CN114454175A - Simple robot stacking control system and method - Google Patents
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- CN114454175A CN114454175A CN202210236173.8A CN202210236173A CN114454175A CN 114454175 A CN114454175 A CN 114454175A CN 202210236173 A CN202210236173 A CN 202210236173A CN 114454175 A CN114454175 A CN 114454175A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
- B25J9/1687—Assembly, peg and hole, palletising, straight line, weaving pattern movement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G61/00—Use of pick-up or transfer devices or of manipulators for stacking or de-stacking articles not otherwise provided for
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention discloses a simple robot stacking control system, which comprises: HMI human-machine interface, PLC controller, robot controller, and sensor assembly; the HMI human-machine interface is configured to be in connection interaction with the PLC controller, and the PLC controller is used for receiving and processing parameters of the HMI human-machine interface so as to enable the HMI human-machine interface to perform human-machine interaction with the PLC controller; the robot controller is configured to communicate with the PLC, the PLC writes stacking formula data of the HMI human-computer interface into the robot controller so that the robot controller sends instructions to control the motion of the robot and generate a stacking task with a motion track finished, the robot controller stores a main program for planning the motion of the robot, and the main program adopts a branch structure programming architecture; the sensor assembly is configured to communicate with the PLC controller to cause the PLC controller to complete detection of a signal fed back by the sensor assembly.
Description
Technical Field
The invention relates to the field of robot stacking, in particular to a simple robot stacking control system and method.
Background
Along with the industrial field to automatic, intelligent orientation development, the heavy repetitive operation has been replaced in the appearance of automatic packaging production line, as the pile up neatly of automatic packaging line last step process, because intensity of labour is big, each big enterprise generally adopts efficient robot pile up neatly at present, and the robot pile up neatly has saved the labour greatly, saves space, and the application is nimble, and stability is high, and the operating efficiency is high. At present, the common robots in the ceramic industry are FANUC (FANUC), Kuka (KUKA), Nazhi-buhui (NACHI), ABB and the like. The existing palletizing robot has various brands, various operating systems of the robot are different, the learning amount is large, the requirement on the capability of an operator is high, the robot has a single function and complex operation of a palletizing process bag, the actual production cannot be met, and a client needs to select corresponding palletizing types and stacking quantities at any time according to different product specifications in the actual production, so that the palletizing system with simple operation needs to be developed to adapt to robots of different types and brands.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide a simple robot stacking control system which comprises an HMI (human machine interface), a PLC (programmable logic controller), a robot controller, an electromagnetic valve assembly and various sensors, wherein the HMI realizes man-machine interaction with the PLC, the stack type selection, stack position switching, stacking number modification, robot stacking position modification and other conventional operations are completed, the PLC controls the production flow of the main line, directs the production of the whole line and exchanges information with the robot, and simultaneously the robot generates a stacking task with a movement track of the finished product. Meanwhile, the robot program design adopts a branch structure with clear programming structure, and is easy to call and debug;
in order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a simple robotic palletizing control system comprising: HMI human-machine interface, PLC controller, robot controller, and sensor assembly;
the HMI human-machine interface is configured to be in connection interaction with the PLC controller, and the PLC controller is used for receiving and processing parameters of the HMI human-machine interface so as to enable the HMI human-machine interface to perform human-machine interaction with the PLC controller;
the robot controller is configured to communicate with the PLC controller, so that the PLC controller and the robot controller perform information interaction, the PLC controller writes stacking formula data of an HMI (human machine interface) into the robot controller and receives information feedback of the robot controller, so that the robot controller sends a command to control the action of the robot and generates a stacking task of a product with a motion track, the robot controller stores a main program for planning the action of the robot, and the main program adopts a branch structure programming architecture; the programming structure of the branch structure is clear, and the calling and debugging are easy;
the sensor assembly is configured to communicate with the PLC controller to enable the PLC controller to complete detection of signals fed back by the sensor assembly, and the sensor assembly comprises a sensor arranged on the robot tail end clamp and a sensor arranged on the conveying line.
