FAMM User Manual V10-09.E1

User manual
AV Flexologic b.v. 02-12-2007

H. Kamerlingh Onnesweg 2
2408 WK Alphen aan de Rijn
The Netherlands V 1.1 alpha
Table of Contents
1 Introduction.......................................................................................................................3
2 Installation of FAMM.......................................................................................................4
2.1 Electrical specifications............................................................................................4
2.2 Mechanical specifications.........................................................................................4
3 General usage of the FAMM.............................................................................................5
3.1 Switching on.............................................................................................................5
3.2 Switching off.............................................................................................................5
3.3 Reset button..............................................................................................................5
3.4 Emergency stop buttons............................................................................................5
3.5 Mechanical maintenance...........................................................................................5
3.6 Optic maintenance.....................................................................................................6
3.7 Login to the computer...............................................................................................6
3.8 Light pillar................................................................................................................6
4 The control software.........................................................................................................6
4.1 Configuring (servicing) the FAMM..........................................................................7
4.2 The basic settings of the FAMM...............................................................................7
4.2.1 System tab.........................................................................................................7
4.2.2 Job defaults tab..................................................................................................8
4.2.3 Camera tab........................................................................................................8
4.2.4 Service tab.........................................................................................................9
4.2.5 Manual control tab............................................................................................9
4.2.6 Info tab..............................................................................................................9
4.3 Creating jobs.............................................................................................................9
4.3.1 Deletion...........................................................................................................12
4.3.2 Search..............................................................................................................12
4.3.3 Overview of cylinder layout............................................................................12
4.4 Importing of jobs.....................................................................................................12
4.4.1 Adobe acrobat ™ plug-in................................................................................13
4.4.2 ESKO graphics® platepatcher™.....................................................................13
4.4.3 Importing a mom file.......................................................................................13
4.4.4 External job creation.......................................................................................15
4.5 Mounting.................................................................................................................16
4.5.1 Initializing the FAMM....................................................................................16
4.5.2 Train of register marks....................................................................................17
4.5.3 Calibration of the cameras...............................................................................18
4.5.4 Preparations before mounting..........................................................................18
4.5.5 Start mounting.................................................................................................19
4.5.6 Automatic mounting process...........................................................................21
4.5.7 Manual mounting............................................................................................22
4.6 Saving the mounting information (reports).............................................................23
4.7 Showing the mounting information (reports)..........................................................23
4.8 Printing the mounting information (reports)............................................................24
4.9 The train screen.......................................................................................................25
4.10 Miscellaneous special functions..............................................................................25
4.10.1 Remount a cliché on a mounted cylinder/sleeve..............................................25
5 Appendix A (Spare parts list)..........................................................................................25
User manual FAMM page 2 of 25

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1 Introduction
The FAMM short for Fully Automatic Mounting Machine is a mounting machine with which
the human factor in the mounting process is eliminated. The operator only needs the make the
preparations for mounting. This means preparing the sleeves for mounting and laying down
the clichés that need to be mounted. With preparing the sleeves is meant applying tape to the
sleeves and maybe even demounting the old clichés and tape before applying new tape. The
sleeve preparation can even de done while the FAMM is mounting meaning the work is done
parallel. When the preparation of the first sleeve is done is can be placed in the FAMM and
the start button can be pressed to start the mounting process The accuracy with which the
FAMM will mount can be set.
Preparations like creating a job, which tells the FAMM where the clichés need to be mounted,
have to be done on the FAMM as well
After mounting there is the possibility to check the position where the cliché is mounted.
There values can also be stored as a quality report.
This data can be viewed and or printed at any time on the FAMM except during mounting
The file structure also makes it possible to import the data into programs like Microsoft Excel.
The goal of the FAMM is to mount every cliché in the same manner at the same position and
that during mounting of the FAMM the operator can parallel do the preparations for the next
sleeve.
This manual will explain the operation of the FAMM and how to operate it.
With the term operation is meant both the machine and the operator software.
AV Flexologic b.v.
H Kamerlingh Onnesweg 2
2408 AW Alphen aan den Rijn
The Netherlands

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2 Installation of FAMM.
The installation of the FAMM will always be done by a service engineer or an agent of AV
Flexologic b.v. unless explicitly mentioned differently in the contract.
2.1 Electrical specifications
H. Kamerlingh Onnesweg 2 H. Kamerlingh Onnesweg 2

2408 AW Alphen aan den Rijn 2408 AW Alphen aan den Rijn
The Netherlands The Netherlands
Tel: (0031)(0) 172 - 43 42 21 Tel: (0031)(0) 172 - 43 42 21
Fax: (0031)(0) 172 - 43 79 19 Fax: (0031)(0) 172 - 43 79 19
Machine type:FAMMModel:1700 of Machine type:FAMMModel:1700 of

2000Serial No:ddmmyy-123Year of 2000Serial No:ddmmyy-123Year of
constructionyyyyElectrical rating380 V constructionyyyyElectrical rating240 V AC60
AC50/60 Hz 3 PH14.16 Hz3 PH17.83 FLAFuse: 20
FLAFuse: 16 ASupply disconnect ASupply disconnect rating11.72 A17.64
rating8.25 A13.85 AICRating of largest AICRating of largest motor/load:2.25
motor/load:2.25 AElectrical drawing AElectrical drawing number:87-1-001-0E
number:87-1-001-0E (FLA: Measured full load of equipment)
(FLA: Measured full load of equipment) (AIC: Amperes interrupt capacity)
(AIC: Amperes interrupt capacity)
www.flexologic.nl
www.flexologic.nl
For European connection of the FAMM For American connection of the FAMM
For electrical drawing see appendix A.
2.2 Mechanical specifications
Below are the sizes and weight for the different models of the FAMM.
FAMM 1700
Height 1520 mm (59 7/8 inch)
Depth 1660 mm (65 2/5 inch)
Width without conveyor 3350 mm (131 7/8 inch)
Width including conveyor 4940 mm (194 ½ inch)
Weight 2500 kg (5512 lbs)


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FAMM 2000
Height 1520 mm (59 7/8 inch)
Depth 1660 mm (65 2/5 inch)
Width without conveyor 3650 mm (143 7/10 inch)
Width including conveyor 5995 mm (236 inch)
Weight 3000 kg (6614 lbs)
3 General usage of the FAMM
3.1 Switching on
Turning the main switch does switching on the FAMM.

