ABB FlexLoader Vision User manual

ROBOTICS
Product manual
FlexLoader Vision

Trace back information:
Workspace Robots and Applications version a41
Checked in 2018-09-14
Skribenta version 5.2.025

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

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.
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 ABB.
Original instructions.
© Copyright 2014-2018 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview of this manual ...................................................................................................................
11Network security ...............................................................................................................................
131 Quick start
152 What is FlexLoader Vision?
173 Overview of the user interface
173.1 Menu ..............................................................................................................
183.2 Tool box ..........................................................................................................
193.3 Alarm ..............................................................................................................
203.4 System information ............................................................................................
214 Teachin
214.1 Introduction ......................................................................................................
224.2 Navigation .......................................................................................................
234.3 Detail ..............................................................................................................
264.4 Image .............................................................................................................
264.4.1 Image settings for 2D cameras ..................................................................
284.4.2 Image settings for 3D cameras ..................................................................
324.5 Positions .........................................................................................................
344.6 Parameters ......................................................................................................
424.7 Tools ..............................................................................................................
484.8 Grip ................................................................................................................
534.9 Supervision ......................................................................................................
564.10 Mechanics .......................................................................................................
604.11 Test & Save .....................................................................................................
635 Advanced teachin settings
635.1 Advanced image settings ....................................................................................
675.2 Advanced position settings .................................................................................
685.3 Advanced parameter settings ..............................................................................
685.3.1 Standard analysis ....................................................................................
745.3.2 Blob analysis ..........................................................................................
765.3.3 3D analysis ............................................................................................
785.3.4 AddOn analysis ......................................................................................
825.4 Advanced grip settings .......................................................................................
875.5 Advanced supervision settings ............................................................................
896 Operation
896.1 Introduction ......................................................................................................
906.2 Starting the system ............................................................................................
916.3 Stopping the system ..........................................................................................
926.4 Operation information ........................................................................................
946.5 Smartphone connection .....................................................................................
977 Camera
977.1 2D camera settings ............................................................................................
1037.2 3D camera settings ............................................................................................
1078 Settings
1078.1 Organizer ........................................................................................................
1098.2 Mechanics .......................................................................................................
1118.3 Service ............................................................................................................
1148.4 Gripping Limitations ...........................................................................................
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Table of contents

1188.5 Master/Slave ....................................................................................................
1219 Troubleshooting
1219.1 Problems with gripping accuracy ..........................................................................
1249.2 Identification problems .......................................................................................
1259.3 Communication problems ...................................................................................
1269.4 Camera problems ..............................................................................................
12710 Installation
12710.1 PC installation ..................................................................................................
13010.2 Basler camera mechanical and electrical installation ................................................
13410.3 VisioNerf 3D camera mechanical and electrical installation .......................................
13711 Commissioning
13711.1 Configuration editor ...........................................................................................
13711.1.1 Introduction ............................................................................................
13811.1.2 Main settings ..........................................................................................
14011.1.3 Camera settings ......................................................................................
14611.1.4 Robot settings ........................................................................................
14911.1.5 Tool settings ..........................................................................................
15011.2 User accounts ..................................................................................................
15211.3 System settings ................................................................................................
15211.3.1 Installed software ....................................................................................
15311.3.2 Settings .................................................................................................
15811.3.3 Licensing ...............................................................................................
15911.3.4 Configuration of user-defined mechanical equipment .....................................
16511.3.5 Robot installation ....................................................................................
16711.3.6 Smartphone connection ...........................................................................
16912 Maintenance
16912.1 General maintenance .........................................................................................
17112.2 Backup and recovery of the hard disk ...................................................................
17912.3 Upgrading FlexLoader Vision ..............................................................................
18113 Robot integration
18113.1 Introduction ......................................................................................................
18213.2 Calibrating the robot ..........................................................................................
19013.3 RAPID program ................................................................................................
19013.3.1 Overview ...............................................................................................
19113.3.2 FlexLoader application functionality ............................................................
19813.3.3 FlexLoader Vision interface .......................................................................
19913.3.4 FlexLoader Vision Lite functionality ............................................................
20113.3.5 FlexLoader assistance and utility functionality ..............................................
20513.3.6 FlexLoader machine tool interface functionality .............................................
20713.3.7 WorldZones ...........................................................................................
20813.4 Communication information ................................................................................
20813.4.1 Communication between FlexLoader Vision and the robot ..............................
21213.4.2 Communication between the robot and the PLC ............................................
21313.4.3 Communication between Master and Slave ..................................................
21613.5 FlexPendant Master (option) ...............................................................................
21914 FlexLoader Vision Lite
21914.1 Introduction ......................................................................................................
22214.2 Operation ........................................................................................................
22514.3 FlexLoader Vision Lite teachin .............................................................................
22614.3.1 Detail ....................................................................................................
22714.3.2 Load .....................................................................................................
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22914.3.3 Unload ..................................................................................................
23314.3.4 Options .................................................................................................
23614.4 Commissioning .................................................................................................
23614.4.1 Robot ....................................................................................................
24114.4.2 FlexLoader Vision Lite master detail ...........................................................
24214.5 FlexLoader Vision Lite configuration .....................................................................
251A Technical information
251A.1 File structure in FlexLoader Vision ........................................................................
253A.2 Logging the operation ........................................................................................
255A.3 Localization ......................................................................................................
256A.4 Manually restoring a backup ................................................................................
257B FlexLoader RAPID reference
257B.1 FlexLoader data type prefix .................................................................................
258B.2 FlexLoader Vision interface .................................................................................
264B.3 FlexLoader application functionality ......................................................................
272B.4 FlexLoader Vision Lite functionality ......................................................................
275B.5 FlexLoader conveyor system control .....................................................................
276B.6 FlexLoader assistance and utility functionality ........................................................
283B.7 FlexLoader machine tool interface functionality .......................................................
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Overview of this manual
About this manual
FlexLoader Vision is a vision system designed to guide industrial robots during
materials handling. 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. FlexLoader Vision Lite is a simplified
and limited, but very efficient and user-friendly version of FlexLoader Vision,
designed specifically for lathe applications.
Organization of this manual
This manual basically consists of three different parts.
Chapter 1 is a quick start guide describing the first steps when using FlexLoader
Vision.
Chapter 2-12 describe how to set up, calibrate, operate and 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
Vision, FlexLoader Vision Lite, that is specially developed for lathe applications.
The appendix gives more detailed information on communication, backup recovery
and RAPID reference.
Usage
This manual should be used during:
• installation and robot integration
• calibration of FlexLoader Vision
• detail teachin
• operation
• backup and recovery
• troubleshooting.
Who should read this manual?
This manual is intended for:
• installation personnel
• FlexLoader Vision users
• FlexLoader Vision integrators
• PLC programmers
• service technicians.
Continues on next page
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Overview of this manual

