Page 1 ROBOTICS Product manual FlexLoader Vision...
Page 2 Trace back information: Workspace Robots and Applications version a41 Checked in 2018-09-14 Skribenta version 5.2.025...
Page 4 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.
Page 5: Table Of Contents
Operation information ..................Smartphone connection ..................Camera 2D camera settings .................... 3D camera settings .................... Settings Organizer ......................Mechanics ....................... Service ......................Gripping Limitations ................... Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 6 13.3.6 FlexLoader machine tool interface functionality ..........13.3.7 WorldZones ................... 13.4 Communication information ................13.4.1 Communication between FlexLoader Vision and the robot ......13.4.2 Communication between the robot and the PLC ..........13.4.3 Communication between Master and Slave ..........13.5 FlexPendant Master (option) ................
Page 7 Table of contents 14.3.3 Unload ....................14.3.4 Options ....................14.4 Commissioning ....................14.4.1 Robot ....................14.4.2 FlexLoader Vision Lite master detail ............14.5 FlexLoader Vision Lite configuration ..............A Technical information File structure in FlexLoader Vision ................ Logging the operation ..................
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Page 9: Overview Of This Manual
This manual describes FlexLoader Vision, how to set up, calibrate, operate, troubleshoot, backup and recover the system. This manual also describes how the ABB robot works together with FlexLoader Vision and how to integrate the robot with the vision system. Finally, this manual describes how to configure and operate FlexLoader Vision Lite.
Page 10 Trademarks FlexLoader is a trademark of ABB. References • The product manual of the robot used together with FlexLoader Vision • The programming manual of the robot used together with FlexLoader Vision • The product manual of the camera/s used together with FlexLoader Vision •...
Page 11: Network Security
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.
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Page 13: Quick Start
1 Quick start 1 Quick start Follow the steps below for a quick startup of a FlexLoader Vision system. The robot shall be installed mechanically and electrically, and be equipped with suitable grippers. Action Become familiar with this manual. Install PC and camera.
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Page 15: What Is Flexloader Vision
The FlexLoader Vision is open to communicate with a variety of camera sensors. It can be used for both 2D and semi-oriented 3D applications. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B ©...
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Page 17: Overview Of The User Interface
3.1 Menu When you start FlexLoader Vision you will see the following window. xx1800000203 At the top of the FlexLoader Vision window is a menu showing a number of menu icons that represent various system activities. Operation Used to start and stop the system. Also shows information on the current operation.
Page 18: Tool Box
3.2 Tool box 3.2 Tool box FlexLoader Vision displays images at many different locations. To the right of each image there is a tool box. Not all the tools are displayed for every image – only the tools that can be used for the concerned operation are displayed. When a tool is selected, the button is highlighted and the tool is used when you click somewhere in the image.
Page 19: Alarm
Click on the alarm notification to open a list of all active alarms and show more information about what has caused the alarms. xx1800000205 Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 20: System Information
3.4 System information 3.4 System information The below window appears when you click on the ABB logotype at the top left of the screen. It contains information about the current version of software, license information and contact information for service and support.
Page 21: Teachin
Teachin window: Detail, Image, Positions, Parameters, Tool, Grip, Supervision, Mechanics and Test & Save. The settings available differ depending on how FlexLoader Vision is configured, for example depending on whether you use a 2D or a 3D camera.
Page 22: Navigation
In Classic mode the help text is not shown, and you can move freely between the different tabs in the teachin process. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 23: Detail
Each group can contain details. An unlimited number of groups and details can be saved in the database. xx1800000207 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 24 This drop-down list only appears if blob searching has been enabled for the system. It lets you choose between the two search methods Standard and Blob. In FlexLoader Vision, so called blobs are details that may sometimes, within specified ranges, vary in shape.
Page 25 SmartPhone connection For SmartPhone connected systems you can enable data reporting and enter the expected cycle time for the detail (see Smartphone connection on page 167). Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 26: Image
Fill inner holes is selected by default. For details with important hole patterns, it may be necessary to deselect this box. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 28: Image Settings For 3D Cameras
2D camera does), so these settings are not visible on the 3D camera user interface. The grey scale in the image below represents height, and lighter colors mean that the object is higher up. xx1800000210 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 29 This dimension directly affects what is visible in the image in FlexLoader Vision. The highest point in the image is white and then it gets darker, down to black, at the specified analysis depth. The upper edge of the pallet collar can lie at a greater height than the highest located point and is therefore also completely white.
Page 30 Interlayer search If the function to search for interlayers is activated, FlexLoader Vision will look for interlayers when no details are identified. When an interlayer is identified, FlexLoader Vision will send information to the robot that an interlayer is found and at what height it is.
Page 31 Pallets without interlayer If searching for interlayers is deactivated, FlexLoader Vision will not search for interlayers when no details are identified. Instead, the highest point in the image is evaluated in order to decide what information is sent to the robot.
Page 32: Positions
Positions tab. In the example below we teach the system to recognize the text FlexLoader Vision. The text can lie in two positions, either the right way up or mirrored. Clicking on the button New position creates a new position. This position must be defined by drawing a red box around the detail in the field of view that corresponds to the position.
Page 34: Parameters
The main parameters that determine the search results are called score and score target. xx1800000214 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 35 85%. However, the Score value for both found positions is 100% because the found positions still have a 100% geometrical match with the teachin position. xx1800001033 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 36 In this example it means that the Score target value for the two teachin positions is unaffected by the extra edges in the position to the right (E). Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 37 Position 1, Score 100%, Score target 100% Figure 4.4: Masking applied If you want FlexLoader Vision to suggest a masked area, click Suggest. Select Outer contour to obtain a suggestion only for outer contour lines. Use the Current position arrows to browse through all the teachin positions.
Page 38 These settings are accessed by clicking on Advanced and described in Advanced teachin settings on page xx1800000216 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 39 The following image shows the difference in compactness for a blob with the same area. xx1800000302 Pos. Area Compactness 1.65 1.00 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 40 A height region must always be defined when using a 3D camera. xx1800000217 When a detail has been identified by FlexLoader Vision, the height region value is used to establish a plane that lies on the detail. The average height of the plane is the height of the detail, and the angle of the plane gives the angles in the x and y axes.
