Page 4
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 6
13.3.6 FlexLoader machine tool interface functionality ..........13.3.7 WorldZones ................... 13.4 Communication information ................13.4.1 Communication between FlexLoader Vision and the robot ......13.4.2 Communication between the robot and the PLC ..........13.4.3 Communication between Master and Slave ..........13.5 FlexPendant Master (option) ................
Page 7
Table of contents 14.3.3 Unload ....................14.3.4 Options ....................14.4 Commissioning ....................14.4.1 Robot ....................14.4.2 FlexLoader Vision Lite master detail ............14.5 FlexLoader Vision Lite configuration ..............A Technical information File structure in FlexLoader Vision ................ Logging the operation ..................
This manual describes FlexLoader Vision, how to set up, calibrate, operate, troubleshoot, backup and recover the system. This manual also describes how the ABB robot works together with FlexLoader Vision and how to integrate the robot with the vision system. Finally, this manual describes how to configure and operate FlexLoader Vision Lite.
Page 10
Trademarks FlexLoader is a trademark of ABB. References • The product manual of the robot used together with FlexLoader Vision • The programming manual of the robot used together with FlexLoader Vision • The product manual of the camera/s used together with FlexLoader Vision •...
ABB Ltd and its entities are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
1 Quick start 1 Quick start Follow the steps below for a quick startup of a FlexLoader Vision system. The robot shall be installed mechanically and electrically, and be equipped with suitable grippers. Action Become familiar with this manual. Install PC and camera.
3.1 Menu When you start FlexLoader Vision you will see the following window. xx1800000203 At the top of the FlexLoader Vision window is a menu showing a number of menu icons that represent various system activities. Operation Used to start and stop the system. Also shows information on the current operation.
3.2 Tool box 3.2 Tool box FlexLoader Vision displays images at many different locations. To the right of each image there is a tool box. Not all the tools are displayed for every image – only the tools that can be used for the concerned operation are displayed. When a tool is selected, the button is highlighted and the tool is used when you click somewhere in the image.
3.4 System information 3.4 System information The below window appears when you click on the ABB logotype at the top left of the screen. It contains information about the current version of software, license information and contact information for service and support.
Teachin window: Detail, Image, Positions, Parameters, Tool, Grip, Supervision, Mechanics and Test & Save. The settings available differ depending on how FlexLoader Vision is configured, for example depending on whether you use a 2D or a 3D camera.
Page 24
This drop-down list only appears if blob searching has been enabled for the system. It lets you choose between the two search methods Standard and Blob. In FlexLoader Vision, so called blobs are details that may sometimes, within specified ranges, vary in shape.
Page 29
This dimension directly affects what is visible in the image in FlexLoader Vision. The highest point in the image is white and then it gets darker, down to black, at the specified analysis depth. The upper edge of the pallet collar can lie at a greater height than the highest located point and is therefore also completely white.
Page 30
Interlayer search If the function to search for interlayers is activated, FlexLoader Vision will look for interlayers when no details are identified. When an interlayer is identified, FlexLoader Vision will send information to the robot that an interlayer is found and at what height it is.
Page 31
Pallets without interlayer If searching for interlayers is deactivated, FlexLoader Vision will not search for interlayers when no details are identified. Instead, the highest point in the image is evaluated in order to decide what information is sent to the robot.
Positions tab. In the example below we teach the system to recognize the text FlexLoader Vision. The text can lie in two positions, either the right way up or mirrored. Clicking on the button New position creates a new position. This position must be defined by drawing a red box around the detail in the field of view that corresponds to the position.
Page 37
Position 1, Score 100%, Score target 100% Figure 4.4: Masking applied If you want FlexLoader Vision to suggest a masked area, click Suggest. Select Outer contour to obtain a suggestion only for outer contour lines. Use the Current position arrows to browse through all the teachin positions.
Page 40
A height region must always be defined when using a 3D camera. xx1800000217 When a detail has been identified by FlexLoader Vision, the height region value is used to establish a plane that lies on the detail. The average height of the plane is the height of the detail, and the angle of the plane gives the angles in the x and y axes.
Page 55
If Allowed overlap is activated, the gripper is allowed to collide with objects in the image to a certain extent. The degree of collision permitted is specified in square millimetres. When tool collision is detected, FlexLoader Vision will compare the collision area with the specified, permitted overlap area.
