Mechanical Installation of the System#
This section describes the mounting and positioning requirements of the key components of the FlexiVision One vision system. Installation must only be carried out after the basic mechanical installation of the FlexiBowl and the optional hopper has been completed.
Warning
Mandatory prerequisites
Before proceeding with installation of the vision components, make sure that:
The FlexiBowl has been mounted and secured to the supporting structure, robot cell
The hopper, if present, has been installed correctly
The support structure for camera and illuminator has been prepared
For FlexiBowl installation, refer to the dedicated manual supplied with the system.
Note
Required skills
Mechanical installation requires:
basic mechanical assembly skills
use of measuring tools such as caliper, level, and tape measure
ability to read technical drawings
VisionController mounting#
The VisionController, industrial PC, manages image processing and communication with the robot.
As a sensitive electronic component, it requires careful positioning to guarantee proper ventilation and protection from contaminants.
Technical specifications#
Screw holes |
M5 |
|---|---|
Feature |
Value |
Width, overall with brackets |
245.00 mm |
Width, body |
227.00 mm |
Connector panel width |
200.00 mm |
Height, overall with brackets |
123.00 mm |
Height, body |
120.00 mm |
Depth |
61.10 mm |
Mounting requirements#
Requirement |
Specifications |
|---|---|
Recommended position |
Inside the electrical cabinet or on a dedicated panel near the robot cell |
Ventilation clearance |
Minimum 50 mm on all sides for air circulation |
Fixing |
35 mm DIN rail or M5 screws on panel |
Ambient temperature |
|
Protection |
Minimum IP40, installation inside an IP54 electrical cabinet is recommended |
Installation procedure#
Mounting with holes#
Phase |
Operating instructions |
|---|---|
1. Support preparation |
Drill the holes according to the technical drawing |
2. Unpacking |
Remove the VisionController from the packaging, taking care not to damage the connectors. Verify product integrity. |
3. Fixing |
Fix the VisionController using M5 screws |
Mounting on DIN rail#
Phase |
Operating instructions |
|---|---|
1. Support preparation |
Verify that the rail is clean and firmly fixed. |
2. Unpacking |
Remove the VisionController from the packaging, taking care not to damage the connectors. Verify product integrity. |
3. Fixing |
Hook the device onto the rail and slide it until it clicks into position. |
Warning
Ventilation
The VisionController generates heat during operation. Always guarantee at least 50 mm of free space around the device. Otherwise the following may occur:
overheating and automatic shutdown
reduced performance
damage to internal components
Camera mounting#
Accurate camera positioning and alignment are critical steps that directly affect calibration accuracy and the performance of the picking system.
Optimal working distance#
The camera must be mounted so that the front face of the lens is positioned at a specific distance, Working Distance, from the surface of the FlexiBowl plate.
For detailed calculation of the optimal distance for your application, refer to Optimal Working Distance Calculation.
FlexiBowl model |
Recommended working distance |
Lens included in the kit, focal length |
|---|---|---|
FB 200 |
800 mm |
35 mm |
FB 350 |
1000 mm |
35 mm |
FB 500 |
1000 mm |
25 mm |
FB 650 |
1000 mm |
16 mm |
FB 800 |
1000 mm |
16 mm |
FB 1200 |
1300 mm |
12 mm |
Positioning and alignment#
Correct camera alignment is essential to obtain high-quality images and guarantee picking accuracy.
Incorrect configurations. The images below show examples of incorrect camera positioning: the field of view, shown in red, is off-center with respect to the viewing area, covering only part of the working area or including zones outside it. These configurations compromise part recognition and vision system performance.
Correct configuration. The camera must be positioned centrally with respect to the FlexiBowl viewing area, backlight zone. In this way the field of view, shown in green, symmetrically covers the whole working area, guaranteeing correct operation of the vision system.
Centering |
|
Orthogonality |
|
Tip
To simplify commissioning and allow future adjustments, it is strongly recommended to design the camera support with micro-adjustment capability:
Z axis, height:
-10 mm / +30 mm, to adapt the working distanceX axis, left-right:
±10 mm, for fine centeringY axis, front-back:
±10 mm, for fine centering
This flexibility is especially useful during initial calibration and for any future recalibration.