Page 41 For the robot to pick the detail correctly, this must be compensated for with the gripper settings on the Grip tab. xx1800000304 Pos. Description Height region Located height Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 43 Note that when a suction cup is used, tool supervision is not active. This is because one suction cup must always be positioned on the detail. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 44 Corresponds to a gripper with a single gripping finger and the tool center point (TCP) offset to the left of the finger. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 45 Gripper [3 finger] xx1800001042 A three finger gripper that can be turned relative to the robots wrist coordinate system. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 46 If none of the predefined tool types are suitable it is also possible to draw the tool you intend to use. xx1800000219 Click the New button under the gripper to bring up the following dialog box: xx1800000220 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 47 Edit. When the tool has been modified you can either save the tool by clicking Save, or save it with a different name by clicking Save As. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 49 The Edge height value directly affects the positioning accuracy during gripping and handling of the position. It is therefore very important that the height is correctly set in the system. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 50 There is no direct connection in the image for x and y rotation. However, the x- and y-axes for the detail are drawn in the image. To understand how the grip device Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 51 This value is used to determine at what height a check for gripper collision occurs. Positioning height has the same function as for 2D cameras. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 52 This value is used to determine what grip height is to be sent to the robot. xx1800000308 Pos. Description Tool center point Grip depth Intrusion depth Positioning height Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 53: Supervision
The resulting collision risk image is updated continuously to permit rapid checking. xx1800000224 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 54 If all pickable details must be picked, this setting should be disabled. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 55 If Allowed overlap is activated, the gripper is allowed to collide with objects in the image to a certain extent. The degree of collision permitted is specified in square millimetres. When tool collision is detected, FlexLoader Vision will compare the collision area with the specified, permitted overlap area.
Page 56: Mechanics
Select the program to be used for the detail and click OK to use it. The path is now updated for the selected program. xx1800000273 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 57 FlexLoader FP 300 If FlexLoader Vision is used in FlexLoader FP 300, it is possible to adjust the parameters that govern mechanical control. On the Mechanics tab you will see an image of FlexLoader FP 300 and you will be able to set the parameters. The available parameters and their functions are described in the product manual of FlexLoader FP 300.
Page 58 Continued FlexLoader FP 400 If FlexLoader Vision is used in FlexLoader FP 400 it is possible to adjust the parameters that govern mechanical control. On the Mechanics tab you will see an image of FlexLoader FP 400 and you will be able to set the parameters. The available parameters and their functions are described in the product manual of FlexLoader FP 400.
Page 59 Continued User-defined settings If specified by the integrator, FlexLoader Vision can be used to control user-defined mechanical equipment. If so, the screen shows an image, two groups of parameters with a maximum of 32 values, and an Update PLC button to transfer these values to PLC.
Page 60: Test & Save
In order to fine-tune the settings it is usually necessary to obtain more information about the identification results. Clicking on Show result opens a window with Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 61 When FlexLoader Vision has identified a pickable detail, a new line is displayed in the list of test results. The new line is marked Pick and it specifies the data that would have been sent to the robot in normal operation.
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Page 63: Advanced Teachin Settings
This gives a large number of possible combinations. The effect of a filter is immediately seen Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 64 The movement supervision takes two images of the image field with a small time difference and compares them. If there are differences between these images, the Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 65 FlexLoader Vision is to analyze. This function can be used to enhance or weaken certain selected colors, or to increase or reduce the contrast between certain colors.
Page 66 5 Advanced teachin settings 5.1 Advanced image settings Continued The calculated black-white image can then be rescaled, either by allowing FlexLoader Vision to automatically determine the upper and lower limits (thresholds), or by specifying certain values. xx1800000232 Product manual - FlexLoader Vision 3HAC051771-001 Revision: B ©...
Page 67: Advanced Position Settings
The effect of changing the settings is updated continuously in the image. Note that the Smoothness settings affect every position in the system. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 68: Advanced Parameter Settings
This is because a number of the details that are found may be impossible to grip due to collision detection. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 69 If shared edges are not allowed, shared edges are counted as belonging to the result that meets the requirements most closely. xx1800000962 Pos. Description Teachin position Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 70 Certainty setting. The Certainty parameter is used to end the search process as soon as a position that meets the certainty setting is found. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 72 Pos. Description Teachin position Found positions Polarity: Same Polarity: Reverse Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 73 If the difference is bigger than the specified x or y position value, or if the Disable checkbox has been selected, both occurrences are found. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 74: Blob Analysis
Use compactness must be selected if the compactness is to be included in the properties that are analyzed and compared with the teachin details. Tick this box to set the permitted deviations for compactness. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 75 The requirements for the two positions must be completely different in at least one aspect, otherwise a warning is displayed. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 76: Analysis
Grip tab exceeds the maximum rotation, the detail will be marked as unpickable. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 78: Addon Analysis
The analysis type Intensity check (if enabled) is used to specify that selected areas should be light or dark. This could be used, for example, to check for material, openings, or labels. xx1800000237 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 79 (1) or those above the edge intensity threshold (1) are marked. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 81 Indicates the expected length of the detail in mm. Allowed length deviation [mm]: Indicates by how much the length of the detail may deviate up or down to still be approved. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 82: Advanced Grip Settings
Worst match: The coordinates of the position that gives the worst identification match are sent first. Because the location for the current worst Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 83 Because the location for the current best match often varies slightly within the field of view, this setting appears to sort positions randomly. xx1800000311 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 84 Direction – Down -> Up: The coordinates of the position at the bottom of the field of view are sent first. xx1800000313 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 85 Direction – Left -> Right: The coordinates of the position at the far left of the field of view are sent first. xx1800001047 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 86 When this is done, you can select the limitations that you want to apply to the detail from this list. The number of limitations that can be activated for a detail is unlimited. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 87: Advanced Supervision Settings
Pos. Description Teachin detail Inner holes filled Inner holes not filled Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 88 If Allowed overlap is activated, the gripper is allowed to collide with objects in the image to a certain extent. The degree of collision permitted is specified in square millimetres. When tool collision is detected, FlexLoader Vision will compare the collision area with the specified, permitted overlap area.
Page 89: Operation
The Group drop-down list for camera 1 is used to select the group for camera 1, the Group drop-down list for camera 2 is used to select the group for camera 2, and so on. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 90: Starting The System
