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Gotting HG G-73650-A Basics, Commissioning And Software

Track guidance controller
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Basics + Software
Track Guidance Controller
Basics, Commissioning and Software
English, Revision 07
Date: 07.03.2018
Götting KG, Celler Str. 5, D-31275 Lehrte - Röddensen (Germany), Tel.: +49 (0) 51 36 / 80 96 -0,
Fax: +49 (0) 51 36 / 80 96 -80, eMail: techdoc@goetting.de, Internet: www.goetting.de
HG G-73650-A
Dev. by:
M.L.
Author(s).:
RAD / A.F.
HG G-73650-A

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  • Page 1 Basics + Software HG G-73650-A                         Track Guidance Controller Basics, Commissioning and Software HG G-73650-A English, Revision 07 Dev.

  • Page 2: Table Of Contents

    Contents HG G-73650-A Contents Introduction ...............4 Virtual tracks ................4 Suitable and unsuitable vehicle types ........5 How it works ................6 1.3.1 System Structure ................6 1.3.2 Steering Controller ................ 6 1.3.3 Sensor Fusion ................7 1.3.4 Track Controller ................7 1.3.5...
  • Page 3 Contents HG G-73650-A 3.1.1 CAN 1 ..................25 3.1.2 CAN 2 ..................25 Profibus ................26 Ethernet ................26 Serial Interfaces ..............26 3.4.1 SIO 1 ..................26 3.4.2 SIO 2 ..................26 3.4.3 SIO 3 ..................26 3.4.4 SIO 4 ..................27 Terminal ................
  • Page 4 Contents HG G-73650-A 4.11.9 (I) Datalogging (Parameterization of the output) ......63 4.12 Display and key pad of the control unit ........65 4.12.1 Status output on the Display ............65 4.12.2 Direct input options at the control unit .......... 67 Trouble Shooting .............

  • Page 5: Introduction

    Introduction HG G-73650-A Introduction The subject of this manual is the track guidance controller for AGV (Automated Guided Vehicles) used for following virtual tracks (see below). This manual describes the fol- lowing components of the track guidance controller: Track control with steering controller, sensor fusion and vehicle control (see...

  • Page 6: Suitable And Unsuitable Vehicle Types

    Introduction HG G-73650-A 1.2 Suitable and unsuitable vehicle types The range of particularly suitable vehicle types covers all vehicles that either have a fixed axle or symmetrical steering. Vehicles such as trucks, forklift trucks, electric tow tractors and some heavy-duty transporters fulfill these requirements. A fixed axle can be applied to the axis of symmetry without the problem of dragging wheels in curves.

  • Page 7: How It Works

    Introduction HG G-73650-A 1.3 How it works 1.3.1 System Structure System Structure Figure 4 Due to the strict separation of steering controller, sensor fusion and navigation system as well as the smart interaction with vehicle controller the track guidance controller of- fers a high degree of flexibility and is suitable for monitoring safety-critical vehicle components.

  • Page 8: Sensor Fusion

    Introduction HG G-73650-A Some steering servos and motor controller can be directly controlled by the steering controller so that a vehicle control unit is not required in every application. Related to monitoring, redundancy and customized modifications to the vehicle, a vehicle control unit (e.g.

  • Page 9: Parameterization

    Introduction HG G-73650-A Travel command: Segments 1, 2, 3, 7 Exemplary layout with travel commands as a combination of segments Figure 5 The vehicle can be placed between the support points. The track controller uses the incoming position data to identify what segment it is on and which support point fol- lows next.

  • Page 10: Preconditions / Options

    Introduction HG G-73650-A 1.4 Preconditions / Options If the internal sensor fusion is to be used, at least one incremental / rotary encoder must be used. Please ensure that this is a push/pull type with output voltage of 5 to 25 V and two tracks perpendicular to each other....

  • Page 11: Guidance Control In Detail

    Guidance Control in Detail HG G-73650-A Guidance Control in Detail The structure of the track guidance controller is shown in Figure 4 on page 6. Two in- cremental encoderscan be connected to the steering controller hardware. This is re- quired when:...