The whole system software design comprises HMI human-machine interface program design, PLC program design and robot program design. The PLC can realize the leading of the production flow on the whole stacking line, direct the production of the whole stacking line and exchange information with the robot.
Preferably, parameters of a touch screen parameter setting picture on the HMI human-computer interface are processed by a stacking formula unit and then transmitted to the PLC, the stacking formula unit comprises a formula name unit and a formula element unit, the formula list element is used for storing product specification serial number data, the formula element unit is used for storing formula element data, and the formula element data comprises stacking type information, the number of packages corresponding to each stacking area of the selected stacking type, product size, tray size and position correction value data of each stacking area. The formula name unit is used for storing product specification serial numbers of specification 1, specification 2, specification 3, specification 4 and specification 5.
Preferably, the robot end gripper further comprises a solenoid valve assembly, wherein the solenoid valve assembly comprises a first solenoid valve and a second solenoid valve, the first solenoid valve is used for controlling the action of the cylinder/electric cylinder on the robot end gripper, and the second solenoid valve is used for controlling the action of the cylinder/electric cylinder on the conveying line.
Preferably, the HMI human-machine interface further includes a robot start-stop control unit, a conveyor line start-stop control unit, an air cylinder/electric cylinder control unit, and a monitoring unit, the robot start-stop control unit is used for controlling the start-stop of the robot, the conveyor line start-stop control unit is used for controlling the start-stop of the conveyor line, the air cylinder/electric cylinder control unit is used for controlling the robot and the action states of various air cylinders/electric cylinders on the conveyor line, and the monitoring unit is used for monitoring the states of the conveyor line and a motor on the robot, the states of the air cylinders/electric cylinders, and the stacking number of the current robot.
Preferably, the PLC controller comprises a manual control module, an automatic operation module and a fault alarm module;
the manual control module is used for storing a robot manual control subprogram, a motor manual control subprogram and a cylinder/electric cylinder manual control subprogram, and the manual control module is used for controlling single action and eliminating faults when the system is started and faults occur;
the PLC receives feedback signals of an external sensor assembly and input instruction signals of an HMI (human machine interface), performs logic operation on the received feedback signals and instruction signals, and calls corresponding subprograms in the automatic operation module according to operation results to complete corresponding actions;
the fault alarm module is used for receiving a device fault signal when a system has a device fault in operation and displaying device fault information on the touch screen in real time. The equipment fault signal field operator makes an important basis for judgment, so that the field operator can find and remove the fault in time; the manual control module and the automatic operation module are not started at the same time.
The PLC controller acts like the human brain, and mainly receives and processes parameters of the HMI, completes detection of external signals, information interaction with the robot and the like. The three modules of the PLC adopt modularized programming, the modules with different functions are mutually independent, the program structure is clear, and the modification and monitoring of the program are convenient. The modular programming has the advantages of two aspects, on one hand, the function block has universality and can be repeatedly called, the workload of programming is reduced, and the system design period is shortened; on the other hand, the operation efficiency is improved, and the corresponding function block is entered when the mode and the variety are switched, rather than executing all programs.
Preferably, the PLC controller controls the operation of each motor by controlling the frequency converter.
Preferably, the robot controller stores main programs including a one-touch waiting program and a palletizing program, the execution of the palletizing task is completed through the one-key returning waiting position program and the palletizing program, the one-key returning waiting position program is used for selecting a proper path to return to the waiting position according to the sizes of products with different specifications and the current position of the robot, the stacking program comprises a left stack stacking program, a right stack stacking program, a left stack data calculation program, a right stack data calculation program and a clamping jaw control program, the left stack stacking program and the right stack stacking program are used for completing left and right stacking actions of the robot according to products with different specifications, the left pile of piles data calculation procedure and right pile of piles data calculation procedure are used for calculating the pile number data of the left and right pile of piles of different specification products, clamping jaw control procedure is used for the control of opening and shutting of the clamping jaw at pile up neatly in-process.
