User Manual. Colour Product Control V Document Version A

Transcription

1 User Manual Colour Product Control V Document Version A

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3 Contents 1 General Instructions 4 2 Hardware: Camera Description Camera Components Camera Operation Connection, Display and Operating Elements Example System Connection Assignment for the System Plugs Field of Application 10 4 Functionality and Definition of Terms 11 5 Using the Camera Keys The Virtual Keyboard Commissioning the Software Instructions for Setting the Control Window Menu Options Production New Reference Code Product Change Edit Product Live Image Colour Tables CPIX Window Parameters RING Window Parameters OBJC Window Parameters General Product Data Product Management Rename, Copy or Delete a Product Display product New product Statistics Start, View and Finish a Batch Show faulty pictures Reset Counters Service Live Image System Parameters User Management Password, Zoom Change Password Zoom On General Error Reports and Troubleshooting Care Technical Data Index 54

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5 1 General Instructions Duty of care of the user The PCE Colour Product Control system has been developed and constructed according to normal standards and technical specifications. It therefore meets technical norms, and affords the highest level of safety during operation. However, the safety of the system while in operation can only be ensured if all the required measures have been taken. The system user has a duty of care to plan in such measures and check that they are taken. The user must ensure that the system is only used as intended, the system is only run fault-free and in full working order, the instruction manual is always remains legible, and is available in full in the place where the machine is installed, only qualified, authorised personnel use and maintain the system, the said personnel are regularly instructed in all relevant issues of safety at work, and are familiar with the instruction manual and all of the safety instructions therein, all the safety-related features of the system are carefully inspected at regular intervals the greater the safety risks associated with this appliance, the more often the regular inspections are carried out. Basic safety measures The following points have to be adhered to for safe operation of the camera system: The camera must be fixed on a stable mechanical mounting that cannot be altered. The camera must be protected from external interference while in operation. The power supply for the appliance is 24 V DC, from an external voltage source. All required safety regulations must be complied with for this type of system. The appliance should only be used by trained, authorised persons, who are familiar with the instruction manual and can use the appliance in compliance therewith. For safe use of the image processing system, all parts relating to safety should be repeatedly checked, particularly the points mentioned above, and the instruction manual should also be followed. 4/55 Colour Product Control - V6.109 User Manual Document Version A

6 Requirements of the operating staff This instruction manual should enable the user to install and use the appliance. However, this instruction manual is in no way a substitute for installation and operation by trained personnel! Transport, set-up and commissioning When the appliance is in transit, please ensure that it is protected against moisture and impact. Minimizing dust-, moisture-, temperature-, and impact-induced stress is standard procedure for setting up the appliance in the industrial environment. The appliance can only be operated safely if it is installed and commissioned by trained expert personnel. To avoid a tripping hazard, please ensure that all appliance connections (cables) are positioned accordingly! Intended use The Colour Product Control system is able to check the colour and surface of several objects within an image. Some of the possible uses are as follows: Checking that boxes or folding boxes are full; checking the presence and location of labels; checking the presence and location of closures; checking for the correct cap colour on vials, for example. If the PCE Colour Product Control system is not used as intended, it cannot be guaranteed to operate safely. If any injury occurs to any person or thing as a result of unintended use, the user of the PCE Colour Product Control system shall be responsible, and not the manufacturer. Colour Product Control - V6.109 User Manual Document Version A 5/55

7 2 Hardware: Camera Description 2.1 Camera Components The Smart Camera consists of an intelligent camera with integrated signal processor and a software which is able to control different characteristics. Further the camera hardware contains memory, network interface, an optical component and illumination. The illumination can be integrated into the camera or mounted around the camera as external illumination. 2.2 Camera Operation The camera is handled with a cable-bound network LAN (Local Area Network). A PC must be present in this LAN for the operation of the camera. With the PLM (PCE Line Manager), METTLER TOLEDO offers a suitable hardware and software, in order to operate the camera comfortably. Descriptive visualizations indicate the adjusting options on the touch display and ensure comfortable operation by means of large sized key top touch areas. The PC offers all the necessary functions to handle the camera. The screen shows e.g. buttons and a keyboard to send commands and characters. For mounting the camera and for calibrating the system, a live image can be displayed on the screen. 2.3 Connection, Display and Operating Elements The following picture shows the back plate of the camera. The exact allocations are specified in the tables on the following pages. LED indication for outputs LED indication for inputs Plug for external illumination Plug for additional inputs and outputs Main system plug Push button for trigger manually Plastic mounting plate 6/55 Colour Product Control - V6.109 User Manual Document Version A

8 With the pushbutton in the camera s rear panel a camera trigger can be released. Thus the camera starts a picture recording and evaluation. The LEDs in the rear panel indicate the input and output signals. They are arranged in lines. A LED flashes, if the appropriate signal applies. Description IN0 IN1 IN2 OUT0 OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 Function Camera trigger from machine or PLC Universal, function belongs to software settings Reset Signal from machine or PLC Good Signal for machine/plc Camera Ready Signal for machine/plc Universal, function belongs to software settings Universal, function belongs to software settings Universal, function belongs to software settings Universal, function belongs to software settings External illumination On/Off Colour Product Control - V6.109 User Manual Document Version A 7/55

