Step 5: Hopper Setup#

This section describes the procedure for configuring the hopper. The hopper is the component that automatically feeds parts onto the FlexiBowl when the fill level drops below a minimum threshold.

Note

Prerequisites

Before proceeding, make sure that:

The Hopper has been installed mechanically
Electrical connections have been completed, including control signals and power supply
The FlexiBowl is already connected

Accessing Hopper configuration#

1	From the main software page, click
2	In the SETUP page, locate and click the Hopper Setup icon Setup page
3	The Hopper configuration page opens

Hopper Setup interface overview#

The Hopper Setup page contains several sections for configuration of the operating parameters of the available hoppers:

Hopper Setup page

Section	Description
Enable Hopper	Switch used to enable or disable Hopper usage in the system
Steps	Number of sequences required for the plate section currently in the viewing area to reach the hopper discharge area
Time	Hopper activation duration in milliseconds
Signal	Number of the digital signal used to control the Hopper
Config Hopper	Button used to configure the hopper in more detail later

Configuration procedure#

Step 1	Enable Hopper	Enable the Enable Hopper checkbox
Step 2	Configure Signal	In the Signal field, enter the digital output number used to control the Hopper
Step 3	Save and complete	Return to the main page and continue with the next setup step

Important

Enable the Hopper only if the device is installed correctly.

Warning

It is essential to enter the correct signal number:

A wrong number will activate the wrong signal, which can be dangerous
Refer to the electrical diagram prepared during installation
If in doubt, contact the person who performed the wiring

Tip

The parameters set at this stage are sufficient for initial system configuration. The remaining aspects of hopper behavior will be defined later in the guided procedure.

Hopper Configuration#

Hopper configuration allows automatic replenishment of components onto the FlexiBowl® plate. The system uses vision to determine when the fill level is insufficient and when the hopper must be activated.

Step 1: Access the configuration#

1	Click the section
2	In the Hopper Setup section, connected loading units can be displayed and managed Hopper Setup page
3	Select Enable Hopper X to activate the corresponding hopper
4	Click Config Hopper X to access the specific configuration

Step 2: Define the control area#

In this phase, the portion of the plate that the camera must monitor for hopper discharge is defined.

5	Modify the blue box on screen so it frames the area where the components will be detected. Support tools: Info: click to display details about the page functions.

Step 3: Define the threshold values#

6	Click to open the Define Value Hopper Cam page, where the system is instructed to distinguish between an empty plate and a full plate. Define Value Hopper Cam page
7	Remove all components from the viewing area and click the first CAPTURE button.
8	Position the minimum number of components that must remain in the viewing area. If the number drops below this threshold, the hopper will activate.
9	Click the second CAPTURE button.
10	By clicking in the Expression Builder, the system automatically calculates Mean and Standard Deviation values.
11	Remove some parts and click .
12	Observe the result indicator: Green 🟢: insufficient level, Hopper activates, discharge required Red 🔴: sufficient level, Hopper does not activate Warning Insufficient calibration If the system does not detect the level correctly: Problem: always green, Hopper always activates -> Threshold too low or interference in the area -> Solution: increase the number of parts in the second acquisition and verify area cleanliness Problem: always red, Hopper never activates -> Threshold too high or monitoring area not representative -> Solution: reduce the number of parts in the second CAPTURE acquisition and repeat AUTO Problem: incorrect behavior, random green-red alternation -> Unstable lighting or area too small -> Solution: verify stable backlight, enlarge the monitoring area, and repeat calibration

Note

Fill Hopper Threshold = …

Step 4: Operating parameters#

Return to the main Hopper Setup screen to define the mechanical behavior.

Hopper Setup page

Operating Parameters#

Parameter

Description and procedure

Steps

Number of FlexiBowl advances, or sequences, needed to bring parts from the viewing area to the hopper discharge area.

Note

How to calculate it

	Empty the FlexiBowl plate completely
	Leave one component in the center of the viewing area
	Execute FlexiBowl sequences until the component reaches the hopper discharge area and count how many advances were needed
	The resulting count is the value to enter in Steps

Time

Hopper activation time in milliseconds. Recommended value: 100-1000 ms, average 500 ms. Adjust by about ±50 ms according to the desired flow.

Tip

Activation time depends not only on the configured value, but also on the volume of components currently present in the hopper bowl. Maintaining a constant load is essential for a uniform flow.

Tip

The Time value is strictly connected to hopper load volume:

With a full hopper, more parts will reach the discharge area
With a half-full hopper, fewer parts will reach the discharge area

An effective activation time depends on:

Part weight (*)	Part behavior	Hopper load volume	Recommended Time
Heavy parts	Tend to jam Do not jam	Less than 30% Between 50% and 80%	Time greater than 600 ms Time greater than 600 ms
Light parts	Tend to jam Do not jam	Less than 30% Between 50% and 80%	Time between 100 and 500 ms Time between 100 and 500 ms

General best practice: keep the hopper constantly filled between 50% and 80% to obtain a uniform flow

(*) Part weight is intended relative to the size of the hopper being used.

Important

In general, it is important never to exceed the maximum load of the hopper being used.

Saving the configuration#

Warning

Saving the recipe is mandatory

At the end of Hopper configuration:

	Verify that all parameters are configured correctly: monitoring area positioned thresholds calibrated, TEST working Steps and Time set
	Return to the main page
	Click
	Confirm the save

IMPORTANT: every change is stored ONLY if the recipe is saved correctly before exiting or changing page.

Without saving, all Hopper settings will be lost when FlexiVision One is closed.

Hopper troubleshooting#

Common problems and solutions#

Warning

Hopper never activates

Symptoms: the plate becomes empty but the Hopper does not discharge

Possible causes:

Threshold configured too low, so the system always thinks the plate is full
Monitoring area positioned incorrectly and not representative
Enable Hopper disabled

Solutions:

Verify that Enable Hopper is active
Repeat threshold calibration using more parts in the second acquisition
Move the monitoring area to a more representative zone
Execute TEST manually to verify the trigger

Warning

Hopper activates too frequently

Symptoms: the Hopper discharges continuously and the plate becomes overfilled

Possible causes:

Threshold configured too high
Discharge time too long
Monitoring area placed in a zone that is always empty

Solutions:

Reduce the threshold, meaning fewer parts in the second CAPTURE acquisition
Reduce Time by 100 to 200 ms
Verify monitoring area positioning

Warning

Discharged parts do not arrive in time

Symptoms: the robot still finds the plate empty immediately after Hopper activation

Possible causes:

Steps too low, so parts do not have enough time to arrive
FlexiBowl sequences not effective
Obstruction in the discharge path

Solutions:

Increase Steps by 1 or 2 units
Verify FlexiBowl configuration parameters, such as speed and angle
Physically inspect the Hopper to plate discharge path

Next steps#

Once Hopper Setup is completed, or skipped if no hopper is present, continue with:

Step 6: Robot Setup - configuration of robot communication

Step 5: Hopper Setup

Contents

Step 5: Hopper Setup#

Accessing Hopper configuration#

Hopper Setup interface overview#

Configuration procedure#

Hopper Configuration#

Step 1: Access the configuration#

Step 2: Define the control area#

Step 3: Define the threshold values#

Step 4: Operating parameters#

Saving the configuration#

Hopper troubleshooting#

Common problems and solutions#

Next steps#