  • Page 12: The Segment File

    Guidance Control in Detail HG G-73650-A cle has to go through segments 10, 1, 7, 6 and 3. Since the vehi- cle drives backwards along segments 6 and 3, the velocity of the segments is negative (see also Figure 7 on page 12).
  • Page 13 Guidance Control in Detail HG G-73650-A Each row of this table is one support point. The first column contains the segment num- ber to which the support point belongs to. The second column contains the support point number. Columns 3 and 4 contain the X and Y coordinates of the support point in mm.

  • Page 14: Segment Search

    Guidance Control in Detail HG G-73650-A Segment FIFO shifting register Figure 8 2.1.1.2 Segment search When the guidance of the vehicle is initialized, only one position of the vehicle is known at first. To identify the currently drivable segments and to transmit them to the central control unit, a segment search can be carried out.

  • Page 15: Table 2 Example: Shifting Of Segments - Part I

    Guidance Control in Detail HG G-73650-A Before Example: After Segment number 33 just FIFO Segment processed FIFO Segment Example: Shifting of segments - part I Table 2 The list will be transferred to the vehicle controller via CAN bus. The vehicle controller can respond to the removed segment, by moving a new segment into the FIFO regis- ter.

  • Page 16: Transmission Of The Segments

    Guidance Control in Detail HG G-73650-A NOTE! In order to prevent the steering controller from reloading a seg- ment currently being changed by the vehicle control unit (the rev- olution period from "reading the list" to "list stored" can take one second), never edit the next segment (FIFO register number 1).

  • Page 17: Calculation Of The Steering Angle

    Guidance Control in Detail HG G-73650-A Segment 0 in the steering controller can be used as a version number of the segment file. Segment 1 is the transition for offset driving on the left. Segment 2 serves as a tran- sition for offset driving on the right.

  • Page 18: Feed Forward Control

    Guidance Control in Detail HG G-73650-A and the feed forward control. If the steering controller is correctly set, 80% of the cal- culated steering angle results from the feed forward control (dependent on the driving conditions). Only the remaining percentage of 20% are provided by the feed back control / regulator.

  • Page 19: Velocity Calculation

    Guidance Control in Detail HG G-73650-A If the vehicle starts moving with this calculated steering angle, the point towards which the vehicle aims moves on. In this way the vehicle returns to its intended track without oscillating, provided the steering velocity is sufficiently fast and the vehicle speed ad- justed.

  • Page 20: Modus Parameter Test

    Guidance Control in Detail HG G-73650-A 2.1.6.2 Modus Parameter Test This mode can only be activated if the vehicle is standing still. In this mode all basic functions can be tested during commissioning. For this purpose the terminal program provides a special menu where you can enter velocity and steering angle via the key- board directly (see section 4.9 on page 40).

  • Page 21: Odometric System

    Guidance Control in Detail HG G-73650-A 2.2.1 Odometric System The odometric system determines the change in the vehicle position and vehicle heading using the wheel rotations and/or steering angle and/or gyro. There are differ- ent odometric systems available: Number Description Advantages / Disadvantages There are 2 monitored wheels on 1 fixed axle.

  • Page 22: Sensors For Navigation

    Guidance Control in Detail HG G-73650-A Trax tag both odometries will be corrected and the difference between both is 0 again. If the encoder is defective, odometry 0 calculates a distance. Odometry 2 measures a distance that is too short. Over a certain distance a considerable differentiation between both odometries exists (inaccuracy from 30% up to 50% of the distance travelled).

  • Page 23: Initialization Of The Transponder Sensor Fusion

    Guidance Control in Detail HG G-73650-A It is the task of these tolerance definitions to protect a sufficient accuracy of the posi- tion against incorrect measurements. Thus over short distances only a measurement of high quality will be accepted. This prevents a positioning quality degradation caused by incorrect readings.

  • Page 24: Sky-Trax

    Guidance Control in Detail HG G-73650-A Number Code X Pos. Y Pos. Attribute 1 Attribute 2 Attribute 3 Attribute 4 -2480 -4555 9000 -2462 -3171 6000 4336 9500 8012 3031 6891 9000 Explanation transponder list Table 5 The first column displays the serial numbers of the transponder tags. The second col- umn includes the transponder or Sky-Trax codes.
  • Page 25 Guidance Control in Detail HG G-73650-A ling vehicle components such as motor controller, brake, speed and steering. In some cases a steering servo (e.g. Berger Lahr) or a motor control can be directly controlled by the vehicle control unit. In addition to the serial interfaces 4 IO channels are available. The configuration de- pends on the set vehicle option.

