Enhanced Storage and Network Function Innovation to Quality Management

Transcription

1 Network Sensor Series (with Digital Interface Cameras) -C10-ETN/ F500-C10-ETN Sensor (with Digital Interface Cameras) F500-C10 Enhanced Storage and Network Function Innovation to Quality Management High accuracy inspection sensing (Digital Interface Camera). Storage for production and quality control (-C10-ETN/F500-C10-ETN). Remote access and operation across a network (-C10-ETN/F500-C10-ETN). Be sure to read Safety Precautions on page 542. Features Functions Digital Interface The Network Sensor Series uses a Digital Interface Camera that is less susceptible to noise and inputs clearer images. Flow Menus Flexible Application Support The menu system flexibly supports applications by combining processing items in response to measurement results and input signals, and giving you multi-point (more than 100*) region settings and multiple image preprocesses. * The number of region varies depending on the size and processing items Inspect product type for defects 1-million-pixel Model Flowchart Image Start Camera image Determine product type Separate inspection conditions according to product type 5 Inspect product type for defects 250,000-pixel Model Typical Screen 0. Scn 0 = set = 0.Camera image 1.Classification 2.Brunch 3.Fine Matching 4.END 5.Fine Matching 6.END 7. ENT:Set SFT+ESC:Edit Macros Easy Customization, and No Need Compiling Easy programming takes care of specific tasks that cannot be handled by menus alone, like displaying only the menus for routine work, carrying out complicated calculations, and simplifying robot communications. This eliminates the need for special programming development. * Reverse Customization part in Customization Manual can help to make the macros easier. 4 End 6 End 530

2 -C10-ETN/F500- Advanced Measurement Algorithms A wealth of original OMRON measurement algorithms are provided. Width Size Blurring Flaws Line width Ideal for detecting minute defects and soiling Fine Matching Leaning Character verification with no dictionary registration required QUEST Character Verification Low-contrast mark positioning ECM Search Storage Functions Storage Functions Are Integrated with the Sensor Evolution from OK or NG Quality Management Inspect Inspect Re-measurement Feedback Trend control Reject Reject Extract the data and images Save the data & images Data with measurement images, values, time stamps, and more can be stored. Highly useful for adjusting the optimal inspection conditions at start-up and producing history reports for quality control. Up to 1,500 images can be stored. Enhanced Image Storage Functions Offline Viewing Compressing images mode: This function can increase the number of images to be stored. Up to 1,500 images can be stored inside the Controller. Offline Analysis No Compressing images mode: The saved images are used to confirm inspection precision or to check results after resetting inspection conditions. 531

3 -C10-ETN/F500- Save Data & Images by Each Inspection Item The flow menus and macros support to store the data and images by each item. This strongly supports the trend control of inspection results and analysis aimed at improving quality. Data Logging NG Data 1 Gray Search NG Gray Search Edge Measurement Conditional Branching Execute Measurement and Storage Functions Independently Data Logging NG Data 2 Edge Measurement NG Storing data onto conventional Compact Flash cards Measure Store Measure Store Long total processing time Network Sensor Measure Store Measure Store Measure Store Shorter tact time Network Functions Monitoring, Setting and Collecting measurement data all remotely via Ethernet. Real-time Monitor Function Industry First You can display images from the Sensor on your personal computer in real time* 1 using Ethernet. This lets you monitor live inspection images from a remote location* 2. You can also simultaneously view the images on a personal computer from several Controllers connected to the network. *1. The transfer speed for live image depends on the network environment. *2. Remote monitoring across a firewall is not possible. Transfer Independent Measurement, Storage and Communications The data stored in the Controller can be transferred to a personal computer at any time. This lets you analyze the data without lowering the rate of operation for your production line. During measurement File transfer Daily Report Daily Report Date Daily Report Date Date Production Quantity Rate Rate Rate of Operation File access 532

4 -C10-ETN/F500- High-speed Ethernet 100Base-TX Even large-volume image files can be transferred at high speed. Naturally, multiple Controllers can be controlled from a single personal computer. 100Mbps max. Remote Operations Better Response Time Operations such as executing or stopping Sensor measurement, setting or changing scene data, and collecting files saved on the Controller can all be done from a personal computer in another part of the plant, or even in a distant location. The operations that were previously done from the Console can all be performed from a personal computer. Conventional 10.4-inch LCD Monitor F500-M10L New proposal Make settings from a personal computer Console F150-KP F160-KP Composer Net and Watcher Two types of PC-tool maximize performance of the Network Sensor. In the Office Composer Net This software covers the design, start-up, operation, and maintenance monitoring of the Sensor, all via Windows UI operation. Composer Watcher This software integrates control over the status of the Controllers. Router Router At the Factory 533