Preferably, the stacking formula data of the HMI human-machine interface is written into the robot controller through a profinet communication protocol PLC controller.
Preferably, the HMI human-computer interface performs human-computer interaction with the PLC to complete stack type selection, stack position switching, stack number modification and robot stacking position modification.
Preferably, robot pile up neatly control system still includes the demonstrator, robot controller still stores the teaching procedure, the teaching procedure with the main program is the parallel relation, the teaching procedure is used for teaching the step of robot pile up neatly in-process, the demonstrator is used for showing the teaching step.
Another object of the present invention is to provide a simple robot palletizing control method, which applies any one of the robot palletizing control systems described above, including the following steps:
s1, initializing a program, and entering the next step;
s2, selecting product specifications, if not, continuing to select, and if so, entering the next step;
s3, transmitting corresponding stacking formula data to the robot controller according to the product specification by the PLC, sending the received formula data to the PLC through verification by the robot controller, entering the next step if the verification is correct, and re-verifying if the verification fails;
and S4, calling the formula data of the left stack or the right stack and a clamp control program by the robot according to the formula data in the robot controller to execute a stacking process.
Compared with the prior art, the invention has the beneficial technical effects that:
1. the robot demonstration system adopts branch structured programming, is easy to call and debug, only needs to enter a corresponding demonstration program to demonstrate standby positions, grabbing positions and stacking reference points in the stacking process no matter what brand of robots are used on site, and is simple to operate, high in universality and low in technical requirement level on operators;
2. the invention can finish the starting, pausing, stack switching, pack number modification, state monitoring and specification of one-key conversion products of the robot on the HMI human-computer interface, thereby improving the visualization and humanization of the work;
3. the system has good adaptability, changes a single stacking mode, improves the stacking intelligence and completes stacking of different stacks of different specifications.
Drawings
FIG. 1 is a system block diagram of a simple robotic pallet control system of the present invention;
FIG. 2 is a PLC program framework diagram of the simple robot palletizing control system of the present invention;
fig. 3 is a robot program framework diagram of the simple robot palletizing control system according to the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments, but the scope of the present invention is not limited to the following embodiments.
Example 1
Referring to fig. 1, the present embodiment discloses a simple robot palletizing control system, which includes: HMI human-machine interface, PLC controller, robot controller, and sensor assembly;
the HMI human-machine interface is configured to be in connection interaction with the PLC controller, and the PLC controller is used for receiving and processing parameters of the HMI human-machine interface so as to enable the HMI human-machine interface to perform human-machine interaction with the PLC controller;
the robot controller is configured to communicate with the PLC controller, so that the PLC controller and the robot controller perform information interaction, the PLC controller writes stacking formula data of an HMI (human machine interface) into the robot controller and receives information feedback of the robot controller, so that the robot controller sends a command to control the action of the robot and generates a stacking task of a product with a motion track, the robot controller stores a main program for planning the action of the robot, and the main program adopts a branch structure programming architecture; the programming structure of the branch structure is clear, and the calling and debugging are easy; and writing the stacking formula data of the HMI human-machine interface into the robot controller through a profinet communication protocol PLC controller.
The HMI human-computer interface performs human-computer interaction with the PLC controller to complete stack type selection, stack position switching, stack number modification and robot stacking position modification.
The sensor assembly is configured to communicate with the PLC controller to enable the PLC controller to complete detection of signals fed back by the sensor assembly, and the sensor assembly comprises a sensor arranged on the robot tail end clamp and a sensor arranged on the conveying line.
The whole system software design comprises HMI human-machine interface program design, PLC program design and robot program design. The PLC can realize the leading of the production flow on the whole stacking line, direct the production of the whole stacking line and exchange information with the robot.
