User Manual. Optical Character / Code Verification OCV 7.001

Transcription

1 User Manual Optical Character / Code Verification OCV 7.001

2 Contents 1 General Instructions Type of Control Numbers and Types of Camera Control Windows (Smart Camera) Operation of the Camera Keys The Virtual Keyboard Camera Start-Up (New Product) Teach-In Control OCR / OCV - Control CODE - Control Pixel - Control Pattern Check Position Control Acquire Image Instructions for Setting the Control Window Instructions for Setting the Grey value Threshold OCV Window Color Normal and Inverted Tracking Linkage Track OCV/TIN/PIX Windows with POS windows Track all windows with PATTERN CHECK Window Color Inspection of the Pixel Window Control Mode of the Pixel Window Tolerances of the Pixel Window New Reference Code Production Mode Menu Overview Product Management Menu Edit Product Font Menu Learn Character Group Train Characters Show Font Confusion List Tolerances Change threshold 1 and threshold Delete pattern Delete character Copying, Renaming, Deleting Font Correct Font Size Temporary Teaching Character Statistics Menu Service Menu Optical Settings Configuration Illumination Image Configuration... 38

3 9.3.1 Image transfer Configuration Image geometry Image resolution Camera Configuration I/O configuration Master Slave Statistic mode Eject Station Control Image server Reader Mode Diagnosis System Parameters Time Out Clock overflow Reference Data receive check On/Off measurement line automatic Trigger edge Save counters Image Shading Language Preferred font color User and Password Management Password, Zoom Change Password Zoom In (Zoom Out) Parameters of OCV / TIN Windows Parameter PATTERN CHECK Window Parameter Position Control Window Parameter Code Window Barcode Quality Control Referring to ISO/IEC Classification of a 1D Barcode Configuration of Quality Control Pixel Window Parameters Data Matrix Window Parameters Data Matrix Quality Control Data Matrix Quality Control in Keeping with ISO/IEC Camera Calibration for Data Matrix Quality Control Reasons QR Code Window Parameters Code Aggregation Appendix Error Messages and Error Recovery Maintenance Further Documents Adjusting the Focus / Reading Distance Specifications for OCR/OCV Control Font Permissible Characters for OCR/OCV Control... 98

4 23 Readable Code Types Index

5 1 General Instructions Operator's Duty to Exercise Due Care The PCE OCV SMART CAMERA was designed and constructed in accordance with the stipulated harmonized standards and other technical specifications. It thereby conforms to state-of-the-art technology and enables an optimum degree of safety during operation. The safety of the system during everyday operation can only be ensured if all the necessary, relevant measures are taken. Planning these measures and controlling their implementation is part of the system operator's responsibility for exercising due care. The operator must ensure that The system is used in accordance with the stipulations, The system is only operated in perfect, fully functional condition, The operation manual is always in complete and readable condition at the location of the machine Only respectively qualified and authorized personnel operate and service the system, This personnel is instructed on a regular basis in all the relevant aspects concerning work safety, and that they are familiar with the Instruction Manual and the safety instructions it contains, All the system features relating to safety are carefully tested at regular intervals, The higher the safety risks of this device the more frequently regular inspections have to be performed Basic Safety Measures For safe operation of the image processing system, the following points must be observed: The camera must be mounted on a stable, mechanically fixed attachment. During operation, the camera must be protected against the influence of external light. The voltage supply system of the device is 24V DC and is supplied from an external voltage source. All the safety instructions necessary for this type of system design are to be observed. The device may only be operated by persons trained and authorized to use the device, who are familiar with the Instruction Manual and are able to operate the device accordingly. To ensure safe operation of the image processing system, repeated inspections of all safety relevant parts must be performed. The points mentioned above and the operating manual must be followed. Requirements for the Operating Personnel The device is operated via user administration. This may only be operated by personnel specifically trained for the respective level. In this connection, please also read the section Operating details and menu structure. This operation manual serves for enabling the user to install and operate the device. However, this operation manual does not replace the installation and the customer service performed by trained personnel! Transport, Installation and Start-up During transport must be ensured that the device is packed and transported so that it is protected against moisture and impact. When installing the device in an industrial environment, this should be done where the effects of dust, moisture, temperature and vibration lowest. Safe operation of the device can only be guaranteed if specially trained personnel have conducted the installation and start-up. Note: To avoid the risk of stumbling, all device connections (cables) must be laid in such a way that they will not cause tripping! Intended Use The PCE OCV SMART CAMERA is suitable for inspecting the readability of: Identification number, lot number, proof of origin, expiry date and variable print on labels, cartons, films and other printed items. The optical character reading monitors the most important errors of: Stamp, hot stamp block, photo plate, thermal transfer, laser or inkjet printers, that render the print unreadable or result in incorrect recognition, for example: Reversed characters; blurred characters; worn characters; merged characters or missing character(s). Typical applications for PCE optical character verification are on: Brochures, labels, vignettes, cartons, tubes and tins. 5

6 Note: If the PCE optical character verification is not used correctly, reliable operation of the system cannot be guaranteed. For all personal and material damage resulting from improper use the operator of the PCE image processing system is responsible, not the manufacturer. 2 Type of Control OCV mode (optical character reading) The individual characters are taught in once by the operator using samples. The sample will be deposited at the character set. When changing the batch the reference characters will be taught-in via keyboard. If the deviation of the character set compared to the reference code is too big, the print will be evaluated as BAD. Application: For bad print, because several samples of one character can be taught in. If there is a small gap or the gap is missing between the characters. OCR mode (optical character reading) As in the OCV mode, reference character samples can be taught-in as one character set. When changing the batch the reference characters will be taught-in via keyboard. During production the actual character will be compared with all samples of the character set. The sample with the least deviation is selected and compared to the reference code. If the matching calculated is too small, the print will be evaluated as bad. The OCR mode is slower than the OCV mode. Spaces have to be available between the characters; otherwise they cannot be recognized individually! Application: If the OCV mode is not sufficient for distinguishing between different characters (example: "O" vs."0" or "8" vs. "B"). If the content of a print job needs to be read and output. If the exact reference code is unknown but only characters from the taught-in character set are allowed. Note: OCV has a greater tolerance for poor quality print and is generally sufficient. Teach-In mode (optical character reading) The operator teaches in the reference character samples as a reference code. No allocation of samples to characters takes place. Application: Constant changes of font type and font sizes; characters must be separated clearly by a gap. Note: This mode should not be used if reference codes are specified by the PLM. Pixel mode In a pixel window the sizes of the black and white areas are verified. The tolerances can be entered as absolute, or relative. Application: Presence control of objects or print. Code mode With the set window, a barcode (1D code) is read and the code content is compared with the reference code. See the "Readable Code Types" chapter for the various possible code types. Application: Object control using code reading. Verification of the code quality (grading) Data Matrix mode With this window, a data matrix code (2D code) can be read and compared with the reference code. See the "Readable Code Types" chapter for the various possible code types currently available. Application: Object control via data matrix code reading. Verification of the print quality of the data matrix code (grading) QR mode With this window, a QR (Quick Response) code can be read and compared with the reference code. See the "Readable Code Types" chapter for the various possible code types currently available. Application: Object control via QR code reading. Verification of the code content. Pattern Check The camera will search for a pattern taught in. The position of pattern and the deviation from reference will be measured. This control type can be used for positioning of OCV/OCR, PIXEL or CODE windows. Application: 6

7 Presence control of correct print. Positioning tool for other control types Position Control The POS window can be used for the absolute and relative position measurement of objects. It can also be used only for the tracking and shifting of windows with each image processing cycle. Application: Position control for example of label positions or cap fitting. Positioning tool for other control types. 7

8 2.1 Numbers and Types of Camera Control Windows (Smart Camera) The following control types are available: Type Name Number # Optical character (OCR, OCV, Teach In) window OCR#, OCV#, TIN# 20 Pixel windows PIX# 20 Barcode window CODE# 5 Data matrix code window DM# 5 QR code window QR# 2 Pattern Check window PC# 4 Position windows POS# 25 The different control types for the sensor cannot be freely combined. The user must decide whether to use the sensor for pixel, optical character, barcode, or data matrix checking. Except for these restrictions, the sensor software functions just like the camera software. The results of the controls (checks) can be AND or OR linked and routed to different outputs. An AND link and OUT0 have been preset as a GOOD output. The sensor cannot be used for code quality verification (grading). 8