5 -C10-ETN/F500- Composer Net Security Function The security function allows you to classify the operations of registered users into three ranks (Administrator, Supervisor, or Operator) depending on their access privileges. Change system data Administrator Register users Add access privileges Supervisor Add model data Re-register models Change inspection items Recording Live images sent by the Controller can be recorded by a personal computer using the AVI format. Effective for trend control. Recorded by personal computer Saved in AVI format live-image transfer Operator Change criteria Change display screens Adjust inspection regions Screen Captures Previously, images were stored via a Compact Flash Card inserted into the Controller. It is now possible to capture network-transferred live images on a personal computer at any desired point in time. Capture on personal computer Save Logging This function lets you accumulate a variety of production data, including images, measurement values, time stamps, production quantity, and defect rates. The macro function in the Controller then makes it possible to process this into the form of data that you need. live-image transfer Composer Watcher Monitor Operating Conditions from a Remote Location Sensor measurement can be started and stopped. Scene data settings can be specified from a remote computer. All operations that were previously possible from the console can be performed remotely from a computer. Controller A Controller B Controller C Inspection A Inspection B Inspection C During operation During maintenance Failure Controller A Controller B Controller C 534

6 -C10-ETN/F500- Applications Connector Lead Measurement The high-resolution 1-million-pixel Camera produces highly precise measurements over a wide field of view, which enables rough positioning and large workpiece measurements with only a small number of passes. Macros Macros are ideal for determining accurate lead lengths to assure linearity near the lead tip, and for statistical processing of measurement data for trend control. LCD Substrate Alignment The sharp, clear images of the Digital Interface Camera and OMRON's original EC technology algorithm lets you attain highprecision positioning even for low-contrast marks and overlaid marks with missing parts. Macros Positioning with even greater precision can be achieved by using original calibration methods. Macros can also be used to match protocols for output to a PLC or stage controller. Character Verification on PCBs The easy setting of OMRON's original Quest character verification algorithm, which requires no dictionary registration, provides a level of recognition that approaches human sensitivity. Using a 1-million-pixel Camera, a character string can be verified in a single pass. Macros Macros can be used to process statistical data, such as the recognition rate and number of NG characters, or to correct for differences between the present time display and an external clock. Detecting Cracks in Ceramic Substrates Cracks can be detected in ceramic substrates with a high degree of stability. An original OMRON algorithm eliminates the effects of irregular lighting and surface roughness to detect only the cracks. Macros When cracks cannot be detected using lighting directed from above, macros can be used to alter the lighting, for example, to enable oblique lighting. (Lighting that is capable of external dimming is required.) 535

7 -C10-ETN/F500- Storage and Network Applications Start-up, Adjustments Determine Optimal Inspection Conditions Accumulated measurement values and images Analysis and verification Daily Report Date Production Quantity Rate of Operation Analyze and verify accumulated measurement values and images Optimal parameters can be determined by analyzing the images and measurement values accumulated in large-capacity storage. When image processing parameters have been changed, stored measurements can be re-measured. 536

8 -C10-ETN/F500- Operation, Management Monitor Operating Conditions for Production Management Save measurement images and values in large-capacity storage. Measurement images Measurement values Daily Report Date Production Quantity Rate of Operation Send stored data in a single transmission Measurement images and values can be saved in large-capacity storage. You can save a wealth of measurement images and values in large-capacity storage. Because measurement and storage functions are independent, they have no effect on processing time. Maintenance Quick Problem Finding and Solving via Network Problem are resolved by network operation LAN connection (Ethernet) Status monitoring from a remote location The operating status can be observed over the network. It is easy to collect historical data for defect analysis and quality control improvements. 537

9 -C10-ETN/F500- System Configuration High-precision Lenses CCTV Lenses F500-LE16 F500-LE25 3Z4S-LE ML-1614 F500-LE50 3Z4S-LE ML Z4S-LE ML-5018 Controllers Digital Interface Camera Cable *1 F500-VS 2M -C10-ETN F500-C10-ETN F500-C10 *2 Camera Cable F500-VS2 2M F500-S1 *3 -S1 *4 LCD Monitors Monitor Cable F150-VM 2M Console Parallel Cable ޓ F160-VP CS CS CS CS CS CS PLC Memory Card F500-M10L F150-M05L F150-KP, F160-KP 64 PC Software F500-CD3E Composer Net (F500) Application Software F500-UM3FE/UM3ME *1. Camera Cable - Consists of camera control and power source cable. *2. The product pictures shown are -C10-ETN and F500-C10-ETN model. *3. F500-S1 model is Camera for F500-C10-ETN and F500-C10. *4. -S1 model is Camera for -C10-ETN USB Serial Communications RS-232C/422 Personal computer F160-N64S(S) 64MB F160-N256S 256MB