9 2.4 Example System Connection The camera is connected via the free cable end to screw terminals in the switch cabinet. The camera can be connected via minimal wiring directly to the LAN interface. A LAN switch is installed for running several camera systems. In addition to the LAN interface, a 24V supply and a connection with the machine signals must also be established. Touch-Screen 230V supply machine signals Camera- power supply and system signals filter, mains adapter, screw terminals etc. Optional: several camera systems Camera- power supply Switch PC Camera- and system signals optional: LAN I/O extension Camera- Standard wiring of a Smart Camera system. (small) switch cabinet 2.5 Assignment for the System Plugs With the 8 pin system plug the camera is supplied with 24V and can be connected with an input and output signal to the machine. The camera establishes a connection to the network LAN (Local Area Network) with four leads. Further inputs and outputs are optional. They are available with a LAN I/O extension or an additional I/O cable. 8/55 Colour Product Control - V6.109 User Manual Document Version A

10 System cable Pin No. Color Description Function of the 8pin plug 1 white / blue +24V Power Supply +24V 2 blue GND Supply GND 3 brown In0 / Trigger Input 0 = Trigger Signal 4 white / brown Out0 / Good Result Output 0 = Good Result Signal Camera connected to PC (according to TIA 568 A) Camera connected to Switch (according to TIA 568 B) I/O-Cable Pin No. via 1:1 LAN cable via 1:1 LAN cable 5 white/orange LAN RJ45 Pin 3 TxD- RJ45 Pin 1 TxD- 6 orange LAN RJ45 Pin 6 TxD+ RJ45 Pin 2 TxD+ 7 white/green LAN RJ45 Pin 1 RxD- RJ45 Pin 3 RxD- 8 green LAN RJ45 Pin 2 RxD+ RJ45 Pin 6 RxD+ of the 8pin plug Color Description Function 1 brown In1 Input 1 = Universal, function belongs to software settings 2 yellow In2 Input 2 = Reset Signal 3 orange Out6 Output 6 = External illumination On/Off 4 black Out1 Output 1 = Camera Ready Signal 5 green Out2 Output 2 = Universal, function belongs to software settings 6 red Out3 Output 3 = Universal, function belongs to software settings 7 blue Out4 Output 4 = Universal, function belongs to software settings 8 violet Out5 Output 5 = Universal, function belongs to software settings External Illumination Connection Pin No. Color Description Function of the 4pin plug green +24V +24V supply for external illumination, delivered from the camera 3 brown Trigger Trigger signal for external illumination, delivered from the camera 4 white GND GND Various external illumination units can be connected to a camera via splitter. Colour Product Control - V6.109 User Manual Document Version A 9/55

11 3 Field of Application Some of the possible inspections of the Colour Product Control system are as follows: - Checking tablets in a blister; - Counting of bottles in a carton or a box; - Checking completeness of the content of a carton or a blister; - checking for correct cap colour - on vials or bottles; - Reading and verifying of color rings on ampoules; 10/55 Colour Product Control - V6.109 User Manual Document Version A

12 4 Functionality and Definition of Terms Under a Product name, several CPIX-, RING- and OBJC- windows can be installed. CPIX check In a CPIX window, the pixels of a particular colour are counted. If the number of pixels measured is outside the tolerance set, the corresponding window will be highlighted red. The colours are entered on the system once (teach-in process) and organised in a colour table. Sensitivity to colour is controlled simply via different tolerance settings or repetition. With white balance and the automatic dynamic exposure times, it is possible to detect tiny differences in colour. Production screen showing active diagnostic analysis Colour Product Control - V6.109 User Manual Document Version A 11/55

13 Pixels within the tolerance are highlighted green, and over-illuminated pixels are highlighted blue. In addition, the corresponding numerical value of the pixels highlighted green can be given. The information display can be switched on and off using the diagnostic analysis function. Please also read the section entitled Service/system parameters/diagnosis. Reference colours and minimum/maximum values are displayed in the status bar on the bottom edge of the screen. The evaluation time, positive/negative figures, current product name and batch record (inactive = blue/active=green) appear at the right-hand edge of the screen. RING check The code sequence of coloured rings is analysed in the RING window along a given scan direction. Within this type of window, the number, code sequence, width and distance of the coloured rings are analysed along several lines of measurement. If all the measurements match the parameters within variable tolerances, the colour code can be verified. Depending on the diagnosis configuration, the complete measurement line will be marked green or the recognized ring segments on the measurement line will be marked. The median ring width and distance can also be shown via the RING window. The information display can be switched on and off using the diagnostic analysis function. Please also read the section entitled Service/system parameters/diagnosis. 12/55 Colour Product Control - V6.109 User Manual Document Version A

