ABB FlexLoader Vision, Product Manual

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 3: ...Product manual FlexLoader Vision R18 1 Document ID 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved ...

Page 4: ...BB for losses damages to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from AB...

Page 5: ...hin settings 63 5 1 Advanced image settings 67 5 2 Advanced position settings 68 5 3 Advanced parameter settings 68 5 3 1 Standard analysis 74 5 3 2 Blob analysis 76 5 3 3 3D analysis 78 5 3 4 AddOn analysis 82 5 4 Advanced grip settings 87 5 5 Advanced supervision settings 89 6 Operation 89 6 1 Introduction 90 6 2 Starting the system 91 6 3 Stopping the system 92 6 4 Operation information 94 6 5 ...

Page 6: ...al maintenance 171 12 2 Backup and recovery of the hard disk 179 12 3 Upgrading FlexLoader Vision 181 13 Robot integration 181 13 1 Introduction 182 13 2 Calibrating the robot 190 13 3 RAPID program 190 13 3 1 Overview 191 13 3 2 FlexLoader application functionality 198 13 3 3 FlexLoader Vision interface 199 13 3 4 FlexLoader Vision Lite functionality 201 13 3 5 FlexLoader assistance and utility f...

Page 7: ...4 Manually restoring a backup 257 B FlexLoader RAPID reference 257 B 1 FlexLoader data type prefix 258 B 2 FlexLoader Vision interface 264 B 3 FlexLoader application functionality 272 B 4 FlexLoader Vision Lite functionality 275 B 5 FlexLoader conveyor system control 276 B 6 FlexLoader assistance and utility functionality 283 B 7 FlexLoader machine tool interface functionality Product manual FlexL...

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Page 9: ...nd troubleshoot FlexLoader Vision Here you can also find technical information and information on communication configuration backup and recovery and how to set up the configuration editor of FlexLoader Vision Chapter 13 describes the interaction of FlexLoader Vision with the robot and the RAPID program structure Chapter 14 describes how to use and configure the simplified version of FlexLoader Vi...

Page 10: ...der Vision The programming manual of the robot used together with FlexLoader Vision The product manual of the camera s used together with FlexLoader Vision The integration manual of the camera s used together with FlexLoader Vision Revisions Description Revision First edition A Complete revision with content and illustration update B 10 Product manual FlexLoader Vision 3HAC051771 001 Revision B Co...

Page 11: ...f firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB Ltd and its entities are not liable for damages and or losses related to such security breaches a...

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Page 13: ...tures 4 See Camera on page 97 If necessary copy and load all necessary RAPID code on the robot 5 See Robot installation on page 165 Calibrate all camera work objects 6 See Calibration on page 98 Calibration on page 103 and Calibrating the robot on page 182 Use a simple detail and perform a basic teachin 7 See Teachin on page 21 Adjust the robot program to fit the needs of the robot cell 8 See RAPI...

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Page 15: ...ion from the picking area and guides the robot with precision in the robot cell The FlexLoader Vision can handle an unlimited number of workpieces in various sizes and with complex geometries without any need for mechanical fixtures thus reducing costs and complexity The FlexLoader Vision is open to communicate with a variety of camera sensors It can be used for both 2D and semi oriented 3D applic...

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Page 17: ...n on the current operation Operation Used to teach the system how to handle details Teachin Used to perform the detail teachin in FlexLoader Vision Lite option Note that the Lite tab is not available in the standard edition Lite Used to calibrate the system and make camera related settings Camera Used to configure service and maintain the system Settings Product manual FlexLoader Vision 17 3HAC051...

Page 18: ...ip Used to draw Click the mouse button to draw a point at the current mouse position Release the mouse button to stop drawing To change the drawing size adjust the slider as required Draw Used to delete objects Click the mouse button to delete the drawing at the current position Release the mouse button to stop deleting To change the delete size adjust the slider as required Clear Used to draw lin...

Page 19: ...f the window in the menu bar It is always the most recent alarm that is displayed xx1800000204 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 19 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 3 Overview of the user interface 3 3 Alarm ...

Page 20: ...reen It contains information about the current version of software license information and contact information for service and support xx1800000206 20 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 3 Overview of the user interface 3 4 System information ...

Page 21: ... divided into a number of stages that you will find on different tabs in the 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 For information on the advanced settings on each tab see Advanced teachin settings on pa...

Page 22: ...n also get extra help during the teachin process If you click the Wizard button help text will guide you through the teachin process step by step in a preset order In Classic mode the help text is not shown and you can move freely between the different tabs in the teachin process 22 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 4 Teachin 4 2...

Page 23: ... database The database is divided into various groups 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 23 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 4 Teachin 4 3 Detail ...

Page 24: ... see a box headed Select Camera This is where you choose which camera to use in the teachin process This box will not appear if there is only one camera connected to the system Selecting analysis type 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...

Page 25: ...To copy a detail select the detail in the database pane and click Copy Enter a new name for the detail The detail will be placed in the same group as the original detail 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 25 3HAC051771 001 Revisio...

Page 26: ...e Blob settings To obtain the search image for so called blobs details that may sometimes within specified ranges vary in shape the image is divided into zones that are considered detail marked as black and zones where the background can be seen white To activate blob image display select Show blob image Selecting Allow boundary details makes it possible to pick details even if they are touching t...

Page 27: ...irregular outer contours are slightly smoothed out There are occurrences where some details are placed on top of each other and are considered as one big blob It might be desirable to split these large blobs for further analysis To do so select Separate blobs and set a threshold value for this Preferably add a number of details with varying overlaps under the camera The threshold must be set so th...

Page 28: ...new pictures the whole time Therefore the 3D images are not automatically updated Use the New image button or short cut Ctrl Shift to take a new image The 3D camera does not need settings for brightness contrast and gain like the 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 obje...

Page 29: ... thereby layered from above and down for best possible search results The stated Seek depth percentage of the analysis depth represents the first search level for FlexLoader Vision If no detail is found on the first search level the next level is added and a new analysis carried out This is repeated until a detail has been identified or the whole analysis depth has been analyzed Note that the numb...

Page 30: ...n starts interlayer detection by fitting a plane to all data points within the specified height of the search volume see camera settings After fitting the plane a check is performed if anything is still present on top of the plane i e the interlayer This parameter specifies the height at which FlexLoader Vision is to search for remaining objects Its value must be less than the height of the parts ...

Page 31: ...ch 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 If the highest point is below the minimum z value in the camera settings see Image size on page 105 the robot is informed to change the pallet Else the robot is informed that no details were found Product manual FlexLoader Vision 31 3HAC0517...

Page 32: ...e defined by drawing a red box around the detail in the field of view that corresponds to the position This is done using the Define position tool Note that a position will be identified even if it is lying in a different angle rotated than it was at teachin xx1800000212 The next position is defined by clicking on New position again and drawing a box around the detail with the mirrored text Contin...

Page 33: ...along the shaft of the screwdriver and could result in incorrect positioning when the detail is gripped or handled It is often best to define a box around the entire position However you should avoid drawing a box that is larger than necessary around the detail The information that exists outside the detail could affect the analysis results in a way that makes it more difficult to set the paramete...

Page 34: ...s where the shape of the detail blob may vary within certain specified ranges To identify a position the system searches for edges in the image The edges found are marked with red lines on the image All the edges that are found are then joined together to form a geometric model that is compared with the teachin geometric model Before adjusting the search settings you need to understand how the sea...

Page 35: ... not match the teachin position in other words extra edges Found edges that do not match those in the teachin position will reduce the score target The image below shows an example in which extra edges have been identified in the found position to the right E In this case the Score target value is reduced to 85 However the Score value for both found positions is 100 because the found positions sti...

Page 36: ...ge below with no masking there are extra edges in the found target to the right E These extra edges have a negative effect on the Score target and in this case the result is 85 xx1800001033 Description Pos Teachin position A Found positions B Position 1 C Position 1 Score 100 Score target 100 D Position 1 Score 100 Score target 85 E Figure 4 3 No masking In the image below parts of the teachin pos...

Page 37: ... 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 xx1800000215 Continues on next page Product manual FlexLoader Vision 37 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 4 Teachin 4 ...

Page 38: ...ation and compactness The analyses of all properties except area can be deselected For all properties an upper Area max deviation and lower Area min deviation limit is specified as a percentage The property requirements for the two positions must be completely different in at least one aspect otherwise a warning is displayed to the user In many cases it is sufficient to specify the area settings t...

Page 39: ...ed The following image shows the difference in elongation for a blob with the same area xx1800000301 Elongation Area Pos 1 1 A 4 1 B 16 1 C Compactness The value of compactness is a measurement of how close all parts of a blob are to each other A circular shaped blob is the most compact with a value of compactness of 1 0 The more the shape deviates from a circle the greater the value of compactnes...

Page 40: ...tablish 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 To avoid problems the height region should be drawn on a surface that lies in the same plane Note that the height region should not be drawn up to the edge of the detail because then the blue area might end up outside of the detail if t...

Page 41: ...e compensated for with the gripper settings on the Grip tab xx1800000304 Description Pos Height region A Located height B Product manual FlexLoader Vision 41 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 4 Teachin 4 6 Parameters Continued ...