Camera dimensions#
CAM-CIC-5000-20G-1 camera dimensions, mm#
Feature |
Value |
|---|---|
Width × Height, body |
29 × 29 mm |
Depth, body |
42.0 mm |
Total depth, including rear connector |
48.9 mm |
Front protrusion, lens mount |
12.60 mm |
Center distance of side mounting holes, M2 |
20.0 × 23.7 mm |
Front mounting holes |
2× M2 depth 3 mm |
Side mounting holes |
4× M2 depth 3.5 mm + 3× M3 depth 3.5 mm |
Weight |
88 g |
Warning
Fixing
Use the 4 M3 mounting holes on the camera body
Recommended screws:
M3 A2 / M3 8.8Tightening torque:
0.5 Nm, do not overtighten to avoid deformation
Tip
Camera position adjustment
To allow future corrections and avoid alignment issues, design the mechanical support with micro-adjustment on all axes:
Z axis, height:
-10 mm / +30 mmX axis, left-right:
±10 mmY axis, front-back:
±10 mm
A support fixed permanently with no adjustment capability makes it impossible to correct camera position after first installation.
Verify lens mounting#
Warning
Before final fixing:
Visually verify that the lens is installed
Check that the focal length is correct for your FlexiBowl model, lens label or order documentation
Make sure the lens is fully screwed in, metal-to-metal contact between lens and camera body
Do not remove or loosen the lens if it is already mounted correctly
Camera installation#
To guarantee correct operation of the vision system, the camera must be installed on a rigid and stable support. The FlexiBowl system itself does not generate vibration, but automated lines may include other vibration sources, such as industrial robots, transfer systems, or other machines in the line.
If such vibrations are transmitted to the camera, the acquired image may become unstable and the coordinates calculated by the vision system may become unreliable, compromising robotic picking accuracy.
Tip
For this reason it is recommended to:
install the camera on a rigid and stable structure
avoid supports affected by vibrations coming from robots or other machines
preferably use a structure independent from the machine
Warning
Camera fixing screws: loosening prevention
Camera fixing screws may loosen over time for the following reasons:
Excessive tightening torque, above 0.5 Nm: can deform the camera body and lead to later loosening. Always tighten with a maximum torque of 0.5 Nm.
Vibrations transmitted by the line: use medium-strength threadlocker on all fixing screws.
Incorrect screws: verify the use of M3 × 8 mm stainless steel screws as recommended.
Camera position adjustment#
The camera support must allow position adjustment to permit correct alignment with the FlexiBowl picking area.
Note
Starting from a nominal position with correct inclination, height, and centering over the backlit area, the following adjustments are recommended:
X/Y adjustment -> ±50 mm
Z adjustment -> ±50 mm
Rotation θ -> ±10°
Caution
Camera damaged during installation
To avoid damaging the camera during installation and adjustment:
Excessive tightening torque: do not exceed 0.5 Nm on M3 screws. Exceeding this value can irreversibly deform the optical body.
Incorrect handling: always handle the camera carefully, avoiding direct pressure on the optical body and sensor.
Impacts during installation: protect the camera during nearby mechanical work such as drilling, milling, or tightening structures.
TopLight mounting#
If the order includes a TopLight, overhead illuminator, it must be mounted on the same support structure as the camera to guarantee uniform illumination of the working surface.
Attention
During installation, the device must be switched off and disconnected from power.
TopLight dimensions#
Length × Width (mm) |
Height (mm) |
Height with fixing plate (mm) |
Central hole diameter |
Maximum useful surface [A × B] |
Maximum useful perimeter |
|---|---|---|---|---|---|
A × B |
C |
C + 10 mm |
D |
- |
- |
500x300 |
45 |
55 |
65 |
0.15 m² |
1.6 m |
700x300 |
45 |
55 |
65 |
0.21 m² |
2 m |
700x500 |
45 |
55 |
65 |
0.35 m² |
2.4 m |
900x600 |
45 |
55 |
65 |
0.54 m² |
3 m |
TopLight positioning#
The TopLight must be positioned centrally with respect to the useful illuminated panel area, with the camera optics mounted inside the central hole and flush with the upper surface of the TopLight.