If you want to continue with the robot running at reduced speed, click Manual. Note that FlexLoader Vision does not load the program that is specified for the detail if you select Manual, instead the correct program must be loaded and started manually.
Page 91: Stopping The System
6.3 Stopping the system 6.3 Stopping the system To stop the system, click Stop in FlexLoader Vision. If the robot is in Auto mode, it will also be stopped. Note that clicking Stop does not make the robot stop immediately. Instead it will stop at the end of its cycle or after a certain time. To stop the robot immediately, you must use the stop button on the robot or, if an emergency situation has arisen, use the emergency stop.
Page 92: Operation Information
Displayed to the right of the image are the latest results that have been sent to the robot. The most recent result always appears at the bottom. The results are shown as follows: Parameter Description Camera number Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 93 6 Operation 6.4 Operation information Continued Parameter Description Position number Score % Score target % In the screenshot above FlexLoader Vision the results are as follows: • Cam: 1 • Pos: 2 • S%: 98.9 • T%: 99.74 This means that a detail has been found in position 2 in an image taken by camera 1.
Page 94: Smartphone Connection
6.5 Smartphone connection 6.5 Smartphone connection Production data from FlexLoader Vision can optionally be visualized with the FlexLoader Vision Smartphone app. Currently the app is limited to systems with one camera. xx1800000511 The main screen shows all FlexLoader systems that are associated with the customer account and their current production status.
Page 95 Select one of the FlexLoader systems to display the most recent production statistics and alarms. This page can be manually updated. Just swipe down the page and release. xx1800000513 Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
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Page 97: Camera
FlexLoader Vision is to analyze. This function can be used to enhance or weaken certain selected colors, or to increase or reduce the contrast between certain colors.
Page 98 Calibration Introduction In order for FlexLoader Vision to send the correct coordinates to the robot, the system must be calibrated together, i.e. the coordinate systems of FlexLoader Vision and the robot must be made to correspond. For this purpose, the supplied calibration plate and calibration tool are used.
Page 99 7.1 2D camera settings Continued Calibrating a 2D camera 1 Select the Calibration tab on the Camera menu in FlexLoader Vision. xx1800000244 2 Select the camera to be calibrated at the bottom of the screen under Active camera (this setting is only available if there are several cameras installed).
Page 100 Under General Settings, enter the correct camera height to ensure that the system sends the correct coordinates to the robot. The camera height is measured in mm Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 101 From the camera viewpoint, details that are in the same location but have different edge heights appear to be in different locations in the field of view (known as parallax error). FlexLoader Vision therefore has a built-in perspective correction technology that automatically compensates for this effect.
Page 103: Camera Settings
Calibration In order for FlexLoader Vision to send the correct coordinates to the robot, the system must be calibrated together, i.e. the coordinate systems of FlexLoader Vision and the robot must be made to correspond. For this purpose, the supplied calibration plate and calibration tool are used.
Page 104 FlexLoader Vision will provide visual feedback about cone identification progress. A blue circle with a cross indicates where the cone was found. The values to the right show the current robot coordinates and the identified camera coordinates.
Page 105 FlexLoader Vision is rectified, which means that it does not have any perspective faults. The grey scale corresponds to the height so that it is possible to find the z coordinates. Some settings must be made in order for FlexLoader Vision to search in an efficient way. xx1800000249...
Page 106 Region of interest The region of interest is a very important parameter when using a 3D camera. When FlexLoader Vision starts searching for a detail, the highest point is identified first. FlexLoader Vision then continues the search downwards until the detail is located, or as far down as is set by the detail analysis depth.
Page 108 Rename Select a group or detail and click Rename. Edit the name of the group or detail and click OK. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 109: Mechanics
FlexLoader Vision is used with. For example you can see the input and output status, as well as various modes, functions and settings. When used with FlexLoader FP 400 Below follows an example of what it may look like when FlexLoader Vision is used together with FlexLoader FP 400. xx1800000256 For more information on the FlexLoader FP 400, refer to the FlexLoader FP 400 product manual.
Page 110 When used with user-defined mechanical equipment The display for user-defined mechanical equipment varies depending on which equipment is used together with FlexLoader Vision. Below follows an example of what the interface may look like. For more information, refer to the product manual of the user-defined equipment.
Page 111: Service
To perform a backup, click Backup on the Settings menu > Service tab. Select where you want to save the backup file and click OK. To restore the system from a backup file, click Restore. FlexLoader Vision must be restarted for the restored values to apply. If the system cannot be restored automatically, you can restore the system manually.
Page 112 Click OK to apply the settings. xx1800000254 In the image above, FlexLoader Vision is backed up every Monday at 17:00. The backup files are saved in the folder C:\FlexLoader Vision\Backup. For information on how to do a complete hard disk backup or recovery, see...
Page 113 Please enter a valid IP address and appropriate user credentials, then click Apply. FlexLoader Vision must be restarted for the new address to be activated. Computer handling Click Restart to restart the computer.
Page 114: Gripping Limitations
The list to the right in the image above shows the limitations that are currently defined for the system. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 115 The reflected section of the limitation will also appear in the image so that it is easy to understand what is covered. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 116 FuzzyRegion. When the gripping limitation area is named this way, the Limitation angle settings pane is enabled. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 117 (typically 1–3). Select Use for all details if you want to enable the setting for all details. Suitable parameters must be found in each project. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 118: Master/Slave
ID number of the Master equipment to a group and a detail in FlexLoader Vision. This is done by entering an ID number in the ID Selection Configuration pane, choosing a group from a drop-down list in the Group column, and then choosing one of the available details from the drop-down list in the Detail column.
Page 119 ID number of the Master equipment to a group and a detail in FlexLoader Vision. This is done by entering an ID number in the ID Selection Configuration pane, choosing a group from a drop-down list in the Group column, and then choosing one of the available details from the drop-down list in the Detail column.
Page 120 This form of master/slave communication is used for operation with the Barcode handler, the Master handler, and the Batch handler. xx1800000258 Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 121: Troubleshooting
Check that the settings for the perspective center and the camera height are correct. • Recalibrate FlexLoader Vision and the robot. Check that the data for the calibration pattern is correctly specified. To prevent the calibration plate from moving during calibration it can be taped to the camera belt. Check that the dot for coordinate 0,0 is visible at the bottom left of the screen.
Page 122 • If the grip point is correctly set, the calibration between the robot and FlexLoader Vision can be offset. Recalibrate according to the above. Positioned slightly wrong when gripping • Check that the camera is perpendicular to the picking area. This is very important for the system.
Page 124: Identification Problems
9 Troubleshooting 9.2 Identification problems 9.2 Identification problems FlexLoader Vision does not find any details • During operation: Check that the correct detail is selected. • During teachin: If the detail is too light or shiny it can be difficult for the system to discern the detail from a conveyor that is light in color.
Page 125: Communication Problems