Page 42: ...lustration of the tool type The red dot represents the tool center point TCP The dimensions can be set in steps of different sizes Select step size by right clicking with the mouse to bring up the following menu xx1800000305 This lets you choose the size of the adjustment to be made The currently selected step size is marked with a tick to the left If none of the predefined tools are suitable you ...

Page 43: ...a gripper with two gripping fingers and offset tool center point TCP The indicated dimensions are with the fingers open Suction cup xx1800001037 Corresponds to a tool with a single suction cup and the tool center point TCP in the center of the suction cup 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 Cont...

Page 44: ...r suction cups and with the tool center point TCP located between the two upper suction cups All suction cups are the same size Note that when the four suction cups are used tool supervision is not active This is because the suction cups must always be positioned on the detail Single sided gripper xx1800001040 Corresponds to a gripper with a single gripping finger and the tool center point TCP off...

Page 45: ...e adapters on the robot arm 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 45 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 4 Teachin 4 7 Tools Continued ...

Page 46: ...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 46 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 4 Teachin 4 7 Tools Continued ...

Page 47: ...represents the tool center point TCP Use the drawing tools to draw the desired tool The entire tool should be marked in red see the example in the image above When you have finished drawing the tool click Save to exit the drawing function If you want to modify a tool you have defined previously select the tool and click Edit When the tool has been modified you can either save the tool by clicking ...

Page 48: ...p size by right clicking with the mouse to bring up the following menu xx1800000306 At teachin you should try to position the detail so that the grip point is located in the center of the image This is particularly important for details with high edges or large grip height If the center of perspective the point in the field of view where the camera is looking vertically down on the conveyor does n...

Page 49: ... illustrated graphically in the image When you adjust rotation x and rotation y you have to do a gripping test to see how the setting works in reality Note that the gripper rotation during blob searches is not unequivocally determined but can be rotated 180 degrees Height settings The edge height must be specified for each position The edge height is the difference in height between the visible ed...

Page 50: ...ed in the same way as for 2D However there are some setting differences as follows Note that the perspective concerns do not exist when the 3D camera is used so there are no problems with this when the grip point is positioned Rotation Z sets the robot tool rotation around z alignment of the detail There is a direct connection with the image of how the grip device rotates just like with the 2D cam...

Page 51: ...he grip device goes below the located detail height at the picking position The depth is measured positively from the located detail height and down 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 51 3HAC051771 001 Revision B Copyright 2014 2018 ABB...

Page 52: ...ively from the located detail height and down This value is used to determine what grip height is to be sent to the robot xx1800000308 Description Pos Tool center point A Grip depth B Intrusion depth C Positioning height D 52 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 4 Teachin 4 8 Grip Continued ...

Page 53: ...d collisions could occur during picking Image supervision In Image supervision data from the entire camera image is used to provide information about the collision risk image The image is built up of zones where there is a collision risk marked in black and zones where there is no risk of collision white To activate image supervision select Image supervision Then adjust the Threshold value so that...

Page 54: ...rked Click Edit in the Supervision area pane to open an image of the teachin detail and mark all parts of the detail that may cause a collision in red for each position This information is used during operation Even the parts of the position that are not visible are included in the collision sensing xx1800000225 Avoid nearby details When Detail supervision is enabled a further advanced setting can...

Page 55: ... cameras are similar to the 2D camera settings apart from the following details Image and detail supervision The image supervision settings are always used when the 3D camera is run and are adjusted automatically The detail supervision works in exactly the same way with a 3D camera as with a 2D camera Note that the drawn red area is always placed at the height where the detail has been identified ...

Page 56: ... robot to start with the program that is currently loaded in the robot select Run with currently loaded program To specify a program enter the path to the program manually in the Robot program name field or click Browse to browse for the program in the file manager In the file manager the HOME file system of the robot is shown together with available folders and files Select the program to be used...

Page 57: ...ible 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 xx1800000227 Continues on next page Product manual FlexLoader Vision 57 3HAC051771 001 Revision B Copyright 2014 2018 ABB All righ...

Page 58: ...ou 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 xx1800000226 Continues on next page 58 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 4 Teachin 4 10 Mechanics Continued ...

Page 59: ...r to the product manual for the user defined equipment for more information User defined settings can also be used to transfer parameters to robot variables This can with advantage be used when working with parametrized robot programs xx1800000228 For more information see Configuration of user defined mechanical equipment on page 159 Product manual FlexLoader Vision 59 3HAC051771 001 Revision B Co...

Page 60: ...era and click Test The identified positions and associated grip positions will be shown in the image xx1800000229 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 60 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights res...

Page 61: ...ab appears again If the Blob analysis type optional setting is selected for the detail the properties of the found blobs are shown in percent in relation to the teachin position 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 T...

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Page 63: ...prevent the details from moving after the images are taken xx1800000231 Filtering With the advanced image settings you can radically change the appearance of an image by adding one or more filters before the image is analyzed further This can be especially useful in cases where the image is very uniform or the detail is not clearly defined against the background etc Up to three filter steps can be...

Page 64: ... area along the entire edge Erode Increases the size of the light areas by adding a small area along the entire edge Dilate A specialized filter that simplifies the identification of details in several cases BlockPickedParts If the coordinates of a detail are sent to the robot a circle with the specified parameter will be drawn in the subsequent images at the location where the detail is identifie...

Page 65: ...maximum number of images the images will be analyzed regardless of whether any movement has been detected or not No images evaluation Specifies the number of images that should be compared Every picture is compared to all other pictures Color settings If a color camera is used the Color separation pane is displayed Here you can determine how to combine the three colors applied to the black and whi...

Page 66: ...ision to automatically determine the upper and lower limits thresholds or by specifying certain values xx1800000232 66 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 5 Advanced teachin settings 5 1 Advanced image settings Continued ...

Page 67: ...etting to High The slider can also be used to make further adjustments to edge detection Very high should normally only be used in exceptional cases and then only on images with very low contrast If this parameter is set to Very high it can make edge detection less reliable and extremely sensitive to lighting or the presence of dirt The effect of changing the settings is updated continuously in th...

Page 68: ...ositions that are to be found Searching for all the positions available takes more time than just searching for one Searching for just one detail is faster but could on the other hand result in finding a detail that cannot be gripped A suitable starting value is 6 If the search takes too long this is one of the parameters you could adjust To send The To send value if available specifies how many r...

Page 69: ...t on the accuracy and a higher accuracy will have a negative effect on the speed The speed and accuracy settings should therefore be balanced against each other and adapted to suit the current application Setting both the speed and accuracy settings to High will have the same result as setting them both to Medium To achieve a longer cycle time the accuracy can be increased and the speed decreased ...

Page 70: ... a score of 85 for instance it will continue searching for a better match until all other possibilities have been ruled out or until it reaches timeout To speed up the identification further use the Certainty setting The Certainty parameter is used to end the search process as soon as a position that meets the certainty setting is found Score target The Acceptance value specifies the minimum value...

Page 71: ...value Max Rotation Z The Max Rotation Z parameter can be used to restrict the system to search for a position within a given range of angles xx1800001046 Description Pos Positive A Negative B Reference C Zero degrees corresponds to the angle of the detail during teachin By changing the reference point and or the positive and negative directions you can control the permitted range of angles for ide...

Page 72: ...tions Settings pane interacts with the Total number parameter in the Detail Settings pane If the Total number set for a detail is lower than the Occurences to find value that is set for positions the maximum number that can be found will be decided by the Total number parameter for the detail If a detail teachin has two positions specified each of which can have four occurrences and the Total numb...

Page 73: ...than the specified scale value or if the Disable checkbox has been selected both occurrences are found Two occurrences of details that have the same position and size but differ in angle If the differ ence is bigger than the specified angle value or if the Disable checkbox has been selected both occurrences are found Two occurrences of details that have the same angle and size but differ in the x ...

Page 74: ...ick this setting to set the permitted deviations for perimeter Use elongation Use elongation must be selected if the elongation 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 elongation Use compactness Use compactness must be selected if the compactness is to be included in the properties that are analyz...

Page 75: ...is noise results in a large number of edges being found even in areas where there are no details Processing all these edges can take relatively long With the Timeout parameter the maximum search time can be limited so that the identification time does not affect the robot cycle time If no timeout is set at all the search could take several minutes in the worst case Position Settings The following ...

Page 76: ...the detail Lock Y angle Locks the rotation around the y axis to 0 degrees However the additional rotation stated on the Grip tab will be added even if you select this box This means that the robot will always pick with the same rotation around y that is stated on the Grip tab Note that this concerns the y axis for the detail Control values Max Rotation X Specifies the maximum rotation around the x...

Page 77: ...y axis together with the additional rotation that is specified on the Grip tab exceeds the maximum rotation the detail will be marked as unpickable Product manual FlexLoader Vision 77 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 5 Advanced teachin settings 5 3 3 3D analysis Continued ...

Page 78: ...vate analysis type You can activate as many analyses as you would like If the conditions for any of the activated AddOn analyses are not met for a found detail the detail will not be picked by the robot Different parameters can be specified for each analysis type In addition to this you can specify the area in which the AddOn analyses are to be performed by drawing a red rectangle on the position ...