9 3 Operation of the Camera The image processing system is operated using simple menu navigation on the display and an integrated touch screen. The areas that shall be inspected are marked and verified using the window technique. Operating instructions are displayed for single products. The following illustration shows the main menu after choosing a camera and pressing Menu on the touch screen. Status Line Menu selection Note: When the system is switched on, the production run the actual control mode is started. After choosing the camera and pressing MENU, the production run can be quit, and the main menu is displayed. 9

10 3.1 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 after releasing a menu item. Quit or cancel a sub-menu using the Exit button. Setting windows, frames and lines: The windows for the different types of control (OCV, OCR, Code, DM, QR, PIX, PC) will be configured on the touch screen via control symbols. The windows can be changed directly via touch screen (mouse). By pressing the center of the window this can be moved, by pressing on the side next to the window the size of the window can be changed. Arrow keys Mode By choosing the center button the active mode can be switched. In scrolling mode the window can be shifted using the arrow keys In zoom in mode the window can be enlarged using the arrow keys. In zoom out 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. 10

11 3.2 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. characters. Changes between capital and small letters as well as numbers and special Confirms the entry of characters or completes the entry. Cancels the entry. Shifts the keyboard upwards,. Shifts the keyboard downwards. allows to freely position the keyboard let the keyboard disappear 11

12 4 Camera Start-Up (New Product) 4.1 Teach-In Control Product administration New product New product name:... Live image Live image with trigger Type of control Teach In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK Window with position control Position reading window: See chapter: "Instructions for setting the measuring lines" Window without position control See also chapter: "Instructions for setting the control window" Setting grey threshold: See also chapter: Instructions for setting the grey threshold 12

13 4.2 OCR / OCV - Control Product administration New product New product name:... Live image Live image with trigger Entry of characters: 12345HN00G Type of control Teach-In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK Position reading window: Setting grey threshold: See also chapter: "Instructions for setting the grey threshold" Use existing font See also chapter: "Instructions for setting the control window" Setting grey threshold: Create new Font See also chapter: "Instructions for setting the control window" Window without position control See chapter: Instructions for setting the grey threshold Window with position control See chapter: "Instructions for setting the measuring lines" 13

14 4.3 CODE - Control Product administration New product New product name:... Live image Live image with trigger Type of control Teach-In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK Determine information for code search All barcodes automatic? Position reading window: Set the size of the codes See chapter: "Instructions for setting control window Pharmacode? Omnidirectional? Static Omnidirectional Set contrast: Chosen code type automatic? See also chapter: Instructions to set the contrast Prior choice of code determination Barcode Pharmacode Code 39 Int 2/5 Code 128 Code 32 UPC_A Code 10 figures UPC_A Code 12 figures EAN 13 Codabar 2-Track Pharmacode GS1 DataBar (RSS) CC-A EAN 8 Manual? 14

15 4.4 Pixel - Control Product administration New product New product name:... Live image Live image with trigger Entry of the tolerances Type of control Teach-In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK See also chapter "Tolerances of the pixel windows" Positioning of pixel-window: Selection of print control or presence control See also chapter "Control mode of the pixel windows" See also chapter: "Instructions for setting the control window" Setting grey threshold: Setting an additional control function See also chapter: "Instructions for setting the grey threshold" Inspection color bright or dark? See also chapter "Inspection color of pixel windows" Window with measuring arrows See also chapter: "Instructions for setting the measuring lines" Window without measuring arrows 15

16 4.5 Pattern Check Product administration New product New product name:... Live image Live image with trigger Type of control Teach-In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK Teach-In reference pattern Teach-In searching area 16

17 4.6 Position Control 17

18 4.7 Acquire Image For adjustment of camera position, focus and aperture, it s necessary to acquire an image. Image acquisition is also required for teaching the control windows and learning patterns and characters. Live image In live image mode the camera is grabbing pictures automatically till NEXT button is pressed. Live image with trigger The camera needs to get a trigger signal (In0) for image acquisition. Load image Flash memory stored image can be loaded and used for the parameter setup. Note: Save and Load images for Test-Evaluation must be activated in Diagnosis menu. Faulty pictures can be stored in batch record -> show faulty pictures menu. 4.8 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 window selected last in the individual mode is displayed in red. All changes in position or size which are done to this reference window will be 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. Individual All at once 18

19 4.9 Instructions for Setting the Grey value Threshold Separating the object from background is done using the grey value threshold, which is set manually by the operator: After the control window has been set, the camera displays the binary image (black/white image). Canceling input Binary Image The black and white part of the binary image can be changed by moving the slider up and down. The image will be updated as soon as the slider is no longer pressed. The histogram on the right shows the amount of grey values within the window. The threshold is set correctly if the characters are displayed in strong black. No black points should be visible in the background. Slider Histogram Accept settings The inkjet filter is also used for adjusting the threshold values of an optical character control window, thus making it easy to check the effect 19

20 4.10 OCV Window Color Normal and Inverted If there is a combination of windows with dark font on light background and light font on dark background in the document, this action can be performed separately for each window in the OCR parameter table ('Parameters of OCV/TIN Windows'). If different settings in the OCR parameter table are used in a product, then for each new window the camera will ask whether dark font on light background or light font on dark background should be used. Optical character window parameters X Control Window name: OCV0 Identifier GTIN Font: tz1 Search area Position: 165/205 Size: 57/46 >>Next>> Search area Threshold: 120 Color: Black Direction: L->R Lines Tilting: 0 Noise pixels 5 Distance: 0 In the production display a window with inverted font (light on dark background) is marked with a window name with inverted font (see image OCV1 below). If the reading direction is vice versa (from right to left / from bottom to top) the reference code will be displayed in an inverted font (see image 0A186A below). 20

21 4.11 Tracking Linkage Some control windows can provide position information like a Data Matrix Code position or the edge position of a label. With this information other windows can be repositioned in the camera image before they are being processed. For repositioning one window by another, the two windows must be linked. The following windows provide position information after they were processed and can shift other windows by the position offset: PC, DM, QR, POS These windows can be shifted by one of the previously named window types: PC (only by other PC windows), POS, CODE, TIN/OCR/OCV, PIX The windows are executed depending on their type in the described order and in numerical order. (PC0, PC1,..., DM0, DM1,, etc.) As a diagnosis option, the display of the brown connection lines can be switched on in the "Diagnosis" menu. The arrow link displays the linking direction and points from the leading window to the one which will be shifted. Example: The yellow windows POS0 and POS1 are searching for the location of the bottle. POS2 is shifted by POS0 and POS1 to the correct position and inspects the cap location on the bottle. POS3 is also shifted by POS0 and POS1 and then checks the label position. Finally the PIX0 window is shifted by POS3 to the correct location on the label and checks for the presence of the printing. Example: The windows OCV0 - OCV3 are all shifted by the position offset of the DataMatrix code, found inside the DM0 window. For changing the processing order (for example to change the linking direction of two linked POS windows) please refer to the Change control window sequence menu in Edit product. Windows which would be shifted outside the camera-image, will be marked magenta on the affected window sides. 21

22 4.12 Track OCV/TIN/PIX Windows with POS windows In case the print position of the text characters differs between the printed labels, the window position should be tracked using POS windows, Data Matrix-Code or a Pattern position. If the Label has a code or a check pattern printed together with the text or pixel you have to control, try to use tracking via Data Matrix or check pattern. On other cases the inquiry Add POS window for tracking? has to be answered with Yes. Adding POS windows for tracking When you are setting a new OCV/OCR/TIN window and confirmed to add POS windows for tracking, the camera will add two POS windows (one horizontal and one vertical) and adjust them automatically. To keep operation expenditure small, the two POS windows should be set only for the first window. All further windows are likewise corrected with these POS windows. When you are setting a new PIX window and confirmed to add POS windows for tracking, you will be asked to set the POS windows manually. Manual setting of POS windows for tracking: If you have set two POS windows for the tracking of one or multiple OCV/OCR/TIN windows you can use the option to align the POS windows automatically. This only works for POS windows which have a horizontal or a vertical search direction. Also the pixel windows can be tracked with POS windows. In case e.g. the black printed area varies several millimeters to the left, right or up and down. First of all the POS windows adjust the yellow control window to the correct position. Afterwards the content of the window is evaluated. It always has to be set to at least two lines. These can be active for only one window, several windows or for all windows. If necessary, individual POS windows can be set for each window. That means each window can be adjusted individually with two lines. Regarding the OCV, OCR and Teach-In control the tracking POS windows can be aligned automatically. Please see also Section Set measuring lines automatic. One measuring line is necessary horizontally or vertically respectively. Inside the capture ranges a changeover from bright / dark is searched across the scanning width. The line indicates the search direction here. 22