The red arrows indicate the fixing screws of the lens rings, one for focus adjustment and one for iris adjustment. As shown in the figure, the TopLight must be mounted so that both screws remain accessible from above.
The camera field of view and the TopLight light beam, shown in green, must be aligned concentrically and perpendicularly with respect to the FlexiBowl viewing area.
As shown in the three views, front, top, and isometric, the TopLight must illuminate exactly the area framed by the camera, with both components centered on the vertical optical axis of the system.
An incorrect position occurs when the TopLight and camera are not centered on the FlexiBowl viewing area.
As illustrated in red, two typical errors are:
shifting forward or backward with respect to the viewing area
rotating the TopLight with respect to it
In both cases, illumination becomes misaligned and not perpendicular, compromising acquisition quality.
Installation procedure#
Phase |
Operating instructions |
|---|---|
1. Positioning |
Fix the TopLight to the support structure in a concentric position with respect to the camera. |
2. Distance from the surface |
Position the illuminator at a distance from the FlexiBowl surface similar to that of the camera in order to:
|
3. Orientation |
Make sure that the emitting surface of the TopLight is parallel to the FlexiBowl plate. |
4. Lighting angle |
Perpendicular to the surface, |
5. Fixing |
According to the chosen fixing method, see the next section. |
Fixing methods#
The TopLight can be fixed in two ways: on the corner or on the side.
Note
Fixing components are not included with the TopLight supply. Mounting can therefore be customized according to installation requirements.
Side fixing, groove: M4 nuts supplied
Corner fixing:
M4x20CHC screws not supplied
In both cases the use of a threadlocker compound, not supplied, is recommended to prevent loosening over time. Recommended tightening torque is between 0.5 and 1.5 Nm.
1. Corner fixing#
Corner fixing uses M4x20 CHC screws, not supplied, applied in the holes located at the four corners of the TopLight.
Corner fixing using M4x20 CHC screw, not supplied.#
2. Side fixing, groove#
Side fixing uses 4 M4 nuts, supplied, to be inserted into the side groove of the TopLight profile. The maximum insertion depth of the nut in the groove is 5 mm.
Side fixing using 4 supplied M4 nuts inserted in the profile groove. Maximum depth: 5 mm.#
Side fixing with brackets#
If the TopLight is mounted using brackets:
Error
Tip
Illuminator wiring#
Parameter |
Requirement / Action |
|---|---|
Voltage |
24 V DC, +/-10%. Minimum operating voltage: 20 V DC at the light input. |
Connector |
M12 5-pole, T-coding. |
Connector pinout |
Pin 1: +24V, brown. Pin 3: GND, blue. Pin 4: STROBE PNP, black. |
STROBE mode, PNP |
From 5 V to 24 V for 100% ON. From 0 V to 1 V for 100% OFF. |
CONTINUOUS mode |
Pin 1, +24V, and Pin 3, GND, connected. Pin 4, PNP, connected to Pin 1. |
Voltage drop, 10 m M12 cable |
1.15V @ 5A - 2.3V @ 10A - 3.5V @ 15A - 4.6V @ 20A, max 20A |
Shielding |
Use shielded cables to reduce electromagnetic interference, EMI. |
Warning
Electrical safety
Respect the indicated supply voltages and connection terminals.
Do not modify or disassemble the product.
Do not connect or clean the device while powered.
Do not look directly at the light source.
Note
For details about electrical connections, refer to Wiring and Connections.
Shielding from ambient light#
The stability of the vision system strongly depends on the consistency of lighting conditions. Variable ambient light can cause inconsistent detections.
Warning
Protection from external light sources
It is strongly recommended to shield the robot cell from:
direct or indirect sunlight
variable artificial lighting, for example lamps with dimmers
reflections from nearby glossy surfaces
flashes or intermittent lights in the area