The robot stacking control system further comprises a solenoid valve assembly, the solenoid valve assembly comprises a first solenoid valve and a second solenoid valve, the first solenoid valve is used for controlling the action of the cylinder/electric cylinder on the robot tail end clamping hand, and the second solenoid valve is used for controlling the action of the cylinder/electric cylinder on the conveying line.
The touch screen parameter setting picture on the HMI human-computer interface adopts a stacking formula unit to process parameters and then transmits the parameters to the PLC, the stacking formula unit comprises a formula name unit and a formula element unit, the formula list element is used for storing product specification serial number data, the formula element unit is used for storing formula element data, and the formula element data comprises stacking type information, the number of packages corresponding to each stacking area of the selected stacking type, product size, tray size and position correction value data of each stacking area. The formula name unit is used for storing product specification serial numbers of specification 1, specification 2, specification 3, specification 4 and specification 5.
The HMI human-computer interface further comprises a robot start-stop control unit, a conveying line start-stop control unit, an air cylinder/electric cylinder control unit and a monitoring unit, wherein the robot start-stop control unit is used for controlling the start and stop of the robot, the conveying line start-stop control unit is used for controlling the start and stop of the conveying line, the air cylinder/electric cylinder control unit is used for controlling the action states of the robot and various air cylinders/electric cylinders on the conveying line, and the monitoring unit is used for monitoring the states of the conveying line and a motor on the robot, the states of the air cylinders/electric cylinders and the stacking number of the current robot.
Referring to fig. 2, the PLC controller is configured to include a manual control module, an automatic operation module, and a malfunction alerting module; the PLC controller is used for acting like a human brain, and mainly receiving and processing parameters of an HMI human-computer interface, finishing detection of external signals, information interaction with a robot and the like. The three modules of the PLC adopt modularized programming, the modules with different functions are mutually independent, the program structure is clear, and the modification and monitoring of the program are convenient. The modular programming has the advantages of two aspects, on one hand, the function block has universality and can be repeatedly called, the workload of programming is reduced, and the system design period is shortened; on the other hand, the operation efficiency is improved, and the corresponding function block is entered when the mode and the variety are switched, rather than executing all programs.
The manual control module is used for storing a robot manual control subprogram, a motor manual control subprogram and a cylinder/electric cylinder manual control subprogram, and the manual control module is used for controlling single action and eliminating faults when the system is started and faults occur; the PLC receives feedback signals of an external sensor assembly and input instruction signals of an HMI (human machine interface), performs logic operation on the received feedback signals and instruction signals, and calls corresponding subprograms in the automatic operation module according to operation results to complete corresponding actions; the fault alarm module is used for receiving a device fault signal when a system has a device fault in operation and displaying device fault information on the touch screen in real time. The equipment fault signal field operator makes an important basis for judgment, so that the field operator can find and remove the fault in time; the manual control module and the automatic operation module are not started at the same time. The PLC controller controls the work of each motor by controlling the frequency converter.
The robot has more tasks in the whole stacking system, the control logic is relatively complex, under the condition that wiring and hardware have no problems, the stability and the efficiency of the whole system are determined by software programming, the framework of a program is particularly important, the stacking robot needs to finish grabbing products according to different products, walk according to a specified track, put down a series of actions such as products and the like, if the program uses a sequence structure, the actual production requirements can not be met obviously, therefore, the program framework of the robot adopts a branch structure to have a clear programming structure, and the robot is easy to call and debug. The main program of robot controller storage includes that a key returns and waits for position procedure and pile up neatly procedure, through the execution of pile up neatly task is accomplished to a key return and waits for position procedure and pile up neatly procedure, a key return waits for the position procedure to be used for selecting suitable route according to the size of different specification products and the current position of robot and returns to waiting for the position, the pile up neatly procedure includes left buttress stacking procedure, right buttress stacking procedure, left buttress data calculation procedure and right buttress data calculation procedure and clamping jaw control program, left buttress stacking procedure, right buttress stacking procedure are used for accomplishing the pile up neatly action about the robot according to different specification products, left buttress data calculation procedure and right buttress data calculation procedure are used for calculating the pile up neatly number data about different specification products, clamping jaw control procedure is used for the control of opening and shutting of the clamping jaw at pile up neatly in-process.