23 Setting the POS window for the horizontal guiding position First, the tracking POS window is set to the horizontal guiding position. By operating the arrow keys you can choose the direction in which the edge should be searched. This is to be set as shown in the example: Correct: For greater clarity in the example, only one window is set around the first line. The line scans the second line from the right and guides the window back into position accordingly. The line is correctly positioned as no other additional print is found in the scanning area of the POS window. Setting the POS window for the vertical guiding position The line for the vertical guidance can scan downwards or upwards. In the example, the line is shown scanning upwards. Correct: The line is positioned correctly because no other additional print can be found in the scanning area of the POS window. Alternative: Setting one POS window for both directions If the area around the corner of the printing is free, you can work with one single POS window, which is scanning in horizontal and vertical direction. Correct: The line is correctly positioned, as no other additional print is found in the scanning area of the POS window A grey value threshold is also defined for each POS window. The threshold is optimally set when the background is an even grey and the print is shown in black with sharp outlines. After setting the POS window for tracking you can still edit parameters for those windows in the Parameter Table for POS windows. 23

24 4.13 Track all windows with PATTERN CHECK Window Instead of measurement lines it is also possible to use a PATTERN CHECK for positioning other control windows. This tool is more flexible, because there are fewer restrictions. To use this feature, measurement lines have to be denied during setting up OCV/TIN/PIX windows. At the end of PATTERN CHECK adjustment, the question arises weather all other active controls ((Data Matrix windows expected) should be tracked using this tool. If Yes is selected, all windows will be moved depending on reference pattern position. Exp = reference pattern; PC0 = Pattern Check window; OCV0 = window, which will be moved; 4.14 Color Inspection of the Pixel Window While teaching in a Pixel window, the message is displayed that asks: Which pixels are to be counted?. There are two answering possibilities, dark pixels or bright pixels. The answer that is suitable for the object has to be chosen. For example dark pixels have to be chosen, if a dark print on a white background shall be inspected. Bright pixels have to be taken, if a white label on a brown bottle shall be inspected Control Mode of the Pixel Window After choosing the pixel color the message Reference value for the tolerances is displayed with the choice of Presence control or Print control. Presence control (absolute measurement) For the absolute measurement, the black area e.g. is displayed as a measured pixel number. When the black area increases, the measured number of pixels increases, and vice versa. The plus tolerances and the minus tolerances are entered as a pixel number. Finally, in the production mode, the measuring value is similarly displayed as a pixel number. Print control (relative measurement) In the relative setting, the size of an area (reference area) is taught in and accepted as 100%. The following measurements can be smaller than 100% if, e.g. the printed area is missing, or greater than 100% if, e.g. there is too much print. The input of the plus and minus tolerance and the display of the measuring values is given as a percentage value. 24

25 4.16 Tolerances of the Pixel Window After selecting and acknowledging with Enter the present measuring value is displayed in pixels or as 100%. The camera waits for the entry of the minimum tolerance. Following this, the maximum tolerance is entered. For the presence control: the minimum tolerance value should be less than the actual pixel value and the maximum tolerance value should be greater than the actual pixel value. For the print control: the minimum tolerance value should be entered less than 100% and the maximum tolerance value greater than 100% New Reference Code The entering of new reference codes depends on the control windows which have been set before. Control window Teach-In OCV OCR Code Pixel Data matrix Pattern Check New Reference Code Reference character will be taught-in by the means of a GOOD-print Reference character will be entered via the keyboard Reference character will be entered via the keyboard Depends on the Teach-in parameter, see the Parameters for the Barcode Window. - Reference character will be entered via the keyboard - Index a./o. Parameter of the code will be taught-in by means of a GOOD code In case of control type "Print Control" the print reference will be taught-in by the means of a GOOD-object. Depending on the parameter Teach-in Code, see Parameter Data matrix window. - Reference character will be entered via the keyboard - Index a./o. Parameter of the code will be taught-in by means of a GOOD code No action Note: If the camera is operated with PLM 4 or higher, reference codes will be transferred from the pilot to the camera at start of production. The input reference codes are of secondary importance in this operating mode, nevertheless this function is useful because the CODE and data matrix windows detect important settings during reference check Production Mode After entering the reference code it is possible to change over to the production mode, and the camera is ready for operation. If only PIXEL or PATTERN CHECK windows are used for inspection, it is possible to change directly to the production mode after creating a new product. The camera is now ready for operation. Note: For safety reasons it is not possible to switch to production mode with the Default Product since there are no control windows set. The warning message No windows set appears on the screen. 25

26 4.19 Menu Overview Main menu Production New reference code Change product Edit product Product management Font Batch record Service Change Password Zoom On Product Management New product Show product Rename product Copy product Delete product Font Learn character group Train characters Show font Copy font Rename font Delete font Correct font size Temporary teaching character Batch record Start batch record Show batch record Stop batch record Show faulty pictures Reset counters Edit product Acquire image Add control window Delete control window Change control window sequence Set DM windows automatically Track windows Parameter OCV/TIN window Parameter CODE window Parameter PIXEL window Parameter DATA MATRIX window Parameter PATTERN CHECK window Parameter QR-Code window Parameter POS window Switch camera ON/OFF Test-Evaluation Tolerances Change matching tolerance Change searching tolerance Change size tolerance Change threshold 1 Change threshold 2 Service Acquire image Optical Settings Configuration illumination Image configuration Camera configuration Diagnosis System parameter User Management 26

27 Image configuration Service Acquire Image Optical settings Configuration illumination Image Configuration Camera Configuration Diagnosis System parameters User Management Image transfer configuration Image geometry Image Resolution Camera configuration I/O configuration Master - Slave Statistic Mode Eject Station Control Mode Image Server Reader Mode Diagnose Level Pattern Check: Current values OCR/OCV Window: Binary Picture OCR/OCV Window: Blank-out OCR/OCV Window: Current Character OCR/OCV Window: Matching Accuracy PIX/POS Window: Binary Picture Data Matrix: Display Edge and Grid Data Matrix: Display Binary Picture PIX Window: Current values Debug Data Matrix searching (exp. mode) Debug character searching (exp. mode) Debug code reading (exp. mode) XML Data on Port 23 (exp. mode) GUI Data on Port 23 (exp. mode) Data Matrix: Display Quality Parameter XML ACK on Port 23 GUI ACK on Port 23 BarCode: Display Quality Parameter Save and Load images for Test-Evaluation Display Tracking Linkage POS: texts on top left Display duration Ref. Data -> Trigger digital testbench mode System parameters Time Out Clock overflow Reference Data receive check On/Off measurement line automatic Save counters Image Shading Language Default text colour 27

28 5 Product Management Menu New product To create a new product, please follow the instructions of section Camera start-up (new product). The teach-in procedure is basically identical for all the camera inspection types (Teach-In, OCV, OCR, code, pixel and Data matrix): image-acquiring, naming the product, and selecting the inspection type, setting windows and different parameters. This procedure is repeated for each control window required. Naming, copying and deleting the product Before a product is renamed, copied or deleted, the required product is selected from the product list. Then the product can be changed or deleted accordingly. Show product The entire data specific to the product are displayed here. To print out the data, drag the slider on the right of the window down until the text line "Print data" at the end of the list appears. Use the touchscreen to select it. By default the question arises weather the data shall be saved (as a PDF-file) or sent directly to a connected printer (via the PCs standard printing menu). The file will be saved by default to the PLM (resp. MscClient) installation folder on the PC. Printing and saving works only for PLM versions above 4.1. Change product After choosing this option, all products created until now are displayed. The required product can be selected. In this way, all the settings stored under this product are called up and activated. 6 Edit Product Use the Menu button to navigate to the Main Menu and then activate the Edit product submenu therein. This submenu contains the various options for changing an existing product. You will need to do this if the window position, window size, reference positions for tracking, etc., are no longer correct. You can make the changes under the corresponding menu items. The description of the parameters for each type of control or inspection you will find in a separate chapter in this manual. Change control window sequence In this menu the index number of the control windows can be changed. This way also the processing order of those windows is affected. When changing the order of two windows of the same type (e.g. PC0 -> PC1 and PC1 -> PC0), which are linked for tracking, the following window will become the leading window and vice versa. It is not possible to change the processing order for windows of different types. Set DM windows automatically This function will let you set a window for one DM code in the camera image. When the camera has read the code it will search for a number of other resembling DM codes and set the control windows for them automatically. Track windows See chapter Tracking linkage 28