10 -C10-ETN/F500- Ordering Controllers Type Model Remarks -C10-ETN --- F500-C10-ETN --- F500-C ,000-pixel Camera with Digital Interface -S million-pixel Camera with Digital Interface F500-S1 --- LCD Monitors Console Memory Cards F500-M10L --- F150-M05L --- F150-KP --- F160-KP --- F160-N64S(S) F160-N256S Memory capacity: 64 MB Memory capacity: 256 MB PC Software ( Composer Net) F500-CD3E --- Application Software High-precision Lenses Cables Camera Cable F500-UM3ME F500-UM3FE Flow menu and Macro format Flow menu format F500-LE F500-LE F500-LE F500-VS F500-VS2 Cable length: 2 m, 5 m, 10 m Monitor Cable F150-VM Cable length: 2 m Parallel Cable F160-VP Loose-wire cable for Parallel I/O Connector Cable length: 2 m Ratings and Specifications Controllers Item Model -C10-ETN F500-C10-ETN F500-C10 Connected Camera -S1 F500-S1 No. of connectable Cameras 2 Processing resolution 512(H) 484(V) 1024(H) 1024(V) No. of scenes Image memory function 32 (can be increased using Memory Cards) 35 images max. Storage 64 MB non-volatile memory 256 MB non-volatile memory --- Operation and settings Menu language Serial communications Measurement items installed using Applications Software. Menu operations used to combine measurement items. Composer Net can be used for operation and settings. Japanese or English (switchable) USB series B: 1 channel; RS-232C/422: 1 channel Network communications Ethernet 100Base-TX/10Base-T --- Parallel I/O Monitor interface Memory Card interface Power supply voltage Current consumption Ambient temperature Ambient humidity Dimensions Weight Accessories 11 inputs, 22 outputs Composite video output: 1 channel, S-VIDEO output: 1 channel Compact Flash card slot, 1 channel 20.4 to 26.4 VDC 2.1 A max. (with two -S1 Cameras connected) Measurement items installed using Applications Software. Menu operations used to combine measurement items. 2.1 A max. (with two F500-S1 Cameras connected) Operating: 0 to 50 C; Storage: -25 to 65 C with no icing or condensation Operating/storage: 35% to 85% with no condensation (W H D) (without connectors and other protrusions) Approx. 1.6 kg (Controller only) Ferrite core for Console (1), Setup Manual 539

11 -C10-ETN/F500- Cameras Item Model -S1 F500-S1 Imaging device 1/3-inch CCD 2/3-inch CCD Pixel size 7.4 µm (H) 7.4 µm (W) 6.45 µm (H) 6.45 µm (W) Shutter Electronic shutter, 8 shutter speeds (1/60 to 1/12,000 s), changed via menu Partial function Seven settings Four settings Communications interface Ambient temperature Ambient humidity Dimensions Conforms to Camera Link Electronic shutter, 10 shutter speeds (1/24 to 1/10,000 s), changed via menu Operating: 0 to 50 C; Storage: -25 to 60 C with no icing or condensation Operating/storage: 35% to 85% with no condensation mm (W H D) (without connectors and other protrusions) Weight Approx. 110 g Approx. 270 g Accessories Instruction manual mm (W H D) (without connectors and other protrusions) LCD Monitor Item Model F500-M10L Size 10.4 inches Type LCD TFT Resolution Brightness 350 cdm/m (typical) Input signal NTSC composite video (1.0 V/75 O termination), S-VIDEO Power supply voltage 20.4 to 26.4 VDC Current consumption 1.0 A max. Ambient temperature Operating: 0 to 50 C; Storage: -20 to 65 C with no icing or condensation Ambient humidity Operating/storage: 30% to 80% with no condensation Weight Approx. 1.8 kg Accessories Instruction manual, 4 mounting brackets Dimensions mm (W H D) System Requirements for Composer Net Item Model F500-CD3E CPU Operating System Memory Hard Disk Monitor Network Sensor Controller Application Software Pentium III 600 MHz min.(pentium III 1 GHz min. recommended) Windows 2000 Professional, Service Pack 4 or higher Windows XP Home Edition, Service Pack 2 or higher Windows XP Professional, Service Pack 2 or higher 192 MB min. (256 MB min. recommended) 300 MB min. available space Resolution: 1, min. Display colors: High Color (16-bit) min. (True Color (32-bit) min. recommended) 10BaseT-compliant network (100Base-TX recommended) -C10-ETN, F500-C10-ETN F500-UM Ver.3.00 or later 540

