with an operator close to the robot, the machine tool and FlexLoader SC 6000 options leads to increased risks for the operator.
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8 Operation 8.4 Operating FlexLoader SC 6000 with FlexLoader Vision Continued FlexLoader SC 6000 can be run with open doors. The robot operating mode must be manual with reduced speed. Upon clicking Start, FlexLoader Vision notifies the operator about the manual mode.
Restarting after emergency stop WARNING Ensure that a restart of FlexLoader SC 6000 does not cause any risks of damage to equipment or personal injury. 1 Twist (or pull out, depending on button model) all activated emergency stop buttons to reset them. The blue reset button on the operating panel starts flashing.
8.6 Entry control 8.6 Entry control Introduction The FlexLoader SC 6000 is well prepared for typical entry control handling. The application RAPID code is expected to handle entry requests and operator interaction through it's I/O system. The optional FlexLoader Standard Safety handles the protective stop and manual operation of equipment.
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As soon as the door has been unlocked, the green lamp is lit without flashing. Manual operation of dangerous equipment By default the protective stop is activated as soon as any FlexLoader SC 6000 door is opened. This deactivates dangerous equipment in the cell. Sometimes, such equipment must be activated for test operation.
(override) is enabled. Cyclic brake check The FlexLoader SC 6000 is programmed to automatically perform the cyclic brake check that is needed for the secure operation with SafeMove. The safety break check is normally performed at the home position of the robot.
This requests permission for manual operation from the robot, and the lamp in the knob starts to flash. The lamp lights continuously as soon as FlexLoader SC 6000 can be run in manual mode. WARNING...
8.10 Indicator lamps 8.10 Indicator lamps The indicator lamps at the front and back of FlexLoader SC 6000 are used to indicate the status of the system and notify the operator of any errors or warnings. Any error messages and warnings are also displayed on the FlexPendant.
Always follow the general safety instructions, see Safety on page This section covers maintenance of both FlexLoader SC 6000 and options that are not included in all installations. If the installation contains further parts, maintenance instructions may also be found in other documentation.
9.2 Mechanical maintenance 9.2 Mechanical maintenance FlexLoader SC 6000 overall cleaning What: Overall cleaning of the FlexLoader SC 6000. When: Once / week. More often if needed. How: Let the robot move to its home position (-> entry request). Clean all surfaces from chips, oil and other material that might disturb correct function.
10.1 Introduction 10 Repair 10.1 Introduction This section describes how to repair FlexLoader SC 6000 and options that are not included in all installations. If the installation contains further parts, repair instructions may also be found in other documentation. Most repairs of FlexLoader SC 6000 are relatively straightforward to carry out. The most important procedures can be found in this section.
Prior to all work with the conveyors: After positioning the belts in suitable positions, safely shut the power to the FlexLoader SC 6000 down and lock against accidental turn-on. Exchange of conveyor belt Exchange a conveyor belt by the following procedure •...
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Adjust belt tension according to instructions in the maintenance section. DANGER Power to the FlexLoader SC 6000 has to be restored prior to mounting the protection caps, in order to perform the belt adjustment. Be careful when adjusting the belt. Risk for finger squeeze.
10.3 Illumination DANGER Prior to work with the illumination: Safely shut the power to the FlexLoader SC 6000 down and lock against accidental turn-on. Exchange of illumination units is described in the maintenance section. In rare cases, the complete luminaires have to be exchanged. Use the following procedure: •...
To replace the camera with the least possible impact on existing detail teachin, use the following procedure: WARNING Before replacing the camera: Switch off the current to FlexLoader SC 6000 and lock the switch to prevent unintentional switching on. 1 Disconnect the camera cable.
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Replacing the camera lens on page 149. 5 Reinstall the camera mounting plate on the FlexLoader SC 6000 frame. Do not tighten the screws firmly yet. 6 Attach the camera cable. 7 Turn on power to the FlexLoader SC 6000.