29 Switching off the camera In the menu Change product the camera can be switched off. During production run, the message Camera is switched off is displayed. The following signal conditions are possible for adaptation to the machine control: Camera ON System Ready = High Good signal(s) as per the setting in the service Camera OFF System Ready = Low Good signal(s) always = High Camera OFF System Ready = High Good signal(s) always = High Note: When the camera is switched off, it always sends a GOOD signal to the machine. Because no check is performed, the light will not flash. Test-Evaluation This option is only available if you activated the corresponding Diagnosis function. With this option you can test your current inspection setup, without entering production mode. You can decide to take a (triggered) Live image or to load a previously save camera image. The inspection will then be applied to this image and you will see the results as they would be displayed in production mode. 29

30 7 Font Menu In this menu characters can be taught in. There is the choice between teaching several characters at once or multiple char sets. Up to 70 different characters can be applied per character set. Please note! A new character set (font) must be created, when size of characters, font type or character orientation (horizontal, vertical, upside down) was changed! 7.1 Learn Character Group After selecting the menu item Learn character group in the sub-menu Character set, an image of a sample object has to be taken. Live-image or Live-image with trigger can be chosen. Afterwards the character set belonging to the characters that shall be taught in can be selected. A teach-in window is inserted in the image acquired. The position and size of the window can now be changed. The active mode is displayed in the lower status line. Depending on the mode, the window can be shifted, enlarged or reduced using the touch screen or the four arrow keys, as mentioned in chapter 5.1. Changing the mode using key Mode ; Acknowledge and terminate the procedure using the ENTER key. With a teach-in window, a complete line can be taught in. The character(s) must lie completely inside this window. For character strings without a gap or for poor printing quality, the teach-in procedure should be carried out for each character separately. In this case, make sure that only this one character and no additional print is inside the teach-in window. After setting the window enter the character (or characters) using the keyboard. For entering letters, press the Alpha key and for capital letters, additionally press the shift key. If the same characters are already available in the character set, a message is displayed asking whether the characters are to be additionally taught in, or whether they should be overwritten. After all the characters have been taught in please change to the mode, "Train characters". 7.2 Train Characters In this special mode a re-correction of the taught-in characters is carried out inside the reading window. For this reason the references for all the windows are scanned. A trigger signal is required for starting. Using the training function, additional character samples are created. The training is used to reduce the Pseudo rejection in the production mode. 30

31 7.3 Show Font In this sub menu all the characters of one character set is displayed. For inspecting the Teach-in and training results, the samples of a character shown as a group of 8 can be viewed. Characters that cannot be read properly can be deleted. The quality of the samples is decisive for the system's readability exactness. Make sure that the character samples are easily readable and can be distinguished well from the samples of other characters. The black character contour should be shown without any discontinuation. The green zone describes the pixels that may be black or white during evaluation. In other words, this is the tolerance zone. For checking how good the separation of characters works, please see ConfusionList. 31

32 7.4 Confusion List The Confusion List shows for each character the most similar character. Since there exists up to 8 different patterns for each character, the number of the most fitting pattern will also be displayed. The values in the last row show the amount of different modules and the matching tolerance (here for example 6 ). In this confusion list, separation of all characters is guaranteed, because for all characters the amount of different modules is greater than matching tolerance. If this is not fulfilled, the matching tolerance for the regarding character can be decreased or the regarding pattern can be deleted. 32

33 7.5 Tolerances Character set tolerances Change matching tolerance Change searching tolerance Change size tolerance Change threshold 1 Change threshold 2 X Change matching tolerance and searching tolerance The matching tolerance specifies the maximum permissible deviation between the actual character and the reference character. If the deviation is less than the matching tolerance, the character is recognized as good. --> Character marked green. The current character will be searched as long as the deviation is smaller than the searching tolerance and larger than the matching tolerance. When the max. search time is exceeded (! TO! marking) or when the end of the window is reached, the search will be terminated and the control window is marked red. Value small Pass tolerance Search tolerance Value large Deviation Green Char. and window red. Only window frame red. A character recognized as Good will be marked green. An incorrect character will be marked red. Matching tolerance is adjustable for each single character! Change size tolerance This factor determines how much the size of a taught-in sample may vary from the read character and still be recognized. The default value is 30%, which means that a taught-in sample and a read character may vary by as much as 30% and still be recognized as Good. This setting can be reduced to less than 10% in order to distinguish between characters that are only different in terms of size, e.g. zero = 0 and O or eight = 8 or B. For such character sets it is also recommended using OCR, because characters are no longer recognized with certainty if the size tolerance is less than 5%. 33

34 7.6 Change threshold 1 and threshold 2 Threshold 1 and threshold 2 define the black and white proportions of a character. Threshold 1 specifies a mean value and threshold 2 a deviation from this mean value. The graphic illustration of the values can be seen in Display character set. The gray background is above threshold 1+(1/2*threshold 2). In Display character set, the characters are displayed as follows: The green area lies within the tolerance specified by threshold 2. And the black area is below threshold 1-(1/2*threshold 2). dark Threshold 1 bright Threshold 2 black green grey black = core area of the character, green = black or white area, grey = background (white) 7.7 Delete pattern By selecting the character and the respective sample number a sample can be deleted. 7.8 Delete character By selecting the character and selecting the "Delete character" menu item, it is possible to delete an entire character with all samples. 34

35 7.9 Copying, Renaming, Deleting Font The simple character set administration allows copying, renaming and deleting a character set. Caution! A complete character set can be deleted here. In the menu item Display character set individual characters can also be deleted Correct Font Size For each character taught-in the width and height is saved. If now, e.g. the reading distance is considerably changed, or the same character set shall be created in another size, it is possible to correct the character size (height and width) in the menu character set. To change the character size, please proceed as follows: 1. Call menu Correct character set/character size ; 2. Acquire image using Live-image or Live-image with trigger ; 3. Select character set required; 4. Use window to completely frame a line with several characters; 5. Set grey value threshold; 6. Enter character sequence of the window; Then the size for all the characters of the selected character set is corrected Temporary Teaching Character The procedure of Temporary teaching character is the same as Learn character group. But in this menu the taught in character will be saved only until the format is changed. After teaching character go to show font to check results. Pattern 1 is marked brown, because this pattern was taught-in temporarily. 35

36 8 Statistics Menu Starting, viewing and ending batch Within the statistics menu, a batch protocol can be started. A batch protocol is intended for documenting the production. All the relevant data, such as the order number, quantity, remarks etc., can be entered in the batch protocol at the start of a batch. The first three lines marked with "<Fix>" have to be entered once and will then appear on every protocol start. The information in the first "<Fix>" line (max. 45 characters in length) will also be displayed in the production run and in the main menu at the top margin of the screen. Hence for example different batches can be distinguished faster. To print out the data, drag the slider on the right of the window down until the text line "Print data" at the end of the list appears, and then use the touchscreen to select it. By default the question whether you want to save (as a PDF-file) or send the data directly to a connected printer (via the PCs standard printing menu) appears. The file will be saved by default to the PLM (resp. MscClient) installation folder on the PC. Printing and saving works only for PLM versions above 4.1. Note: To display the menu screen after changes are made a restart of the system is required. Display error images Depending on the configuration, up to four error images, generated during the last production run, can be displayed. Options Buttons: [Continue] Displays the next error image [Cancel] Ends the display [Accept] Accepts the error image as current sample, so it is available for teaching in characters and other improvements. Note: The error images are lost once the system is switched off. In the Service menu can be selected, whether no, one or four error images shall be displayed. Delete counter The counters for good and bad readability are set to zero. The deletion of the counters is only active if no batch protocol has been started. 36