14 If the number of measurement lines evaluated positive reaches a certain threshold set by the user, the scan result is positive (the window is highlighted green); otherwise, the scan result is negative (the window is highlighted red). The actual colour code that had been read and the number of lines that have been evaluated as positive will be shown inside the window. The reference colour codes for all coloured ring windows are displayed in the status bar at the bottom edge of the screen. In the status bar on the right, a list of all colours which are defined in the Colour Table is displayed with their according Colour IDs. OBJC Inspection An OBJC Window counts the number of objects of a specified color inside of the window. An object is a cluster of connected pixels. The following features will be checked for each object: Correct object size; Correct object location; Correct object color; Correct number of objects in total; Colour Product Control - V6.109 User Manual Document Version A 13/55

15 Possible errors are: wrong color wrong location wrong number too big too small The object colors must be once teached and saved into a Color Table, the same way as it is done for the CPIX- and RING-Inspection. Recognized and counted Objects will be marked with green frames in the camera image. The number of objects which were found inside of the window will be shown in the upper left corner of the window. 14/55 Colour Product Control - V6.109 User Manual Document Version A

16 If the correct number of objects was found, the OBJC-Window will be green. In any other case it will be red. There are additional options for the display like showing the pixel area of each object, a binary display and the display of invalid objects. These visualizations can be activated through the Diagnosis Functions. Therefore please read chapter Service / System parameters / Diagnostic analysis. The camera requires an external trigger signal - flank change 0 to 24V. Next, the camera triggers the flash via fast output. The flash goes off immediately, and an image is captured. The button on the back of the camera can also be used to test the trigger. Colour Product Control - V6.109 User Manual Document Version A 15/55

17 5 Using the Camera The software can be operated solely via the touch-screen, no keyboard or mouse is needed. The areas to be examined are marked and checked by means of windows; instructions on individual items will be displayed. Turning on the system starts the production run (the actual analysis mode). The production run can be exited by pressing the "Menu" button. The main menu will then appear. The following image shows the main menu after a camera has been selected and the Menu button on the touch-screen has been pressed. Operating instructions Menu selection Selection box Full user admin is available in the camera software. NB. On delivery, the user is entered as admin, with the password 000! 16/55 Colour Product Control - V6.109 User Manual Document Version A

18 5.1 Keys The following key assignments are valid in the menus: A menu item can be selected via touch-screen. A menu item will be selected upon release of a menu item. Quit a sub-menu or cancel using the ESC button. Setting windows, frames and lines: The windows for the different types of control (CPIX, RING, OBJC, ) will be configured on the touchscreen via control symbols. This symbol appears whenever such a window needs to be input or modified. Mode Arrow keys By choosing the centre button the active mode can be switched. In shifting mode the window can be shifted using the arrow keys. In enlargement mode the window can be enlarged using the arrow keys. In reduction mode the window can be reduced using the arrow keys. The entry will be acknowledged using the button. The entry will be cancelled using the button. The windows can be changed directly via touch-screen Colour Product Control - V6.109 User Manual Document Version A 17/55

19 5.2 The Virtual Keyboard Alphanumeric characters (passwords, set texts, codes) will be entered via touch-screen using the virtual keyboard. This will be displayed as soon as an entry has to be made. Changes between capital and small letters as well as numbers and special characters. Confirms the entered characters. This key enables the shifting of the virtual keyboard with the touch-screen. Cancels the entry. Shifts the keyboard upwards. Shifts the keyboard downwards. 18/55 Colour Product Control - V6.109 User Manual Document Version A

20 Menu Overview Main menu Production New reference code Product change Edit product Product management Statistics Service Change password Zoom on Edit product Live image Add control window Delete control window Colour tables Parameter CPIX-window Parameter RING-window Parameter OBJC-window General product data Product management New product Display product Rename product Copy product Delete product Colour tables Display colour table Rename colour table Copy colour table Delete colour table Batch record Start batch record Show batch record Stop batch record Show faulty pictures Reset counters Service Live image System parameter User management Menu system parameter Diagnosis I/O configuration Number of failure images Gain Trigger Edge Configuration illumination Config. of image transfer Save Counters Language Colour Product Control - V6.109 User Manual Document Version A 19/55

21 6 Commissioning the Software Below are the individual steps for the initial commissioning of the software. Step 1: Please assign a new product name under Product management/new product. Step 2: Now please select Create new colour table and enter a name for the colour table. Step 3: Select between Colour Area and Colour Point for teaching the colour. Colour area will use the median value of all pixels within the teaching window. Colour Point uses single pixels for calculation. Step 4: Now the White Balance has to be done. You can choose to do a Shading-Correction addidtionally to the White Balance. You should do this, if the camera image is unevenly illuminated. Please place a sheet of white paper at reading distance from the camera. Press the Next-Button and adjust the region if needed. Step 5: Please position the product in front of the camera and teach in all the colours to be inspected. Step 6: Please select the desired inspection type: COLPIX Control, COLORRING.Control or OBJECTCOUNT Control. Then position the window for the first region to be checked. Enter the inspection tool relevant data. Repeat this step for all regions to be inspected. Step 7: The commissioning of the software has now been completed. You can now call up the Production screen. Please refer to subsequent sections for more detailed information on the individual steps. 20/55 Colour Product Control - V6.109 User Manual Document Version A