Page 57
FlexLoader FP 300 If FlexLoader Vision is used in FlexLoader FP 300, it is possible to adjust the parameters that govern mechanical control. On the Mechanics tab you will see an image of FlexLoader FP 300 and you will be able to set the parameters. The available parameters and their functions are described in the product manual of FlexLoader FP 300.
Page 58
Continued FlexLoader FP 400 If FlexLoader Vision is used in FlexLoader FP 400 it is possible to adjust the parameters that govern mechanical control. On the Mechanics tab you will see an image of FlexLoader FP 400 and you will be able to set the parameters. The available parameters and their functions are described in the product manual of FlexLoader FP 400.
Page 59
Continued User-defined settings If specified by the integrator, FlexLoader Vision can be used to control user-defined mechanical equipment. If so, the screen shows an image, two groups of parameters with a maximum of 32 values, and an Update PLC button to transfer these values to PLC.
Page 61
When FlexLoader Vision has identified a pickable detail, a new line is displayed in the list of test results. The new line is marked Pick and it specifies the data that would have been sent to the robot in normal operation.
Page 65
FlexLoader Vision is to analyze. This function can be used to enhance or weaken certain selected colors, or to increase or reduce the contrast between certain colors.
Page 88
If Allowed overlap is activated, the gripper is allowed to collide with objects in the image to a certain extent. The degree of collision permitted is specified in square millimetres. When tool collision is detected, FlexLoader Vision will compare the collision area with the specified, permitted overlap area.
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.
6.3 Stopping the system 6.3 Stopping the system To stop the system, click Stop in FlexLoader Vision. If the robot is in Auto mode, it will also be stopped. Note that clicking Stop does not make the robot stop immediately. Instead it will stop at the end of its cycle or after a certain time. To stop the robot immediately, you must use the stop button on the robot or, if an emergency situation has arisen, use the emergency stop.
Page 93
6 Operation 6.4 Operation information Continued Parameter Description Position number Score % Score target % In the screenshot above FlexLoader Vision the results are as follows: • Cam: 1 • Pos: 2 • S%: 98.9 • T%: 99.74 This means that a detail has been found in position 2 in an image taken by camera 1.
6.5 Smartphone connection 6.5 Smartphone connection Production data from FlexLoader Vision can optionally be visualized with the FlexLoader Vision Smartphone app. Currently the app is limited to systems with one camera. xx1800000511 The main screen shows all FlexLoader systems that are associated with the customer account and their current production status.
FlexLoader Vision is to analyze. This function can be used to enhance or weaken certain selected colors, or to increase or reduce the contrast between certain colors.
Page 98
Calibration Introduction In order for FlexLoader Vision to send the correct coordinates to the robot, the system must be calibrated together, i.e. the coordinate systems of FlexLoader Vision and the robot must be made to correspond. For this purpose, the supplied calibration plate and calibration tool are used.
Page 99
7.1 2D camera settings Continued Calibrating a 2D camera 1 Select the Calibration tab on the Camera menu in FlexLoader Vision. xx1800000244 2 Select the camera to be calibrated at the bottom of the screen under Active camera (this setting is only available if there are several cameras installed).
Page 101
From the camera viewpoint, details that are in the same location but have different edge heights appear to be in different locations in the field of view (known as parallax error). FlexLoader Vision therefore has a built-in perspective correction technology that automatically compensates for this effect.
Calibration In order for FlexLoader Vision to send the correct coordinates to the robot, the system must be calibrated together, i.e. the coordinate systems of FlexLoader Vision and the robot must be made to correspond. For this purpose, the supplied calibration plate and calibration tool are used.
Page 104
FlexLoader Vision will provide visual feedback about cone identification progress. A blue circle with a cross indicates where the cone was found. The values to the right show the current robot coordinates and the identified camera coordinates.
Page 105
FlexLoader Vision is rectified, which means that it does not have any perspective faults. The grey scale corresponds to the height so that it is possible to find the z coordinates. Some settings must be made in order for FlexLoader Vision to search in an efficient way. xx1800000249...
Page 106
Region of interest The region of interest is a very important parameter when using a 3D camera. When FlexLoader Vision starts searching for a detail, the highest point is identified first. FlexLoader Vision then continues the search downwards until the detail is located, or as far down as is set by the detail analysis depth.