Page 79: ...nsity above 80 If more than 40 of the pixels in the red box meet the conditions the analysis is approved EdgeCheck The analysis type EdgeCheck if enabled is used to ensure that the selected parts of the detail position consist of a certain amount of edges i e visible structures This could be used for example to check for holes embossing or large defects on a flat surface xx1800000238 Description P...

Page 80: ... its center position First the length of the object is measured by locating the end points according to the operator settings Next the center position of the found detail is adjusted to the center of the detail regardless of where it was initially found In the red box the original center position is drawn with a dash in the center The found end points are drawn with circles around a dash that mark...

Page 81: ...il correctly lon gitudinally Indicates the minimum brightness change that is re quired to assume there is an edge Min contrast Indicates whether the background is darker than the detail 0 or lighter than the detail 1 Black 0 White 1 Indicates the expected length of the detail in mm Expected length mm Indicates by how much the length of the detail may deviate up or down to still be approved Allowed...

Page 82: ...some cases however it may be preferable to let the robot pick from a certain direction or in a certain way first With the sorting settings you can control how the coordinates are sorted and sent 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 82 Product manual FlexLoader Vision 3H...

Page 83: ...ntification match are sent first 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 83 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 5 Advanced teachin settings 5 4 Advanced grip settings Continued ...

Page 84: ...12 Direction Down Up The coordinates of the position at the bottom of the field of view are sent first xx1800000313 Continues on next page 84 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 5 Advanced teachin settings 5 4 Advanced grip settings Continued ...

Page 85: ...0314 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 85 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 5 Advanced teachin settings 5 4 Advanced grip settings Continued ...

Page 86: ... prevent the robot from gripping or handling details when they are lying in certain positions and or angles This is done by specifying gripping limitations for the detail Before you can activate the gripping limitations they must be defined in the system For more information on this see Gripping Limitations on page 114 When this is done you can select the limitations that you want to apply to the ...

Page 87: ...he default setting for collision detection is to fill the inner holes of details However in some cases this can give an inaccurate image of the detail xx1800001054 Description Pos Teachin detail A Inner holes filled B Inner holes not filled C Continues on next page Product manual FlexLoader Vision 87 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 5 Advanced teachin settings ...

Page 88: ...for positioning of the gripper outside the edges of the image These tolerances can be activated on the chosen edges To do so select the concerned Tolerate outside boxes and enter the required tolerance dimensions The designations of the edges right left upper lower refer to the camera image that is seen on the screen Allowed overlap If Allowed overlap is activated the gripper is allowed to collide...

Page 89: ...800000242 The drop down lists are now provided for the group and detail for each camera 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 89 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 6 Operation 6 1 Introduction ...

Page 90: ...n auto mode put the robot in auto mode and click OK 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 We recommend to start the system at least once with the robot in auto mode in order to load all mod...

Page 91: ...n turn will stop everything as usual as described above In case the user clicks Stop in FlexLoader Vision again while FlexLoader Vision is awaiting the call to StopFlexLoader Vision FlexLoader Vision will enforce a stop This means that FlexLoader Vision will no longer be waiting for the robot but will instead stop as usual as in the case where FlexLoader Vision is configured to control the robot s...

Page 92: ...Description Meaning Letter The detail does not meet the set requirements for minimum position coverage Coverage C The detail lies within an active limitation Limitation L The detail lies too close to a previously picked detail Proximity P A tool collision would occur if the detail were to be picked Tool T Collision risk images are drawn with green contours Displayed to the right of the image are t...

Page 93: ...os 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 It has been identified with a 98 9 score certainty and a 99 74 score target certainty Product manual FlexLoader Vision 93 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 6 Operation 6 4 Operation information Continued ...

Page 94: ...e 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 Continues on next page 94 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 6 Operation 6 5 Smartphone connection ...

Page 95: ...ader 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 95 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 6 Operation 6 5 Smartphone connection Continued ...

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Page 97: ...brightness and Focus a higher value usually corresponds to a better focus is enlarged These two values help setting up the cameras for servicing and maintenance Color settings If a color camera is used the Color separation pane is displayed Here you can determine how to combine the three colors applied to the black and white image that FlexLoader Vision is to analyze This function can be used to e...

Page 98: ...he 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 The following information describes how to calibrate FlexLoader Vision For information about how to calibrate the robot see the separate robot product manual ...

Page 99: ... plate so that no partial dots are seen the partially visible row must be covered 4 Under Camera Settings adjust Brightness Contrast and Gain to create as sharp a contrast as possible between the dots and the background 5 Adjust the number of columns vertical under No of columns and the number of rows horizontal under No of rows Click Suggest if you want the system to display suggested values for ...

Page 100: ...tion plate Select the define position tool and draw a red rectangle around the valid calibration dots Then perform the calibration as described above Settings General Settings xx1800000248 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 100 Product manual FlexLoade...

Page 101: ...rtically down on to the conveyor must be specified in order for the automated correction to work There are three ways of finding the perspective center Place a mirror on the conveyor underneath the camera Look for the camera lens in the image a dark round spot Right click on the image and select Show cursor position followed by Position in pixels Point at the middle of the camera lens spot and not...

Page 102: ...e and select Show cursor position followed by Position in pixels Move the cursor to the lightest point read the coordinates and enter them Normalization steepness is set between 0 and 10 This value is used to adjust the correction at the edges of the image A low value results in a correction that decreases towards the center of image A high value results in a stronger correction at the edges but h...

Page 103: ...ibration For more information on this see Calibrating for use with a 3D camera on page 188 All positions should lie in wCamera1 the 3D camera is camera 1 and be within the robot s range and the camera s measurement range The calibration cone should point directly upwards at each point If the camera is inclined in relation to wCamera1 inclined cone positions should be considered FlexLoader Vision n...

Page 104: ...ne the information on calibration quality is displayed The operator can choose to accept the new calibration or revert to the previous one Note that the image size needs to be adjusted to fit the new calibration In some cases a temporary manual adjustment of the characteristics of the 3D camera is required in order to perform a calibration Click Advanced on the Calibration tab and adjust the image...

Page 105: ... that the measurement volume is slightly larger in the x and y axis than the actual pick volume For a pallet it is important for example that the whole pallet collar is always visible in the image When operating without interlayers the lowest height value Z min should be specified so that the floor or bottom of the pallet is not shown in the image The FlexLoader Vision image must always contain en...

Page 106: ...h downwards until the detail is located or as far down as is set by the detail analysis depth When searching for the highest point the pallet collar must not be included Therefore there is a region of interest which specifies within which area FlexLoader Vision is to search Note that the details that are outside the region of interest will not be included in the search for the highest point The re...

Page 107: ...erent systems Select the desired detail or group and click Export Choose a location for the file and click OK This saves all data associated with that detail to a file This can be very useful when you have several identical systems or if you want to carry out the teachin process on another computer Note If the exported detail is to be used on another system the camera geometry and settings on that...

Page 108: ...useful when you have several systems with identical tools Note If the exported tool is to be used on another system the camera geometry and settings on that system i e the camera height camera lens and aperture setting must be the same as on the old system Import Click Import to import tools that have been exported from another system Select the exported file and click OK The details are imported ...

Page 109: ...d 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 Continues on next page Product manual FlexLoader Vision 109 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 8 Settin...

Page 110: ...ow follows an example of what the interface may look like For more information refer to the product manual of the user defined equipment xx1800000257 For more information see Configuration of user defined mechanical equipment on page 159 110 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 8 Settings 8 2 Mechanics Continued ...

Page 111: ...not be restored automatically you can restore the system manually For more information on how to do a manual restore see Manually restoring a backup on page 256 Note Additional backup data may be created for 3D cameras in a separate folder e g Camera_1_CirrusBackup These files have to be manually copied to the sensor if needed To schedule a backup procedure click Schedule Select which day s and wh...

Page 112: ...em is password protected on the Intermediate level you must enter a password to view the Teachin menu If the system is password protected on the Expert level you must enter a password to view the Settings and Calibration tabs on the Camera menu and the complete Settings menu To set a password for one of the levels select the desired level and click Set Leave the Old password field blank and then e...

Page 113: ...ta Here you can change the IP address for the robot You can also enter data for the robots user authentication system that is used for connecting to the robot 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 Click Shutdown to turn the comp...

Page 114: ... lying at certain angles The gripping limitations can be used to define an unlimited number of limitations for the system These limitations can be applied during the teachin process of a detail xx1800000251 The list to the right in the image above shows the limitations that are currently defined for the system Continues on next page 114 Product manual FlexLoader Vision 3HAC051771 001 Revision B Co...

Page 115: ...utton can be used to change the name of a limitation To remove a limitation click Delete Note that if you delete a defined limitation that has been enabled for one or more details it will cease to apply to all those details You will still be able to run the detail in the system but without the deleted limitation If a defined limitation has been enabled for one or more details you will be asked for...

Page 116: ...limitation area is named this way the Limitation angle settings pane is enabled The circle parameter determines if the area is rectangular Circle 0 or rounded Circle 1 The outside parameter determines if the area is drawn inside the region Outside 0 or outside the region Outside 1 Select Use for all details if you want to enable the setting for all details xx1800000965 FuzzyRegion To replace the g...

Page 117: ...y times bright objects are finally dilated 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 117 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 8 Settings 8 4 Gripping Limitations Continued ...