22 6.1 Instructions for Setting the Control Window The described procedure is valid for all types of windows (verification types) of the camera. The control window is superimposed as a yellow frame. The position and size of the window can be changed. Detailed description of the keys on the touch screen can be found in section 5.1 Keys. The active mode is shown on the mode key between the arrow keys. Shift window, Enlarge window, Reduce window. Shifting the window or changing the size is carried out either via touch screen (follow cursor) or using the four arrow keys which are also suitable for fine adjustment. Change the mode using the key between the arrow keys. Complete and save the procedure by pressing "ENTER" Editing multiple windows Existing windows can still be edited in position and size. The Editing Menu is accessible through the windows parameter tables. If multiple windows of the same type are existing, this Editing Menu will provide a multi edit mode. The possible options in this mode are Individual and All at once. The active option is marked green. Individual: The currently selected window is shown yellow. This window is the one which is currently editable. Another window can be selected by pressing near its center. All at once: The last selected window is shown red. All changes in position or size which are done to this reference window will be also applied simultaneously to the other (yellow) windows. The reference window can be switched by selecting Individual mode, choosing your preferred window and switching back to All-at-once mode. Mode: Individual Mode: All at once Colour Product Control - V6.109 User Manual Document Version A 21/55

23 7 Menu Options 7.1 Production The production screen is explained in more detail in the section entitled Functionality and definition of terms. When the production menu option is called up, the shutter speed will be set depending on reference colours of the inspections. 7.2 New Reference Code When the New reference code menu has been called up, the names of the available colours will appear at the top right of the image. Please select the reference colour for each window. The entry should consist of the characters allocated to the colours entered on the system in the teach-in, and which should be entered according to the sequence of the coloured rings in the direction of the scan for the RINGCODE windows. Before you can enter a reference code, you must first set the inspection windows and teach in the corresponding colours! 22/55 Colour Product Control - V6.109 User Manual Document Version A

24 7.3 Product Change A number of product features are saved under the current product name. When the Product change menu has been called up, a list will appear showing products already created. To select the desired product, press on product name. All the settings saved under this product are then called up and activated. 7.4 Edit Product In this menu, all product-specific settings can be carried out. Before product settings can be changed, a current image of the object to be inspected must be taken Live Image For stationary inspection, please select Live image. If inspection can only be done in motion, please select Live image with trigger. In this mode, the camera only takes a picture if the trigger input switches from 0V to 24V Colour Tables All colours to be inspected are stored in the colour tables. When the menu option Edit Product/Colour Table/Display Colour Table is called up, the following table appears: Colour-set coltab White-balance: (R)1640(G)1000(B)2075(Sh)1070 Shading-Corr.:ON X NEXT>> Teach-In White-Bal. Shutter Sett. Tolerances Learn-Mode Colour name [ID] Y value Red Green Blue Shutter (1/2) red [1] 167+/ / / / green [2] 098+/ / / / blue [3] 100+/ / / / yellow [4] 479+/ / / / It will be always called the color table which is used in current product. If you want to display another color table, first go to menu Edit Product/General Product Data and change name of color table. Colour Product Control - V6.109 User Manual Document Version A 23/55

25 Teach-in Additional, new colour values can be entered into the colour table (teach-in). A colour can also be entered on the system several times, to increase the tolerance for the colour, for example. When Teach-in is selected, a live image will appear. Now the object to be inspected can be positioned in front of the camera. Please press the Enter key. Depending on the particular teach-in mode set (see section Learn-Mode ), a selector box or a cross cursor will appear for entering the colour on the system. Use the selector box to move the window to the colour that needs to be entered on the system. The window should always be completely filled with the colour being entered on the system. Otherwise, move the cross cursor to the desired colour. The values for the position and colour of the current position of the cross cursor or the colour area will appear in the right hand status bar. The coloured square shows a preview of the colour which is currently marked in the image or the colour of the mean value of the colour area. If the current colour value is already listed in the colour table, the name of the recognized colour will be displayed. (This only applies for the shutter value of the current image.) Select colour name X Create new color name Delete color value Yellow Red Blue Brown green Next, please select the name of the colour or create a new colour name. If there is an area where a wrong colour was detected please select the correct colour name or choose Delete Color Value. Delete Color Value will reduce the tolerances of the next existing colour entry so that current value is out of tolerance and detected as unknown. The teach-in process will continue up to 5 different exposure times (shutter speed values). The new values will then appear in an information box. 24/55 Colour Product Control - V6.109 User Manual Document Version A