The switch is located on the back of the machine on the left hand side (looking at the machine
from the back). When switching on the machine the computer is also switched on.
3.2 Switching off
When the FAMM is being switched off first the computer needs to be switched off. When the
computer has switched off then the FAMM can be switched off by turning the main switch.
When turning the main switch off the safety gate will open.
3.3 Reset button
The reset button, which is located at the front on the left side of the FAMM, must be pressed
after switching on the FAMM. This button will allow all the drivers to be powered up by
enabling the safety relay. Pressing the reset button will not initiate any movement within the
FAMM!
When an emergency stop button has been pressed and released the reset button must be
pressed to reset the safety relay. The reset button being pressed is indicated by the light within
the button (light on means pressed)
3.4 Emergency stop buttons
The FAMM is equipped with 2 emergency stop buttons. These buttons are situated at the front
of the machine, one on the left and one on the right side of the safety gate. Their buttons are
for situations in with the FAMM needs to immediately stop all actions. When one of these
buttons was pressed this situation must first be relieved before being able to use the FAMM
again. Relieving the emergency situation is done by turning the pressed button to the right
(clockwise) until it pops out. After this was done the reset button can be pressed again and the
reset light will go on.
3.5 Mechanical maintenance

The FAMM hardly needs any mechanical maintenance. Some of the moving parts have grease
nipples but they are already filled before delivery and don’t need additional filling. It is
however important to keep the room where the FAMM is placed clean because some of the
parts have been grease and dirt or dust can easily stick to it causing friction and wear.

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3.6 Optic maintenance
The optics of the FAMM consists of 2 cameras with lenses and so called doal lighting.
The doal’s are the black rectangular boxes underneath the cameras and lenses.
These doal’s have a see through mirror and a halogen light bulb with reflector.
When dust gathers on the mirror it will influence the quality of the images that the cameras
receive and therefore the recognition level will also go down. It is important to clean the
mirrors on a regular basis depending on the amount of dust present in the room. It might be
from once a week to once a month. Clean the mirrors by blowing clean air over them. Don’t
use the regular air because it might have oil in it to lubricate the equipment. Use cans with
clean air instead.
3.7 Login to the computer
When the FAMM is switched on the computer will also boot up.
When the boot is finished it will ask to login.
Username: Operator
Password: avmom
The FAMM control software will automatically startup and show the main screen.
The next chapter will explain the functionality of the program
3.8 Light pillar

The light pillar can distinguish 4 different conditions that the FAMM can be in.
Light Light form Meaning

color
Green Burn Busy mounting
Green Flash Sleeve ready and swing out for change (need help to continue)
Red Burn Emergency stop pressed
Red Flash Error occurred, need help to continue
4 The control software

The different functions of the control software can be divided into these main tasks:
1. Configuring (adjusting) the FAMM
2. The basic settings of the FAMM
3. Creating jobs
4. Importing jobs (optional)
5. Controlling the FAMM, the actual mounting.
6. Storing the mounting values (reports)
7. Showing the mounting values
8. Printing the mounting values
9. Miscellaneous specific functions
These different tasks will be explained in the following paragraphs

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When explaining the functionality it is presumed that the operator of the FAMM has some
experience in operating a computer using Windows as the operating system. Opening and
closing files, selecting, scrolling and using the mouse is not completely new.
4.1 Configuring (servicing) the FAMM
With the fraise configuring is meant the mechanical and software adjustments needed to make
the FAMM operational. This will as mentioned earlier only be done by engineers from AV
Flexologic b.v. unless specifically mentioned otherwise. This should only be done when
placing the machine. Only in case of moving the machine of replacing parts it may be
necessary to partially reconfigure the FAMM.
This part of the software can be found by selecting the button ‘Options’ in the main screen
and then select the tab called ‘service’. The software now requires a username and password
to open the screen. This means that this part of the functionality is shielded from the daily
operator.
Changes made in the service screen will in most cases influence the performance of the
FAMM.
This is why only trained engineers are allowed to access.
4.2 The basic settings of the FAMM
With basic settings is meant the default setting when using the FAMM
These are default settings that the operator can and may change. It may look like configuring
the FAMM but they only specify how the operator wants the FAMM to perform the mounting
process.
To view and or change the default setting we need to select the ‘Options’ button on the main
screen. This will open a new screen containing several tabs (sub screens).
Each tab will now be explained in a separate paragraph.
4.2.1 System tab
This tab will always become visible first when opening this screen.
It contains some general system setting which will be explained in the below table.
Setting Influence
Language The language in which the program is displayed
Units The units in which values are displayed
Conveyor Number of detections before concluding the register mark was not
Amount of movements found.
before message
Conveyor Number of movements without camera searching for register mark
Amount of movements so that something resembling register mark may be skipped.
before detection
Import location Default file location where import files (*.mom files) can be
found. This setting can only be changed when import option is
active.

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4.2.2 Job defaults tab
In this tab the default values can be set that will be assigned when a new job is created. These
values can be changed afterwards but if new jobs are often created and the needed values are
mostly the same it is advisable to change the default settings to the required values. It will
also prevent problems during mounting because of incorrect values.
The following job fields are changeable in default value:

Field Influence
Cylinder Width The width of the to be used cylinder
Cylinder Repeat The repeat of the to be used cylinder including buildup
Mount tolerance Tolerance within to be positioned
Check tolerance Tolerance within mounting can be accepted
Extra press length Additional rotation length to fully press on the cliché
Mount and check setting possibilities

Checks Influence
None Only mount on checks (Quickest option)
Mount only Mount and check only the mounted marks (considerably slower
because process can not be combined)
Mount and repeat Mount and check both mounting and repeat marks (Full report but
very slow because all register marks need to be positioned for
checking)
Mounting position (X direction) options:

X position Influence
Left mark When positioning a cliché only look at X value for left register
mark.
Average X When positioning a cliché average X value of left and right
register marks.
4.2.3 Camera tab
On the camera tab the current settings of both cameras are displayed. They cannot be changed
from this screen (only from the service screen). The color with which the name of the camera
is displayed shows the current status of the camera.
Color Status
Green OK
Red Error
Yellow Not used (demo mode)
There is also a button on the screen called ‘Test cameras”. Pressing this button will open a
new screen showing more details about the current status of the cameras and also the PLC and
database connection. The cameras can be manually triggered by clicking the ‘Trigger’ button
and the answers from the cameras are made visible in the data fields. The ‘Trigger’ button is
only active when both cameras have the green OK status. To make the data and additional
status information visible click on the ‘Details’ button. It is also possible to switch the camera
lights on and off. It is possible to save the data that was send back by the cameras by clicking

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with the right mouse button on the data field. In the dialog that becomes visible the details for
saving can be filled in. It will only save the data for the selected data field.
4.2.4 Service tab
To get to the actual functionality you have to login first. The service functionality is not
needed for normal operation of the FAMM. The service is only needed when the FAMM is
installed and or when parts have been replaced. It is only necessary for service engineers from
AV Flexologic b.v. to have access to this part of the software. Might a situation occur in
which it is necessary to have access to the service screen it is then possible to have single time
access to it.
To have single time access click the ‘Generate user’ button. Let the appropriate employee of
AV Flexologic b.v. know the generated code by e-mail, phone or fax. In the mean time do not
close the current screen because regenerating a user code will generate a different one. And
typing in the same generated code will not work. When you receive the password code fill it
in and click ‘OK’. You now have access to the service screen. Make the necessary change(s)
and close the screen again. Be very careful with the service screen, you might unknowingly
change setting of the FAMM causing it not to operate (correctly) anymore!
4.2.5 Manual control tab
In this tab it is possible to initiate individual actions (movements) by clicking on the

appropriate buttons. It may be possible that in a certain situation the position of for instance
the manipulator of press roll needs to be changed or checked.
Movement / action Remarks

Manipulator up/down
Press roll up/down
Cylinder in/out Only possible when FAMM is initialized
Sleeve air on/off
Gate open/closed Closed only possible if FAMM is initialized
Trigger Cameras Ask for new data from cameras
Camera lights on/off
Turn Format cylinder Only possible when FAMM is initialized (direction can be
selected)
Ax to defined (selected) Only available when logged on as administrator
position
4.2.6 Info tab
Gives general information about FAMM and software version.
4.3 Creating jobs
Before the creating of jobs can be explained first the definition of a job needs to be explained.
A job means all the information needed for the FAMM to be able to mount the clichés and
find the information again afterwards a job consists in general of three parts:
1. The general job information
2. The cylinder(s) information

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3. The cliché(s) information (in the software also called plates).
Below a schematic explanation of the job structure.
General Cylinder Cliché

job Cilinder
Information Cilinder
Information
Cilinder Cilinder
Information gegevens gegevens
gegevens gegevens
Below is a schematic explenation of a cliche with 3 register pairs.

The middle pair is used for mounting and the top and bottom pair are used for checking.
It is also possible to mount cliches with only one registerpair.
If the cliches only have 1 registerpair it would be advisable to have those in or close to the
center of the cliche. The center of the clishe in the height (Y-direction) as shown below. This
will improve the total accuracy of the mounted cliché.
0,0 punt
Press overshoot
Repeat mark
Top height
Y coordinate
Top height
Mounting mark
X coordinate Width
Bottom height
Bottom height
Repeat mark
Press overshoot
Cliché with 3 register mark pairs Cliché with 1 register mark pair
paren
To create (add) a new job in the job structure on the left hand side of the screen the line ‘Add
a job…’ needs to be selected.
The following values can/need to be filled in for the new job.
Field name Description Mandatory

Job name Name of the job as free text X
Job number Number of the job as free text X
Job date Date of job being created (added by system)
Number of cylinders Amount of cylinders/sleeves (colors) in job X
Cylinder width The cylinder/sleeve width of the cylinder used X
Cylinder repeat The repeat length of the cylinder/sleeve used including X
length buildup

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Tolerance The accepted tolerance for mounting X
Check tolerance The accepted tolerance for checking X
Press overshoot Additional press distance to press down the entire cliché X
Plate data Name of plate type selected X
Tape data Name of tape type selected X
Operator Name of operator creating the job
Remarks Additional job information field
After filling in all the required data it can be stored by clicking the ‘Save’ button
Every time data is added to a job or changed in a job it needs to be confirmed by clicking the
‘Save’ button. When the ‘save’ button is pressed all entered data is checked whether the
values are within the boundaries. In case it isn’t accepted a message will appear stating which
value is not accepted and between what values (boundaries) it will be accepted. This
unaccepted value needs to be changed and then tried again by pressing the ‘Save’ button.
Mandatory fields cannot be left empty and will then not be accepted.
When all values are accepted the new job will be stored in the database and the next step can
de undertaken namely creating the cylinders.

Cylinder color Description of the color to be printed with this
cylinder/sleeve
Sectors Equal division in rotation (Y) direction for stackered
mounting. Y value will be calculated when selecting sector
In this case also with every addition or change confirm it by pressing the ‘Save’ button.
It is possible to add cylinders or to delete them. Adding them can be done by filling in the
required amount in the general job information. Or by pressing the line ‘Add a cylinder…’ in
the Job structure for the correct job.
When the import option is active it is also possible to add custom designed colors.
For additional information please refer to paragraph 4.9.2 Add colors.
Now that the cylinders have been defined we can add clichés (plates) to the cylinders.
This is done by clicking ‘Add a plate…’ in the job structure for the correct cylinder.