If the PLC does not respond, check the network wiring and the switch. • In FlexLoader Vision ConfigurationEditor, check that the IP-address for the PLC is correct. FlexLoader Vision robot FlexLoader Vision has no contact with the robot •...
Page 126: Camera Problems
If the image is still too light or too dark, adjust the aperture. Do not forget to recalibrate the robot and vision system when you have adjusted the camera. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 127: Installation
10.1 PC installation Mechanical installation Note When FlexLoader Vision is pre-installed as part of a function package or standard cell, all hardware installation is already done. The PC shall be mechanically installed in an electrical cabinet. It can be oriented vertically or horizontally.
Page 128 Power connector latch Screws Switch on power and check that the PC is booting as expected. Note FlexLoader Vision software is always pre-installed on the PC. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 129 153. xx1800002351 Feeders, safety units and I/O are typically connected to the same internal network. xx1800002352 The robot and the FlexLoader Vision PC can be connected to a separate factory network as shown below. xx1800002353 Product manual - FlexLoader Vision 3HAC051771-001 Revision: B ©...
Page 130: Basler Camera Mechanical And Electrical Installation
The camera shall be mechanically installed at a suitable location. It is normally oriented aiming downward or forward. Camera dimensions with screw location information is shown in the following picture. xx1800002001 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 131 Continued Fit the camera to the isolating plastic mounting plate that is delivered with FlexLoader Vision and install it at the intended location. xx1800002006 Connect the camera to the PoE1 network port of the PC with a network cable (cat6).
Page 132 The field of view of the camera depends on the height of the camera (i.e. working distance) and the focal length of the lens. Approximate values for the size of the Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 133 For detailed information about the Basler camera please refer to the manufacturers manual. It is located in the FlexLoader Vision documentation folder on the PC. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 134: Visionerf 3D Camera Mechanical And Electrical Installation
We recommend a stabilized power supply with 24 VDC, 10 A. Prepare the Power & I/O cable according to the following table. Wire color Designation Blue Brown/Green White/Green 24 VDC White 24 VDC Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 135 USB device connector (optional) VGA cable connector (optional) If necessary, an optional VGA display and USB mouse/keyboard can be connected to the camera. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 136 This will ensure maximum image resolution for a given pallet. For detailed information about the VisioNerf camera please refer to the manufacturers manual. It is located in the FlexLoader Vision documentation folder on the PC. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B ©...
Page 137: Commissioning
11 Commissioning 11.1 Configuration editor 11.1.1 Introduction FlexLoader Vision is able to handle a wide variety of machine types and working conditions, with one or more cameras, in various FlexLoader function packages and standard cells. This section describes the available parameters.
Page 138: Main Settings
11.1.2 Main settings The main window is shown at startup. The default configuration file is loaded automatically. The configuration file (FlexLoaderVision.cfg) is stored in the FlexLoader Vision configuration folder, typically located at D:\Program Files\ABB Industrial IT\Robotics IT\FlexLoader Vision\Configuration\. Be sure to load and save the correct configuration file when specifying files manually.
Page 139 Start, stop and selection of details is possible. Standalone FlexLoader Vision operates as standalone system. Slave (through robot) FlexLoader Vision is controlled by the robot. Slave (through TCP/IP) FlexLoader Vision can be controlled by a TCP/IP based application. Slave (through PLC) FlexLoader Vision can be controlled by the PLC.
Page 140: Camera Settings
Camera settings Description Default Enable color mode Enables the use of color extraction and combination. Only possible with Matrox GigE Ace interface. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 141 3D camera settings For 3D cameras, select DllCamera3D. Then specify the correct DLL file and XML configuration file. These files are provided by ABB. Typically the files used are CirrusSensor.xml and CirrusSensor.dll. 3D camera settings...
Page 142 For the 2D case, configure several cameras in the configuration editor, and select Ignore GigE camera IP adress for each camera. Configure the camera for IP address 192.168.2.2. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 143 Can be selected for some feeders. Has rotation unit Can be selected for some feeders. Has user defined data Can be selected for some feeders. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 144 Each of the mechanical feeders have settings for their PLC IP address and feeder specific options. xx1800000440 Figure 11.3: Available settings for FP 400 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 145 11 Commissioning 11.1.3 Camera settings Continued xx1800000441 Figure 11.4: Available settings for FP 300 xx1800000442 Figure 11.5: Available settings for extra tipper Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 146: Robot Settings
Offset angle (XY) The grip angle of the located details (rotation in x-y plane) will be offset by this value. Robot Type The production systems work with the ABB ABB (produc- robot. The DllRobot type is only used during tion system) system tests.
Page 147 Useful in cells with extensive time demands on cycle stops. When DllRobot is selected, the corresponding DLL file and XML configuration file must be specified. These files are provided by ABB. Typical settings are SockekComRobot.xml and SockekComRobot.dll. This configuration is only used for testing.
Page 149: Tool Settings
Do not change if not instructed. xx1800000437 Password settings This dialog lets you specify the passwords for intermediate and expert user levels. xx1800000438 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 150: User Accounts
11.2 User accounts General CAUTION There are several default user accounts used in FlexLoader Vision. 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.
Page 151 Password FlexLoaderAdmin FlexLoaderAdmin Robot Default credentials according to ABB default settings. User name Password Default User robotics Follow ABB’s advice for administration of user permissions. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 152: System Settings
Several utilities are pre-installed or ready to install for ease-of-use and interactions with other FlexLoader function packages and standard cells. • ABB RobotStudio (for configuration and advanced setting of the robot). • ABB PlutoManager (for configuration and advanced setting of FlexLoader safety solutions).
Page 153: Settings
Otherwise, use a PoE switch in order to connect more than one camera to the "PoE1" port. Factory network The FlexLoader Vision PC can be connected to a factory network. The PC network connection is named Factory on physical port PoE2. Please refer to the robot controller product manual for setting the robot IP configuration.
Page 154 Settings for Basler GigE cameras Network setting for cameras The following instructions assume that ABB’s standard IP address settings are used. The same steps must be followed if alternative IP addresses are to be used. The only difference is in the addresses that must be entered.
Page 155 The camera settings should first be made via the settings options in Pylon Viewer, but can also be programmed in Matrox’s own software IntelliCam. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 156 To save to the camera memory, select User Set Save and click Execute. xx1800000303 Troubleshooting If the camera is not detected by FlexLoader Vision, this may be due to several circumstances. First check the configuration of the IP settings for both the computer and the camera.
Page 157 Click File > Save as ... and save the camera configuration file as follows in FlexLoader Vision’s configuration folder. xx1800000981 Close IntelliCam and restart FlexLoader Vision. Check that the camera is detected correctly and shows images in FlexLoader Vision. Settings for 3D cameras See separate instructions for information about 3D cameras.
Page 158: Licensing
By installing and using FlexLoader Vision you agree to Microsoft and Matrox licensing agreements. Licensing FlexLoader Vision In order to run FlexLoader Vision, the robot license option 1554-1 Prepared for FLexLoader Vision is required. Contact ABB for licensing on existing previous installations.
Page 159: Configuration Of User-Defined Mechanical Equipment