Page 118: ...municates using one of the robot s I O units for example through a Profibus Slave card with Master equipment The SlaveThroughRobot settings are used to set the translation between the ID number and the FlexLoader Vision detail The Master equipment can choose one of the teachin details for operation according to a translation table that links the ID number of the Master equipment to a group and a d...

Page 119: ...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 xx1800000259 To set the communication settings for PLC click the Settings button Enter the IP address for the PLC and click OK To communicate with the Master control system the PLC memory addresses must be entered for each command and associated confirmation signal ...

Page 120: ...communication This form of master slave communication is used for operation with the Barcode handler the Master handler and the Batch handler xx1800000258 120 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 8 Settings 8 5 Master Slave Continued ...

Page 121: ... parameter settings especially Score Score target Speed Timeout and Accuracy 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 c...

Page 122: ...es the specified value If not change the value so that it corresponds with the reality Check that the robot s coordinate system by the camera is correct This is done by using the robot and jogging to a point on or just above the belt Then the z value specified in the coordinate system for the camera should be 0 or close to 0 xx1800000323 Description Pos TCP A Calibration plate B Camera belt C Chec...

Page 123: ...y to grip these details If this leads to positioning faults it may indicate that the camera position needs to be adjusted according to the above or that the set camera height or machine height is incorrect xx1800000324 Product manual FlexLoader Vision 123 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 9 Troubleshooting 9 1 Problems with gripping accuracy Continued ...

Page 124: ... light a matt black disc or similar can be placed temporarily underneath the camera and a new teachin carried out If this works the problem can be solved by changing to a dark conveyor Note that the operation of previous teachin details may be affected by the new conveyor color FlexLoader Vision identifies an incorrect position Redefine the masked surface Try to find an identification surface of t...

Page 125: ...t can be reached via the network Run ping 192 168 125 1 adjust the IP address to the relevant system settings in a command window If the robot does not respond check the network wiring switch and the network settings of the robot Check that the robot has all necessary options and hardware installed to communicate via the network Check that Windows firewall is configured correctly Messages about mi...

Page 126: ...tch and the network settings of the camera The camera image is far too light or too dark Check the lighting Go to the image settings and check the settings for contrast brightness and gain 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 126 Product manual FlexLoader Vision 3HAC051771 001 Revi...

Page 127: ...on is shown in the following picture xx1800002002 For detailed information about the PC please refer to the manufacturers manual It is located in the FlexLoader Vision documentation folder on the PC Electrical installation WARNING Be sure to turn off the power to the unit and all peripherals as well as unplug the power from the unit before adding or removing devices or cameras Connect other periph...

Page 128: ...y and protective earth to it according to the designation shown on the PC Use the screws on the power connector latch to secure it into place in the power connector xx1800002004 Description Pos Power connector A Power connector latch B Screws C 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 128 P...

Page 129: ...network settings on page153 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 129 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 10 Installation 10 1 PC installation Contin...

Page 130: ...y oriented aiming downward or forward Camera dimensions with screw location information is shown in the following picture xx1800002001 Continues on next page 130 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 10 Installation 10 2 Basler camera mechanical and electrical installation ...

Page 131: ...he camera to the PoE1 network port of the PC with a network cable cat6 We recommend the use of shielded network cables The power to the camera is Continues on next page Product manual FlexLoader Vision 131 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 10 Installation 10 2 Basler camera mechanical and electrical installation Continued ...

Page 132: ...able connection D 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 132 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 10 Installation 10 2 Basler camera mechanical and electrical installation Continued ...

Page 133: ...ormation 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 133 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 10 Installation 10 2 Basler camera mechanical and electrical installation Continued ...

Page 134: ...x1800002007 Connect the camera to the PoE1 network port of the PC with a network cable cat6 We recommend the use of shielded network cables We recommend a stabilized power supply with 24 VDC 10 A Prepare the Power I O cable according to the following table Designation Wire color 0 V Blue 0 V Brown Green 24 VDC White Green 24 VDC White Continues on next page 134 Product manual FlexLoader Vision 3HA...

Page 135: ...e connector optional C VGA cable connector optional D If necessary an optional VGA display and USB mouse keyboard can be connected to the camera Continues on next page Product manual FlexLoader Vision 135 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 10 Installation 10 3 VisioNerf 3D camera mechanical and electrical installation Continued ...

Page 136: ...rus family Tip Pallets shall be preferably placed as close as possible to the sensor without violating the minimum stand off distance 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 136 Product manual FlexLoader Vision 3HAC0...

Page 137: ...red upon delivery Only trained and experienced users should do changes to the FlexLoader Vision configuration Errors in the configuration can result in malfunctioning of the system Note Some configuration features are used for testing and maintenance and are not to be used for production systems Other features are used for handling of legacy functionality and should be avoided in new production sy...

Page 138: ...e use of FlexLoader Vision Lite features General teachin is not accessible FlexLoader Vision Lite No Enables the use of FlexLoader Vision Lite features General teachin features are access ible as well FlexLoader Vision Lite Full Access No Normally only one coordinate is sent to the robot This flag enables sending of several coordinates to the robot see Advanced parameter settings on page 68 Allow ...

Page 139: ...ugh robot No FlexLoader Vision can be controlled by a TCP IP based application Slave through TCP IP No FlexLoader Vision can be controlled by the PLC Slave through PLC Default Description Camera settings 1 Select the correct number of cameras Click on the number associated to the camera to configure it Number of cameras Default Description Alarm and logging settings All Selectable level of severit...

Page 140: ...ce No Used for system testing Basler Pylon GigE USB No Used for 3D camera communication DllCamera3D GigE_Current State dcf Configuration file used for Matrox GigE and DllCamera3D Configuration file Default Description Camera settings No Enables the use of color extraction and combination Enable color mode Only possible with Matrox GigE Ace interface Continues on next page 140 Product manual FlexLo...

Page 141: ...ong term stability by teaching a fixed object within the field of view of the camera No Normally the gripper is drawn at a height location that corresponds to the mask height setting during teachin Display tool with perspective correction Activate this setting if the gripper is to be drawn at a different height location corres ponding to the actual grip height The teachin for all details has to be...

Page 142: ...s and one or more Cirrus 3D configured as DllCamera3D can be shared to several Cirrus 3D 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 142 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Comm...

Page 143: ...s Communication information is used during system initialization and operation Default Description Mechanical settings Yes No data is exchanged with external PLC and no information is shown on HMI None PLC No Selects FP 300 specific settings for this camera FP 300 No Selects FP 400 specific settings for this camera FP 400 No Selects user defined specific settings for this camera UserDefined No Can...

Page 144: ...ress and feeder specific options xx1800000440 Figure 11 3 Available settings for FP 400 Continues on next page 144 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Commissioning 11 1 3 Camera settings Continued ...

Page 145: ...settings for FP 300 xx1800000442 Figure 11 5 Available settings for extra tipper Product manual FlexLoader Vision 145 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Commissioning 11 1 3 Camera settings Continued ...

Page 146: ...gle of the located details rotation in x y plane will be offset by this value Offset angle XY ABB produc tion system The production systems work with the ABB robot The DllRobot type is only used during system tests Robot Type 192 168 2 2 Enter the robot IP address Click Scan to detect an available robot system IP Address No System signals are used for starting the ro bot Can be useful in multitask...

Page 147: ...nished the image ac quisition process Useful in applications with secondary camera checks and demands on short cycle times Use DOF_ImageTakenCamX No Used when setting camera gain exposure time and contrast Absolute values from robot If not checked these values are sent as per centage 1 100 If checked the values are sent as shown on the corresponding sliders on the user inter face 1 255 No Allows t...

Page 148: ...xx1800000446 148 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Commissioning 11 1 4 Robot settings Continued ...

Page 149: ...ted User name for data reporting User name Do not change if not instructed Password for data reporting Password Do not change if not instructed URL for data reporting Service URL 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 149 3H...

Page 150: ...ce the risk of unauthorized access to important system parameters Follow ABB s advice for administration of user permissions Note Please refer to the section on cyber security in the robot Integrator s guide for additional information FlexLoader Vision Normally the FlexLoader Vision system has two default user accounts For operation Password User name FlexLoaderVision FlexLoaderVision Continues on...

Page 151: ...ials according to ABB default settings Password User name robotics Default User Follow ABB s advice for administration of user permissions Product manual FlexLoader Vision 151 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Commissioning 11 2 User accounts Continued ...

Page 152: ...ities 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 Several utilities for viewing documentation editing configuration files and enabling remote access Please ref...

Page 153: ...rnal network The PC network connection is named GigE on physical port PoE1 The following standard settings are used Gateway IP address Equipment Do not specify gateway 192 168 2 1 PC Do not specify gateway 192 168 2 2 Camera 1 Do not specify gateway 192 168 2 3 Camera 2 Do not specify gateway 192 168 2 4 Camera 3 Do not specify gateway 192 168 2 5 Camera 4 Note If no factory network is used the Po...

Page 154: ...must be entered 1 Connect the camera to the computer Start Pylon IP Configuration Tool and check that a connected camera can be seen Select the camera xx1800000966 2 Select the radio buttons in the IP Configuration Protocol pane according to the image below Specify the correct Device User ID Camera1 Camera2 Camera3 Camera4 for the respective camera and the correct data in the Static IP address pan...