Referring to fig. 3, wherein "Main _ Go _ Home" is a one-key return waiting position program, the function of which is to select an appropriate path to return to the waiting position according to the size of different products and the current position of the robot. "Size _ main" is a stacking program, "Size 1_ main" is a specification 1 stacking program, "Size 1_ L is a specification 1 left stacking program," Size1_ R "is a specification 1 right stacking program," Size2_ main "is a specification 2 stacking program," Size2_ L "is a specification 2 left stacking program," Size2_ R "is a specification 2 right stacking program," Size _ N _ main "is a specification N stacking program," Size _ L "is a specification N left stacking program," Size _ R "is a specification N right stacking program; "Size 1_ L _ Data" is a specification 1 left stack Data calculation program, "Size 1_ R _ Data" is a specification 1 right stack Data calculation program, "Size 2_ L _ Data" is a specification 2 left stack Data calculation program, "Size 2_ R _ Data" is a specification 2 right stack Data calculation program, "Size _ N _ L _ Data" is a specification N left stack Data calculation program, "Size _ N _ R _ Data" is a specification N right stack Data calculation program, and "Open or Close" is a clamping jaw control program.
Robot pile up neatly control system still includes the demonstrator, robot controller still stores the teaching procedure, as shown in FIG. 3, "Teach" is the teaching procedure, the teaching procedure with the main program is the relation side by side, the teaching procedure is used for teaching the step of robot pile up neatly in-process, the demonstrator is used for showing the teaching step.
A simple robot stacking control method applies the robot stacking control system and comprises the following steps:
s1, initializing a program, and entering the next step;
s2, selecting product specifications, if not, continuing to select, and if so, entering the next step;
s3, transmitting corresponding stacking formula data to the robot controller according to the product specification by the PLC, sending the received formula data to the PLC through verification by the robot controller, entering the next step if the verification is correct, and re-verifying if the verification fails;
and S4, calling the formula data of the left stack or the right stack and a clamp control program by the robot according to the formula data in the robot controller to execute a stacking process.
Variations and modifications to the above-described embodiments may occur to those skilled in the art, which fall within the scope and spirit of the above description. Therefore, the present invention is not limited to the specific embodiments disclosed and described above, and some modifications and variations of the present invention should fall within the scope of the claims of the present invention. Furthermore, although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
Claims (10)
1. The utility model provides a simple and easy robot pile up neatly control system which characterized in that includes: HMI human-machine interface, PLC controller, robot controller, and sensor assembly;
the HMI human-machine interface is configured to be in connection interaction with the PLC controller, and the PLC controller is used for receiving and processing parameters of the HMI human-machine interface so as to enable the HMI human-machine interface to perform human-machine interaction with the PLC controller;
the robot controller is configured to communicate with the PLC controller, so that the PLC controller and the robot controller perform information interaction, the PLC controller writes stacking formula data of an HMI (human machine interface) into the robot controller and receives information feedback of the robot controller, so that the robot controller sends a command to control the action of the robot and generates a stacking task of a product with a motion track, the robot controller stores a main program for planning the action of the robot, and the main program adopts a branch structure programming architecture;
the sensor assembly is configured to communicate with the PLC controller to enable the PLC controller to complete detection of signals fed back by the sensor assembly, and the sensor assembly comprises a sensor arranged on the robot tail end clamp and a sensor arranged on the conveying line.
2. The simple robot palletizing control system according to claim 1, wherein a touch screen parameter setting screen on the HMI human-machine interface transmits parameters processed by a palletizing recipe unit to the PLC controller, the palletizing recipe unit includes a recipe name unit and a recipe element unit, the recipe list element is used for storing product specification serial number data, the recipe element unit is used for storing recipe element data, and the recipe element data includes palletizing type information, a number of packages corresponding to each palletizing region selected, a product size, a tray size, and position correction value data of each palletizing region.