Plate number Unique number for the entire job X
X coordinate Distance from zero position to center of left register mark. X
Y coordinate Distance from zero position to center of left register mark. X
Width Distance between centers of left and right register marks X
Top height Distance between centers of mounting and top register marks
Bottom height Distance between centers of mounting and bottom register
marks
Sector Sector number which register mark is assigned to
Rotate Plaat moet geroteerd worden gemonteerd weergave
Mirror Plaat moet gespiegeld worden gemonteerd weergave
After filling in all the values for the different fields they can be stored by pressing the ‘Save’
button. When the ‘save’ button is pressed all entered data is checked whether the values are
within the boundaries. In case it isn’t accepted a message will appear stating which value is

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not accepted and between what values (boundaries) it will be accepted. This unaccepted value
needs to be changed and then tried again by pressing the ‘Save’ button.
Mandatory fields cannot be left empty and will not be accepted.
4.3.1 Deletion
To delete something it first needs to be selected in the job structure so that the program know
what needs to be deleted. Then press the ‘Delete’ button. First a confirmation for deletion is
asked. When this is confirmed the actual deletion will be executed.
When a job is selected for deletion it will be deleted including it’s cylinders and the cylinders
including the clichés. When a cylinder is selected for deletion the cylinder is deleted including
its clichés. All remaining cylinders with higher numbers will be renumbered so the are no
gaps in the cylinder numbers. When a cliché is selected for deletion only the selected cliché is
deleted.
All remaining clichés are not renumbered.
4.3.2 Search
It is possible to have the job structure show only a limited number of jobs instead of all the
jobs.
This can be done by applying a filter that only shows the jobs that comply with the given
criteria.
Applying this filter is done by selecting the line ‘Search for jobs…’ in the job structure.
It is then possible to specify the search criteria to which the job must comply.
There are three kinds of criteria that can be specified.
First select the field to use as criteria then fill in the criteria and finally click on ‘Search’.
Field Criteria specification

Job name The complete name or a part of the name
Job number The complete number or a part of the number
Job date All jobs between the start and end date
4.3.3 Overview of cylinder layout
It is possible to look at the layout of a created cylinder. In this layout the created clichés will
be shown and is sectors were selected they will also be shown.
The layout window can be made visible by clicking the ‘Layout’ button on the main screen.
The created sectors are shown as horizontal doted lines on the layout and show the sector
division on the cylinder.
Every created plate has a diagonal line in (default) the left upper corner. This diagonal line
shows the orientation of the cliché for mounting. When the fields mirror and rotate are also
used the location of the diagonal line in the cliché will change showing the orientation of the
cliché for mounting.
4.4 Importing of jobs
The creation of jobs is time consuming and prevents the FAMM from mounting.
This makes the creating of jobs an inefficient action executed on the FAMM

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It is also sensitive to errors because of all de data that needs to be entered it’s easy to mix up
values or type in the wrong value. In most cases the error is only discovered during or after
mounting, being during printing. The will be a very costly discovery because of time and
material being wasted. There are however more efficient and reliable ways to get the job
information into the FAMM.
The possible alternatives are:

1. Adobe acrobat ™ plug-in
2. ESKO graphics plate patcher ™
These 2 alternatives will be explained in more detail in the coming 2 paragraphs.
4.4.1 Adobe acrobat ™ plug-in
The PDF plug-in was developed to increase the efficiency and accuracy in the pre-press
process.
The pre press process starts at the DTP-department and end in the mounting department.
The plug-in stores the coordinates of the register marks made by the DTP department and
saves them into a separate files with the extension ‘mom’, short for Mount ‘O’ Matic, and
from now on called mom files. This generated mom file can be read (imported) by the
FAMM. The mom file contains all the information to automatically generate a new job that
contains all the necessary information. All data does not need to be added manually anymore
which saves time and prevents errors.
To be able to use the PDF plug-in first Adobe Acrobat ™ standard or professional needs to be
installed.
For further information on how to operate the PDF plug-in please refer to the PDF plug-in
manual.
4.4.2 ESKO graphics® platepatcher™
The DTP software developed by ESKO graphics® named Plate patcher™ also has the
possibility to generate mom files that can be imported by the FAMM. This software has 2
additional features being:
1. The possibility to generate clichés with multiple register mark pairs (as the FAMM
supports)
2. The possibility to include the plot file that can be read in and drawn by the mounting
machine (Not supported by the FAMM)
This makes it possible to generate the clichés that have the three register mark pairs
automatically.
For further information on how to operate the plate patcher™ software please refer to the
plate patcher™ manual.
4.4.3 Importing a mom file
To import a mom file we need to open the import screen which can be done by clicking the
“Import’ button on the main screen. In the import screen you can select the mom file to be
imported. It is also possible to manipulate the coordinates in the mom file during import.

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The choices are mirror horizontally, mirror vertically, rotate or do nothing.
The choice made will not influence the contents of the mom file this will not be changed by it.
The entire image that is read in will then be manipulated and stored in the database as a new
job.
The DTP department has to define an area in which all the clichés are located. This area will
be used as the reference for the optional manipulation during import.
An example to clarify the functionality:

The mom file consists of three clichés positioned as shown below.
Area from DTP

1 2
When ‘No mirror’ is selected the job is created with the clichés positioned as shown below.
.
1 2 1 2
3 3
As in mom file After ‘No mirror’
With ‘Hor. Mirror’ they are mirrored over a vertical ax.
1 2 2 1
3 3
As in mom file After ‘Hor. mirror’
With ‘Vert. Mirror’ they are mirrored over a horizontal ax.
1 2 3
3 1 2
As in mom file After ‘Vert mirror’
When doing a horizontal and vertical at the same time its equal to a 180 o rotation.
1 2 3

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3 2 1
As in mom file After ‘hor. en vert. mirror’
Every time a mom file is imported a new job is created. Not all fields in the imported job may
be filled in correctly. The fields that are not present in the mom file will be filled in with the
default values. These default values are the same as when a new job is created manually.
If these default values are not the correct values for this job they need to be changed before
you can start mounting. The values that might need changing after import are:
Field name Description

Cylinder width With of the to be used cylinder/sleeve
Cylinder repeat The repeat of cylinder /sleeve including buildup
Tolerance The accepted mounting tolerance
Check tolerance The accepted check tolerance for OK or NOK
Press overshoot Additional press distance to press down the entire cliché
Plaat data Name of plate type selected
Tape data Name of tape type selected
Remarks Will indicate this was an imported job
4.4.4 External job creation
There is besides the usage of the plug-in software also the possibility of having an additional
PC dedicated for entering the jobs. This PC is also known as the Offline Filling Database
(OFD).
The advantage is that even though the jobs are entered manually the FAMM can still mount in
the mean time. Both computers are connected via a network cable and share the database
containing the jobs. The OFD computer is dedicated for creating jobs and cannot control the
FAMM.
There are 2 different ways to implement this system and they will now both be explained.
Ethernet (TCP/IP) connection
OFD computer
FAMM with control computer
Option 1
Above picture shows the so-called ‘stand alone’ solution.
The FAMM is connected to the OFD using a cross-link Ethernet cable.
The jobs will be stored on 1 of the computers, preferably the FAMM computer, and the other
computer has access through the Ethernet connection. The computer that holds the jobs must