37 9 Service Menu When calling up the menu item Service the password for access to the service settings is required. The password after delivery of the device is "000". To make any specific settings on the system select the menu item Service in the main menu. Note: If changes to the service settings shall be made, a documentation is available in the chapter "Form Settings ". 9.1 Optical Settings Shutter The shutter value states the exposure duration of an image in µs. The image will get brighter using high values and darker using low values. The exposure duration is also related to the flash duration of the internal or external LEDs and the exposure duration of the image acquired by the camera. High shutter times and fast moving products may cause a motion blur in the images acquired. The shutter can be adjusted via a slider that switches between high and low values if needed. Shutter X Shutter X OK OK The cameras will be delivered with the following values: Type Resolution [Pixel] Description Shutter [µs] x 1280 Standard

38 Note: If the camera is equipped with a dimmable internal illumination always set dimmer values to maximum before adjusting the shutter values. For data matrix quality analysis, it is recommended that these values are not changed. The values may be different for cameras with external illumination, UV illumination, or for special requirements. Dimmer Some cameras might be equipped with a dimmer for the internal illumination. The shutter can only be adjusted in steps of µs dependent on the camera model used. Dimming the illumination allows a precise adjustment of image brightness for Print Quality inspection. If the camera does not support brightness adjustment via illumination, the iris has to be changed instead of the illumination. Focus & Autofocus Some cameras are equipped with a variable lens, so adjusting the focus can be done manually via a slider after pressing the Focus button or automatically by using Autofocus. 9.2 Configuration Illumination It is possible to switch between internal, external and internal, and external lighting here. The setting is stored under the current format name. This function is only available for certain types of cameras! 9.3 Image Configuration All settings regarding the image can be set using this menu Image transfer Configuration Here the quality of the transferred images can be modified or turned off. Depending on the value used for image quality, the transfer is activated or deactivated; the screen will be updated accordingly in the production mode. Image transfer is turned on (activated) and set to a quality of '2' by default, which means that with a resolution of 640 x 480, only every second pixel in X and only every second pixel in Y will be transferred. The evaluation time could increase to 30 ms if every pixel were transferred. Caution: If image transfer is deactivated, in the production mode the screen will not be updated, including counters. Internally, however, the recorded image will be analyzed and all signals will be emitted as usual. It is possible to call up the main menu at any time with MENU. In this case image transfer is always activated! Image geometry The geometry of the recorded image can be adjusted for presentation and processing. A typical application is the correction of an upside-down image. Possible options are: turn image by 180 degree, mirror image horizontally, rotate image by 90 degree to the right, rotate image by 90 degree to the left, mirror image vertically, and normal image. 38

39 9.3.3 Image resolution If only a part of the field of view is needed it can be reduced by changing the resolution. The resolution can be changed to 640x480 pixel, 1024x768 pixel, 1280x1024 or full resolution. The sector that shall be inspected can be selected by shifting the image. Note: If the image resolution shall be changed while inspection windows already set the resolution and the possible image position is limited to the windows set. For example, if the total Field of view of all windows set is larger than 640 pixel, this resolution value cannot be chosen. Also the position of the image is limited so all inspection windows are still within the field of view. 9.4 Camera Configuration Settings regarding the camera can be adjusted using this menu I/O configuration Good outputs and results-linking for window groups Control windows can be organized into groups. Each control window must be in exactly one group. The first group is G0 in the basic setting for each window. The good output of a group defines on which camera output the result of all control window of this group is displayed. The good/bad results of the control window or window groups is given in the basic settings on the good output (OUT0) of the camera. There is a further output (OUT2) of the camera available which can be used as a second good output. Within a group, the results of window control are linked to one another, and return a group result. The results are linked with AND using the basic settings. If the results of several groups go through the same output, the group results are always connected together using the logic AND. Linking logic: AND - already bad reading from only one control window leads to a total 'bad' result. ( Bad wins ) OR - already a good reading from only one control window leads to a total 'good' result. ( Good wins ) 39

40 Group G0 Group G1 CODE0 (Good) CODE1 (Bad) PIX0 (Good) PIX1 (Bad) AND OR Bad Good Output OUT0 Bad 40

41 The camera offers a good signal ; it is high during a good reading (+24V) and low during a poor reading (0V). There are four variations of good signal behavior to choose from. Mode 0: For the setting Good pulse after evaluation up until the next trigger the good signal is high or low, depending on each evaluation after a trigger pulse. During the evaluation time, the good signal is low. Mode1: For the setting Latch mode the good signal remains low after a poor evaluation, even if other trigger pulses and possible good readings follow. For resetting a poor reading, the quit key therefore has to be pressed. The quit key is located on the terminal, or separately on the machine. During the evaluation time the good output remains high. Mode 2: For the setting Good pulse after evaluation up until expiry of the defined time 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. Mode 3: not supported at the present time. Caution: In order for the camera to be able to recognize the negative trigger edge, the white quit lead has to be connected to the brown trigger lead. Mode 4: not supported at the present time. Mode 5: not supported at the present time. Mode 6: For the setting like configuration ' 2 ', only with additional RESULT-READY 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. 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 there will be a delayed emission of a GOOD impulse at a precisely defined time after the trigger. The mode has been programmed for applications in which a good signal confirms the position and content of a code at a precise time. The delay interval and the pulse length are adjustable. A second trigger before the possible output will be ignored. 41

42 The following diagram clearly shows the different signal samples. Signal overview of the trigger and good signal. Trigger signal from the machine: 24V 0V Result (Mode 0): 24V Evaluation time Evaluation time Evaluation time 0V Good reading Error "Good pulse after evaluation Good reading Result (Mode 1): ö 24V Evaluation time "Latch-mode" 0V Good reading Error Good reading Quit Result (Mode 2): 24V 0V Evaluation time Length can be set between 5-100ms Evaluation time Evaluation time "Good pulse with def. length after evaluation. Good reading Error Good reading 42

43 Trigger signal from the machine: 24V 0V Result (Mode 3): 24V 0V Evaluation time Length can be set between 5-100ms Evaluation time Evaluation time "Good pulse with def. length after neg. edge, one cycle later. Good reading Good reading Error Good reading Result (Mode 4): 24V Evaluation time Evaluation time Evaluation time Good pulse one cycle later with pos. trigger edge up until the next pos. edge 0V Good reading Good reading Error Good reading 43

44 Trigger signal from the machine: 24V 0V Result (Modes 6&7): OUT0 Good Signal 24V Evaluation time Evaluation time "Good pulse with def. length and DataValid on OUT3." 0V OUT3 Data Valid Good Reading Length can be set between 5-100ms Error 24V 0V Result: (Mode 8) OUT0 Good Signal Delay time ms Delay time 24V 0V Good Reading Error 44

45 False code The universal camera output OUT2 can, as an option, also be used for displaying a false code. This additional signal is High (24V) if the code agrees with the reference. If the code is not legible or has false contents, the signal is Low (0V). In this mode OUT2 can be used together with OUT0 in order to discover sub-mixes. When using this function, all DataMatrix, Barcodes and OCR controls are checked. Furthermore, OUT2 can no longer be used as a good output. A false code error (OUT2->Low) occurs in the following cases: DM Code OCR If at least one DM code has a legible contents which deviates from the reference code. OR If at least one barcode code has a legible contents which deviates from the reference code. OR If at least one OCR window reads a string in which at least one character does not match the reference character, but a different character from the character set or if the character set does not match. DataValid- / Data ready signal See good output configuration, modes 6 & 7. Control output OUT3 Using the option Control output OUT3, one can choose depending upon format whether the output OUT3 is switched with 0V or 24V. At this output, for example, an additional illumination can be switched on. So that the choice of a specific format in which this output is set to 24V, the external illumination is switched on Master Slave Statistic mode This option is only available if the needed extension program OCRMSS is installed on the camera and only work with a compatible PLM version. This parameter controls a Master-Slave Statistic messaging system. In this mode multiple cameras, acting as Slave Cameras, send their statistic data to one Master Camera. This Master Camera bundles all statistic data into on statistic message for transmission via the VDMAXML communication interface e.g. to the Pilot Line Manager (PLM). Master Mode: The Master Camera is ready to accept a connection from a Slave Camera when it is in Production state. All messages the Master Camera receives from the Slave Cameras are put into a queue. After a trigger was received the Master Camera processes its own inspection. After that it generates a Statistic Message, which contains the Masters Statistic Data from the current cycle and the oldest Statistic Data from the queue for each Slave Camera and sends it to the PLM. If the queue is empty for any of the Slave Cameras, the Master Camera will wait for this data before it sends the Statistic Message to the PLM. One Master Camera can handle 4 Slave Cameras at maximum. Slave Mode: The Slave Camera connects to the Master Camera as soon as it enters Production state. In Production state after a trigger was received, it processes its inspection function and afterwards sends the resulting statistic data to the Master Camera. 45