Page 155: ...ply xx1800000967 General information about camera settings 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 155 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Commissioning 11 3 2 Settings Continued ...

Page 156: ...pecify User Set 1 as Default Startup Set After making the desired changes to the configuration the changes must be saved to the camera memory This keeps the settings safe in the event of a power cut 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 ...

Page 157: ...r 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 Product manual FlexLoader Vision 157 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Commissioning 11 3 2 Settings Con...

Page 158: ...d for FLexLoader Vision is required Contact ABB for licensing on existing previous installations Licensing Matrox Imaging Library Licensing for Matrox Imaging Library is done through Matrox hardware Normally no USB dongle or license code is needed Contact ABB for licensing on non Matrox hardware 158 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reser...

Page 159: ...ic parameters The following parameter areas can be configured xx1800000983 General data designation in FlexLoader Vision interface among other things Up to 32 parameters that can be sent to PLC at each start up Up to 64 error messages that are connected to PLC Up to 16 user defined inputs Up to 16 user defined outputs Up to 8 memory cells that can be used for manual control of the equipment A star...

Page 160: ...emory PLC Address Specifies the size of the variable and how the sent value is to be inter preted 0 integer as byte 1 integer as word 2 integer as double word 3 1 10 value as word 4 1 10 value as double word 5 1 10 value as byte 6 1 100 value as word 7 1 100 value as double word 8 1 100 value as byte 9 numerical value sent to robot variable 10 float value as float 4 bytes in PLC 11 0 1 value sent ...

Page 161: ...cription 9 Other bytes in the PLC word memory start at ErrorDescription 1 Description Parameter Enter memory location for error messages 1 16 Enter 0 if this ad dress is not to be used AddressErrorWord1 As above but for error messages 17 32 33 48 49 64 AddressError Word2 3 4 Text that is shown if corresponding bit in corresponding AddressEr rorWord is 1 ErrorDescriptionX xx1800000985 Continues on ...

Page 162: ...ies in PLC 2 DataType xx1800000987 User defined outputs PLC outputs that are to be shown for the user are defined here There are up to 16 user defined outputs which can be freely defined These are used to show the status of the equipment in FlexLoader Vision Description Parameter Text that appears on FlexLoader Vision s user interface Enter NONE if the output is not used Name If DataType is set to...

Page 163: ...der 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 Both ResetBit and ResetBit2 are available This may be useful if reset needs to be sent to both the robot and the PLC Description Parameter Text that appears on FlexLoader Vision s user interface Enter NONE i...

Page 164: ...x1800000982 164 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Commissioning 11 3 4 Configuration of user defined mechanical equipment Continued ...

Page 165: ...Home MainModule mod Home DetailModules ModCam1 mod Home MoveRobotTo mod Home System Vision sys Home System Common sys Home System TemplateMachine sys Home Background VisionCom mod Home Background EntryControl sys Home Background IndicationLights sys Home Background UserCommuication sys Home Background MessageConfiguration sys Home UserTexts_en txt Home Background ToolControlMenu mod Home Backgroun...

Page 166: ...ould be for the robot gripper The z direction is always down or into the image When defining grippers it is usually necessary to choose how x should point in relation to how the fingers are positioned When defining the picking position it is possible to rotate the entire gripper to match the detail correctly Depending on how the gripper and the cell look physically it may be important to make sure...

Page 167: ...nter your customer login as obtained from ABB xx1800000514 For more information contact any of the application centers shown in the app xx1800000515 Continues on next page Product manual FlexLoader Vision 167 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 11 Commissioning 11 3 6 Smartphone connection ...

Page 168: ...ion is to have a default gateway specified Data is stored locally in case of lost network connectivity Upon reconnection this data is reported to the app The data and time settings on the PC must be correctly set and match the smartphone settings Using a smartphone connection with FlexLoader Vision Lite requires an additional setting in FlexLoaderVisionLite xml In the section BaseData set the valu...

Page 169: ...the hard drive After major system up dates Check the cables and cable racks What Check the cables and cable racks When Every 3 months How Inspect the entire cable rack fixing points dirt deposits wear and remedy any breaks Check all cables Replace any damaged cables Extend cables that rub against sharp edges Check the connections What Check the connections When Every 3 months How Inspect all conne...

Page 170: ...system How Create a backup on the Service tab on the Settings menu and save it onto a secure media Backup the robot program 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 170 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 12 Maintenance 12 1 Gene...

Page 171: ...he PC hard disk as well as continuous backup of FlexLoader Vision data Tip We strongly recommend to duplicate the USB memory and or to save the backup files at a safe location The backup and restore tool used here is Redo Backup which is available under the GNU public license but any other tool for hard disk imaging can be used Backup To perform a backup turn off the computer and put the backup US...

Page 172: ... Step 1 Select the source device containing Windows and FlexLoader Vision in the drop down list and click Next xx1800000396 Continues on next page 172 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 12 Maintenance 12 2 Backup and recovery of the hard disk Continued ...

Page 173: ...ct the USB device 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 173 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 12 Maintenance 12 2 Backup and recovery of the hard disk Continued ...

Page 174: ...the backup xx1800000401 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 174 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 12 Maintenance 12 2 Backup and recovery of the hard disk Continued ...

Page 175: ...er the boot device manager by pressing Esc when the startup screen is shown 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 175 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 12 Maintenance 12 2 Backup and recovery of t...

Page 176: ...8 Step 1 Select the USB device Drive 2 Part 1 as source drive xx1800000389 Continues on next page 176 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 12 Maintenance 12 2 Backup and recovery of the hard disk Continued ...

Page 177: ... 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 177 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 12 Maintenance 12 2 Backup and recovery of the hard disk Continued ...

Page 178: ... pop up message that the restore procedure is complete is displayed Click OK xx1800000395 Remove the USB memory and restart the computer xx1800000403 178 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 12 Maintenance 12 2 Backup and recovery of the hard disk Continued ...

Page 179: ...see the version history of FlexLoader Vision Note Always make a complete backup before carrying out an upgrade Restoring a backup of FlexLoader Vision To restore FlexLoader Vision from a backup click the Settings icon in FlexLoader Vision and select the Service tab Click Restore and enter the path to the backup file When the backup has been restored FlexLoader Vision must be restarted For more inf...

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Page 181: ...ordinates 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 Use the supplied calibration plate and calibration tool during the calibration See Camera on page 97 for information on camera calibration Product manual FlexLoader Vision 181 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights...

Page 182: ... and a calibration tool is needed Note that the calibration plate must not be moved until the robot calibration is complete To ensure that the calibration plate is not moved it can be taped to the camera belt xx1800000260 Figure 13 1 The calibration tool positioned over the calibration plate Continues on next page 182 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 A...

Page 183: ...dant and select Jogging tCalibTool xx1800000263 Defining the work object 1 Open the main menu and select Programdata wobjdata Show data 2 Select the work object to be calibrated wCamArea1 for camera 1 wCamArea2 for camera 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 183 3HAC051771 ...

Page 184: ...points For Object method select No change xx1800000265 Continues on next page 184 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 2 Calibrating the robot Continued ...

Page 185: ...ear X1 can be selected xx1800000261 Figure 13 2 Positioning the calibration tool 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 185 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 2 Calibrating the robot Con...

Page 186: ... avoid the risk of losing it when the system is started up the next time xx1800000267 Saving the calibration file 1 Open the ProgramEditor xx1800000315 Continues on next page 186 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 2 Calibrating the robot Continued ...

Page 187: ...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 187 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 2 Calibrating the robot Continued ...

Page 188: ...alibrate the coordinate system wCamera1 if the 3D camera is camera 1 A suitable positioning is for example on the pallet guides if a pallet is used The z axis should be pointing upwards and the x axis should be aligned with the long side of the pallet See the previous section for help with defining and saving the work object The RAPID module Calibration3D sys includes robot demo code that supports...

Page 189: ...e 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 The RAPID module contains code that communicates with FlexLoader Vision and sends all the information needed to FlexLoader Vision Note The module name Calibration3D must not be changed Neither may the names of the com...

Page 190: ...covers the basic structure of the robot program More or less extensive additions and adjustments are required depending on the design and the functionality of the robot cell For more information on robot programming see the programming manual of the robot The FlexLoader RAPID code consists of several main blocks that supports the functionality of FlexLoader systems FlexLoader application functiona...

Page 191: ...tails to be run Below these are called ModCamX for a general reference to any ModCam module or specifically ModCam1 for details to be run using camera 1 Modcam2 for details to be run using camera 2 and so on These files can be renamed according to project needs The program memory always contains two more loaded system modules Vision sys for all communication with FlexLoader Vision and Common sys f...

Page 192: ...m has been adjusted and tested for the specific robot cell RAPID example MainModule mod MainModule mod contains the main routine which is the standard entry point Some typical example application skeleton for MainModule mod are shown below All examples use the same initialization code PROC Main set system specific control parameters InitializeMain set vision specific control parameters InitFlexLoa...

Page 193: ...IF nAction nCameraNumber NO_DETAILS OR nAction nCameraNumber MANY_DETAILS_NO_GRAB THEN TODO Decide what to do when this camera can t find anything If there is more than one camera it could be an good idea to return here instead of stopping to give next camera a chance If no auto grab and there is a feeder try start feeder to get new parts in position TPWrite Didn t find anything in image ELSEIF nA...