FlexLoader Vision is used with. For example you can see the input and output status, as well as various modes, functions and settings. When used with FlexLoader FP 400 Below follows an example of what it may look like when FlexLoader Vision is used together with FlexLoader FP 400. xx1800000256 For more information on the FlexLoader FP 400, refer to the FlexLoader FP 400 product manual.
Page 110
When used with user-defined mechanical equipment The display for user-defined mechanical equipment varies depending on which equipment is used together with FlexLoader Vision. Below follows an example of what the interface may look like. For more information, refer to the product manual of the user-defined equipment.
To perform a backup, click Backup on the Settings menu > Service tab. Select where you want to save the backup file and click OK. To restore the system from a backup file, click Restore. FlexLoader Vision must be restarted for the restored values to apply. If the system cannot be restored automatically, you can restore the system manually.
Page 112
Click OK to apply the settings. xx1800000254 In the image above, FlexLoader Vision is backed up every Monday at 17:00. The backup files are saved in the folder C:\FlexLoader Vision\Backup. For information on how to do a complete hard disk backup or recovery, see...
Page 113
Please enter a valid IP address and appropriate user credentials, then click Apply. FlexLoader Vision must be restarted for the new address to be activated. Computer handling Click Restart to restart the computer.
ID number of the Master equipment to a group and a detail in FlexLoader Vision. This is done by entering an ID number in the ID Selection Configuration pane, choosing a group from a drop-down list in the Group column, and then choosing one of the available details from the drop-down list in the Detail column.
Page 119
ID number of the Master equipment to a group and a detail in FlexLoader Vision. This is done by entering an ID number in the ID Selection Configuration pane, choosing a group from a drop-down list in the Group column, and then choosing one of the available details from the drop-down list in the Detail column.
Check that the settings for the perspective center and the camera height are correct. • Recalibrate FlexLoader Vision and the robot. Check that the data for the calibration pattern is correctly specified. To prevent the calibration plate from moving during calibration it can be taped to the camera belt. Check that the dot for coordinate 0,0 is visible at the bottom left of the screen.
Page 122
• If the grip point is correctly set, the calibration between the robot and FlexLoader Vision can be offset. Recalibrate according to the above. Positioned slightly wrong when gripping • Check that the camera is perpendicular to the picking area. This is very important for the system.
9 Troubleshooting 9.2 Identification problems 9.2 Identification problems FlexLoader Vision does not find any details • During operation: Check that the correct detail is selected. • During teachin: If the detail is too light or shiny it can be difficult for the system to discern the detail from a conveyor that is light in color.
If the PLC does not respond, check the network wiring and the switch. • In FlexLoader Vision ConfigurationEditor, check that the IP-address for the PLC is correct. FlexLoader Vision robot FlexLoader Vision has no contact with the robot •...
10.1 PC installation Mechanical installation Note When FlexLoader Vision is pre-installed as part of a function package or standard cell, all hardware installation is already done. The PC shall be mechanically installed in an electrical cabinet. It can be oriented vertically or horizontally.
Page 131
Continued Fit the camera to the isolating plastic mounting plate that is delivered with FlexLoader Vision and install it at the intended location. xx1800002006 Connect the camera to the PoE1 network port of the PC with a network cable (cat6).
11 Commissioning 11.1 Configuration editor 11.1.1 Introduction FlexLoader Vision is able to handle a wide variety of machine types and working conditions, with one or more cameras, in various FlexLoader function packages and standard cells. This section describes the available parameters.
11.1.2 Main settings The main window is shown at startup. The default configuration file is loaded automatically. The configuration file (FlexLoaderVision.cfg) is stored in the FlexLoader Vision configuration folder, typically located at D:\Program Files\ABB Industrial IT\Robotics IT\FlexLoader Vision\Configuration\. Be sure to load and save the correct configuration file when specifying files manually.
Page 139
Start, stop and selection of details is possible. Standalone FlexLoader Vision operates as standalone system. Slave (through robot) FlexLoader Vision is controlled by the robot. Slave (through TCP/IP) FlexLoader Vision can be controlled by a TCP/IP based application. Slave (through PLC) FlexLoader Vision can be controlled by the PLC.