  • Page 26: Interfaces

    Interfaces HG G-73650-A Interfaces The steering controller has several interface options providing data transmission. These include 2 CAN, 1 Profibus, 1 Ethernet and 4 serial RS232 interfaces. Addition- ally the optional internal radio modem can be accessed via an integrated interface.

  • Page 27: Profibus

    Interfaces HG G-73650-A 3.2 Profibus The device works as a slave with profibus-DP V0 according to DIN E 19245 T3. The interface offers an automatic baud rate detection. The profibus address may be ad- justed. You will find detailed specifications accordingly in the reference manual.

  • Page 28: Sio 4

    Interfaces HG G-73650-A 3.4.4 SIO 4 SIO4 is an adjustable RS 232 interface with the following default values: baud rate 8 bit, no parity and 1 stop bit. The following protocols can be configured via parameters: Name Description Convoi Leader...

  • Page 29: Commissioning

    Commissioning HG G-73650-A Commissioning For hardware mounting please see our included hardware description for control unit HG 61430. CAUTION! When starting the commissioning of the vehicle ensure that all safety devices are installed and functional! NOTE! At the beginning of commissioning, the vehicle has to be lifted up...

  • Page 30: Commissioning Terminal Program

    Commissioning HG G-73650-A 4.2 Commissioning Terminal Program For further commissioning purposes use the operating software running on the steer- ing controller. The software can be called up via the RS 232 interface and a connected PC running a terminal program.

  • Page 31: Parameter Settings

    Commissioning HG G-73650-A 4.2.2 Parameter Settings The following parameter settings are required. Adapt the COM-Port, if necessary (see below): Terminal Settings Monitor Program Baud rate 115200 Baud Also possible: 9600, 19200, 38400 und 57600 Baud Terminal emulation ANSI Terminal 24 lines, 80 columns...

  • Page 32: Main Menu

    Commissioning HG G-73650-A 4.4 Main Menu Main Menu HG73650V10.04 14.05.09 Kompilat Jun 03 2009 Main Monitor Navigation Main Monitor Sensorfusion Vehicle Monitor Datalogging Test Monitor Errorlogger Parameters Navigation Load Parameters form EEPROM Save changed Parameters Update Parameters (PC -> Controller) Download Parameters (Controller ->...

  • Page 33: A) Main Monitor Navigation

    Commissioning HG G-73650-A 4.5 (A) Main Monitor Navigation  Once has been selected in the main menu, the following display appears. Main Monitor Navigation Vehicle: Target: Deviation: Angle: 0.00 [ ° ] Angle: 0.00 [ ° ] Angle: 0.00 [ ° ] Pos X: 0.00 [ m ]...

  • Page 34: Table 11 Main Monitor Navigation: Section "Target

    Commissioning HG G-73650-A Parameters "Target" summarize the nominal values of the current segment. Name Description Unit Angle nominal vehicle heading degrees Pos X Set value for X component of position of the symmetrical axis meters of the vehicle Pos Y...

  • Page 35: Table 14 Main Monitor Navigation: Section "Error

    Commissioning HG G-73650-A Name Description Sample Position between the support points. When starting a segment, sample is set to 1, raises up to 3 and is reset to 2 when reaching the third support point of the same segment (the next support points are used for the reconstruction of the track).

  • Page 36: Input Options

    Commissioning HG G-73650-A In case "Clearance" is set to 1, the vehicle control unit can operate the steering con- troller. If there are any manual entries via the terminal software, this clearance will be cancelled. Then the steering controller only reacts to inputs from the terminal software.

  • Page 37: Table 18 Main Monitor Sensorfusion: Section Antenna 1

    Commissioning HG G-73650-A "Antenna 1" defines the status of antenna 1. Name Description Unit Status Bit coded antenna status (see reference manual) Code Read transponder code Delta Y Position of the transponder underneath the antenna in Y direction Sum Vo.

  • Page 38: Table 21 Main Monitor Sensorfusion: Section Odometry 1

    Commissioning HG G-73650-A Name Description Unit Pos Y Y position of the vehicle meters Speed Velocity of the vehicle meters / second Accur. Number of transponder readings Main Monitor Sensorfusion: Section odometry (part 2 of 2) Table 20 "Odometrie1" defines the status of the odometric system of antenna 1.