12 Flow Menus Flow Menu Procedure -C10-ETN/F500- Image Input Complete Image Processing Items Image Input Position Compensation Measurement Camera Image The camera image is read synced on an external signal. Switch Camera The camera can be selected when two cameras are connected. Changing Filtering Filtering can be performed that is different from that performed when the image was read. Filtering Again Filtering can be performed many times for the same image. Branching Control Measurement Support Position Compensation Results Output Results Display Binary Position Compensation Positioning is compensated based on the center of gravity and axis angle found using binary processing. EC Position Compensation EC position compensation is effective for low contrast marks that vary in size. Edge Position Compensation Positioning is compensated based on the outline of the workpiece found through edge processing. Model Position Compensation Positioning is compensated based on search points found by matching with registered models. Scroll Images read using X,Y coordinates and angle data found with measurement functions can be scrolled. Reset Scroll Images that have been scrolled can be reset to their original positions. List of Processing Items Positioning Presence and Direction Inspections Appearance (Defect) Inspections Dimensions Application Packages Binary Processing Gray-scale Processing EC Processing Gravity and Axis Gray Search (x-y: Pixel Level) Precise Search (x-y: Subpixel Level) Rotation Search (x-y: Subpixel Level) Circular Angle ECM Search EC Positioning Gravity and Area Binary Defect Labeling Label Data (counting possible) Density Data (Average and Deviation) Gray Search (x-y: Pixel Level) EC Circle Count * The same F500-UM Applications Software is used for the, F250, and F270 model. Area (Var. Box) Density Defect # Defect Defect (Var. Box) Fine Matching Flexible Search EC Circle Defect EC Defect Edge Position_1 Edge Position_8 (Number of areas drawn differs) Edge Width (Width between edges measured) T-Edge Position BGA

13 -C10-ETN/F500- Branching Control Conditional Branching Measurement conditions can be changed based on measurement values and results. DI Branching Processing can be branched based on the input status of the parallel interface. End End indicates the end of the process flow. (No settings are required.) Measurement Support Calculation Calculations, such as basic arithmetic, tangent, cosine, and distance calculations, can be performed on the measurement data found using measurement functions. Macros Elapsed Time The processing time to a specified point in the process flow can be measured. This can be used for the required processing, such as canceling measurements for time delays. Wait The processing flow can be temporarily paused to place processing on standby for a set period of time. Set Unit Data Setting data can be overwritten. Trend Monitor Measurement time can be displayed on a graph along a time axis. Results Output Memory Card Data Measurement values can be output to a Memory Card inserted in the Controller. DO Data Measurement values can be output as binary or BCD data on the parallel interface. DO Judgement The OK/NG judgement results can be output on the parallel interface. Host Link Data Host Link Data OMRON's PLC Host Link communications can be used for measurement commands, judgement results, measurement values, and other data without special programming. Normal Data RS-232C communications can be used for measurement commands, judgement results, measurement values, and other data. Data Logging Measurement data and images can be stored inside the Controller. Results Display Display String Display Measure Display Judge Display Item Display Time Display Figure Display Line Display Box Display Circle Display Cursor Safety Precautions Refer to Warranty and Limitations of Liability on page F-2. WARNING This product is not designed or rated for ensuring safety of persons. Do not use it for such purpose. Precautions for Correct Use Do not use the product in atmospheres or environments that exceed product ratings. 542

14 -C10-ETN/F500- Dimensions Controllers -C10-ETN F500-C10-ETN F500-C Cameras -S1 Four, R (Unit: mm) 100 Four, M4, depth 8 60± F500-S C-mount /4-20 UNC tap, depth 9 Two, M4, depth ± ± Four, R Two, ridges, R M3, depth Four, 20 dia (14.05) C-mount Four, M4, depth ±0.2 1/4-20 UNC tap, depth Note:The product pictures shown are -C10-ETN and F500-C10-ETN model dia., depth ±0.2 14±0.2 Four, M3, depth 8 LCD Monitor F500-M10L Console F160-KP Mounting bracket min Monitor cable F150-VM 47 max. Mounting plate thickness: Panel Cutout Dimensions 276±1 216±1 4.8 dia dia. 2,000 Cat. No. E856-E1-01 In the interest of product improvement, specifications are subject to change without notice. 543