Page 141
3D camera settings For 3D cameras, select DllCamera3D. Then specify the correct DLL file and XML configuration file. These files are provided by ABB. Typically the files used are CirrusSensor.xml and CirrusSensor.dll. 3D camera settings...
Offset angle (XY) The grip angle of the located details (rotation in x-y plane) will be offset by this value. Robot Type The production systems work with the ABB ABB (produc- robot. The DllRobot type is only used during tion system) system tests.
Page 147
Useful in cells with extensive time demands on cycle stops. When DllRobot is selected, the corresponding DLL file and XML configuration file must be specified. These files are provided by ABB. Typical settings are SockekComRobot.xml and SockekComRobot.dll. This configuration is only used for testing.
11.2 User accounts General CAUTION There are several default user accounts used in FlexLoader Vision. It is strongly recommended to change the default passwords to reduce the risk of unauthorized access to important system parameters. Follow ABB’s advice for administration of user permissions.
Several utilities are pre-installed or ready to install for ease-of-use and interactions with other FlexLoader function packages and standard cells. • ABB RobotStudio (for configuration and advanced setting of the robot). • ABB PlutoManager (for configuration and advanced setting of FlexLoader safety solutions).
Otherwise, use a PoE switch in order to connect more than one camera to the "PoE1" port. Factory network The FlexLoader Vision PC can be connected to a factory network. The PC network connection is named Factory on physical port PoE2. Please refer to the robot controller product manual for setting the robot IP configuration.
Page 154
Settings for Basler GigE cameras Network setting for cameras The following instructions assume that ABB’s standard IP address settings are used. The same steps must be followed if alternative IP addresses are to be used. The only difference is in the addresses that must be entered.
Page 156
To save to the camera memory, select User Set Save and click Execute. xx1800000303 Troubleshooting If the camera is not detected by FlexLoader Vision, this may be due to several circumstances. First check the configuration of the IP settings for both the computer and the camera.
Page 157
Click File > Save as ... and save the camera configuration file as follows in FlexLoader Vision’s configuration folder. xx1800000981 Close IntelliCam and restart FlexLoader Vision. Check that the camera is detected correctly and shows images in FlexLoader Vision. Settings for 3D cameras See separate instructions for information about 3D cameras.
By installing and using FlexLoader Vision you agree to Microsoft and Matrox licensing agreements. Licensing FlexLoader Vision In order to run FlexLoader Vision, the robot license option 1554-1 Prepared for FLexLoader Vision is required. Contact ABB for licensing on existing previous installations.
A free number of hidden parameters. None of these will be displayed in FlexLoader Vision. They are sent to the PLC in the same way as the usual parameters. This is useful for more general parameters which may need to be set from time to time.
Page 160
UserDefinedPlcCamera_1_Tab2.xml. Note that only the sections "General" and "user-defined parameters" (see below) are used in this case. General Here principal text is configured that is shown on FlexLoader Vision’s user interface. xx1800000984 On the Mechanics tabs (on the Teachin and the Settings menus), during teachin and servicing, the image UserDefinedPlcImage.bmp, is shown, which should be...
Page 162
PLC inputs that are to be shown for the user are defined here. There are up to 16 user-defined inputs, which can be freely defined. These are used to show the status of the equipment in FlexLoader Vision. Inputs can also be defined as memory bits or datablock memories (datablock 1) in the PLC.
Page 163
Start, stop and reset bit PLC markers that are used at start and stop in FlexLoader Vision are defined here. These are used to synchronize the equipment with FlexLoader Vision. The PLC marker is set to 1 for 0.5 s at start, stop or reset Note that you can use dual reset bits.
11.3.5 Robot installation Operating system and options FlexLoader Vision is prepared for use with RobotWare 6.01 or above. Slight changes in configuration files may enable use with RobotWare 5.15 and 5.61. The following options must be available for the robot: •...
Page 166
Messages that the program pointer has changed are normal. Coordinate system for the robot gripper When setting the gripping positions during teachin, FlexLoader Vision always draws a blue line independent of the areas that visualize the gripping fingers themselves.
11.3.6 Smartphone connection Download and install the app. Start the app and enter the settings. Turn off the demo mode and enter your customer login as obtained from ABB. xx1800000514 For more information contact any of the application centers shown in the app.