Prerequisites
The reader should have basic knowledge of:
• robot programming
• Microsoft Windows systems
• PLC programming
• mechanical and electrical installation work.
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
•The integration manual of the camera/s used together with FlexLoader Vision
Revisions
DescriptionRevision
First edition.A
Complete revision with content and illustration update.B
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Overview of this manual
Continued

Network security
Network security
This product is designed to be connected to and to communicate information and
data via a network interface, It is your sole responsibility to provide and continuously
ensure a secure connection between the product and to your network or any other
network (as the case may be). You shall establish and maintain any appropriate
measures (such as but not limited to the installation of 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, any unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
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Network security

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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.1
Install PC and camera.2
See Installation on page 127.
If necessary, make appropriate configuration changes.3
See Configuration editor on page 137.
Use the Camera -> Live window to adjust the camera (2D: focus, aperture; 3D: image
acquisition parameters) for good contrast and visibility of part features.
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 RAPID program on page 190 and FlexLoader RAPID reference on page 257
Perform a first pick with the robot at low speed.9
See Operation on page 89.
Make final teachin and refinements to to robot code.10
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1 Quick start

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2 What is FlexLoader Vision?
FlexLoader Vision is a vision system that guides ABB industrial robots during
materials handling with outstanding performance. It is a proven system offering
high speed, short teachin times, reliable production and a user-friendly interface.
ABB offers a software that identifies the workpiece location and orientation 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 applications.
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2 What is FlexLoader Vision?

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3 Overview of the user interface
3.1 Menu
When you start FlexLoader Vision you will see the following window.
xx1800000203
At the top of the FlexLoader Vision window is a menu showing a number of menu
icons that represent various system activities.
Used to start and stop the system. Also shows information 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
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3 Overview of the user interface
3.1 Menu

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. The functions of each of the icons in the tool box are described below.
Used to zoom in or out of an image and view the image at normal
scale again.
Reset zoom
Used to zoom in on an image.Zoom in
Used to zoom out of an image.Zoom out
If you have zoomed in on an image you can use this tool to move
around the image. Click the mouse button and drag the mouse to
pan. Then release the mouse button.
Pan
Used to define a position, area or gripper limit. Click the mouse
button, drag the mouse diagonally to draw a box of the desired size,
then release the mouse button.
Define posi-
tion
Used to define a grip. Click the mouse button to place the grip point
at the current mouse position.
Define grip
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 lines. Click the mouse button where you want the line
to start, drag the mouse to the point where you want the line to end,
then release the button.
Draw line
Used to draw boxes. Click the mouse button where you want the
box to start, drag the mouse to the point where you want the box to
end, then release the button.
Draw box
Used to draw circles. Click the mouse button where you want the
circle to start, drag the mouse to the point where you want the circle
to end, then release the button.
Draw circle
Used to undo the last drawing action.Undo
Used to changing the brush size for drawing. The brush size is dis-
played as a ring and the size can be adjusted with the mouse scroll
wheel.
Brush size
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3 Overview of the user interface
3.2 Tool box

3.3 Alarm
The system continuously carries out tests to check that all the units are working.
If a unit is not working it triggers an alarm that appears as a notification at the top
of 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
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3 Overview of the user interface
3.3 Alarm

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.
xx1800000206
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3 Overview of the user interface
3.4 System information