A free number of hidden parameters. None of these will be displayed in FlexLoader Vision. They are sent to the PLC in the same way as the usual parameters. This is useful for more general parameters which may need to be set from time to time.
Page 160 UserDefinedPlcCamera_1_Tab2.xml. Note that only the sections "General" and "user-defined parameters" (see below) are used in this case. General Here principal text is configured that is shown on FlexLoader Vision’s user interface. xx1800000984 On the Mechanics tabs (on the Teachin and the Settings menus), during teachin and servicing, the image UserDefinedPlcImage.bmp, is shown, which should be...
Page 161 As above, but for error messages 17–32, 33–48, 49–64. Word2,3,4 ErrorDescriptionX Text that is shown if corresponding bit in corresponding AddressEr- rorWord is 1. xx1800000985 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 162 PLC inputs that are to be shown for the user are defined here. There are up to 16 user-defined inputs, which can be freely defined. These are used to show the status of the equipment in FlexLoader Vision. Inputs can also be defined as memory bits or datablock memories (datablock 1) in the PLC.
Page 163 Start, stop and reset bit PLC markers that are used at start and stop in FlexLoader Vision are defined here. These are used to synchronize the equipment with FlexLoader Vision. The PLC marker is set to 1 for 0.5 s at start, stop or reset Note that you can use dual reset bits.
Page 164 11 Commissioning 11.3.4 Configuration of user-defined mechanical equipment Continued xx1800000982 Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 165: Robot Installation
11.3.5 Robot installation Operating system and options FlexLoader Vision is prepared for use with RobotWare 6.01 or above. Slight changes in configuration files may enable use with RobotWare 5.15 and 5.61. The following options must be available for the robot: •...
Page 166 Messages that the program pointer has changed are normal. Coordinate system for the robot gripper When setting the gripping positions during teachin, FlexLoader Vision always draws a blue line independent of the areas that visualize the gripping fingers themselves.
Page 167: Smartphone Connection
11.3.6 Smartphone connection Download and install the app. Start the app and enter the settings. Turn off the demo mode and enter your customer login as obtained from ABB. xx1800000514 For more information contact any of the application centers shown in the app.
Page 168 11 Commissioning 11.3.6 Smartphone connection Continued Make sure that the FlexLoader Vision PC is connected to the internet and that the smartphone settings are enabled and configured in the configuration editor (see License data on page 149). In case of connectivity problems ensure that network configuration is correct. A common problem is that a default gateway has been configured for the Robot or GigE connection.
Page 169: Maintenance
12.1 General maintenance 12 Maintenance 12.1 General maintenance This section covers maintenance of FlexLoader Vision. If the installation contains further parts, maintenance instructions may also be found in other documentation. FlexLoader Vision is made of components that have a minimal maintenance requirement.
Page 170 What: Do a backup of the robot program. When: When you have made a program change. How: Follow the robot manual and save the copy onto a secure media. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 171: Backup And Recovery Of The Hard Disk
12.2 Backup and recovery of the hard disk Introduction This section describes how to backup and restore the entire FlexLoader Vision PC hard disk. The backup can be used to restore the PC in case of a hard disk failure. Backups are normally made after an initial system installation and after major system changes (e.g.
Page 172 Click Start Redo Backup (or wait). xx1800000387 Click Backup. xx1800000388 Step 1: Select the source device containing Windows and FlexLoader Vision in the drop-down list and click Next. xx1800000396 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B...
Page 173 (Drive 2, Part 1) as destination drive in the drop-down list and click Next. xx1800000398 Step 4: Click Next. There is no need to specify a destination folder. xx1800000399 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 174 When the pop-up message that the back up is complete is displayed, click OK. xx1800000402 Remove the USB memory and restart the computer. xx1800000403 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 175 If the computer boots into Windows, you need to restart and try again. Select Boot manager. xx1800000385 Choose to boot from the USB device. xx1800000386 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 176 Click Start Redo Backup (or wait). xx1800000387 Click Restore. xx1800000388 Step 1: Select the USB device (Drive 2, Part 1) as source drive. xx1800000389 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 177 Step 3: Select Drive 1 as destination drive in the drop-down list and click Next. xx1800000392 Click Yes to confirm that you want to overwrite the FlexLoader Vision harddrive. xx1800000393 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B ©...
Page 178 In a couple of minutes the process is completed and a pop-up message that the restore procedure is complete is displayed. Click OK. xx1800000395 Remove the USB memory and restart the computer: xx1800000403 Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 179: Upgrading Flexloader Vision
Backup and restore FlexLoader Vision on page 111. If the restore operation fails and FlexLoader Vision cannot be restarted at all, you need to do a manual backup, where the contents in the backup directory are copied directly to the FlexLoader Vision directory. For more information on this, see Manually restoring a backup on page 256.
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Page 181: Robot Integration
This chapter describes how the ABB robot communicates and works together with FlexLoader Vision and how to integrate the ABB robot with FlexLoader Vision. In order for FlexLoader Vision to send the correct coordinates to the robot, the systems must be calibrated together, so that for example the coordinate systems of FlexLoader Vision and the robot are made to correspond.
Page 182: Calibrating The Robot
13.2 Calibrating the robot 13.2 Calibrating the robot General When the calibration of FlexLoader Vision is complete, you will need to calibrate the robot. This is done from the FlexPendant. Calibrating for use with a 2D camera When calibrating the robot for use with a 2D camera, a calibration plate and a calibration tool is needed.
Page 183 2, etc. Then tap Edit > Define. Note wCamera is only used temporarily in the robot and should not be calibrated. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 184 13 Robot integration 13.2 Calibrating the robot Continued xx1800000264 3 For User method, select 3 points. For Object method, select No change. xx1800000265 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 185 2 Select User point X1 > Modify position. Repeat the jogging and position modifying process for positions X2 and Y1. Then tap OK. xx1800000266 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 186 Saving the calibration file 1 Open the ProgramEditor. xx1800000315 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 187 4 Browse to the folder HOME:/System. Normally, there already is a file called Common.sys in this folder. Tap OK to confirm this is where you want save the calibration file. xx1800000270 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 188 There are 15 recommended positions defined. Fit and activate the calibration cone as a tool with the tool center point (TCP) at the top of the cone. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 189 Change Calibration3DRoutine accordingly so that the robot moves to the positions to be used. When FlexLoader Vision requests to start the robot at the time of calibration, the routine Calibration3DRoutine must be called from the FlexPendant. If all movements are already tested, the robot can be switched to automatic mode to simplify the calibration process.
Page 190: Rapid Program
Before programming the FlexLoader Vision, it is your responsibility to carefully read the chapter on safety, to become familiar with the FlexLoader Vision and its options, and to become familiar with the safety devices.
Page 191: Flexloader Application Functionality
Main structure Main.pgf and MainModule.mod are automatically loaded into the controller when a detail is started from FlexLoader Vision. During the following initialization, project modules with detail specific information are loaded. This happens upon every start. MainModule.mod is always the same for all details and all operating modes of the robot cell.
Page 192 Example files The following example programs show the principle structure of the robot code and how the robot program should communicate with FlexLoader Vision. There is no guarantee that any of the examples work unless the program has been adjusted and tested for the specific robot cell.