Page 168
11 Commissioning 11.3.6 Smartphone connection Continued Make sure that the FlexLoader Vision PC is connected to the internet and that the smartphone settings are enabled and configured in the configuration editor (see License data on page 149). In case of connectivity problems ensure that network configuration is correct. A common problem is that a default gateway has been configured for the Robot or GigE connection.
12.1 General maintenance 12 Maintenance 12.1 General maintenance This section covers maintenance of FlexLoader Vision. If the installation contains further parts, maintenance instructions may also be found in other documentation. FlexLoader Vision is made of components that have a minimal maintenance requirement.
12.2 Backup and recovery of the hard disk Introduction This section describes how to backup and restore the entire FlexLoader Vision PC hard disk. The backup can be used to restore the PC in case of a hard disk failure. Backups are normally made after an initial system installation and after major system changes (e.g.
Page 172
Click Start Redo Backup (or wait). xx1800000387 Click Backup. xx1800000388 Step 1: Select the source device containing Windows and FlexLoader Vision in the drop-down list and click Next. xx1800000396 Continues on next page Product manual - FlexLoader Vision 3HAC051771-001 Revision: B...
Backup and restore FlexLoader Vision on page 111. If the restore operation fails and FlexLoader Vision cannot be restarted at all, you need to do a manual backup, where the contents in the backup directory are copied directly to the FlexLoader Vision directory. For more information on this, see Manually restoring a backup on page 256.
This chapter describes how the ABB robot communicates and works together with FlexLoader Vision and how to integrate the ABB robot with FlexLoader Vision. In order for FlexLoader Vision to send the correct coordinates to the robot, the systems must be calibrated together, so that for example the coordinate systems of FlexLoader Vision and the robot are made to correspond.
13.2 Calibrating the robot 13.2 Calibrating the robot General When the calibration of FlexLoader Vision is complete, you will need to calibrate the robot. This is done from the FlexPendant. Calibrating for use with a 2D camera When calibrating the robot for use with a 2D camera, a calibration plate and a calibration tool is needed.
Page 189
Change Calibration3DRoutine accordingly so that the robot moves to the positions to be used. When FlexLoader Vision requests to start the robot at the time of calibration, the routine Calibration3DRoutine must be called from the FlexPendant. If all movements are already tested, the robot can be switched to automatic mode to simplify the calibration process.
Before programming the FlexLoader Vision, it is your responsibility to carefully read the chapter on safety, to become familiar with the FlexLoader Vision and its options, and to become familiar with the safety devices.
Main structure Main.pgf and MainModule.mod are automatically loaded into the controller when a detail is started from FlexLoader Vision. During the following initialization, project modules with detail specific information are loaded. This happens upon every start. MainModule.mod is always the same for all details and all operating modes of the robot cell.
Page 192
Example files The following example programs show the principle structure of the robot code and how the robot program should communicate with FlexLoader Vision. There is no guarantee that any of the examples work unless the program has been adjusted and tested for the specific robot cell.
Page 196
! Camera setting: Never grab an image automatically ALLOW_AUTO_GRAB{CAMERA_NO_1}:=FALSE; RAPID example MoveRobotTo.mod The principal motion in the FlexLoader Vision is controlled by the MoveRobotTo-routine, which moves the robot from known zone positions to a target zone position. From these zone positions (via positions), movement within certain areas of the FlexLoader Vision can be initiated.
Overview The FlexLoader Vision interface code handles the interface and the communication to and from FlexLoader Vision. No changes should be made to this code. The basic application related use of the FlexLoader Vision interface is described above, see RapidProgramApplication. This section describes additional functionality that can be used for a large variety of purposes.
13.3.4 FlexLoader Vision Lite functionality 13.3.4 FlexLoader Vision Lite functionality Overview The application code for FlexLoader Vision Lite provides an extension to the general teachin described previously. This extension is used for parameter-based simplified teachin for upright standing cylindrical details, the so called FlexLoader Vision Lite. Normally, this code needs no changes.
Page 200
In some cases of machine tending, the cell must be emptied from parts, i.e. the machine shall be unloaded without loading the next part. For FlexLoader Vision Lite, this behavior is pre-programmed. By setting the output DOF_EmptyCell to “1”, the robot will finish a cycle by unloading a finished part without loading the next raw part.
ResetMessage ALL_MESSAGES; Message handling can then be used for e.g. messages, alarms and user input. If selected, the information is transferred to the FlexLoader Vision information system as well. If present, the indication lights are updated according to the message severity.