DANGER Before carrying out work on the gripper: Safely shut down the pneumatic supply to FlexLoader SC 6000 and lock the switch to prevent unintentional switching Replacing the gripping module on the gripper To replace one or more gripping modules (Schunk): 1 Move the robot to a suitable service position.
10.7 Turn station DANGER Prior to work with the turn station: Safely shut the pneumatic supply to the FlexLoader SC 6000 down and lock against accidental turn-on. Exchange of gripping module on turn station The gripping module (Schunk) can be exchanged by the following procedure •...
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If there are any changes in position/design between the new and old unit the robot positions need to be updated. xx1900000397 FlexLoader SC 6000 turn station, showing the rotation module and the valve positioning Exchange of valves For exchange of valve modules in the turn station follow the first steps of instructions above (exchange of rotation module) in order to obtain access to the valve package.
Safety DANGER Before carrying out work on the air cleaning box: Safely shut down the pneumatic supply to the FlexLoader SC 6000 and lock the switch to prevent unintentional switching on. Components of the air cleaning box and deburring tool xx1900000398 Pos.
DANGER Before carrying out work on the grinding or deburring units: Safely shut down the pneumatic supply to the FlexLoader SC 6000 and lock the switch to prevent unintentional switching on. Components of the air cleaning box and deburring tool xx1900000398 Pos.
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4 Replace the valve with a new one. 5 Reinstall the air cleaning box in reverse order. Make sure the air cleaning box is correctly connected to the pins placed in the FlexLoader SC 6000 frame. Continues on next page...
It deals with how to handle potentially dangerous components and potentially hazardous materials. When decommissioning the FlexLoader SC 6000, start with decommissioning of the robot according to the robot product manual. Disposal of storage media Before disposal of any storage equipment (anything from an SD card to a complete controller), make sure that all sensitive information has been deleted.
8, Number of stop bits: 1, Flow control: None, Duplex: Full FlexLoader Vision pre-configuration FlexLoader Vision is pre-configured with the options that are present in the delivered FlexLoader SC 6000. If needed, this pre-configuration can be changed. See the FlexLoader Vision manual for detailed information on configuration. Air preparation pre-configuration The pressure switch and the safety valve are pre-configured.
ACS355 which is used in the FlexLoader SC 6000. The document specifies the settings of the essential parameters that are required for tuning the FlexLoader SC 6000. Further optimization and settings can be done, for this refer to User’s manual ACS355 user's manual (3AUA0000066143), which can be found on the ABB website.
F FlexLoader RAPID reference F.3 FlexLoader application functionality F.3 FlexLoader application functionality Overview The FlexLoader SC 6000 application functionality handles application and part specific aspects of the robot cell. The integrator is responsible for adapting this functionality to the actual application. Module Description Main.pgf...
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F FlexLoader RAPID reference F.3 FlexLoader application functionality Continued The pre-configured setup of FlexLoader SC 6000 zones is shown in the figure thereafter. xx1900000400 Schematic motion overview Continues on next page Product manual - FlexLoader SC 6000 3HAC051768-001 Revision: D...
F.5 FlexLoader conveyor system control F.5 FlexLoader conveyor system control Overview The FlexLoader SC 6000 conveyor system control is structured according to the following overviews. These modules are part of the internal control system and must not be changed. Module Description FeedLine.mod...
FeederOut.sys Functionality for control of outconveyor and leave pattern calcula- tion. Could be used in all motion tasks. GlobalCodeAndCon- Shared module containing global code for FlexLoader SC 6000 fig.sys RAPID code. IndicationLights.mod Module for handling indicator lights according to operational status.
Overview The FlexLoader SC 6000 application functionality handles machine tool and part specific aspects of the FlexLoader SC 6000. The integrator is fully responsible for adopting this functionality to the actual application. Described below is two different template modules. Those describes which routines and data that is needed to communicate with a machine.