Page 193 ! TODO - Do something to take care of interlayer AND pallet change, can be removed if not a pallet picker cell ELSE CallByVar "RefPosInCam_",nCameraNumber; CallByVar "PickCam_",nCameraNumber; CallByVar "RefPosOutCam_",nCameraNumber; ENDIF Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 194 All camera image acquisitions are controlled manually due to process requirements. ! definition in Vision.sys or InitializeCamX PERS num BELT_ACTION{4}:=[RUN_NEVER, RUN_NEVER, Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 195 ! handle that parts occasionally are not found. WHILE nAction{CAMERA_NO_2} <= NO_DETAIL DO ! change camera settings if necessary DiscardAndTakeNewImage CAMERA_NO_2; WaitUntil bCoordReceived{CAMERA_NO_2}=TRUE; SetNextTarget CAMERA_NO_2; Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 196 ! Camera setting: Never grab an image automatically ALLOW_AUTO_GRAB{CAMERA_NO_1}:=FALSE; RAPID example MoveRobotTo.mod The principal motion in the FlexLoader Vision is controlled by the 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 Vision can be initiated.
Page 197 MoveRobotTo routine can execute without risk for collisions. The MoveRobotTo routine is - by default - part specific. When starting the robot from unknown positions, collisions can occur. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 198: Flexloader Vision Interface
Overview The FlexLoader Vision interface code handles the interface and the communication to and from FlexLoader Vision. No changes should be made to this code. The basic application related use of the FlexLoader Vision interface is described above, see RapidProgramApplication. This section describes additional functionality that can be used for a large variety of purposes.
Page 199: Flexloader Vision Lite Functionality
13.3.4 FlexLoader Vision Lite functionality 13.3.4 FlexLoader Vision Lite functionality Overview The application code for FlexLoader Vision Lite provides an extension to the general teachin described previously. This extension is used for parameter-based simplified teachin for upright standing cylindrical details, the so called FlexLoader Vision Lite. Normally, this code needs no changes.
Page 200 In some cases of machine tending, the cell must be emptied from parts, i.e. the machine shall be unloaded without loading the next part. For FlexLoader Vision Lite, this behavior is pre-programmed. By setting the output DOF_EmptyCell to “1”, the robot will finish a cycle by unloading a finished part without loading the next raw part.
Page 201: Flexloader Assistance And Utility Functionality
ResetMessage ALL_MESSAGES; Message handling can then be used for e.g. messages, alarms and user input. If selected, the information is transferred to the FlexLoader Vision information system as well. If present, the indication lights are updated according to the message severity.
Page 202 ! It is also ok to define exactly which gripper should perform action ToolAction\Tool:=GRIPPER_1\Release; ENDIF ! If you have reason to think someone opened gripper in manual Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 203 ! predefined lamps: BLUE_LAMP, GREEN_LAMP, ORANGE_LAMP, ! RED_LAMP, WHITE_LAMP, YELLOW_LAMP LightTowerSetup\AlarmType:=RED_LAMP\WarningType:=ORANGE_LAMP \InformationType:=WHITE_LAMP \QuestionType:=BLUE_LAMP \CycleOn:=GREEN_LAMP \FlashLightTower; Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 204 ! force question indication on Set DOF_Question; ! switch back to automatic control Reset DOF_Question; Light indications should always be accompanied with user messages for explanation. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 205: Flexloader Machine Tool Interface Functionality
13.3.6 FlexLoader machine tool interface functionality 13.3.6 FlexLoader machine tool interface functionality Overview The FlexLoader Vision standard modules communicate with the machine tool by means of the interface module TemplateMachine.sys, which must be modified and adapted to the actual machine tool by the integrator.
Page 206 ! TODO - Send signal to machine DEFAULT: ! TODO - No valid action to perform, ! create alarm or do something if needed ENDTEST ENDPROC Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 207: Worldzones
FlexLoader Vision offers predefined WorldZone handling in the module Common.sys. The FlexLoader Vision defined WorldZones are active in both jogging mode and automatic mode. The following zone is predefined and must be configured during commissioning.
Page 208: Communication Information
13.4 Communication information 13.4.1 Communication between FlexLoader Vision and the robot FlexLoader Vision and the robot communicates via PC SDK and Robot WebServices. The information is transmitted between the robot and FlexLoader Vision through direct reading/writing to/from variables and I/O signals.
Page 209 13 Robot integration 13.4.1 Communication between FlexLoader Vision and the robot Continued Other commands From FlexLoader Vision From the robot Description/result bClearSend Clear the coordinate queue. This should be used in all ma- chine types at each start. DOF_EndCycle Stop the program at a suitable point.
Page 210 Cross-connected to the system output Error. Used so that FlexLoader Vision can receive information about fault incidents. DOF_EndCycle Used so that FlexLoader Vision can stop the robot when a cor- rect cycle is completed and not in the middle of a cycle. DOF_CycleEnded Response signal from robot on DOF_EndCycle.
Page 211 13 Robot integration 13.4.1 Communication between FlexLoader Vision and the robot Continued Signal Description DOF_InPosition1...4 Cross-connected to Feeder1(...4)InPosition. Used by Vision- Com to check when a new detail has reached camera 1-4. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B...
Page 212: Communication Between The Robot And The Plc
The robot and the PLC communicates via digital signals. The typical communication between part feeder and robot is shown below. xx1800001066 Pos. Description Taking images and picking. The conveyor is running. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 213: Communication Between Master And Slave
0, after which the reply is set to 0. Note that in most cases there are two alternative replies. When the program is started all signals are reset to 0. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 214 13.4.3 Communication between Master and Slave Continued The handshaking sequences for AutomaticStart, CycleStop and SelectIdCamX are shown in the diagrams below. xx1800001015 xx1800001016 xx1800001017 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 215 Robot It is possible to allow an external PLC to be Master for FlexLoader Vision via the robot. This means that the external PLC can stop, start and change detail in FlexLoader Vision. The robot acts as an intermediary to get it to work. The following signals can be exchanged between the robot and the PLC.
Page 216: Flexpendant Master (Option)
13.5 FlexPendant Master (option) The FlexPendant Master function is a graphical interface in the FlexPendant that makes it easy for the operator to manage FlexLoader Vision from the FlexPendant. Only information that is required for operation of the robot cell during production is displayed in the interface.
Page 217 13.5 FlexPendant Master (option) Continued To open the FlexPendant Master interface when this is done, tap the FlexLoader Vision icon that is now visible on the ABB menu on the FlexPendant. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
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Page 219: Flexloader Vision Lite
ABB’s proven proprietary vision system, FlexLoader Vision, which guides the robot to pick the parts directly from the buffer belt. The robot is equipped with a double gripper with three finger gripping and adjustable fingers.
Page 220 In addition, CNC operators can easily and quickly operate loading and unloading. One limitation in a FlexLoader Vision Lite system is that it can handle axially symmetrical parts only. For customers who, in the future, come across other types of parts that need loading with the correct rotation or require different types of post processing (e.g.
Page 221 Integrated in FlexLoader Vision (and then run on the FlexLoader Vision computer). • On the operating panel of the lathe, as a Master to FlexLoader Vision. There it is possible to choose details, start and stop the system, and perform teachins of new parts.
Page 222: Operation
The following Operation view is shown when the system is integrated in FlexLoader Vision: xx1800000278 The following Operation view is shown when the system is integrated in the lathe operators panel: xx1800000279 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 223 Note that the program must be started from the beginning. Stopping the system To stop the system, click Stop in FlexLoader Vision. If the robot is in Auto mode, it will also be stopped. Note that clicking Stop does not make the robot stop immediately.