26 The colour yellow entered with 5 different exposure times (teach-in) Each colour value is defined according to the following parameters: Y: brightness of the colour; R: proportion of red in the colour; G: proportion of green in the colour; B: proportion of blue in the colour; Sh: shutter speed value (exposure time) Tol: Y/R/G/B tolerances During each teach-in procedure, colours already entered on the system are also checked. Values are only saved if they are not within the tolerance of existing values. If the white balance has not been carried out for the current colour table, call up Teach-in to start the white balance, which is described below. Teach-in with Error Images When a faulty product is recognized while production, the current image will be saved as an Error Image. This Error Image can be used as basis for teaching in colours. For teaching in a colour from an Error Image first you have to select Teach-In in the Colour Table as usual. When the Live Image is displayed, the button Load Error-Image will appear. When pressing the button, the camera will switch to the Error-Image View. There you can switch through the existing Error Images and load one by pressing Enter. Now a colour can be taught-in from this image into your Colour Table as usual. Note: When teaching-in colours from an Error Image, the colour values can only be determined for the Shutter Value which was used when taking the image. Colour Product Control - V6.109 User Manual Document Version A 25/55

27 White balance & Shading-Correction WB & SC X Only White Balance White Balance with Shading-Correction Only Shading-Correction Remove Shading-Correction The camera shows a live image. Please place a sheet of white paper in reading distance under the camera and press the Next key. The adjustable blue window will define the image region which will be used for calculating the white balance data as well as the area to which the shading correction will be applied to, if selected. Confirm the adjusted image region by pressing the Enter key. The camera will now raise its shutter slowly and measure the brightness of the red, green and blue channels. As soon as a channel exceeds a minimum value, the correction values for red, green and blue are saved against the corresponding shutter speed value. If the white balance fails, the whole image will go dark. Possible solutions are as follows: - Open lens aperture wider; - Raise the Gain level in Service/System parameters; - Increase max shutter speed; - Adjust flash to brighter; The white balance can be repeated at any time. The parameters of existing colour values will be corrected accordingly. For example, with white balance, the deterioration of the flash (brightness/colour) can be compensated for within certain limits. 26/55 Colour Product Control - V6.109 User Manual Document Version A

28 Optional Shading-Correction The white balance function can be extended by a shading correction. This one is used for the compensation of uneven illumination or shadowing. For the definition of the correction data, a white flat reference surface must be placed in front of the camera in product distance. The reference surface must be filling up the whole image region, which shall be corrected later. Shutter Setting Shutter Sett. X Max. Shutter Number of Shutter Values Max shutter This value shows how high the shutter speed can be during white balance. The shutter must be limited to a maximum value, as, with long exposure times and inspection under movement dependent on speed, motion blur can occur. Factory setting: 10,000 microseconds; Number of Shutter Values A colour value will be stored for all here defined different shutter values. In production mode the system will choose automatically the best fitting shutter value depending on colour combination and brightness of each colour. Up to 5 shutter values are possible. Default setting is 2. Tolerances Default colour tolerance (only for Learn-Mode: Colour-Point) Shows which tolerances for Y/R/G/B parameters are recorded for a colour value in the teach-in process. Factory setting: 80 Maximum colour tolerance (only for Learn-Mode: Colour-Area) When using the Colour-Area for teaching new colours, the tolerances will be automatically defined, depending on all colour variations occurring inside the area. This parameter specifies the maximum tolerance which is allowed. Edge colour threshold (only for Learn-Mode: Colour-Area) Colour Product Control - V6.109 User Manual Document Version A 27/55

29 This is the allowed maximum difference between two adjacent colour pixels inside the colour area. Pixels with higher differences will be ignored to prevent errors caused by erratic colour values. Learn-Mode Shows how the colours should be entered on the system, either as a median colour value or area (selection tool: box) or as the colour value of an individual pixel (selection tool: cross cursor). When this option is selected, a menu appears, which you can use to view and change the current setting. Factory setting: Coloured Area NEXT>> The camera always tabulates all values entered on the system with the same shutter speed. Use NEXT to go to the next table and shutter speed. There are 5 tables in all. 28/55 Colour Product Control - V6.109 User Manual Document Version A

30 Changing the parameter tolerances To change the colour tolerances, touch directly onto the value. You can enter a new value and then, if desired, change all the entries with the same colour name. Rename colour or delete table entry To rename/delete a colour, please touch directly onto the name. Rename colour: e.g. from blue to light blue ; all blue entries will be changed to light blue. Delete value: Only the table entry/line which is selected will be deleted. Colour Product Control - V6.109 User Manual Document Version A 29/55

31 Delete colour: All table entries of this colour will be deleted. This way the given colour will be completely erased from the colour table. Change ID: The ID is used as a short form for the different colours and is being displayed in square brackets behind the colour name. The IDs are used for the input of reference codes. The ID of a new colour will be assigned automatically while teach-in and can be changed afterwards in this menu. Overexposed Colors (white entries) Bright colors may be overexposed for specific shutter configurations. An overexposed colour is too bright for containing any useful colour information. Overexposed colors will be marked as white entries in the Colour Table. These entries should normally not be deleted. The camera system uses them as an indication that this specific shutter value should be avoided when inspecting this overexposed colour. Overlapping Colours (red entries) Colours may overlap considering the tolerance. In this case these colours will be marked red. In production the system selects the tab value which is closest to the measured one. Rename, copy or delete colour table Before a colour table can be renamed, copied or deleted, you must select the desired colour table from the list. The name can then be changed or deleted accordingly. NB: Colour tables should only be deleted if they are no longer being used for a product! The following characters can be used to enter names into colour tables: -the full alphabet (upper and lower case); -numbers 0-9; -the special symbols _ & ; - no umlauts; The name can be up to 8 figures long. 30/55 Colour Product Control - V6.109 User Manual Document Version A