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be switched on for the other to reach them. This is why it is preferred to locate the jobs on the
FAMM computer.
FAMM network Customer network

Ethernet (TCP/IP) connection
OFD computer Server or workstation
FAMM with control computer
Option 2
The ‘stand alone’ network of the FAMM is connected to the existing company network using
a switch of hub. In this way the FAMM is integrated in to the total company network. The
jobs can also be located on the company server. Which in most cases is never switched off.
Disadvantage of option 1 compared to option 2 is that if the jobs are stored locally there are
no automatic backups of the jobs.
4.5 Mounting
4.5.1 Initializing the FAMM
Before the FAMM can actually start mounting it first needs to complete an initialization
procedure. This procedure makes sure that the machine knows the exact position of all
moving parts. This procedure must be executed in a specific order to prevent parts from
colliding. During the execution of this procedure the current status of all moving parts is
shown on screen.
When the procedure was executed successfully the buttons needed for the mounting process
will become active on the main screen.
The initialization button on the main screen will only be active when a job is selected and the
initialization procedure has not been executed before.
The initialization routine can only succeed when the covers of the FAMM are closed and the
reset button was pressed, meaning that the light in the reset button in on. If the light of the
reset button does not stay on after pressing the button please check if one of the emergency
stop buttons is still active. If so release it by turning it clockwise until it pops out and the try
the reset button again.
The covers of the FAMM have several functions:

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1. They protect against dirt and dust.
2. They keep out the environment light that may influence the cameras.
3. As protection to prevent possible injury from moving parts of the FAMM.
4.5.2 Train of register marks
To be able to work with the FAMM the camera system first needs to be told what type of
register mark it needs to recognize. To learn the system what type of register mark it needs to
recognize is called ‘Train’ in the program. Both cameras need to be told what to recognize.
When the train screen is opened is consists of two tabs (or screens). The screen that is shown
after opening is called ‘cameras’. The other one is called ‘Library’ and contains a list of
locations to store trained register marks.
To train a register mark first move the left camera to the pick-up position. This can be done
on the train screen in the left lower corner. The required camera can be moved to the
requested position by clicking the option. Place the register mark that needs to be recognized,
and now trained, underneath the left camera. If the lights are not on switch them on. Now
click on the ‘Trigger’ button to get new images with the cameras. The register mark does not
need to be placed exactly in the middle of the camera screen. The register mark that needs to
be trained must however be fully in view.
For the train action itself a ‘Train’ button is placed for either camera. These buttons are
default disabled to prevent an accidental train. These buttons can be activated on the library
tab by clicking the ‘Password to save library’. The username is: FAMM and the password is:
service. When these are filled in click on ‘Log on’ and the buttons will be activated.
Next to the train button of the left camera is a selection possibility called ‘Dual train’.
When this is selected the train button for the right camera disappears.
With this selection the train of the left camera is also used for the right camera.
Both cameras will use the same trained register mark. This will have a positive influence on
the accuracy of the FAMM.
The Region Of Interest or in short ROI (the orange rectangle) must now be placed over the
register mark or the par of it that needs to be recognized. The size of the ROI rectangle can be
altered so it always fits. When the ROI is placed the ‘Train’ button can be clicked. When the
train routine is finished the contours of what was recognized will be high lighted with dark
blue lines. Also 2 red lines appear indicating the center of the found register mark. This can
be corrected by moving the ROI and/or changing its dimensions and train again.
By using the dual train selection both cameras are now trained with the current register mark.
The cameras are now ready for use. When a new train is done it will overwrite the current
one. When the FAMM is switched off and on again the cameras will have forgotten the last
train and will be loaded with the last saved train for recognition. When after a train the ‘Save’
button is pressed the current train will be saved in the camera. This will be remembered even
after a switch off and on of the FAMM. The ‘Save’ button must be pressed for each camera
separately. When the FAMM is only used with one type of register mark then this is sufficient
for the system to run. It does not need to be stored into the library. The system will
automatically load this register mark type for recognition.
When the use of 2 or more register mark type is required the different types can be stored into
the library up to a maximum of 10 different types. Ones stored they can be selected and

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loaded for use. When a register mark is trained it can be stored into the library by first
selecting the location in the library for storage. Fill in a description for the register mark type
to be stored. When the description is filled in the ‘Save’ button for each camera can be
clicked. When the saving is finished the descriptions appear in the selected locations and the
bulb changes to green indication that the location is used.
To load a register mark fro the library it first needs to be selected. After selection the ‘Load
from library’ button needs to be clicked for both cameras. The cameras are now ready to
recognize the loaded register marks.
To remove a register mark from the library is needs to be selected first and the click the
“Flush selected’ button to delete the register mark. The descriptions will be removed and the
‘bulb’ will change to grey. This needs to be done separately for each camera. The ‘Flush
selected’ button is only available when the user is logged in.
When the option dual train is not used, which is not recommended because it could lead to a
mounting difference between automatic and manual mounting, The train routine must be done
for both left and right camera separately. The rest of the functionality stays the same.
4.5.3 Calibration of the cameras
The calibration of the cameras is partially equal to setting the reference position of the
cameras.
At the location where the calibration position is defined a register mark must be placed that is
recognizable for the cameras. For calibrating the cameras the ‘Train’ screen must be used.
The register mark must be placed in (or as close as possible to) the center of the camera
image. This is indicated with the blue lines. For positioning the register mark it is easiest to
first position the left or right camera at the calibration position. This can be done on the train
screen at the left lower corner. To position the register mark use the ‘Auto trigger’ option for
triggering the cameras to show new images. When the register mark is in the required position
the calibration routine can be started. When the routine is started the left camera will first
move to the calibration position and make and image and then the right camera will do the
same. After this the new calibration value will be shown on screen. If the train screen was
opened from the main or mounting screen the calibration values will automatically be saved.
If the train screen was opened from the service screen the values need to be saved using the
‘Save’ button on the service screen.
This functionality will have the FAMM take in account any minor differences between the 2
cameras.
It is necessary to calibrate every time the cameras and/or lenses have been mechanically
adjusted. It is also advisable to calibrate periodically. This depends on how intensively the
FAMM is being used but with normal use a period a week is the maximum.
4.5.4 Preparations before mounting.
A couple of preparations have to be made before the FAMM can start mounting the cliché
automatically. The FAMM will start the mounting process when the ‘Start’ button has been
pressed. The preparations are the following:
1. The creation or selection of a job.

