From Days to Hours: Seamless Integration of Photoneo 3D Vision into ABB Robotics

For years, manufacturers have faced integration bottlenecks – the complex, time-consuming gap between advanced 3D vision and robotic control. But this has to change. 

On December 11th, we hosted an exclusive webinar with experts from Photoneo and ABB Robotics to present how we merged Locator Studio and Bin Picking Studio directly into the ABB Robotics Ecosystem and OmniCore controller. 

By allowing CAD-based and AI-driven applications to run within the familiar ABB Robotics environment, we’ve proven that what once took days of programming can now be accomplished in mere hours. 

The session, led by Benoît Gerber (ABB Robotics), František Takáč, and Martin Tabačiar (Photoneo), went deep into how this synergy boosts ROI and simplifies the deployment.  

Now, let’s look at the answers to your questions from the webinar’s live Q&A session.

Hardware Compatibility & Installation

Q: Is the system compatible with large robots like the IRB 6700? 

Yes. The Photoneo software can be installed on all ABB robots. There are plugins available for all sizes of robots, ensuring scalability from small collaborative setups to large industrial applications.

Q: Do I need an Industrial PC (IPC)? 

Yes. The architecture requires three main parts:

1. The Vision Device: (3D Scanner or Camera) to acquire the scan.
2. The Visual Controller: An industrial PC where the point cloud is processed, and localization/path planning occurs.
3. The Robot Controller: Communicates with the visual controller via TCP/IP. 

Note: If you buy the full ecosystem kit, the Industrial PC is included.

Q: Can I manage two robots with a single sensor? 

While physically possible to connect, it is not a standard or recommended configuration. Using one vision controller for two robots makes path planning and collision calculations problematic. The standard recommendation is one sensor per robot (or utilizing ABB Robotics MultiMove for coordinated control, though distinct sensors remain best practice).

Q: Is it possible to use the system with a robot mounted on a 7th axis (linear track)? 

Yes. We have successful applications where the robot moves on a linear axis using Locator Studio. The camera can be mounted on the robot body, and calibration is fully supported.

Hardware & Integration Requirements

Q: Do I need to purchase a separate industrial PC for Bin Picking Studio or Locator Studio?

An industrial PC is included in the kit provided by Photoneo. However, if your setup already has a suitable PC, you can contact Photoneo to order the kit without it.

Q: Is it difficult to mount a PhoXi 3D Scanner to a GoFa robot for “Hand-Eye” sensing? I’m worried about collisions.

We provide standard adapters to mount scanners directly to the robot. You have two options: mounting at the flange (axis 6) or alongside one of the arms to reduce the footprint. 

Regarding collisions, the sensor is integrated into the collision avoidance system. The software treats the scanner as part of the robot’s body, so it will automatically prevent the sensor from hitting bin walls or other obstacles.

Scanners vs. Cameras: Choosing the Right 3D Sensor

Q: Why use a 3D Scanner vs. a 3D Camera?  

The choice depends on the nature of your scene:

• 3D Scanner (e.g., PhoXi 3D Scanner): Best for static scenes requiring high resolution. It uses structured light projection.
• 3D Camera (e.g., MotionCam-3D): Best for dynamic scenes. It can capture objects in motion (using parallel structured light).

Q: Can we perform continuous scanning on a conveyor? 

Yes. By using the MotionCam-3D, you can perform very fast scans (10–20ms). When paired with an encoder to track the conveyor speed, the system can accurately pick moving objects.

Q: What is the point density/precision?  

It depends on the sensor model.

• Small Sensor (S size): ~0.2mm point-to-point distance.
• Large Sensor (XL size): ~0.9mm point-to-point distance (covering pallets up to 2.6m high).
• Summary: The technology offers sub-millimeter accuracy.

To find the best 3D sensor for your needs, check out our application fit guide! 

Software: RobotStudio & Picking Solutions

Q: Is RobotStudio required for installation?  

Technically, you can install the ABB Robotics add-in without it, but practically, yes, you need RobotStudio. 

You will need it to:

• Enable the firewall for socket communication.
• Configure Input/Output signals for gripper control.
• Run the actual application effectively.