13.3.6 FlexLoader machine tool interface functionality 13.3.6 FlexLoader machine tool interface functionality Overview The FlexLoader Vision standard modules communicate with the machine tool by means of the interface module TemplateMachine.sys, which must be modified and adapted to the actual machine tool by the integrator.
FlexLoader Vision offers predefined WorldZone handling in the module Common.sys. The FlexLoader Vision defined WorldZones are active in both jogging mode and automatic mode. The following zone is predefined and must be configured during commissioning.
13.4 Communication information 13.4.1 Communication between FlexLoader Vision and the robot FlexLoader Vision and the robot communicates via PC SDK and Robot WebServices. The information is transmitted between the robot and FlexLoader Vision through direct reading/writing to/from variables and I/O signals.
Page 209
13 Robot integration 13.4.1 Communication between FlexLoader Vision and the robot Continued Other commands From FlexLoader Vision From the robot Description/result bClearSend Clear the coordinate queue. This should be used in all ma- chine types at each start. DOF_EndCycle Stop the program at a suitable point.
Page 210
Cross-connected to the system output Error. Used so that FlexLoader Vision can receive information about fault incidents. DOF_EndCycle Used so that FlexLoader Vision can stop the robot when a cor- rect cycle is completed and not in the middle of a cycle. DOF_CycleEnded Response signal from robot on DOF_EndCycle.
Page 211
13 Robot integration 13.4.1 Communication between FlexLoader Vision and the robot Continued Signal Description DOF_InPosition1...4 Cross-connected to Feeder1(...4)InPosition. Used by Vision- Com to check when a new detail has reached camera 1-4. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B...
Page 215
Robot It is possible to allow an external PLC to be Master for FlexLoader Vision via the robot. This means that the external PLC can stop, start and change detail in FlexLoader Vision. The robot acts as an intermediary to get it to work. The following signals can be exchanged between the robot and the PLC.
13.5 FlexPendant Master (option) The FlexPendant Master function is a graphical interface in the FlexPendant that makes it easy for the operator to manage FlexLoader Vision from the FlexPendant. Only information that is required for operation of the robot cell during production is displayed in the interface.
ABB’s proven proprietary vision system, FlexLoader Vision, which guides the robot to pick the parts directly from the buffer belt. The robot is equipped with a double gripper with three finger gripping and adjustable fingers.
Page 220
In addition, CNC operators can easily and quickly operate loading and unloading. One limitation in a FlexLoader Vision Lite system is that it can handle axially symmetrical parts only. For customers who, in the future, come across other types of parts that need loading with the correct rotation or require different types of post processing (e.g.
Page 221
Integrated in FlexLoader Vision (and then run on the FlexLoader Vision computer). • On the operating panel of the lathe, as a Master to FlexLoader Vision. There it is possible to choose details, start and stop the system, and perform teachins of new parts.
Page 223
Note that the program must be started from the beginning. Stopping the system To stop the system, click Stop in FlexLoader Vision. If the robot is in Auto mode, it will also be stopped. Note that clicking Stop does not make the robot stop immediately.
To perform a teachin in the operator panel of the lathe, click Teachin. To perform a Lite teachin on the FlexLoader Vision PC, click the Lite icon. On the FlexLoader Vision Lite menu there are four tabs to choose between: Detail, Load, Unload and Options.
14.3.1 Detail 14.3.1 Detail Overview xx1800000280 On the Detail tab, a list of all FlexLoader Vision Lite details that are in the system is displayed. Detail creator To edit a detail, select the detail and click Edit. To create a new detail, click New and enter a new name. Click OK.
Page 228
Unloading only When turning from bar material the option Unloading only can be activated. Note that this checkbox can be hidden through a setting in the configuration file, see FlexLoader Vision Lite configuration on page 242. Synchroneous mode If you need to operate the system in synchronous mode, select Synchroneous mode.
Page 231
Unloading of remains is done by the loading gripper. Note that the Unload remains checkbox can be hidden through a setting in the configuration file, see FlexLoader Vision Lite configuration on page 242. xx1800000284 Continues on next page...
14.3.4 Options Overview There are a number of options available for FlexLoader Vision Lite. The options selected for the current system are displayed on the Options tab. If there are no options added to the system, the Options tab does not appear at all. The following options are available: •...