2. Initializing the FAMM.

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3. Placing a prepared (taped) sleeve into the FAMM.
4. Placing the clichés on the conveyor.
The first three points have already been discussed

Item number 4 needs some further explanation
The conveyor has a line running through the middle and is a reference for placing the clichés.
The clichés need to be placed with the register marks that are going to be used for mounting
on top of the reference line. When placing the clichés there is a margin of about 10 mm (1/2
inch) around the reference line (Plus 5 mm / ¼ inch and minus 5 mm / ¼ inch). When more
clichés are placed on the conveyor there should be a gap of about 10 cm / 4 inch between the
clichés.
This cap is needed to prevent the manipulator from taking 2 clichés at ones.
The FAMM mounts the clichés from right to left (standing in front of the FAMM) because the
zero position is on the right hand side. This will also mean that the plates need to be placed
upside down on the conveyor. It means that the plate that is placed first on the conveyor is
mounted on the far right side of the sleeve closest to zero.
4.5.5 Start mounting
The mounting screen can be opened by clicking the ‘Mounting’ button on the main screen.
The mounting screen shows a table that contains all the created clichés of the currently
selected cylinder. If no cylinder was selected it will show the first cylinder.
It is possible to scroll through the created cylinders by clicking the next and previous button at
the top of the screen. The currently selected (shown) cylinder is the cylinder that will be
mounted when the start button is pressed. Before the mounting is started it is possible the
change the mounting options. If a mounting report already exists for this job then the options
are not changeable anymore. The report needs to be deleted before the options can be changed
again.
The possible options for checking are:
Checks Influence
None Only mount on checks (Quickest option)
Mount only Mount and check only the mounted marks (considerably slower
because process can not be combined)
Mount and repeat Mount and check both mounting and repeat marks (Full report but
very slow because all register marks need to be positioned for
checking)
Checking repeat marks only makes sense when the clichés actually do have these register
mark pairs. When this option is selected the cliché table will also be enlarged because there is
more data that will be used, checked and stored. This will of course also take more time.
The possible options for mounting are:
X position Influence
Left mark When positioning a cliché only look at X value for left register
mark.

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Average X When positioning a cliché average X value of left and right
register marks.
At the top of the screen some general job information is displayed to show which job is
currently being mounted.
On this mounting screen there are some buttons visible of which some are enabled and some
are not. Depending on the current status of the FAMM and software these statuses will
change.
Below all visible buttons will be explained.
Button Function
Start / Stop Start the actual mounting process after starting the button will read
‘Stop’ to be able to stop the mounting by pressing the same button
again.
Manual Mount the currently selected cliché manually
Pause / Continue If this button is pressed the mounting is paused and the button will
now read ‘Continue’. If the button is pressed again the mounting
will resume and the button will read “Pause’ again.
Change sleeve To initiate the sleeve change routine at a different moment then the
system would automatically start it.
Continue sleeve change Finish the sleeve change routine initiated by the system
Sleeve air on / sleeve air Stops the airflow for changing a sleeve and if pressed again
off resume the airflow.
Train If the cameras need to recognize a different register mark or they
need to be calibrated. It is also possible to learn (train) a new
register mark.
In the left lower corner a frame will be loaded that will show the current camera images. The
frame needs to connect to the cameras (it will show connecting dialogs) that might take a
while. Please wait for it to finish and then scroll the frame down so that the complete camera
image is shown. If in a new camera image the register mark is recognized it will show the
determined center using red hairlines. At the top of the camera images the so-called match
score is shown telling the percentage in match (resemblance) between the trained image and
the to be recognized image.
To the right of the camera images there is a frame in which all the moving items of the
FAMM are mentioned with their current status and/or position.
During mounting the cliché table will be updated with current data for the currently mounted
cliché. This information is the mounting duration, number of corrections for positioning and
the current position values. While the current values are not within the set tolerance value the
FAMM will keep adjusting the position of the cliché until the current values are within the set
tolerance.
If current values are outside tolerance the will be shown in red and it=f they are within
tolerance they will be shown in green. The values may be shown in grey if they are not
important like with mounting on only the left register mark the values for the right register
mark are then ignored and therefore grey. As soon as all values are green the FAMM will stop
positioning and start the actual mounting routine. When the current cliché is mounted the
FAMM will directly proceed with picking up the next cliché and start positioning it. This will
continue until all defined cliché for this sleeve have been mounted and the FAMM will then
automatically swing out the sleeve to be able to replace it with the next (empty) sleeve. When

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the new sleeve is placed and the change routine completed the cliché table on the mounting
screen will automatically go to the next sleeve to be mounted. The only thing that needs to be
done now is place the clichés on the conveyor en press ‘Start’.
It is possible to specify before mounting which plates need to be skipped of remounted.