46 Master-IP: The Master IP is the IP address of the Master Camera. It has to be entered once, so that the Slave Camera can connect to the right camera when entering Production Mode. On the production screen of the Master Camera the IP addresses of all connected Slave Cameras are displayed. If there are currently messages in the queue, the number of messages will be displayed behind the corresponding Slave Camera IP. On the production screen of a Slave Camera, the IP address of the connected Master Camera is displayed Eject Station Control In this mode the camera can track a product and control an eject station without a PLC. The camera must be mounted directly next to the eject station. There must be no other products in between the camera and the eject station, until the last evaluated product has passed the station. The camera uses three 24V inputs for handling the tracking. Furthermore one 24V output is used for controlling the eject station and one 24V output (System Ready) for stopping the machine, if an error occurs. Sensor1/Trigger The product is at the camera position and should be inspected. Sensor2/Eject Station The product has arrived at the eject station. Sensor3/Counter Check Product has passed the eject station. 46

47 Eject Station Control Settings Sensor Signals - Sensor2 / Sensor3: If set to Rising Edge, the camera will detect a product with the rising edge of the sensor signal. If set to Falling Edge, the camera will detect the product with the falling edge of the sensor signal. Eject Signal - Logic If set to 24V the camera will set the ejection output to 24V to activate the ejector. If set to 0V instead, the camera ejection output will be 24V by default and will be set to 0V to activate the ejector. Eject Signal - Delay Specifies the time until the eject signal will be set after the product has been detected at Sensor 2. Eject Signal - Duration The time frame for how long the ejection signal should persist. Counter Check - Timeout From the moment when the product has been detected by Sensor 1, this defines the timeframe in which a good product must have passed the eject station and been detected by counter check Sensor 3. If a bad product which has not been ejected is detected by Sensor 3 or if a good product was not detected by Sensor 3 within the timeframe, the system will be stopped. Notes: The following product must not pass Sensor1 before the current timeframe is closed. For Error recovery, please refer to Appendix 23.1Error Messages and Error Recovery Image server This option is only available if the needed extension program OCRIMG is installed on the camera. With this option there is the possibility to transfer all faulty pictures to an external storage space. The images will be stored in a reduced resolution with integrated overlay graphics in a special format. For this feature a FTP client is running in program OCRIMG. On server or PC side a standard FTP server e.g. IIS FTP, FileZillaServer, WingFTPServer, Quick&EasyFTP, or other is needed. Please use mtpceftp as user name and password on FTP server side. The camera will generate a sub directory 100.xxx. xxx is depending on IP address of camera. The Filename will have the following syntax: <format name><error counter>.999 While ftp server is running, press on text Image server off. Image Server Settings FTP Connection Image server off X IP address server FTP user FTP password mtpceftp mtpceftp FTP Subdirectory Camera will try to connect with server. When successful, the IP address of the server will appear in the table 47

48 Image Server Settings FTP Connection Connected IP address server FTP user mtpceftp FTP password mtpceftp FTP Subdirectory X The faulty images can t be displayed with a standard image viewer. For displaying images, please see Inspection Manager (IM) or PCE-Line-Manager (PLM) user manual Reader Mode Standard: Camera is waiting for the trigger signal on input 0. With rising or falling edge (adjustable) a picture will be taken. After that the camera starts with evaluating the image. When finished, the good signal will be set. Auto-Read: When gate signal on input 1 is high, camera grabs a picture and evaluate the image. This will be repeated till end of gate signal or positive reading result. Aggregation: Please see Chapter Code Aggregation. Aggregation (partial rejection): Please see Chapter Code Aggregation. Peel-Off Check: This mode is dedicated for when the Smart Camera is doing a regular product/label inspection but is also used as a counter check for rejections. While the signal on input 1 (IN1) is high the Smart Camera: - will not increase the good or bad counters - will not send any results via the VDMAXML interface (to the PLM for example) - will invert the result signal logic (high signal on bad and low signal on good evaluation) 48

49 9.5 Diagnosis In order to switch the different display functions of the system on and off, the diagnosis value is changed. The diagnosis value is also a helpful instrument for seeking errors. Currently the following functions can be called up for diagnosis: Diagnose Level Pattern Check: Current values OCR/OCV Window: Binary Picture OCR/OCV Window: Blank-out OCR/OCV Window: Current Character OCR/OCV Window: Matching Accuracy PIX/POS Window: Binary Picture Data Matrix: Display Edge and Grid Data Matrix: Display Binary Picture PIX Window: Current values Debug Data Matrix searching (exp. mode) Debug character searching (exp. mode) Debug code reading (exp. mode) XML Data on Port 23 (exp. mode) GUI Data on Port 23 (exp. mode) Data Matrix: Display Quality Parameter XML ACK on Port 23 GUI ACK on Port 23 BarCode: Display Quality Parameter Save and Load images for Test- Evaluation Display Tracking Linkage POS: texts on top left Display duration Ref. Data -> Trigger digital testbench mode X Note: Please observe that changes in the diagnosis level can increase the evaluation time of the camera. The debugging display functions cannot be used during machine run. Data that sent via the serial interface to Port 23 (Ethernet, TCP/IP, Telnet-Port) can be received by a PC, e.g. with the PCE service program JDATATRANS, or can be visualized via a laptop and a suitable terminal program. 49

50 9.6 System Parameters Specific camera parameters that as a general rule only have to be changed when mounting the camera are set in the System Parameters submenu Time Out Using this value, the maximum evaluation time of the camera can be changed. The value is given in milliseconds [ms]. A typical product with a data matrix window and three OCV windows requires less than 100 ms on a standard camera. These times could vary through bad print quality, grading, switched on diagnosis functions, or high image quality image transfer setting Clock overflow The camera offers a function for detecting when the machine is running too fast. If the camera is triggered within the evaluation time, then the error message Machine over clocked is shown on the display. This can be deleted by pressing any key. The speed of the machine must be reduced if this message appears. The function can be switched on and off. Caution: If for example the trigger signal bounces it is recommended switching off the over clocking protection Reference Data receive check With each trigger, the camera will check if it has received new reference data for all applicable Control Windows via the VDMAXML_P interface (e.g. the PLM). If one or more windows have not received any new data, the camera will stop the machine by switching off the System Ready signal On/Off measurement line automatic When this menu item is active, the measuring lines for position guiding are automatically set during setting up a new product and activating measurement arrows. After selecting automatic a grey offset (basic setting 15%) can be set for the measuring lines. Finally the maximum permissible position tolerance in the reading direction (basic setting 50) has to be entered Trigger edge With this option can be adjusted whether the camera takes an image after the rising trigger edge from 0V to 24V, or after the falling edge from 24V on 0V. The rising edge is set by default Save counters If this option is active and a High signal is applying at input IN3, the counters (ALL and GOOD) are stored in the file _counter.110 in the Flash. This option prevents that the counters of the camera are lost during power loss. The supply voltage of the camera has to be buffered longer than 100 ms. In the frame buffer the message appears!power fail! Counters are saved!. 50