Page 194: ...ToPositionForSecondImage Confirm first image and take new image ConfirmPick1 WaitUntil bCoordReceived CAMERA_NO_1 TRUE SetNextTarget CAMERA_NO_1 IF nAction CAMERA_NO_1 NO_DETAIL THEN handle that no part is found EXIT ENDIF Use information from the second image as you need data can be found in pPick revert to previous settings BELT_ACTION CAMERA_NO_1 RUN_NO_DETAIL DisablePosition CAMERA_NO_1 1000 E...

Page 195: ...ake care of pallet change can be removed if not a pallet picker cell ELSEIF nAction nCameraNumber PICK_INTERLAYER THEN TODO Do something to take care of interlayer can be removed if not a pallet picker cell ELSEIF nAction nCameraNumber PICK_INTERLAYER_AND_CHANGE_BIN THEN TODO Do something to take care of interlayer AND pallet change can be removed if not a pallet picker cell ELSE PickCam_1 RefPosO...

Page 196: ...hese routines are provided as example code Always ensure that they are working with the actual details and processes Programming of e g Cam1Position_1 Cam1Position_2 Cam2Position_1 for all used cameras and positions must be done RAPID example for InitializeCam1 Belt setting Run belt directly after last detail is picked BELT_ACTION CAMERA_NO_1 RUN_ONE_DETAIL Camera setting Never grab an image autom...

Page 197: ... conditions are changed the integrator has to ensure that the 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 197 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 3 2 FlexLoader application ...

Page 198: ...in can be controlled from the robot set contrast for camera 1 to 50 CameraContrast CAMERA_NO_1 50 set exposure time for camera 2 to 10 CameraExposureTime CAMERA_NO_2 10 set gain for camera 3 to 30 CameraContrast CAMERA_NO_3 30 Positions for the currently used detail can be switched on and off if required by the application enable all positions for camera 1 EnablePosition CAMERA_NO_1 1000 disable p...

Page 199: ...eters in FlexLoader Vision The module contains parametric movement instructions option handling and machine tool handling In this case a single ModCam1 mod is used for all details and only parametrized code can be executed It is located in HOME FlexLoaderVisionLite Note The handling routines are called for each detail Make sure your code works with all details If not activate the special robot pro...

Page 200: ...ishedDetailDiameter nFinishedDetailOuterDiameter nGripHeightFinishedDetail allowedDetailsInHeight getAllowedNumberToStack detailHeight nFinishedDetailHeight hasLeftOverPart bIsThereLeftOverPart leftOverPartWidth nLeftOverPartDiameter leftOverPartLength nLeftOverPartDiameter leftOverPartHeightToTCP nGripHeightLeftOverPart Cell emptying In some cases of machine tending the cell must be emptied from ...

Page 201: ...ed by alternative language codes 1 Message1_Header Message 1 line 2 Message 1 line 3 2 Message2_Header Message 2 line 2 Message 2 line 3 3 Message3_Header Message 3 line 2 Message 3 line 3 The message handling must be initialized at program start e g in InitializeMain in MainModule mod Initialize all texts and reset messages InitializeUserTexts ResetMessage ALL_MESSAGES Message handling can then b...

Page 202: ...IPPER_1 Release WaitingTime 0 1 ToolAction Tool GRIPPER_2 Release WaitingTime 0 1 Set gripper 1 to active store the tooldata for gripper 1 in tTool this will also update gripload for robot tTool SetActiveTool GRIPPER_1 Grip a raw part with current active tool also updates gripload ToolAction Grip PartType RAW_PART Grip a MACHINED_PART with gripper 2 ToolAction Tool GRIPPER_2 Grip PartType MACHINED...

Page 203: ... in a background task Conditions and indication light colors are defined during program initialization A color is assigned to all conditions and the integrator selects flashing or static lights In most cases RGB lighting is used predefined colors RED GREEN BLUE WHITE YELLOW IndicationLightsSetupRGBLights AlarmFlashingColor RED CycleOnColor GREEN InformationFlashingColor WHITE QuestionFlashingColor...

Page 204: ...force information indication on Set DOF_Information switch back to automatic control Reset DOF_Information 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 204 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Rob...

Page 205: ...ows Note that no movement is included in this schematic code Prepare for machine tool interaction Machine1Action INIT_MACHINE WaitUntil Machine1Check LOAD_MAIN_OK TRUE Machine1Action OPEN_DOOR WaitUntil Machine1Wait DOOR_OPENED 10 Enter machine tool and load part in main chuck Machine1Action CLOSE_CHUCK_MAIN grip detail in sub chuck Machine1Action OPEN_CHUCK_SUB leave machine Machine1Action CLOSE_...

Page 206: ...EPARE_LOAD_MAIN TODO Send signal to machine WaitUntil Machine1Wait MAIN_CHUCK_OPENED 30 TRUE CASE PREPARE_UNLOAD_MAIN TODO Send signal to machine CASE PREPARE_UNLOAD_SUB TODO Send signal to machine CASE OPEN_DOOR TODO Send signal to machine CASE CYCLE_START TODO Send signal to machine PulseDO High PLength 0 5 doMachineSpare04 CASE INIT_MACHINE TODO Send signal to machine CASE STOP_MACHINE TODO Sen...

Page 207: ...e robot from moving through the forbidden volume The following zones are predefined for integrator convenience and can be configured during commissioning safeVolume The robot could be started from here directly Connected to DOF_SafeZone machineVolume Robot is outside of machine tool Connected to DOF_LoaderOut The definition of these WorldZones can be changed by geometrical data defined in Common s...

Page 208: ...ail amount 2 option nAmountOfDetails2 Detail amount 3 option nAmountOfDetails3 Set to coordinates printing DOF_Coord Coordinator received bCoord Camera number cam The result information reports how many pickable details there are in the image field No details action 1 precisely one detail action 2 or more than one detail action 4 When the option for multi coordinate gripping is used additional res...

Page 209: ...ace and retrieve input from the operator sMsgAnswer as suggested answer sMsgAnswer sInputBox Text entered by the operator sMsgResponse Disables the selected position for camera 1 2 3 or 4 Disables all positions if the value is 9999 nDisablePosCam1 4 Enables the selected position for camera 1 2 3 or 4 Enables all positions if the value is 9999 nEnablePosCam1 4 Colors details of the image field blac...

Page 210: ...n This signal is checked before the coordinates are sent If the robot is not running an alarm is displayed and FlexLoader Vision waits until the robot program starts again before coordinates are sent DOF_CycleOn Cross connected to the system output AutoOn This signal is checked upon startup and stop through FlexLoader Vision DOF_AutoOn Cross connected to the system input ResetEStop Used so that Fl...

Page 211: ...on Com to check when a new detail has reached camera 1 4 DOF_InPosition1 4 Product manual FlexLoader Vision 211 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 4 1 Communication between FlexLoader Vision and the robot Continued ...

Page 212: ...communication between part feeder and robot is shown below xx1800001066 Description Pos Taking images and picking A The conveyor is running B 212 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 4 2 Communication between the robot and the PLC ...

Page 213: ... see diagram below SelectIdCam1 4 byte 0 1 ID Value is locked by the SelectIdCamX command and must therefore be set before hand ID No double word Choice of ID successful SelectIdOk byte 0 1 Choice of ID unsuccessful SelectIdNok byte 0 1 The default handshaking process is performed as follows The command must be 0 before the sequence begins The command is then set to 1 The machine begins to carry o...

Page 214: ...e shown in the diagrams below xx1800001015 xx1800001016 xx1800001017 Continues on next page 214 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 4 3 Communication between Master and Slave Continued ...

Page 215: ...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 AutomaticStart CycleStop SelectIdCamX AutomaticStrtOk AutomaticStrtNok CycleStopOk CycleStopNok SelectIdOk SelectIdNok IdArticle group input 16 bits Note that both background modules for the Slave function throug...

Page 216: ...xLoader Vision View the latest image taken during operation View the status of the FlexLoader Vision connection Indicates any contact or what FlexLoader Vision is currently doing View the latest alarm from FlexLoader Vision with a possibility of resetting the alarms displayed at the top of the window Select whether the latest camera image is shown or not Note that the cycle time for FlexLoader Vis...

Page 217: ...ne tap the FlexLoader Vision icon that is now visible on the ABB menu on the FlexPendant Product manual FlexLoader Vision 217 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 13 Robot integration 13 5 FlexPendant Master option Continued ...

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Page 219: ...edge of robot programming The teachin is carried out in a way that feels intuitive and obvious to operators who are used to programming CNC machines xx1800000275 How it works The raw material is placed on a conveyor belt in the robot cell The positions of the blanks or pipes are identified using ABB s proven proprietary vision system FlexLoader Vision which guides the robot to pick the parts direc...

Page 220: ...lanks and pipes possible 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 deburring marking or air cleaning ...

Page 221: ...First loading in main spindle then unloading from main or sub spindle First unloading from main or sub spindle then loading in main spindle Unloading from sub spindle No loading is performed Used with bar feeders Handling of remains After unloading the selected actions are carried out according to the actions chosen on the Options tab Both one and two spindle lathes are supported General operation...