By double clicking the cliché table at the mounted column a popup menu appears.
With this menu it is possible to specify what needs to be done with all clichés of the sleeve or
the selected cliché.
The popup menu has the following options:
Menu option Functionality

Set mounted Skip this cliché during mounting of this sleeve
Reset mounted Mount or remount this cliché during mounting of this sleeve
Set all mounted Skip all clichés of this sleeve
Reset all mounted Mount or remount all clichés of this sleeve
Check mounted Check the mounting register marks of this mounted cliché
Check top Check the top repeat register marks of this cliché
Check bottom Check the bottom repeat register marks of this cliché
Correction for next plate Read the correction of the current cliché to use as extra offset for next
cliché.
4.5.6 Automatic mounting process.
When all preparations have been made the actual mounting can start.
The (general) actions that the FAMM will now execute are:
1. All axes go to the set positions to pick up a cliché.

a. Table up
b. Lift up
c. Rotate table horizontal
d. Table to close position (horizontal)
e. Manipulator to pickup position
f. Right camera to pickup position
2. Conveyor moves clichés into the FAMM.
3. Stop conveyor when cliché is detected.
4. Conveyor moves in intervals and look for register marks.
5. When register mark found, manipulator lowered and moves cliché to mounting
position.
6. Cameras move to mounting positions.
7. Register mark positions read and display values
8. If positions not within tolerance position corrected with manipulator.
9. Step 7 and 8 repeated until positions within tolerance.
10. Table moves to open position (horizontal).
11. Cylinder/sleeve moves up (lift).
12. Press roll moves down.
13. Cylinder turns forwards and let table guide cliché.
14. Cylinder turns back together with table and still guide cliché.
15. Cylinder turns backwards without moving table
16. Press roll moves up.
17. In case of check now checking routine is started else goes to step 2 for next cliché.
18. All clichés mounted then cylinder/sleeve is swung out.

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The FAMM will during the mounting process indicate the current state using the light pillar.
On the bottom of the screen is shown what action is currently being executed. After the
‘Continue sleeve change’ button was pressed to indicate that this action was finished the
sleeve will be swung back into the machine and the table on the screen will move to the next
sleeve. The FAMM will then wait for the start button to be pressed to mount the current new
sleeve.
Problems that might occur during mounting.
Problem – The register mark of cliché not recognized at pickup position.
Reason – register mark is damaged

Solution – Mount manually
Reason – register mark to far from reference line on conveyor

Solution – Reposition on conveyor and try again.
Problem – One or both register marks are not recognized at mounting position.
Reason – Register mark(s) damaged

Solution – Mount manually
Reason – Register mark(s) outside FOV of cameras

Solution – Correct cliché position by hand and click ‘continue not found’ to try again.
Reason – Cliché slides underneath manipulator during transport to mount position

Solution – Increase the air pressure or adjust the mechanical stop of the manipulator.
4.5.7 Manual mounting.
Manual mounting in general look very much like automatic mounting. The main difference is
that with manual mounting the FAMM need continuous input from the operator. All
preparations are analogue to automatic mounting. To be able to mount a cliché manually it
needs to be selected in the table first. When this was done the ‘Manual’ button will be enabled
and can be clicked on.
This will open the manual-mounting screen that looks like the train screen. At the top of the
screen the selected cliché data and current position is displayed. The camera images are
displayed and there are yellow lines instead of the red ones. The yellow lines are movable and
with these lines the center of the displayed register marks can be indicated. So instead of the
system showing where it found the center of the register marks (the red lines) the operator
now has to tell the system where the center of the register marks are (positioning the yellow
lines).
The following steps must be taken to mount a cliché manually.
1. All axes go to the set positions to pick up a cliché.

a. Table up
b. Lift up
c. Rotate table horizontal
d. Table to close position (horizontal)

V1.00 alpha
e. Manipulator to pickup position
f. Right camera to pickup position
2. Conveyor moves clichés into the FAMM.
3. Stop conveyor when cliché is detected.
4. If register mark not in right camera image click ‘Skip’ button.
5. Conveyor moves an interval and cameras display a new image.
6. Repeat steps 5 and 6 until register mark is visible in right camera image.
7. Position the yellow lines on the center of the register mark and click the ‘Accept’
button.
8. Manipulator lowered and moves cliché to mounting position.
9. Cameras move to mounting positions.
10. Mark position of register marks by placing the yellow lines on the center and click
‘Accept‘ button.
11. If positions not within tolerance manipulator will correct cliché position.
12. Repeat steps 10 and 11 until all values are within tolerance or click ‘Ready’ button.
13. If positions are within tolerance or ‘Ready’ was pressed FAMM will start the
mounting.
a. Table moves to open position (horizontal).
b. Cylinder/sleeve moves up (lift).
c. Press roll moves down.
d. Cylinder turns forwards and let table guide cliché.
e. Cylinder turns back together with table and still guide cliché.
f. Cylinder turns backwards without moving table
g. Press roll moves up.
14. Close manual mount screen to finish the mounting of this cliché.
15. If this was the last cliché for the cylinder/sleeve now trigger the change routine.
4.6 Saving the mounting information (reports).
When closing the mounting screen you will be asked to save the mounting information or not.
If this is answered with ‘No’ the information will be lost. If it is answered with ‘Yes’ the data
will be stored at a location resembling the job name with a fixed (report.rpt) name.
This report can be opened with the FAMM software or imported with for instance Microsoft®
Excel™. If at a later date the job is opened again the mounting information will be shown
again.
If the job needs to be mounted at a later date it is advisable to first delete all mounting
information from the previous time. This is done by clicking the ‘Delete report’ button on the
main screen after selecting the job in question.
After deletion of the report it is also possible the change the mounting options again before
mounting.
4.7 Showing the mounting information (reports).
If for a mounted job the mounting information needs to be displayed this can be done by
selecting the job and then clicking the ‘Quality’ button on the main screen. To be able to show
mounting information in the quality screen the FAMM does not need to be initialized first.
The quality screen resembles the mounting screen except for all the control buttons and
camera images that are now missing. Instead of the control buttons it now contains buttons to
view the graphs of make a print out of the report and or graph(s).

V1.00 alpha
When the ‘Graphs’ button is pressed a new screen is opened containing a table and graphs.
This table contains all clichés of every cylinder/sleeve sorted on so-called ‘Sets’
A set op clichés means several clichés on different cylinders/sleeves but all with the same
coordinates. Meaning they will eventually be printed on top of each other creating the total
multicolor image.
The accuracy of the mounting is in the spread of the register mark positions for clichés within
a set. The graphs at the bottom of the screen will show the register mark positions of the
clichés from the set selected in the table above the graphs. To show another set in the graphs
select it by clicking op the set line in the table (may be any column).
The table below shows the meaning of the different colors used in the set table.
Color Meaning
Green OK mounted
Red Not OK (NOK) mounted.
Blue Not mounted
The assignment of the colors in the graphs is possible in 2 ways.