51 9.6.7 Image Shading If the camera image has an unevenly or inhomogeneous brightness distribution, we talk about image shading. This shading can for example be caused by the illumination or the camera optics. For these cases the camera has a correction function to compensate the shading. For using this shading correction the camera has to be calibrated once. Calibration The camera switches to the Live Image view. You need to place a plane, white surface into the cameras field of view in the same distance as the product, which the camera will inspect. It will be used as a reference for defining the appearance of the shading. Before calibration: Calibrating (full correction range): The range of the correction is adjustable while calibrating. For a low range value, only pixels with a strong deviation will be corrected, for a high value, also pixels with a small deviation will be corrected. A higher range value will cause a more homogenous image but also increases the calculation time. Correction On/Off The correction data is global but the correction can be activated or deactivated for each product. In this menu the shading correction can be turned on or off for the current product. This menu will show a live image preview, to see the effect of the correction and also the time consumption of the processing. View Shading Template This menu displays the correction template/image for diagnosis purposes. 51

52 9.6.8 Language The language of the user interface can be changed here. The corresponding language files must be installed on the camera. In some cases the currently existing language files are only available upon request. German =ocr_de.222, English = ocr_en.222, French = ocr_fr.222, Italian = ocr_it.222, Spanish = ocr_es.222, Danish = ocr_da.222, Hungarian = ocr_hu.222, Dutch = ocr_nl.222, Norwegian = ocr_no.222 Polish = ocr_pl.222 Portuguese = ocr_pt.222, Slovenian = ocr_sl.222, English = ocr_en.222, Swedish = ocr_sv.222, Turkish = ocr_tr.222, Preferred font color Here the pre-selection of the preferred font color for OCR, OCV or Teach-In windows can be selected. This color is also valid for teaching in fonts. Depending on the setting, dark print on light background or light print on dark background will be the default for creating a window or teaching in a character set. The camera analyzes the set reading fields and queries again if there is an obvious deviation from the preset text color. If both is specified as the preferred font color, the camera will then query the desired font color for each new font window. 52

53 9.7 User and Password Management The default password for all the menu levels is 000. This can be freely configured in the User management or under Changing the password. The password 000 allows Administrator rights. By default, the password is requested on the menu levels: Change product, Product Management, "Character set" Service, Change password requested. Note: The pilot software will handle user management if the camera is used with Version 4 or more recent versions. User management Several users with user names, passwords and different rights can be set up. These settings are made in the User management menu. In the basic setting, the user is admin with password 000. The selection of the menu levels for which a password is requested, can be set in the user admin. By pressing the key admin twice the settings Change password, Define password, Minimum password length and Logout time. Under define password, the required password levels can be defined. A password is required for the levels marked red. The levels marked blue can be reached without password. The following password levels/rights can be assigned: A Product new, delete or rename, B Delete or rename character set, C Start or end batch protocol, D Reference code, E Change product, F Product management or Edit product, G Change character set, H Service, I Switch on/off camera, J Temporary characters, If a new user is created, a blank window will be opened via clicking twice, here the desired user name and password have to be entered. Subsequently the requested right or the requested rights are assigned to the user. If clicking twice on the entry of an existing user, the menu User management appears with the items Change user profile, Delete user and Switch password invalid When a user registers for the first time he has to change his password. The administrator can block or delete users. Changing the password Here for example, the password 000 can be changed if Administrator only (default) is created as user. If several users are created, all the created users can change their password. When changing the password, first the user name, then the new password must be entered twice. 53

54 10 Password, Zoom 10.1 Change Password In the Change password menu item, the user can change his/her actual password on the camera Zoom In (Zoom Out) In the Zoom in menu item, the camera display mode can be changed to Zoom in order to highlight details for teaching in fonts or creating products. After the Zoom function is selected, the software expects the user to select the center of the zone that shall be enlarged. Only a magnification by a factor of two is possible at the present time. Please only use the view in the Zoom mode for teaching in the product or for error searches. With continuous operation in the zoom mode, there is a risk of mix-ups with the actual image size occurring. 54

55 11 Parameters of OCV / TIN Windows With an OCV Control window, plain texts can be checked in the TIN (Teach In), OCV (Optical Character Verification), and OCR (Optical Character Recognition) modes. Texts can be read horizontally or vertically, and also forwards or backwards; this is governed by the orientation of the control window and also the setting of the reading direction. Parameters of TIN, OCV, OCR Windows X Control Window name: OCV0 Alias GTIN Font: test Search area Position: 165/205 Size: 57/46 >>Next>> Search area Threshold: 120 Color: Black Direction: L->R Lines Tilting: 0 Noise pixel: 5 Distance: 0 Character Min. size: 5 Max. width: 100 Check quantity: Off Character Character search: standard Gap: Special characters Min. w. wildcard: 5 Check. a. 0/ Filter Ink-Jet: 0,0 Reflection: 0 Brightness correction: OFF Filter Delete border pix: 0 Noise reduction: OFF ---- Reference code Compare: --- Dynamic: OFF from Data Matrix: --- Control Window name The name of the window currently being processed is shown here. By selecting a window, a menu will open in which the TIN (Teach In), OCV (Optical Character Verification), and OCR (Optical Character Recognition) modes for that window can be selected. Note: Before changing to production, a teach-in window will analyze the text portions and create a character set with the name #auto for them. The sample is not allocated alphabetically; hence these windows cannot be used with version 4 of the pilot software, which sends reference values to the camera. Alias It is possible to give a window an additional name. This identifier is used by older versions of the pilot software to assign reference values. The reference code from data matrix option also uses these additional identifiers. Font Here subsequent changes to the character set for a control window can be made. 55

56 Search area: The position and size of the control window can be changed by selecting a parameter. The values shown here define the coordinates of the control window in which the OCR process is being performed. >>Next>> By clicking this field the different windows taught in can be selected. Only windows created beforehand will be displayed. Search area: Threshold The grey value threshold for the OCR is shown in this window. The setting can be changed here. Details can be found in the Instructions for Setting the Grey Value Threshold section Color This function can be used to adjust the color of the print relative to the background: Black stands for "dark font on light background", White stands for "light font on dark background". The default for creating an OCV window is black, but it will change if there are only white windows or if there is a combination of black and white windows. Direction Here the reading direction can be adjusted relative to the screen layout. Possible settings: L->R: Left to right R->L: Right to left U->D: Up to down D->U: Down to Up Lines: Tilting The maximum degree, that the text line may be tilted in production, can be adjusted here with a slider. Text tilted horizontally by -10 degrees Text tilted vertically by +12 degrees Tilting A maximum tilting up to +/-44 degrees is possible. The basic setting is 0 degrees. The greater the permissible tilting, the longer the analysis time may last. This setting is valid for all TIN, OCV, or OCR windows 56

57 Noise pixels The maximum number of pixels that can be contained in an empty line is adjustable here. Example: Parts of the barcode are located above (and within) the text line. The black pixels of the barcode will interfere with the empty line needed for searching. The Max. Empty Line Pixels has been set to 30 in the example (the basic setting is 5). Note: For some parameters an input in pixels is expected. A size expressed in millimeters can be converted to pixels if the camera resolution and the image size are known. For the standard camera, the resolution in X is 1600 pixels and the image size in X is 95 mm. A character with a width of 2.5 mm would thus have a width of 2.5/95*1600 = 42 pixels. This setting is valid for all TIN, OCV, or OCR windows Distance: The minimum number of pixel lines for the empty space between two lines is adjustable here. Line spacing =1 Line spacing = 5 If characters consisting of several non-connected parts (e. g., Ü, Ä, À, B...) are being checked, the line spacing must be set to a value greater than the largest gap within the character so that all parts will be combined into one character. This setting is valid for all TIN, OCV, or OCR windows 57

58 Character: Min. size: The minimum character size setting removes objects that are too small for a character. Any objects which are smaller than the size of the adjusted pixel number will be masked. It is thus possible to eliminate disruptive dots in the background. This setting is valid for all TIN, OCV, or OCR windows Max. width: Here the maximum character width for character recognition can be specified. The value corresponds to the pixel width of a character. If a character in a Teach-In-Window is wider than that, this character is cut in two pieces. This setting effects only the TIN-Windows (in production mode and when teaching in a new reference code) Note: This value plays an important role in character recognition in the Teach-in or character set teach-in modes. The setting is valid for all TIN windows. Check quantity If the character number check is activated, an error message will be generated if additional characters are detected in the reading window in front of or after the reference characters. This setting is valid for all TIN, OCV, or OCR windows Special characters Gap Here the size (in pixels) of the gap between two characters can be adjusted. This setting has different meanings for OCV- and OCR-mode: In OCV-mode or TIN-mode, the next character will be searched from this position relative to the previous character, so if there is no gap between two characters, please enter a negative value for the gap size. In this case the next character will be searched within the previous character. In OCR-mode, if the value is greater than zero, then characters which have a smaller gap to each other than this value will be merged. If the value is zero, it depends on the setting character search, what happens: If the character search is set to advanced, then characters, which overlap each other vertically slightly, will be separated. If the character search is set to standard, then nothing happens. This setting is valid for all TIN, OCV, or OCR windows Wildcard If for example the quality is not adequate for an OCV/OCR control, characters can simply be checked for presence. To do so, the operator enters a star (*) in the reference code for the character in question. A B C D E F G 1 * 3 4 This setting is valid for all OCV windows. 58