Page 235
Special robot program By default, the robot movement in FlexLoader Vision Lite is controlled by the module ModCam1.mod, which contains the default movements in their default workflow.
In addition to this, the following instructions should be followed. FlexLoader Vision Lite assumes a specific geometry and coordinate system in the robot to work optimally. The FlexLoaderVisionLite.sys module must be adapted to the actual cell geometry.
Page 239
Load induced lowering of the robot arm, in nLoadCompensate Load that was used for measuring nLoadCom- pensateDistance Gripper The following gripper is used in a FlexLoader Vision Lite system: Robot data Description tCalibTool1 Calibration gripper that attaches to gripper 1.
Page 240
Sequences Standardized sequences are used to load and unload details in the machine, using the detail data from FlexLoader Vision. These sequences must be checked prior to each commissioning. The sequences are based on the machine being loaded from the front. If the machine is loaded from above or if anything else is unusual, some adjustments are required.
The detail FlexLoaderVisionLite must be taught in the Masters group. Each time a detail is saved in FlexLoader Vision Lite, the base values are copied from this master detail and adapted for that specific teachin detail. This applies, for example, to settings for exposure times, image preparations, advanced position settings, accuracy requirements, settings for collision monitoring etc.
The instructions below are for integrators, ABB’s own technicians and for information. The customer usually does not need to edit this configuration. The instructions below assume knowledge of the general setup of ABB’s system and handling of XML files. For operation of FlexLoader Vision Lite, the file FlexLoaderVisionLite.xml file must be configured.
Page 243
Gripper data In a FlexLoader Vision Lite system the gripper data must be known to be able to perform collision checks and to provide information to the operator on how the gripper fingers are to be positioned on the robot.
Page 244
GripperNumber Serial number for gripper data. Must start at 1 and must be continuous for each gripper that is configured. This is the number that can be selected in FlexLoader Vision Lite user in- terface. GripperStroke Stroke per finger in mm.
Page 247
• Specify the language as per requirements. • Specify the IP address of the FlexLoader Vision computer as well as the port number (same if specified in MasterSlave.xml). • The values for the hasFlexLoaderVisionInterface, hasTeachIn and teachInType parameters are specified according to the image below.
(*.dcf), and some system images (*.tif). The latest applicable configuration file (FlexLoaderVision.cfg.LastGoodKnown) is also stored here. It can be used if a change has been made in FlexLoader Vision or if a system crash has made FlexLoaderVision.cfg unusable. When updating, some of these files may need to be replaced.
Page 252
If a 3D camera is used, there is also a *.HeightAnalysisArea-file. FlexLoader Vision\Database In this folder, the FlexLoader Vision database (FlexLoaderVision.mdb) is stored. When FlexLoader Vision is run, there is also a FlexLoaderVision.ldb file. Product manual - FlexLoader Vision 3HAC051771-001 Revision: B...
Vision’s program folder. The folders Database, Data, and Configuration are found in both the backup folder and FlexLoader Vision’s program folder. 2 Make a safety copy of the whole of FlexLoader Vision’s program folder. 3 Copy the whole Database folder from the backup folder to FlexLoader Vision’s program folder.
B FlexLoader RAPID reference B.2 FlexLoader Vision interface B.2 FlexLoader Vision interface Overview The FlexLoader Vision interface consists of the following modules. Module Description VisionCom.mod Background task for base communication with FlexLoader Vision. Vision.sys Base communication with FlexLoader Vision and interface towards the application RAPID code.
Page 259
VisionCom.mod This module contains routines needed for background communication between the robot and FlexLoader Vision and must not be changed. VisionCom synchronizes the vision system and conveyor events with robot program execution. It relieves the foreground task from handling feeding devices and coordinate reception from the vision system.
Page 260
Called up by the user to take a new image with the selected camera. The routine waits until the accompanying signal InPosi- tion is 1 and sends a command to FlexLoader Vision to take a new image with nCamera. Note Do not use GrabImage if the camera is set to AL- LOW_AUTO_GRAB = TRUE (set in IntitializeCamX in ModCamX).
Page 261
Called up to check how many times a certain position occurs in Present(nCamera, the results sent by FlexLoader Vision. nPosition) ResetAlarm(sMessage) Called up to reset a certain alarm that was set in FlexLoader Vision from the robot. ResetInformation(sMes- Called up to reset a specific information message that was set in sage) FlexLoader Vision from the robot.