  • Page 39: Table 23 Main Monitor Sensorfusion: Section Sky-Trax

    Commissioning HG G-73650-A Name Description Unit MW1/MW2 Left Tag angle of the first tag Right Tag angle of the second Tag Counter Left Counts all characters received from Sky-Trax Right Counter of all calculated positions Distance Left Measured distance of both tags...

  • Page 40: C) Vehicle Monitor

    Commissioning HG G-73650-A Unter Gyro sind die wichtigsten Werte des Gyro zusammengefasst. Name Description Unit Angle Angle of the gyro without drift correction and angle offset degrees Offset Offset for correction of drift while standing degrees Move Status is 1 if the vehicle is moving Main Monitor Sensorfusion: Section "Gyro"...

  • Page 41: E) Test Monitor

    Commissioning HG G-73650-A ATTENTION! Only then you should press the space bar! A correct sequence of these steps is essential. Otherwise the heading of data recording and the related allocation of these data would be lost. When quitting the data logging, first terminate the capture by following the sequence Hyperterm ->...

  • Page 42: Input Options

    Commissioning HG G-73650-A "Odometric System" outputs the sensor data for the odometry. Name Description Unit Inkrements left Increments of the left wheel Inkrements right Increments of the right wheel Gyro Angle of the gyro without offsets degrees Test Monitor: Section "Odometric System"...

  • Page 43: F) Error Logger

    Commissioning HG G-73650-A Description Unit Nominal velocity +0,5 meters / second Nominal velocity -0,1 meters / second Nominal velocity - 0,5 meters / second Space bar Nominal velocity = 0 meters / second Increase brake (if available in the selected...

  • Page 44: Table 31 Errorlogger: Vehicle Status

    Commissioning HG G-73650-A ATTENTION! Only then you should press the space bar! A correct sequence of these steps is essential. Otherwise the heading of data recording and the related allocation of these data would be lost. When quitting the data logging, first terminate the capture by following the sequence Hyperterm ->...
  • Page 45 Commissioning HG G-73650-A Column Name Description M_auswertung Bitcoded; indicates the type of the latest calculation 0 x 10 individual evaluation antenna 1 0 x 20 individual evaluation antenna 2 0 x 40 double evaluation of antenna 1 0 x 80 double evaluation of antenna 2...
  • Page 46 Commissioning HG G-73650-A Column Name Description Odo_Rechnung_1a.dY_Neu Odometry- based Y position for antenna 1 since last Transponder [m] Odo_Rechnung_1a.dSumme_Weg Odometry- based distance traveled for Antenna 2 since last transponder [m] Odo_Rechnung_2.dW_Neu Odometry-based for antenna 2 since current transponder [ Odo_Rechnung_2.dX_Neu...
  • Page 47 Commissioning HG G-73650-A Column Name Description Zustand_Rechnung_2 Status of position calculation with antenna 2: 0: no calculation 1: single measurement 2: double measurement t_Spannung_1 Signal strength generated by the transponder antenna 1 (should be > 400) t_Spannung_2 Signal strength generated by the transponder antenna 2 (should be >...
  • Page 48 Commissioning HG G-73650-A Column Name Description Fehler_Counter_7 Error counter for single measurement with antenna 2 Constant: everything OK +1: transponder distance does not fit +10: direction not OK (parameter) - Distance of transponders too small (parameter) - Same transponder code as before...
  • Page 49 Commissioning HG G-73650-A Column Name Description System_Time Increments every 50 ms, module 16 bits o_Lenkwinkel Actual steering angle of the vehicle Odo_LenkdW_Neu Actual steering angle odometry-based [ Odo_LenkdX_Neu Actual position, X component [m] odometry-based Odo_LenkdY_Neu Actual position, Y component [m] odomtry- based...

  • Page 50: G) Parameters Navigation

    Commissioning HG G-73650-A Column Name Description Sprung_Status Indicates, why the calculated position was not trans- ferred into odometry 0x01: Abs_Fehler_W > Abw_Tab_Winkel_Wert 0x02: Abs_Fehler_Quer > Abw_Tab_Quer_Wert 0x04: Abs_Fehler_Laengs > Abw_Tab:Laengs_Wert 0x08: fabs(t_dy_1) > 0.25 m OdodSumme_Weg Distance since last used transponder...