Page 224 Letting the robot control the stop situation is, for example, useful when running special cycles that cannot be stopped in the middle of operation. In this case, the robot normally knows when a stop is appropriate. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 225: Flexloader Vision Lite Teachin
To perform a teachin in the operator panel of the lathe, click Teachin. To perform a Lite teachin on the FlexLoader Vision PC, click the Lite icon. On the FlexLoader Vision Lite menu there are four tabs to choose between: Detail, Load, Unload and Options.
Page 226: Detail
14.3.1 Detail 14.3.1 Detail Overview xx1800000280 On the Detail tab, a list of all FlexLoader Vision Lite details that are in the system is displayed. Detail creator To edit a detail, select the detail and click Edit. To create a new detail, click New and enter a new name. Click OK.
Page 227: Load
3 The robot retrieves the finished detail in the machine with its empty gripper. 4 The robot exits the machine, performs any activated options and leaves the finished detail on the outconveyor. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 228 Unloading only When turning from bar material the option Unloading only can be activated. Note that this checkbox can be hidden through a setting in the configuration file, see FlexLoader Vision Lite configuration on page 242. Synchroneous mode If you need to operate the system in synchronous mode, select Synchroneous mode.
Page 229: Unload
Unloading from main-spindle The normal loading and unloading procedure is specified above, see Normal loading procedure on page 227. xx1800000282 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 230 14 FlexLoader Vision Lite 14.3.3 Unload Continued Unloading from sub-spindle When activating unloading from a sub spindle, a spindle offset can be specified. xx1800000283 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 231 Unloading of remains is done by the loading gripper. Note that the Unload remains checkbox can be hidden through a setting in the configuration file, see FlexLoader Vision Lite configuration on page 242. xx1800000284 Continues on next page...
Page 233: Options
14.3.4 Options Overview There are a number of options available for FlexLoader Vision Lite. The options selected for the current system are displayed on the Options tab. If there are no options added to the system, the Options tab does not appear at all. The following options are available: •...
Page 234 The four activation boxes can then be connected with the new function(s). This makes it possible to activate the special functions for selected details. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 235 Special robot program By default, the robot movement in FlexLoader Vision Lite is controlled by the module ModCam1.mod, which contains the default movements in their default workflow.
Page 236: Commissioning
In addition to this, the following instructions should be followed. FlexLoader Vision Lite assumes a specific geometry and coordinate system in the robot to work optimally. The FlexLoaderVisionLite.sys module must be adapted to the actual cell geometry.
Page 237 CalibMainChuck chuck of the first lathe (main spindle). wSubChuckM1 Coordinate system for right chuck CalibSubChuck of the first lathe (sub spindle). Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 238 All dimensions are in mm. Robot data Description FEEDER_WIDTH Width of outconveyor. SPACE_BETWEEN_PARTS Space to be left between details on the out- conveyor. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 239 Load induced lowering of the robot arm, in nLoadCompensate Load that was used for measuring nLoadCom- pensateDistance Gripper The following gripper is used in a FlexLoader Vision Lite system: Robot data Description tCalibTool1 Calibration gripper that attaches to gripper 1.
Page 240 Sequences Standardized sequences are used to load and unload details in the machine, using the detail data from FlexLoader Vision. These sequences must be checked prior to each commissioning. The sequences are based on the machine being loaded from the front. If the machine is loaded from above or if anything else is unusual, some adjustments are required.
Page 241: Flexloader Vision Lite Master Detail
The detail FlexLoaderVisionLite must be taught in the Masters group. Each time a detail is saved in FlexLoader Vision Lite, the base values are copied from this master detail and adapted for that specific teachin detail. This applies, for example, to settings for exposure times, image preparations, advanced position settings, accuracy requirements, settings for collision monitoring etc.
Page 242: Flexloader Vision Lite Configuration
The instructions below are for integrators, ABB’s own technicians and for information. The customer usually does not need to edit this configuration. The instructions below assume knowledge of the general setup of ABB’s system and handling of XML files. For operation of FlexLoader Vision Lite, the file FlexLoaderVisionLite.xml file must be configured.
Page 243 Gripper data In a FlexLoader Vision Lite system the gripper data must be known to be able to perform collision checks and to provide information to the operator on how the gripper fingers are to be positioned on the robot.
Page 244 GripperNumber Serial number for gripper data. Must start at 1 and must be continuous for each gripper that is configured. This is the number that can be selected in FlexLoader Vision Lite user in- terface. GripperStroke Stroke per finger in mm.
Page 245 As a rule, UpperDiameter and LowerDiameter are to be placed so that the gripper ranges for the different positions are positioned adjacent to each other, but do not overlap. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 246 The relationship between the parameters for a gripper range during internal gripping is illustrated in the image below: xx1800000321 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 247 • Specify the language as per requirements. • Specify the IP address of the FlexLoader Vision computer as well as the port number (same if specified in MasterSlave.xml). • The values for the hasFlexLoaderVisionInterface, hasTeachIn and teachInType parameters are specified according to the image below.
Page 248 Communication variables robot Variable mapping Writing of variables to the robot is done according to the following diagrams: xx1800000289 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 249 14 FlexLoader Vision Lite 14.5 FlexLoader Vision Lite configuration Continued xx1800000290 xx1800000291 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 250 14 FlexLoader Vision Lite 14.5 FlexLoader Vision Lite configuration Continued xx1800000292 Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 251: A Technical Information
(*.dcf), and some system images (*.tif). The latest applicable configuration file (FlexLoaderVision.cfg.LastGoodKnown) is also stored here. It can be used if a change has been made in FlexLoader Vision or if a system crash has made FlexLoaderVision.cfg unusable. When updating, some of these files may need to be replaced.
Page 252 If a 3D camera is used, there is also a *.HeightAnalysisArea-file. FlexLoader Vision\Database In this folder, the FlexLoader Vision database (FlexLoaderVision.mdb) is stored. When FlexLoader Vision is run, there is also a FlexLoaderVision.ldb file. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B...
Page 253: Logging The Operation
Then the special log window must be activated. This is done by first clicking the Operation icon and then pressing Ctrl+L. Select Run Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 254 The slide show can either occur at a fixed interval (select Run continuously) or by pressing the Next button (select Pause after each image). Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 255: Localization
For any specific project, an override text can be defined in a separate file, Language.Override.xml. Elements that are to be overridden must adhere to exactly the same XML structure as used in the main language file. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 256: Manually Restoring A Backup
Vision’s program folder. The folders Database, Data, and Configuration are found in both the backup folder and FlexLoader Vision’s program folder. 2 Make a safety copy of the whole of FlexLoader Vision’s program folder. 3 Copy the whole Database folder from the backup folder to FlexLoader Vision’s program folder.
Page 257: B Flexloader Rapid Reference
Constant prefixes and naming Constants do not have any prefix. They are named with capital letters, with words divided by “_”. Examples are LOW_AIR_PRESSURE and STATE_LOAD_MAIN. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 258: Flexloader Vision Interface
B FlexLoader RAPID reference B.2 FlexLoader Vision interface B.2 FlexLoader Vision interface Overview The FlexLoader Vision interface consists of the following modules. Module Description VisionCom.mod Background task for base communication with FlexLoader Vision. Vision.sys Base communication with FlexLoader Vision and interface towards the application RAPID code.