32 7.4.3 CPIX Window Parameters Parameters for windows CPIX0 to CPIX4 are arranged in columns in the table. Use NEXT>> to move to the next selection (CPIX5 to CPIX9). Parameter of CPIC - windows X Window name CPIX0 CPIX1 CPIX2 CPIX3 PX/PY/DX/DY 19/82/310/ /83/310/ /74/310/ /74/310/331 Colour Blue Blue All Colours All Colours Min.Tol Max.Tol <<< >>> PX, PY, DX, DY Please touch here if you wish to change the position or size of the corresponding CPIX window. Colour The reference colour of the particular window appears here. The reference colour cannot be changed in this table. (To change a reference colour, select New reference colour in the Menu) Min and max tolerance Tolerances for the number of reference pixels can be defined here. Colour Product Control - V6.109 User Manual Document Version A 31/55

33 7.4.4 RING Window Parameters Parameters for windows RING0 to RING4 are arranged in columns in the table. Use NEXT>> to move to the next selection (RING5...9 etc). Parameter of Colourring (RING) - windows X Window name RING0 RING1 RING2 RING3 PX/PY/DX/DY 19/82/310/ /83/310/ /74/310/ /74/310/331 No. of Rings Reading Dir. Left->right Left->right Left->right Left->right Resolution Full Resol. Full Resol. Full Resol. Full Resol. Stepsize Min.Ringw Max.Ringw Measure Ring Geom. OFF OFF OFF OFF Ringdistance Tol.Ringdist No. of Scans Ignored Colours <<< >>> PX, PY, DX, DY Please select one of the four values if you wish to change the position or size of the corresponding RING window. Number of rings The reference number of the coloured rings for the particular window appears here. The reference number of the coloured rings is composed of the number of characters in the reference code, and can 32/55 Colour Product Control - V6.109 User Manual Document Version A

34 therefore not be changed in this table. (To change the reference code, please change under New reference code in the Menu) Reading direction The direction within the colour ring window can be defined here. Resolution The resolution along the line of measurement can be defined here. At full resolution, each pixel along the line of measurement is processed, and, at half resolution, every second one is processed. The resolution selected will impact on the computing time required. Stepsize Stepsize defines the distance between two lines of measurement appears here, and can also be changed. You can use this option to control the number of lines of measurement and the associated requirement for computing time. Minimum ring width The minimum permitted ring width in pixels appears here, and can also be changed. Maximum ring width The maximum permitted ring width in pixels appears here, and can also be changed. Maximum ring width The maximum permitted ring width in pixels appears here, and can also be changed. Measure Ring Geometry To reduce the impact of reflections from bubbles or foam, which often appear between ampoule rings, the measurement of the ring geometry can be deactivated here. This makes the inspection more stable against interferences. However this way the evaluation of the quality of the rings is not possible anymore. Ring distance tolerance The permitted ring distance tolerance in pixels appears here, and can also be changed. Number of scans The lowest number of positive value measurement lines necessary for an overall positive result for the inspection window appears here via the inspection window. Ignored Colors With this parameter, the user can define al list of colors, which should be ignored by the RING- Inspection. This way e.g. it is possible to teach-in the background color without resulting in bad reading, caused by detection of the new color between the rings. Colour Product Control - V6.109 User Manual Document Version A 33/55

35 7.4.5 OBJC Window Parameters The parameters for each OBJC window are arranged in columns in the table. Single parameters can be modified by selecting the entry. OBJC windows X Window name OBJC0 OBJC1 OBJC2 OBJC3 PX/PY/DX/DY 848/81/600/ /83/310/ /74/310/ /74/310/331 Colour All Colours All Colours All Colours All Colours Obj. opening(-)/closing(+) Obj. shrink(-)/extend(+) Noise-pixel reduction Tolerance object size Detection object size Object count Position tolerance 78 OFF OFF OFF Detect wrong colour objects ON ON ON ON <<< >>> PX, PY, DX, DY Please select one of the four values if you wish to change the position or size of the corresponding OBJC window. Color The reference colours which are used for the object searching. (The colour can be changed by setting a New reference code in the Main Menu) Object opening/closing This parameter can be used for closing (positive value) small spaces inside of the objects which were found or for increasing those spaces even more (negative value). 34/55 Colour Product Control - V6.109 User Manual Document Version A