Page 222: ...oader Vision xx1800000278 The following Operation view is shown when the system is integrated in the lathe operators panel xx1800000279 Continues on next page 222 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 2 Operation ...

Page 223: ...xLoader 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 If FlexLoader Vision is configured so that the robot should con...

Page 224: ...cial cycles that cannot be stopped in the middle of operation In this case the robot normally knows when a stop is appropriate 224 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 2 Operation Continued ...

Page 225: ... 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 Continues on next page Product manual FlexLoader Vision 225 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 3 FlexLoader Vision Lite teachin ...

Page 226: ...tail and click Edit To create a new detail click New and enter a new name Click OK To rename a detail select the detail click Rename and specify a new name To delete a detail select the detail and click Delete Then confirm the deletion 226 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 3 1 Detail ...

Page 227: ...b spindle If enabled by the integrator activation codes for user defined sequences can be sent to the robot xx1800000275 Normal loading procedure Normally the new raw material is loaded first and the finished detail is unloaded later 1 The robot retrieves the detail on the camera belt 2 The robot loads the new detail in the machine 3 The robot retrieves the finished detail in the machine with its ...

Page 228: ...his 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 In this mode a part is picked from the inconveyor the sub spindle is emptied the robot leaves the machine the machine docks from the main spindle to the sub spindle the robot load...

Page 229: ...as the ID number of the gripper fingers The grip diameter and outer diameter for a finished detail can differ from the dimensions of the original detail and are specified separately If you want the finished parts to be stacked select Stack finished parts and specify the number of parts that should be stacked Unloading from main spindle The normal loading and unloading procedure is specified above ...

Page 230: ...ding from a sub spindle a spindle offset can be specified xx1800000283 Continues on next page 230 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 3 3 Unload Continued ...

Page 231: ...e 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 Product manual FlexLoader Vision 231 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 3 3 Unload Continued ...

Page 232: ...xx1800000285 232 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 3 3 Unload Continued ...

Page 233: ...inable texts User definable values xx1800000286 The specified options are performed just before the detail is left on the outconveyor If several options have been selected they are performed in the order defined in the robot program If this order is not suitable a simple adjustment in the robot program is required Note that Actions and Robot program are different regarding function For more inform...

Page 234: ...s correspond to three setup files in the marking controller The maximum number of characters for the mark text will change depending on the selected font size If too many characters are entered the mark text will automatically be shortened to the maximum length In addition a warning appears that the maximum length has been reached No extra robot programming is required for simple operation The det...

Page 235: ...used To select a special robot program on the robot that is adapted for the specific detail select Use special program in robot and specifiy a program file in the list below Note All special programs must be programmed and tested before being selected on the Options tab As the program is completely detail specific other options can be placed in the robot program depending on the project requiremen...

Page 236: ...ith either the x or y axis parallel with the front of the lathe The following coordinate system is used in a FlexLoader Vision Lite system Description Robot data Coordinate system for picking from the feeder incon veyor calibrated according to the calibration instruc tions for FlexLoader Vision see Camera on page 97 wCamera1 Coordinate system for leaving on outconveyor The x axis is above the shaf...

Page 237: ...the center of the details will be placed Coordinate system for the statist ical outlet Calibration similar to wFeederOut wSample Manual calibration Coordinate system for the de burring units Calibration similar to wFeederOut wDeburr CalibWasher place zero position in the center of the washing box on a height where washing of the lower end of a detail is to start Coordinate system for the wash ing ...

Page 238: ...bration sys and follow the instructions On request a detail must be gripped with the sub chuck Position the robot so that this detail can be gripped by the robot gripper precisely centered Confirm to the calibration routine From the current robot position wSubChuckM1 is moved to be located exactly in the sub spindle center If the sub spindle is movable the calibration must be checked so that the z...

Page 239: ...ensation of load induced deviations Close to loading position put a reasonable additional weight on the gripper and measure the load induced lowering of the robot arm Description Robot data Load induced lowering of the robot arm in mm nLoadCompensateDistance Load that was used for measuring nLoadCom pensateDistance nLoadCompensate Gripper The following gripper is used in a FlexLoader Vision Lite s...

Page 240: ...place as pHome jpSoftwareSyncPos 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 For details se...

Page 241: ...ly to settings for the appearance of the detail and grip data An update of all details must be made after a change to the master detail This update is made on the Detail tab on the FlexLoader Vision Lite menu Press the Ctrl key so that the Update all from Master button becomes visible Click on it to update all details The automatic update of details upon saving can be disabled by checking No autom...

Page 242: ...rs is to be checked or not Also specify whether the lathe has a sub spindle or not Indicate for each option if it is used or not The options are air cleaning box wash box marking unit statistical outlet deburr actions and special program for robot If marking is to be used the maximum mark text lengths for small medium and large must also be specified These are connected to the mark data files that...

Page 243: ...gripper data for standard gripper fingers The standard fingers that are not to be used must be removed for the relevant application If special fingers are used these must be defined The GripRanges interface contains individual sections for each gripper used If necessary copy the existing gripper data to a new gripper The name of the section is the name that appears in the FlexLoader Vision Lite in...

Page 244: ...he open position to the largest diameter that can be gripped Typically 2 3 mm See the images below OuterGripSafety Indicates the rotation of the gripper when installing the robot Used when the gripper is drawn in FlexLoader Vision Typically 0 30 60 or 90 D in the image below GripperBaseRotation Each section for a grip finger contains basic data about the grip finger as well as the set up of the po...

Page 245: ... text that appears when the operator selects a detail It specifies in which position the gripper finger is to be positioned to run the detail UserInformation xx1800001023 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 24...

Page 246: ... relationship between the parameters for a gripper range during internal gripping is illustrated in the image below xx1800000321 Continues on next page 246 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 5 FlexLoader Vision Lite configuration Continued ...

Page 247: ...xternal operator panel 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 xx1800000970 FlexLoaderVisionLite xml The FlexLoaderVisionLite xml file must be config...

Page 248: ...e main file Robot Regularly create a backup of the robot Save the file in a safe place to protect yourself from data losses Communication variables robot Variable mapping Writing of variables to the robot is done according to the following diagrams xx1800000289 Continues on next page 248 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexL...

Page 249: ...800000291 Continues on next page Product manual FlexLoader Vision 249 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 5 FlexLoader Vision Lite configuration Continued ...

Page 250: ...xx1800000292 250 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved 14 FlexLoader Vision Lite 14 5 FlexLoader Vision Lite configuration Continued ...

Page 251: ...there are any problems When updating some of the files in this folder may need to be replaced FlexLoader Vision Configuration In this folder many of the different configuration files required for FlexLoader Vision are stored such as the camera calibration files cal the language file Language xml the Master Slave control file MasterSlave xml the FlexLoader Vision configuration file FlexLoaderVision...

Page 252: ...group name There is a Detail file for each detail and for each position a n CollisionImage and a n TeachinImage where represents the detail name and n represents the position number If the secondary search has been activated for a detail there is also a Secondary Detail file If a 3D camera is used there is also a HeightAnalysisArea file FlexLoader Vision Database In this folder the FlexLoader Visi...

Page 253: ...es are saved on a rolling basis with a maximum of 19 999 images The logging affects the cycle times because saving to file takes time The image files are saved in the format CAMX_YYYYY tif where X is the camera number 0 3 and YYYYY is a serial number Operating with logged images only 2D Images that were logged as above can then be used to run from file To run a detail with logged images the detail...

Page 254: ...tons xx1800001068 The slide show can either occur at a fixed interval select Run continuously or by pressing the Next button select Pause after each image 254 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved A Technical information A 2 Logging the operation Continued ...

Page 255: ...00000505 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 255 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved A Technical information A 3 Localization ...

Page 256: ... FlexLoader Vision s program folder 3 Copy the whole Database folder from the backup folder to FlexLoader Vision s program folder Overwrite the existing files 4 Delete the whole Data folder from FlexLoader Vision s program folder 5 Copy the whole Data folder from the backup folder to FlexLoader Vision s program folder 6 Copy the following files from the Configuration folder to the Configuration fo...

Page 257: ...nFeederOut t tooldata e g tCalibTool1 v speeddata e g vLowSpeed w wobjdata e g wCamera1 Several seldom used data types do not obtain their own prefix e g shapedata errnum wzstationary Variables inside records do not use prefixes either Variables are named with prefix and a descriptive name where start of new words is indicated with capital letters see examples above Constant prefixes and naming Co...

Page 258: ...n RAPID code Vision sys Support module used when calibrating FlexLoader Vision with a 3D camera Calibration3D sys Background task used for external control of FlexLoader Vision by means of a master system PvSlave mod FlexPendant HMI for user interaction with FlexLoader Vision TpsView files Continues on next page 258 Product manual FlexLoader Vision 3HAC051771 001 Revision B Copyright 2014 2018 ABB...

Page 259: ...the last detail has been found in the image RUN_NEVER Never run the conveyor belt RUN_MANY_DETAILS Run the conveyor belt after each pick Note When running with the setting RUN_NEVER e g when picking from pallets If FlexLoader Vision does not find anything after taking a new image the robot must have some type of manage ment for this The user must check the Action variable before calling up SetNext...