3. The simple robot palletizing control system according to claim 1, further comprising a solenoid valve assembly, wherein the solenoid valve assembly comprises a first solenoid valve and a second solenoid valve, the first solenoid valve is used for controlling the action of a cylinder/electric cylinder on the robot end gripper, and the second solenoid valve is used for controlling the action of a cylinder/electric cylinder on the conveying line.
4. The simple robot palletizing control system according to any one of claims 1 to 3, wherein the HMI further comprises a robot start/stop control unit, a conveyor line start/stop control unit, a cylinder/electric cylinder control unit and a monitoring unit, the robot start/stop control unit is used for controlling the start/stop of the robot, the conveyor line start/stop control unit is used for controlling the start/stop of the conveyor line, the cylinder/electric cylinder control unit is used for controlling the robot and the action states of various cylinders/electric cylinders on the conveyor line, and the monitoring unit is used for monitoring the states of motors on the conveyor line and the robot, the states of the cylinders/electric cylinders and the stacking number of the current robot.
5. The simple robotic palletization control system according to claim 3, wherein the PLC comprises a manual control module, an automatic operation module and a fault alarm module;
the manual control module is used for storing a robot manual control subprogram, a motor manual control subprogram and a cylinder/electric cylinder manual control subprogram, and the manual control module is used for controlling single action and eliminating faults when the system is started and faults occur;
the PLC receives feedback signals of an external sensor assembly and input instruction signals of an HMI (human machine interface), performs logic operation on the received feedback signals and instruction signals, and calls corresponding subprograms in the automatic operation module according to operation results to complete corresponding actions;
the fault alarm module is used for receiving a device fault signal when a system has a device fault in operation and displaying device fault information on the touch screen in real time.
6. The simple robot palletizing control system according to claim 1, wherein the main programs stored by the robot controller include a one-click waiting program and a palletizing program, the execution of palletizing tasks is completed through the one-click waiting program and the palletizing program, the one-click waiting program is used for selecting an appropriate path to return to a waiting position according to the sizes of products with different specifications and the current position of the robot, the palletizing program comprises a left palletizing program, a right palletizing program, a left palletizing data calculating program, a right palletizing data calculating program and a clamping jaw control program, the left palletizing program and the right palletizing program are used for completing left and right palletizing actions of the robot according to products with different specifications, the left palletizing data calculating program and the right palletizing data calculating program are used for calculating left and right palletizing data of products with different specifications, the clamping jaw control program is used for controlling the opening and closing of the clamping jaws in the stacking process.
7. The simplified robotic palletising control system of claim 1, wherein palletising recipe data for an HMI human machine interface is written into the robotic controller by a profinet communication protocol PLC controller.
8. The simple robotic palletizing control system according to claim 1, wherein the HMI human machine interface performs human machine interaction with the PLC controller to perform stack type selection, stack position switching, palletizing number modification, and robot palletizing position modification.
9. The simple robot palletizing control system according to claim 6, wherein the robot palletizing control system further comprises a teach pendant, the robot controller further stores a teaching program, the teaching program and the main program are in a parallel relationship, the teaching program is used for teaching steps in the robot palletizing process, and the teach pendant is used for displaying the teaching steps.
10. A simple robot palletizing control method, wherein the control method applies the robot palletizing control system of any one of claims 1 to 9, and comprises the following steps:
s1, initializing a program, and entering the next step;
s2, selecting product specifications, if not, continuing to select, and if so, entering the next step;
s3, transmitting corresponding stacking formula data to the robot controller according to the product specification by the PLC, sending the received formula data to the PLC through verification by the robot controller, entering the next step if the verification is correct, and re-verifying if the verification fails;
and S4, calling the formula data of the left stack or the right stack and a clamp control program by the robot according to the formula data in the robot controller to execute a stacking process.
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