36 Object shrink/extend If the objects which are searched by colour are not found completely because they are fragmented, a positive value for this parameter can extend these fragments, so that they are merging to the complete objects again. Contrary to this, a negative value can help to disjoin objects, which are touching each other, by shrinking them. Noise-pixel reduction If there happen to be scattered noise pixels in the image of the same colour as the reference, they may obstruct the Object Search. By setting this parameter to a value higher than zero, those noise pixels may be filtered out. Tolerance object size Objects with a smaller or a higher amount of pixels than configured in those parameters will be marked blue and be counted as bad. Detection object size Objects with a smaller or higher amount of pixels than configured in those parameters will not be marked and counted. Object count This is the minimum and maximum number of objects which have to be found inside of the OBJC window to create a GOOD reading result. Position Tolerance This value is the radius of a circle around the centre of gravity of each learned object. If the COG of an object is outside of this circle, the object position is wrong and the result is bad. To deactivate this inspection set value to zero. Detect wrong colour objects If this inspection is switched ON, all objects with wrong colour and minimum detection size will be marked red. If one or more wrong objects are inside OBJC window, result will be bad. Colour Product Control - V6.109 User Manual Document Version A 35/55

37 7.4.6 General Product Data Colour table: Shows the name of the colour table being used for the current product. Can be changed here. Display brightness: The brightness of the display can be set here between 1 and 255. The setting will have no impact on the evaluation. Factory setting: 148 Timeout: Timeout defines the maximum permitted evaluation time. Evaluation is stopped and the result set to BAD if the time is exceeded. Can be set between 1 and 1000 ms (1000 ms -> Timeout inactive); Factory setting: 200 ms; 36/55 Colour Product Control - V6.109 User Manual Document Version A

38 Control: The inspection can be switched ON and OFF here. If inspection is switched off, the camera will always show a positive signal, regardless of image content. There are two variations in the OFF position: System Ready = Low -> output OUT1 is set to 0V; System Ready = High -> output OUT1 is set to +24V; Shutter speed (exposure time) for current product The shutter speed setting for the current product is dependent on the reference colours selected. Dark colours have a longer flash, and bright colours a shorter one. The value entered here can be automatically changed again as required by entering a new reference code. You can change the shutter speed value here to set the camera in live image mode, for example. Colour Product Control - V6.109 User Manual Document Version A 37/55

39 7.5 Product Management Rename, Copy or Delete a Product Before renaming, copying or deleting a product, the desired product must be selected from the product list. The product can then be changed or deleted accordingly. The following characters can be used to enter names into colour tables: -the full alphabet (upper and lower case); -numbers 0-9; -the special symbols _ & ; - no umlauts; -The name can be up to 8 figures long Display product All of the settings for the current product are displayed here. The slider (scroll bar) can be moved in the window by using the touch-screen. # PRINT DATA # Press print data to store protocol in default directory and/or print it out via standard printer New product When setting up a new product, the user is guided through the program step by step. You will find a list of the steps in the section entitled Commissioning the software 7.6 Statistics Start, View and Finish a Batch A batch record can be started in the statistics menu. A batch record is designed to make a record of production. At the start of a batch, all the relevant data e.g. job number, item number, notes etc can be entered in the batch record. The first three lines, labelled <Fix>, are entered on the system once only, and will subsequently appear at the start of every record. There is also as positive/negative statistic. # PRINT DATA # Press print data to store protocol in default directory and/or print it out via standard printer. NB: The LAN on the Smart Camera does not have its own clock. For this reason, batch start and end times cannot be given accurately! 38/55 Colour Product Control - V6.109 User Manual Document Version A

40 7.6.2 Show faulty pictures According to the configuration set under Service/System parameters/number of defect images, 0, 1 or 4 images of the last defect will appear. To exit the display, please press the ESC key. Defect images will disappear when the system is switched off Reset Counters Positive and negative counters are set to zero. Faulty images are also deleted. The counter will only reset if no batch record has been started. Colour Product Control - V6.109 User Manual Document Version A 39/55

41 Service Live Image Please see the description in the section entitled Change product/live image System Parameters The system parameters are global, meaning that any changes will affect all products. Diagnosis Diagnosis level X Display window name CPIX: Mark positive pixels green CPIX: Display total of all positive pixels CPIX: Mark outshined pixels blue RING: Debug Ringwidth and -distance RING: Mark known colour (blue) and ref. colour (yellow) RING: Mark positive scans RING: Display reading direction OBJC: Mark positive pixels green To activate the corresponding diagnostic level select and press the key. OBJC: Display binary image OBJC: Display pixel number for each object Send XML Data on Port 23 BLUE = Diagnostic level active RED = Diagnostic level inactive Send GUI Data on Port Send XML ACK on Port 23 Display Trigger-Button Display window name Writes the name in the production screen in the upper left corner of the inspection window. CPIX: Mark positive pixels green Pixels within the tolerance of the reference colour are highlighted green. CPIX: Display total of all positive pixels Displays total of all pixels within the tolerance of the reference colour. 40/55 Colour Product Control - V6.109 User Manual Document Version A