The color that was assigned tot the cylinder is used in the graphs.
If the cylinder was not assigned a color it will be assigned one by the software.
The legend on the right of the graphs shows the colors used in the graphs.
The red dotted line in the graphs shows the assigned mounting tolerance.
The green dotted line shows the assigned checking tolerance.
4.8 Printing the mounting information (reports).
It is possible to print out the mounting reports. This can be initiated on both the quality and
the graphs screen. When the ‘Print’ button is pressed a dialog is shown in which can be
specified what needs to be printed.
These are the possible print options.
p
Option Result
Job information General job information.
Set information The table with set information.
Mounting marks Coordinates table with mounting marks information sorted on
information sets.
Repeat marks information Coordinates table including report marks information (only
possible when job was mounted with this option) sorted on sets.
Graphs The graphs of the selected set(s).
4.9 The train screen

The train screen contains some additional functionality besides the ones already explained for
training and maintaining the library. The camera tab has a selection called ‘Find train area’
which when selected shows the contours of the found register mark. With the selection
‘Found cross’ you can make the red centerlines of the found register mark visible. It may be
convenient to be able to switch it off because it’s in the way of the camera image itself.
There is a field named ‘Minimum match score’ and the value tells the level of match required.
This means that what is in the camera image must resemble what was trained with at least this
filled in value in % to have recognition. The default value is 80. A high value may cause

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problems with reliable recognition. A low value may cause incorrect recognition. Incorrect
recognition means having recognition on something that is not a register mark. May
circumstances demand changing this minimum match score value it is possible after logging
in on the library tab. The current value can be typed over and confirmed by pressing the
‘Enter’ key.
4.10 Miscellaneous special functions
The software contains some additional features that are not needed for the mounting process
but are use-full. These functions will be explained in the coming paragraphs.
4.10.1 Remount a cliché on a mounted cylinder/sleeve.
When a cliché on an already mounted sleeve needs to be replaced because of wrong

mounting, damage or wear it can be remounted on the FAMM. First remove the cliché in
question and apply new tape where the (new) cliché needs to be (re) mounted. Place the
sleeve in the FAMM as it were an empty sleeve taking in account the zero position of the
sleeve.
All preparations need to be made as with normal mounting of a ‘new’ job.
The sleeve will never be mounted exactly the way it was when the still mounted clichés were
mounted. This difference will first have to be measured by the FAMM.
In the job that was used or a job that has similar clichés at the same location for this repair
select the correct cylinder. Select in the table one of the clichés still mounted on the sleeve
and double click the table on the column ‘Mounted’. Select the option ‘Correction for next
plate’. The FAMM will now position the cameras and format cylinders at the order
coordinates. It will detect the register marks and store the difference between where the
register marks should be and where they are detected. This difference will be used when the
cliché is mounted.
It will only use this extra offset for the next cliché mounted. When more clichés need to be
remounted on 1 sleeve between every mount the correction needs to be restored.
When the repair is done with an empty job don’t forget to set the already mounted clichés to
mounted.
5 Appendix A (Spare parts list)

Part description Part number Amount used in Advised amount
FAMM on stock
Initialization sensor (separate) C-17-E0462 7 1
Initialization sensor (for linear C-17-A0640 4 1
guidance)
Sensor air cylinders C-02-L1005 8 1
Halogeen light C-25-E78023500 2 2
TLD 011 F Stepping motor driver C-17-E39035 13 1
Hasberg Table edge blade (5 meter C-17-D1012 2 * 2 meter (approx) 1 roll (5 meter)
roll) used
Spring to pull manipulator up 2 2

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User manual

AV Flexologic b.v. 02-12-2007

User manual FAMM page 2 of 25

User manual FAMM page 3 of 25

2.1 Electrical specifications

H. Kamerlingh Onnesweg 2 H. Kamerlingh Onnesweg 2

Machine type:FAMMModel:1700 of Machine type:FAMMModel:1700 of

For electrical drawing see appendix A.

2.2 Mechanical specifications

User manual FAMM page 4 of 25

3 General usage of the FAMM

Turning the main switch does switching on the FAMM.

3.2 Switching off

3.3 Reset button

3.4 Emergency stop buttons

3.5 Mechanical maintenance

User manual FAMM page 5 of 25

3.7 Login to the computer

3.8 Light pillar

Light Light form Meaning

4 The control software

These different tasks will be explained in the following paragraphs

User manual FAMM page 6 of 25

4.1 Configuring (servicing) the FAMM

4.2 The basic settings of the FAMM

4.2.1 System tab

User manual FAMM page 7 of 25

The following job fields are changeable in default value:

Mount and check setting possibilities

Mounting position (X direction) options:

4.2.3 Camera tab

User manual FAMM page 8 of 25

4.2.4 Service tab

4.2.5 Manual control tab

In this tab it is possible to initiate individual actions (movements) by clicking on the

Movement / action Remarks

4.2.6 Info tab

Gives general information about FAMM and software version.

4.3 Creating jobs

User manual FAMM page 9 of 25

Below a schematic explanation of the job structure.

General Cylinder Cliché

Below is a schematic explenation of a cliche with 3 register pairs.

The following values can/need to be filled in for the new job.

Field name Description Mandatory

User manual FAMM page 10 of 25

Field name Description Mandatory

Field name Description Mandatory

User manual FAMM page 11 of 25

Field Criteria specification

4.3.3 Overview of cylinder layout

4.4 Importing of jobs

User manual FAMM page 12 of 25

The possible alternatives are:

These 2 alternatives will be explained in more detail in the coming 2 paragraphs.

4.4.1 Adobe acrobat ™ plug-in

4.4.2 ESKO graphics® platepatcher™

4.4.3 Importing a mom file

User manual FAMM page 13 of 25

An example to clarify the functionality:

Area from DTP

With ‘Hor. Mirror’ they are mirrored over a vertical ax.

With ‘Vert. Mirror’ they are mirrored over a horizontal ax.