Page 260: ... have full control of all image taking to prevent that double images are taken a new im age is taken before the previous image has been processed DiscardAndStart Belt nCamera 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 Gra...

Page 261: ...te a certain teachin position in FlexLoader Vision All positions can be locked at the same time by specifying a value nPosition 999 DisablePosition nCam era nPosition Called up to activate a certain teachin position in FlexLoader Vis ion All positions can be enabled at the same time by specifying a value nPosition 999 EnablePosition nCam era nPosition For system internal usage ForceInPosition Call...

Page 262: ... SelectDetailOnTheFly else unpredict able behaviour or system crashes might occur SelectDetailOn TheFly nCamera sGroupName sDetail Name Called up to set a new edge height in the selected camera Usually used when running stacks on the belt SendEdgeHeight nCam era nEdgeHeight For system internal usage SendGrab nCamera For system internal usage SendStop Called up to set an alarm in FlexLoader Vision ...

Page 263: ...n AutoStartTrap Handles Stop requests from external master and stops FlexLoader Vision CycleStopTrap Handles SelectId requests from external master and changes detail in FlexLoader Vision SelectIdTrapCam1 4 Initializes the various request handlers Init Product manual FlexLoader Vision 263 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved B FlexLoader RAPID reference B 2 FlexLoa...

Page 264: ...fer to chapter on world zones Common sys This module handle robot movement between via positions gen eral movements in the cell MoveRobotVia mod 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 Description Routine Checks whether anyone has requested entry to the cell or has been inside ...

Page 265: ...Cam1Position_n Initializes the camera and detail specific data InitializeCam1 This routine performs the actual picking of a detail from the con veyor at camera position PickCam_1 This routine is called to approach an intermediate position towards the conveyor before picking Update this position to suite the current application RefPosInCam_1 This is an intermediate position used when leaving the pi...

Page 266: ...1 pViaMachine1 see above In this example code pViaMachine is a position just outside the machine tool where the robot can request the machine to close its door This procedure is for loading the main chuck in the machine tool PROC LoadMa chine_MAIN This procedure loads the detail in the main chuck Make sure to use EnterMachine before all loading unloading and ExitMa chine after all loading unloadin...

Page 267: ...s system module is accessible by all programs and by storing the data in this module all programs always have access to the right data All other data that is common to all programs as well as program code that is common to all programs should be stored here Description Routine This routine checks if inconveyor is in position i e ready to take a new image It is only to be used if the cell use a in ...

Page 268: ...e modified the MoveRobotTo routine has to be verified again CAUTION When starting the robot from unknown positions collisions can occur Description Routine This procedure checks where the robot is positioned Returns correct number for the zone the robot currently is positioned in CheckPos Moves robot to home position GoHome Not to be used from any position Make sure robot can move to closest via p...

Page 269: ...d ZONE_WASHER pViaAirClean The zone in which the blow box is located ZONE_AIR_CLEAN pViaSampleOutlet The zone in which the sample detail is located ZONE_SAMPLE_OUTLET pViaDeburr The zone in which the deburring is located ZONE_DEBURR pViaTurnStation The zone in which the turn station is located ZONE_TURN_STATION pViaRegrip The zone in which the regrip station is located ZONE_REGRIP The following co...

Page 270: ... zone ZONE_AIR_CLEAN_START End of air cleaning box zone ZONE_AIR_CLEAN_STOP Start of statistical outlet zone ZONE_SAMPLE_OUTLET_START End of statistical outlet zone ZONE_SAMPLE_OUTLET_STOP Start of deburr zone ZONE_DEBURR_START End of deburr zone ZONE_DEBURR_STOP Start of turn station zone ZONE_TURN_STATION_START End of turn station zone ZONE_TURN_STATION_STOP Start of regrip zone ZONE_REGRIP_STAR...

Page 271: ...obot A Machine tool B Inconveyor C OutConveyor D Turn station E Washer station F Statistical outlet G Air cleaning station H Door I Product manual FlexLoader Vision 271 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved B FlexLoader RAPID reference B 3 FlexLoader application functionality Continued ...

Page 272: ...ding of the machine tool The variable names in this module must not be changed as FlexLoader Vision transfers data to these variables Description Routine Calculate load compensation when leaving and picking from chuck FUNC num calcLoad Compensation num gripLoadMass Calculate load position inside machine FUNC pos calcPosLoad Machine num nSpindleOffset Calculate grip position for left over part FUNC...

Page 273: ... CalcFeed erOutLeaveOffset inout num presentLayer num feederNo bool leftOver Part User should use the returned offsets for the leave position when leaving detail and then call ConfirmLeaveFeederOut when finished If no confirm then robot will get the same leave offsets next time this function is called If using SetUpFeederOutBelt the leave position pLeaveFeederOut is forced to x y z 0 0 0 in this f...

Page 274: ...feederNo num feederWidth num feeder Speed num spaceB etweenParts num spaceToEdge num yDistanceToLeave bool leaveFromLeft string RunFeederDOSignal Name string Al lowLeaveDOSignal Name stringFeederHas MovedDOSignal Name string Block EmptyingModeSignal Name Setup restrictions for out feeder detail This procedure should be called once before start using RunFeederOut or CalcFeederOut LeaveOffset PROC S...

Page 275: ...with short response time regular operation with InPosi tion sensor FeedLineInPosition mod Specialized task for handling start and stop of inconveyor with short response time regular operation with ToFar sensor FeedLineToFar mod Specialized task for checking if operator has manually oper ated any conveyor FeedersSuperVision mod Optional files for control of conveyor system through the FlexPendant T...

Page 276: ...serCommunication sys MessageConfigura tion sys Shared module containing global code for FlexLoader Vision RAPID code GlobalCodeAndCon fig sys Module for convenient and common tool handling Tools sys Module for handling entry request entry indication lamp and door lock signals EntryControl mod Module for handling indicator lights according to operational status IndicationLights mod Continues on nex...

Page 277: ...hould be FILE_PREFIX sUsedLan guage FILE_SUFFIX this is for example UserTexts_en txt for english File structure like this 1 MessageRow1 Header MessageRow2 MessageRow11 2 MessageRow1 Header MessageRow2 MessageRow11 MAX_MESSAGES MessageRow1 Header MessageRow2 MessageRow11 PROC InitializeUser Texts Note The number first in every row points to which message also look at to CONSTANT declarations in thi...

Page 278: ...oader Vision if necessary PROC ResetMessage Writes active messages to file PROC WriteActiveMes sagesToFile Writes an error message to the FlexPendant event log and Flex Loader Vision if wanted Also sets error flag for correct indication at light tower Program execution continues PROC WriteError num TextNumber bool Show InFlexLoader Vision Arguments TextNumber Number of text to be shown ShowInFlexL...

Page 279: ...ad type also holds information about how the robot should pick with this tool inside or outside grip Description Routine Returns true if all robot mounted tools are empty FUNC bool checkAllRo botToolsEmpty Clears all stored load types defined in this task PROC ClearToolLoads Clears part data for a tool This should be called if a load was manually removed If uncertain ask operator with a question i...

Page 280: ...e tool load This routine must be called at startup once for each load type that can be used in the currently run pro gram Note This will change depending on detail program currently run For example load types are normally a raw part machined part and maybe a left over part PROC SetupTool Load num LoadNum ber bool Inside Grip loaddata partLoad Data num Weight pos COGFromTCP Performs a tool action b...

Page 281: ... the indicator lights according to operational status Description Routine Main loop for task PROC main Sets blue light in RGB PROC BlueLight Sets green light in RGB PROC GreenLight Sets red light in RGB PROC RedLight Sets white light in RGB PROC WhiteLight Sets yellow light in RGB PROC YellowLight Sets no light in RGB PROC NoLight Controls and checks if lights would be switched on or off PROC Visi...

Page 282: ...essage type PROC IndicationLights SetupLightTower Assign correct color to each message type PROC IndicationLights SetupRGBLights Returns highest value of two num variables FUNC num maxNum Value Returns lowest value of two num variables FUNC num minNum Value Remove log file older then 7 days PROC RemoveOldLog files Reset the cycle time calculation PROC ResetCycle Times Returns tooldata value with o...

Page 283: ...or information transfer with machine tool Description Name Receives information from machine tool that a detail soon needs to be loaded If needed add code to confirm to the machine tool that a signal has been received TRAP PrePickTrap Used on machine tools with slow doors Signal is caught by trap instead of foreground program so that the robot can continue working Confirms to the machine tool that...

Page 284: ...Wait are correctly implemented Malfunction and collisions might otherwise occur Note We recommend the use of an additional background task if the robot cell requires time critical machine tool communication Note Operation with more than one machine requires the creation of these routines with equivalent names e g Machine2Action and Machine3Wait States and actions This module uses a number of prede...

Page 285: ...NE There are further predefined values in GlobalCodeAndConfig sys that can be implemented in TemplateMachine sys Product manual FlexLoader Vision 285 3HAC051771 001 Revision B Copyright 2014 2018 ABB All rights reserved B FlexLoader RAPID reference B 7 FlexLoader machine tool interface functionality Continued ...

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Page 288: ...265 N 4349 BRYNE Norway Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd 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 USA Telephone 1 248 391 9000 abb com robotics 3HAC051771 001 Rev B en Copyright 2014 2018 ABB All rights reserved ...