Page 259 VisionCom.mod This module contains routines needed for background communication between the robot and FlexLoader Vision and must not be changed. VisionCom synchronizes the vision system and conveyor events with robot program execution. It relieves the foreground task from handling feeding devices and coordinate reception from the vision system.
Page 260 Called up by the user to take a new image with the selected camera. The routine waits until the accompanying signal InPosi- tion is 1 and sends a command to FlexLoader Vision to take a new image with nCamera. Note Do not use GrabImage if the camera is set to AL- LOW_AUTO_GRAB = TRUE (set in IntitializeCamX in ModCamX).
Page 261 Called up to check how many times a certain position occurs in Present(nCamera, the results sent by FlexLoader Vision. nPosition) ResetAlarm(sMessage) Called up to reset a certain alarm that was set in FlexLoader Vision from the robot. ResetInformation(sMes- Called up to reset a specific information message that was set in sage) FlexLoader Vision from the robot.
Page 262 SendGrab(nCamera) For system internal usage. SendStop() For system internal usage. SetAlarm(sMessage) Called up to set an alarm in FlexLoader Vision from the robot. SetInformation(sMes- Called up to set an information message in FlexLoader Vision sage) from the robot. SetWarning(sMessage) Called up to set a warning in FlexLoader Vision from the robot.
Page 263 Handles Stop requests from external master and stops FlexLoader Vision. SelectIdTrapCam1..4 Handles SelectId requests from external master and changes detail in FlexLoader Vision. Init Initializes the various request handlers. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 264: Flexloader Application Functionality
MoveRobotVia.mod This module handle robot movement between via positions (gen- eral movements in the cell). MainModule.mod MainModule.mod is always supplied with FlexLoader Vision. It is the main robot program of the system. MainModule.mod provides the following routines: Routine Description CheckSystem() Checks whether anyone has requested entry to the cell or has been inside the cell.
Page 265 Description LoadCameraModules() Loads relevant module files for each camera. The name of each module that is to be loaded is provided by FlexLoader Vision. Main() Pre-programmed and should only be modified where it is explicitly stated that conditions must or can be added.
Page 266 Routine Description PROC MainRoutine() This is the main routine for FlexLoader Vision Lite. It checks for entry request, maintenance request and other production breaking conditions. Then it calls the state logic to decide what to do next. PROC PerformFinishin-...
Page 267 The unload position is always calculated. X and Y is set to 0 and Z is calculated with the help from FlexLoader Vision values. To change the unload position, the work object has to be adjusted until the position is correct.
Page 268 Set up all used tools in the cell. MoveRobotVia.mod The principal motion in the FlexLoader Vision is controlled by the 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 robot cell can be initiated.
Page 269 End of home zone. ZONE_FEEDLINE_START Start of Feedline zone. ZONE_FEEDLINE_STOP End of Feedline zone. ZONE_OUTBELT_START Start of outconveyor zone. ZONE_OUTBELT_STOP End of outconveyor zone. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 270 End of regrip zone. A schematic view of an example robot cell with typical via positions is shown in in the next figure. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 271 A schematic setup of the same robot cell with its typical zone setup is shown in figure thereafter. Pos. Description Robot Machine tool Inconveyor OutConveyor Turn station Washer station Statistical outlet Air cleaning station Door Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 272: Flexloader Vision Lite Functionality
The module FlexLoaderVisionLite.sys contains a number of predefined procedures/functions that enables the parametrized loading and unloading of the machine tool. The variable names in this module must not be changed, as FlexLoader Vision transfers data to these variables. Routine Description FUNC num calcLoad- Calculate load compensation when leaving and picking from chuck.
Page 273 Branch() Standardized sequences are used to load and unload details in the machine, using the detail data from FlexLoader Vision. These sequences must be checked prior to each commissioning. The sequences are based on the machine being loaded from the front. If the machine is loaded from above or if anything else is unusual, some adjustments are required.
Page 274 The routine also calculates how many details fit in each row and Length,num height- if a left over part space should be reserved. ToTCP,\num allowedDe- tailsInHeight,\num detail- Height, \num xDistan- ceToTCP,\bool hasLeftOverPart,\num leftOverPartWidth,\num leftOverPartLength,\num leftOverPartHeight- ToTCP) Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 275: Flexloader Conveyor System Control
B FlexLoader RAPID reference B.5 FlexLoader conveyor system control B.5 FlexLoader conveyor system control Overview The FlexLoader Vision 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...
Page 276: Flexloader Assistance And Utility Functionality
MessageConfigura- Shared module containing message and localization information. tion.sys Is needed for UserCommunication.sys. GlobalCodeAndCon- Shared module containing global code for FlexLoader Vision fig.sys RAPID code. Tools.sys Module for convenient and common tool handling. EntryControl.mod Module for handling entry request, entry indication lamp and door lock signals.
Page 277 B FlexLoader RAPID reference B.6 FlexLoader assistance and utility functionality Continued UserCommunication.sys The FlexLoader Vision standard modules integrate a localizable user communication interface. The module UserComunication.sys contains a number of predefined procedures/functions for interacting with the operator. Name Description Func num activeMes- Check active types of messages.
Page 278 PROC WriteWarn- Writes a warning message to the FlexPendant event log and ing(num TextNum- FlexLoader Vision if wanted. Also sets warning flag for correct ber,bool ShowInFlex- indication at light tower. Program execution continues. Loader Vision) Arguments as in WriteError.
Page 279 If needed, new values can be added. However, do not remove or change values, as they are used in the FlexLoader Vision core functionality. Use range 1 .. 200 for integrator messages. Other identifier ranges are reserved for predefined system messages.
Page 280 This module depends on the use of Tool.sys in every robot motion task. As long as Tool.sys is used, no further input is needed in ToolControlMenu.mod. Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 281 Routine Description FUNC num cal- Calculates mm value from Inch. cInchToMM() FUNC num calcLb- Calculates Kg value from Lb. ToKg() Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 282 FlexLoader Vision. Use this procedure first before teaching or using positions that need a TCP that is attached to the FlexLoader Vision position. Use with caution. FUNC num getCycle- Returns cycle time in seconds as a num. If no valid cycle time Time() calculated, return value will be -1.
Page 283: Flexloader Machine Tool Interface Functionality
B.7 FlexLoader machine tool interface functionality B.7 FlexLoader machine tool interface functionality Overview The FlexLoader Vision application functionality handles machine tool and part specific aspects of the FlexLoader Vision. The integrator is fully responsible for adopting this functionality to the actual application. Module Description TemplateMachine.sys...
Page 284 DOOR_OPENED, PREPICK_OK, LOAD_SUB_OK, LOAD_MAIN_OK, UNLOAD_SUB_OK, UNLOAD_MAIN_OK, HOME_POSITION_OK, MAIN_CHUCK_OPENED, MAIN_CHUCK_CLOSED, SUB_CHUCK_OPENED, SUB_CHUCK_CLOSED • Examples for predefined machine actions: CLOSE_CHUCK_MAIN, CLOSE_CHUCK_SUB, CLOSE_DOOR, OPEN_CHUCK_MAIN, OPEN_CHUCK_SUB, OPEN_DOOR, Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 285 B.7 FlexLoader machine tool interface functionality Continued PREPARE_LOAD_MAIN, PREPARE_LOAD_SUB, PREPARE_UNLOAD_MAIN, PREPARE_UNLOAD_SUB, CYCLE_START, INIT_MACHINE, STOP_MACHINE There are further predefined values in GlobalCodeAndConfig.sys that can be implemented in TemplateMachine.sys. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B © Copyright 2014-2018 ABB. All rights reserved.
Page 288 Robotics and Motion No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2014-2018 ABB. All rights reserved.

ABB FlexLoader Vision Product Manual

1 Quick Start

2 What Is Flexloader Vision

3 Overview of the User Interface

4 Teachin

5 Advanced Teachin Settings

6 Operation

7 Camera

8 Settings

9 Troubleshooting

10 Installation

11 Commissioning

12 Maintenance

13 Robot Integration

14 Flexloader Vision Lite

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