  • Page 51: A) Main

    Commissioning HG G-73650-A 4.11.1 (A) Main Using this menu the parameters for the sensor fusion and for the steering controller can be set Following selection screen appears: Main Menue -> Parameter Menue -> Main Program Variables Vehicle Option (current: Stapler...
  • Page 52 Commissioning HG G-73650-A Name Description RS 232 3 Baudrate Baud rate of serial interface 3 9600, 19200, 38400, 57600, 115200 are the options For all baud rates, the parameters are: 8 data bits, no parity, one stop bit RS232 4 Protocoll...

  • Page 53: B) Geometric

    Commissioning HG G-73650-A Name Description Simulation BR Can be switched on for debuging purposes. Sensor fusion will then be stopped. The steering controller calculates its position using the selected segments. Profibus address Profibus Adress: 0 to 126 At Profibus address 127 the bus is switched off Ethernet IP Ethernet IP: 1.1.1.1 up to 255.255.255.255.

  • Page 54: Table 33 Parameters Navigation > Geometric

    Commissioning HG G-73650-A Name Description Raddurchmesser Rechts Effective diameter of the right wheel at a given resolution of the encoder. If the encoder rotates with the same rotational speed as the wheel, then the effective diameter is the same as the wheel diameter.

  • Page 55: C) Accuracy

    Commissioning HG G-73650-A 4.11.3 (C) Accuracy This menu allows adjusting thresholds, where the vehicle shall be stopped. Main Menue -> Parameter Menue -> Main Accuracy Variables Accuracy Teach In (current: 20.000000 [ m ] ) Accuracy Track 0 (current: 20.000000...

  • Page 56: D) Steering

    Commissioning HG G-73650-A Name Description Accuracy Teach In Minimal necessary accuracy of the position for starting Teach In procedure (Note: Teach In is not yet implemented) Accuracy Track 0 Minimal necessary accuracy of the position for automatic operation, if the attribute is ATTRIBUT_ABWEICHUNGS_UMSCHALT = 0...

  • Page 57: Steering Correction

    Commissioning HG G-73650-A Name Descriptio Steering min Lowest limit of steering Steering Middle Center setting of steering Steering max Upper limit of steering Steering Scaling Resolution of steering on interface: if the angle is transmitted with of 1/ , the parameter must be 100 Comp.

  • Page 58: E) Stering Controller

    Commissioning HG G-73650-A Calculation of the correction coefficients Figure 26 Column A describes the required steps, column B the theoretical steering angles and column C the given steering angles. Comp. Middel is the average offset of both equations (see Table 35 on page 56).

  • Page 59: Table 36 Parameters Navigation > Steering Controller

    Commissioning HG G-73650-A Main Menue -> Parameter Menue -> Angle Controller Variables Angle Control Kp (current: 12.000000 Angle Control Tn (current: 0.000000 Angle Control Tv (current: 3.000000 Angle Control Td (current: 0.010000 Speed Comp. Fix (current: 1.000000 Speed Comp. Var (current: 0.000000...
  • Page 60 Commissioning HG G-73650-A Name Description Speed Comp. Var Variable proportion of the gradient of the steering angle ramp in 50ms (multiplied by the vehicle velocity in m/s). lower Limit Lower limit of the angle control (first part of the steering angle cont-...

  • Page 61: F) Speed Controller

    Commissioning HG G-73650-A 4.11.6 (F) Speed Controller The speed controller is not yet used in any vehicle. Up to this point the speed control is accomplished by the vehicle control unit. Main Menue -> Parameter Menue -> Speed Controller Variables Speed Control Kp (current: 100.000000...

  • Page 62: G) Sensor Fusion

    Commissioning HG G-73650-A Name Description Controller Type: Should always be set to 0 (PID controller with parameterizable parts (see point A - D)) Ringspeicher Peri Time delay for the cyclic buffer of the velocity estimator (not requi- red for controller type 0)

  • Page 63: Table 38 Parameters Navigation > Sensor Fusion

    Commissioning HG G-73650-A Name Description Min Dist. Reading The antenna will only trigger a position impulse if a certain minimum distance is covered. This prevents a side lobe from generating a position impulse. Min Dist. Single Minimum distance required for positioning calculation between two transponders with one antenna and two different transponders.