Page 262
SendGrab(nCamera) For system internal usage. SendStop() For system internal usage. SetAlarm(sMessage) Called up to set an alarm in FlexLoader Vision from the robot. SetInformation(sMes- Called up to set an information message in FlexLoader Vision sage) from the robot. SetWarning(sMessage) Called up to set a warning in FlexLoader Vision from the robot.
MoveRobotVia.mod This module handle robot movement between via positions (gen- eral movements in the cell). MainModule.mod MainModule.mod is always supplied with FlexLoader Vision. It is the main robot program of the system. MainModule.mod provides the following routines: Routine Description CheckSystem() Checks whether anyone has requested entry to the cell or has been inside the cell.
Page 265
Description LoadCameraModules() Loads relevant module files for each camera. The name of each module that is to be loaded is provided by FlexLoader Vision. Main() Pre-programmed and should only be modified where it is explicitly stated that conditions must or can be added.
Page 266
Routine Description PROC MainRoutine() This is the main routine for FlexLoader Vision Lite. It checks for entry request, maintenance request and other production breaking conditions. Then it calls the state logic to decide what to do next. PROC PerformFinishin-...
Page 267
The unload position is always calculated. X and Y is set to 0 and Z is calculated with the help from FlexLoader Vision values. To change the unload position, the work object has to be adjusted until the position is correct.
Page 268
Set up all used tools in the cell. MoveRobotVia.mod The principal motion in the FlexLoader Vision is controlled by the MoveRobotTo routine, which moves the robot from known zone positions to a target zone position. From these zone positions (via-positions), movement within certain areas of the robot cell can be initiated.
The module FlexLoaderVisionLite.sys contains a number of predefined procedures/functions that enables the parametrized loading and unloading of the machine tool. The variable names in this module must not be changed, as FlexLoader Vision transfers data to these variables. Routine Description FUNC num calcLoad- Calculate load compensation when leaving and picking from chuck.
Page 273
Branch() Standardized sequences are used to load and unload details in the machine, using the detail data from FlexLoader Vision. These sequences must be checked prior to each commissioning. The sequences are based on the machine being loaded from the front. If the machine is loaded from above or if anything else is unusual, some adjustments are required.
B FlexLoader RAPID reference B.5 FlexLoader conveyor system control B.5 FlexLoader conveyor system control Overview The FlexLoader Vision conveyor system control is structured according to the following overviews. These modules are part of the internal control system and must not be changed. Module Description FeedLine.mod...
MessageConfigura- Shared module containing message and localization information. tion.sys Is needed for UserCommunication.sys. GlobalCodeAndCon- Shared module containing global code for FlexLoader Vision fig.sys RAPID code. Tools.sys Module for convenient and common tool handling. EntryControl.mod Module for handling entry request, entry indication lamp and door lock signals.
Page 277
B FlexLoader RAPID reference B.6 FlexLoader assistance and utility functionality Continued UserCommunication.sys The FlexLoader Vision standard modules integrate a localizable user communication interface. The module UserComunication.sys contains a number of predefined procedures/functions for interacting with the operator. Name Description Func num activeMes- Check active types of messages.
Page 278
PROC WriteWarn- Writes a warning message to the FlexPendant event log and ing(num TextNum- FlexLoader Vision if wanted. Also sets warning flag for correct ber,bool ShowInFlex- indication at light tower. Program execution continues. Loader Vision) Arguments as in WriteError.
Page 279
If needed, new values can be added. However, do not remove or change values, as they are used in the FlexLoader Vision core functionality. Use range 1 .. 200 for integrator messages. Other identifier ranges are reserved for predefined system messages.
Page 282
FlexLoader Vision. Use this procedure first before teaching or using positions that need a TCP that is attached to the FlexLoader Vision position. Use with caution. FUNC num getCycle- Returns cycle time in seconds as a num. If no valid cycle time Time() calculated, return value will be -1.
B.7 FlexLoader machine tool interface functionality B.7 FlexLoader machine tool interface functionality Overview The FlexLoader Vision application functionality handles machine tool and part specific aspects of the FlexLoader Vision. The integrator is fully responsible for adopting this functionality to the actual application. Module Description TemplateMachine.sys...