Q: What is the difference between Locator Studio and Bin Picking Studio? 

• Locator Studio: Reports the 6D pose of objects in the scene. It is ideal if you have multiple grippers or semi-oriented parts.
• Bin Picking Studio: A complete solution that calculates the specific trajectory for the robot to pick an object without collision. This is best for parts that are randomly oriented in a deep bin.

Q: Is collision avoidance included?  

Yes. In the Bin Picking Studio, collision avoidance is calculated internally. The trajectory provided to the robot is already verified to be collision-free regarding the bin, the tool, and the environment.

AI, Localization & Software Logic

Q: Can I use CAD-based localization and AI-based picking in the same application?

Yes. You can switch between CAD-based and AI-based solutions. However, keep in mind that switching often requires a gripper change (e.g., switching from a magnetic gripper for metal parts to a vacuum gripper for cardboard).

There are technical challenges to manage here. You’ll need to rename certain “requests” in the system module to avoid naming conflicts and manage when the “background task state server” is active, as Bin Picking Studio uses it while Locator Studio does not. It is technically possible but requires careful setup.

Q: Can the system handle bins with mixed parts or tangled items?

Yes. You can configure multiple vision systems within one solution, each handling a different part. This allows the system to manage variety within a single bin.

Deployment & Support

Q: Can customers train the robot themselves, or is a technician required on-site?

If you have basic robot skills, you can do it yourself. Deployment is fast. Usually, we can get a system running in 1 to 3 hours.

We also offer remote support. If your vision controller is connected to the internet, our team can log in to help you tune scanning parameters, debug code, or walk you through the solution in real-time.

Q: Is there a way to “try before we buy” or run a feasibility study?

We offer two great options:

1. Rentals: You can rent a demo bundle for one month for testing.
2. Simulation: We can take a CAD model of your part and real scan data from your factory, then simulate the entire process in RobotStudio. This validates the solution before you spend a penny on production hardware.

Handling Challenging Materials & Environments

Q: How do you handle shiny metals or changing ambient light? 

• Shiny/Reflective Objects: We utilize different laser projections. The Blue Laser technology typically performs better on reflective or semi-transparent surfaces than red lasers.
• Ambient Light: The PhoXi 3D Scanner features “Ambient Light Suppression Gen 3,” allowing it to scan even in direct sunlight (up to 100,000 lux).

Q: Can the system detect transparent objects like glass bottles? 

• Semi-transparent (PET/Plastic): Yes, the Blue Laser performs well here.
• Clear Glass: This is difficult. Pure clear glass is hard to capture with point clouds alone. However, utilizing the RGB sensor for texture can help, but full transparency remains a physical challenge for light-based scanning.

Q: Can it be used in harsh environments (Dust/Welding)? 

Yes.

• Standard Protection: Sensors come with IP65 rating.
• Harsh Protection: For extreme dust, welding flashes, or foundries, IP69 protective housings with active cooling or heating are available.
• Welding Applications: The sensors are thermally calibrated and can be used to scan large workpieces to generate welding trajectories.

Q: How sensitive is the camera to vibration?

If vibrations are heavy, we recommend using dampers between the construction and the camera. Alternatively, using the MotionCam-3D is advised because its rapid acquisition time (snapshot) eliminates motion blur caused by vibrations.

Advanced Applications

Q: Can I manage two robots with a single static sensor?

In theory, yes. Using ABB Robotics MultiMove system, you can control multiple robots with one controller. By connecting the sensor to the “master” robot, you can distribute tasks to the second robot.

Q: Is it possible to scan objects continuously on a moving conveyor?

Yes. This requires the Conveyor Tracking option. When paired with our MotionCam-3D, you can handle randomly placed objects because the camera provides high-quality 3D data even while in motion.

Q: Can I use two different grippers in a single solution?

In Locator Studio, yes – the system simply reports the pose, and you control the grippers. In Bin Picking Studio, it isn’t supported currently, but it is scheduled for a future release.

Want to see these systems in action? Contact our team to request a demo or a feasibility study for your specific parts.

Rewatch the full webinar on demand! 

Click on the image to re-watch the webinar