  • Page 64: H) Vehicle Specials

    Commissioning HG G-73650-A Name Description Secondary ONS Typ Secondary odometry is compared to primary odometry. Should large differences between primary and secondary odometry arise (see D, E and F), the accuracy of the internal sensor fusion will be set to a poor value and the vehicle stops. Therefore defective sen- sors can be detected.
  • Page 65 Commissioning HG G-73650-A Data Logging Navigation: Sensorfusion: 1: Ist Position H: Inkremente 2: Soll Position I: Odometrie 1 3: Achs Position J: Odometrie 2 4: Hilfs Position K: Odometrie Rechnung 1 5: Ziel Position L: Odometrie Rechnung 2 6: Abweichungen...

  • Page 66: Display And Key Pad Of The Control Unit

    Commissioning HG G-73650-A 4.12 Display and key pad of the control unit The display of the control unit provides an overview on the operating status of the steering controller, even without a laptop. Display of the control unit HG 61430...

  • Page 67: Table 40 Display Control Unit: Section Bahnregler

    Commissioning HG G-73650-A Name Description Unit Ubat Left: minimum supply voltage value Center: current value of supply voltage Right: maximum value of supply voltage Minimum and Maximum values adjust themselves to the current value within a short time. Nothalt See emergency stop (reference manual)

  • Page 68: Direct Input Options At The Control Unit

    Commissioning HG G-73650-A Name Description Unit Segment 1 Left: Segment 1 preset by the vehicle controller (next upcoming segment) Right: segment 1 processed by the steering controller (next upcoming segment) Segment 2 Left: segment 2 preset by the vehicle controller (next segment after next)

  • Page 69: Table 42 Display Control Unit: Input Options

    Commissioning HG G-73650-A Name Description Toggling start release Switch mode from driving in automatic mode / standby mode Browsing of vehicle errors Browsing of request errors Browsing of automatic mode errors Preset segment 0 Preset segment 1 Preset segment 2...

  • Page 70: Trouble Shooting

    Trouble Shooting HG G-73650-A Trouble Shooting Following you will find a tabular listing of any possible malfunctions. This troubleshoot- ing chart lists occurring symptoms and the malfunctions that may be causing the symptoms. In the third column you'll find instructions how to detect errors and how errors can ide- ally be resolved.
  • Page 71 Trouble Shooting HG G-73650-A Possible diagnosis / trouble- Error Possible causes of failure shooting Vehicle does not steer 1. Some vehicle types only steer 1. Try steering while driving while driving 2. Check the following parame- 2. Steering angle not properly ters.

  • Page 72: List Of Images

    List of Images HG G-73650-A List of Images Figure 1 Example: Virtual track with support points .......... 4 Figure 2 Example: A selection of vehicle types..........5 Figure 3 Sketch: Suitable vehicle types............. 5 Figure 4 System Structure.................. 6 Figure 5...

  • Page 73: List Of Tables

    List of Tables HG G-73650-A List of Tables Table 1 Explanation of a segment list with support points ......11 Table 2 Example: Shifting of segments - part I ..........14 Table 3 Example: Shifting of segments - part II ..........14...
  • Page 74 List of Tables HG G-73650-A Table 36 Parameters Navigation > Steering Controller........58 Table 37 Parameters Navigation > Speed Controller........60 Table 38 Parameters Navigation > Sensor Fusion ........... 62 Table 39 Display Control Unit: Section Sensor Fusion ........65 Table 40 Display Control Unit: Section Bahnregler ..........

  • Page 75: Essential Information For Reading This Manual

    Essential Information for Reading this Manual HG G-73650-A Essential Information for Reading this Manual In documentations of Götting KG the following symbols and assignments were used at the time of printing this manual:  Security advices have the following symbols, depending on the emphasis and the...

  • Page 76: Copyright And Terms Of Liability

    Copyright and Terms of Liability HG G-73650-A Copyright and Terms of Liability 9.1 Copyright This manual is protected by copyright. All rights reserved. Violations are subject to pe- nal legislation of the Copyright. 9.2 Exclusion of Liability Any information given is to be understood as system description only, but is not to be taken as guaranteed features.

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