42 CPIX: Mark outshined pixels blue Pixels that give values over 250 in the red, green or blue channel are too bright, and cannot therefore be measured. These pixels are highlighted blue. RING: Debug ring width and distance The median ring width and distance are obtained from all lines of measurement scanned positive, and displayed via the window in production. If the measurement of the ring geometry is deactivated, rings which are too slim or too wide will be marked red. At the same time, all lines of measurement of all windows scanned negative are exported coded lengthways via the Telnet. Caution, this increases computing time! RING: Mark known colour (blue) and reference colour (yellow) When scanning the colour ring code, known colours will be marked blue in the image. If the recognized colour is also appearing somewhere in the reference code, it will be marked yellow. RING: Mark positive scans For positive readings, the corresponding scan line will be visualized in green color. RING: Display reading direction For each RING window the reading direction will be indicated by a yellow arrow. OBJC: Mark positive pixels green All pixels which are corresponding to the reference color will be marked green inside of the window. OBJC: Display binary image The binary image of each object which was found will be shown in the image. OBJC: Display pixel number for each object For all found objects which are marked inside of the window the object size in pixels will be shown. Display Trigger-Button Displays a Trigger-Button in production mode next to the Menu-Button, which can be used to release a Manual Trigger for test purposes. Colour Product Control - V6.109 User Manual Document Version A 41/55

43 I/O configuration Good outputs and results-linking for windows groups Inspection windows can be organized into groups. Each inspection window must be in exactly one group. In the basic setting, all windows are in the first group G0. The Good Output of a group determines, on which output of the camera the results of the group windows will be released. The good/bad results of the inspection window resp. window groups will in the basic setting be released on the "Good output" (OUT0) of the camera. There are, however, 2 additional outputs (OUT2 & OUT3) of the camera available, which can be used as good outputs. Within a group, the results of window inspections are linked to one another, and therefore generate one single group result. In the basic setting, the results are logically linked by AND. If the results from several groups go to the same output, these group results are always logically linked by AND. 42/55 Colour Product Control - V6.109 User Manual Document Version A

44 Linking logic: AND already the bad reading of only one inspection window leads to a total 'bad' result. ("Bad wins") OR - already the good reading of only one inspection window leads to a total 'good' result. ("Good wins") Group G0 Group G1 RING0 (Good) RING1 (Bad) CPIX0 (Good) CPIX1 (Bad) AND OR Bad Good Output OUT0 Bad Colour Product Control - V6.109 User Manual Document Version A 43/55

45 Configuration of the good outputs There is a choice of 5 types of positive signal procedure. The configuration is the same for all positive outputs used. Mode 0: On the Positive impulse on evaluation up to next trigger setting, the positive output is high or low, depending on each evaluation after a trigger impulse. The positive output during evaluation is low. Mode1: On the Latch operation setting, the positive evaluation remains low after a negative evaluation, even if followed by further trigger impulses or positive readings. To reset a negative reading, press the quit key. The quit key is on the terminal, or separate on the machine. The positive output remains high during the evaluation period. Mode 2: On the Positive impulse after evaluation until defined time elapsed setting, the output after the evaluation period is set to an adjustable lapse of time. With a negative reading, the output remains low. The length of the positive impulse can be set between 5 and 100 ms. Mode 3: On the Positive impulse a beat later with negative trigger flank and until defined period elapsed setting, a pulse is emitted with an adjustable pulse length of 5-100ms. This is emitted with the negative flank of the trigger signal. If the reading is negative, the signal remains at GND level. NB: This mode is not currently implemented! Mode 4: Positive impulse a beat later with positive trigger flank and until the next positive trigger flank NB: This mode is not currently implemented. Mode 6: For the setting "like configuration ' 2 ', only with additional DATA-VALID signal on exit 'OUT3' the output is set after the evaluation time up until the expiry of a settable time. In the case of a negative reading result the output remains at Low. The GOOD pulse length can be set between 5 and 100 ms. In addition the output ' OUT3 ' is set on High. This means that starting from this time a GOOD signal can be measured. Thus 2 identical signals come at the same time during a positive reading. 44/55 Colour Product Control - V6.109 User Manual Document Version A

46 Mode 7: For the setting "like configuration 6, but GOOD signal and the next trigger can be overlapping if the output is set after the evaluation time up until the expiry of a settable time. In the case of a negative reading result the output remains at Low. The GOOD pulse length can be set between 5 and 100 ms. In addition the output ' OUT3 ' is set on High. This means that starting from this time a GOOD signal can be measured. Thus 2 identical signals come at the same time during a positive reading. In addition, it is possible that the GOOD signal and the next trigger are overlapping, without any problems. Mode 8: In this mode, each Window-Group has its own result signal. The result signal of each Group will be put out successively on the Output OUT0 as a GOOD-Pulse (High or Low), each followed by a Pause (Low) of the same length. The pulse length can be set between 1 and 100 ms. Every GOOD-Pulse will be accompanied by a Data-Valid-Pulse on Output OUT2. From the beginning of the GOOD-Pulse of the first Group Result until the end of the GOOD-Pulse of the last Group Result, an additional Reading-Gate-Signal on Output OUT3 will be High. A PLC may read these 3 signals from OUT0, OUT2 and OUT3 and release the GOOD-Signal of each Group on a separate PLC Output. Output OUT 1 System Ready: On output OUT1, the system ready signal is emitted. Camera is in the product screen -> OUT1 = +24V Camera is in the menu -> OUT1 = 0V The output can be used for example to block machine start-up and display a corresponding error message. Colour Product Control - V6.109 User Manual Document Version A 45/55