59 Control. and Distinguishing. (dot) from (hyphens) If the camera should do a very precise dot and hyphen check, in this menu two parameters can be set: the limit value and the tolerance. The first pixel value indicates a limit value for the black surface, e.g., 150 means that each character smaller than 150 pixels will be evaluated as a dot or a hyphen. The length of the dot or hyphen is then measured with the accuracy specified in the Tolerance setting. For example, the Tolerance can be +/-3 pixels. The size of the tolerance value can be used to distinguish between dots and hyphens. 8 A 5 W The length of characters with an area of, e.g. more than 150 pixels = threshold value, is not measured. Characters with less than e.g. 150 pixels are verified in their length using the tolerance value. This setting is valid for all TIN, OCV or OCR windows Filter: Inkjet The inkjet filter must be used for inkjet printing or for similar printing results. The filter function enlarges individual dots so that undesired white spaces between the dots are filled in. Setting the value of the filter size in x- and y- direction to zero (Filter size = 0,0) will turn off the filter. The Inkjet filter turned off The Inkjet filter turned on The size of the Inkjet-filter is adjustable in x- and y-direction, so that the single dots of a stretched inkjet print can be merged. Note: Character sets should always be taught in with each inkjet filter. In other words, if the filter is changed, then a character set needs to be taught in again. This filter is used for all TIN, OCV, or OCR windows 59

60 Reflection You can adjust the reflection filter to reduce disruptive reflections (such as those on aluminum blisters). The value is specified as a %. Excessively bright areas in the window will thus be darkened. This filter is used for all TIN, OCV, or OCR windows Brightness correction With the "Brightness correction" filter you can make the background more evenly colored. The filter should be turned on if the brightness of the background is not uniform. Areas that are too dark will be made brighter. This setting is valid for all TIN, OCV, or OCR windows Filter: Delete border pix This filter deletes black pixels projecting from the outside into the edge area of an OCV field; the parameter defines how large the interruptions may be. This function is especially useful for optical character fields with disruptions in the edge areas. Such disruptions interfere with tilting recognition. Noise reduction This filter suppresses noisy background when switched on. Character search This setting is a switch between the standard and advanced character search. If the character search is set to advanced, it is possible to separate vertically overlapping characters, like it is shown in the figures below. Standard character search Advanced character search Note: This setting only affects the OCR-windows and the teach-in of new characters. Reference code: Compare The camera normally always performs a comparison between target and reference values in OCR windows. If the camera only reads window content, however, the result of the reading can be obtained from the statistics report in the VDMAXML log. In this case the target/reference comparison for OCR windows can be turned off. This setting is valid for all OCR windows Caution: If this function is active, there will be no comparison between the read characters and the reference code. The camera works for character reading and display. Dynamic The Dynamic reference code setting should only be turned on when checking sequential number series. A listing or counting of the code is thus possible. The setting can be turned ON or OFF individually for each OCV window, OCV0-OCV3, or code window. It is thus possible to check dynamic and static print simultaneously. The dynamic counter is not increased until after the first GOOD reading. 60

61 From Data Matrix: This function is designed for stand-alone systems in which pilot software does not specify dynamic reference values. A data matrix code reading is used as a source for OCV reference codes. The content in the data matrix code must be in GS1 format. The content is allocated via the identifiers of the windows. Identifier Function DMx : DMX DM window as source of data in GS1 format OCVx : GTIN OCV window as target, GTIN data OCVx : LOT OCV window as target, BATCH (LOT) data OCVx EXP OCV window as target, expiration date OCVx : PROD OCV window as target, manufacturer date OCVx : SER OCV window as target, serial number A wizard will help with the selection once the function has been activated: Example of an application: 61

62 12 Parameter PATTERN CHECK Window Within the search region, a previously learned pattern will be searched. The position with the lowest deviation between located and learned pattern will be marked. This tool can be used also for positioning other control windows. Parameter Pattern Check X Control PC0 <<< >>> Pattern Show Change 53x46 Search Region Change 50/50 400x199 Congruency 0% Group Control Window name The name of the window currently being processed is shown here. Show only! <<< >>> Select next or previous control window. Pattern Show Displays the learned pattern; Change Learn the reference pattern. Window can be moved only inside the search region. Maximum size of reference pattern is 200 x 200 Pixel. Search region Change Learn the search region. Moving the search window is limited by pattern window. Congruency Is a tolerance which indicates how well the learned pattern must match the found pattern. 0% means: Search for the best match, matching value is minor. 100% means: Only if learned pattern and found pattern are absolutely identical, the result is good; Group This is the number of the group which this control window belongs to. Show only! chapter System Parameters/ I/O configuration. For modifying this setting see 62

63 13 Parameter Position Control Window A position control window (POS window) searches for a gray value edge in the image. The reference positions of the edge are taught in with the aid of a Good Product. The user can set a tolerance range for this edge. The window will be rated as Good as long as the edge lies within the tolerance range. Parameters of Position Windows >>NEXT>> POS0 POS1 POS2 Mode tracking Inspection tracking Search Area 54/413/83/53 38/225/83/53 271/207/83/53 Edge threshold Edge height X Edge length Edge pixels 10[%] 10[%] 10[%] Pixel in tolerance 0[%] 0[%] 0[%] Direction 3( ) 1( ) 0( ) Increment X target pos px 82 px Y target pos 26 px X pos tolerance / + 12 px OFF Y Pos tolerance OFF Group-No Linkage none none none Reference Reference Reference Reference 63

64 Fig.: Gray value edge and parameters Position control parameters Mode: The mode is an indicator to show, if this window is doing an inspection on the position or if it is only used for tracking. The mode is depending on the tolerance settings. If all tolerances (X and Y) are set to 0 (off), this window is in tracking mode. Search area: The search area is defined with windows. For each line or column in the search window, a light/dark transition will be sought, and its position will be marked in green. Edge threshold: The slider can be used to adjust the gray value for the edge threshold. The edge threshold defines the border value between light and dark (see above). Edge height: For detecting an edge, the criterion of edge height must also be fulfilled in addition to that of edge threshold. Edge height describes the gray value difference of the adjacent pixels. Edge length: Edge length describes the distance between pixels for determining the edge height. The edge length is equal to 2 pixels in the above figure. 64

65 Edge pixels: "Edge pixels" is a percentage value and relates to the total number of pixels marked in green (edge points) (see below). Edge pixels = 15% Edge pixels = 50% Edge pixels = 80% 65

66 Direction: This defines the direction in which the edge is searched for: Increment: The increment specifies the interval for scanning for the edge. In other words, if the increment is set to 1, an edge will be searched for in each line or column within the POS window. If the increment is set to 2, only every other line or column will be scanned. The evaluation time can be shortened by selecting a larger increment. The number of edge points, however, will also be reduced. X target position, Y target position: The reference position can be taught in (see "Referencing") or set by hand here. The zero position is always the left window border for the X position and the top window border for the Y position. X position tolerance, Y position tolerance: The allowable position tolerance in the X and Y directions is set here (see the figure: "Gray value edge and parameters"). The unit is pixels. When set to 0, the tolerance will not be checked but the position information will still be calculated and can be used for Window Tracking. Linkage: Opens the window linkage menu, where for example POS windows can be linked with each other. The window with the smaller number (e.g. "POS0") is calculated first. The linked window (e.g. "POS1") is shifted by the corresponding position offset. The display of the brown connection lines can be switched on with "Display service/diagnosis/linkage. Referencing: The target edge positions of all POS windows are recalculated with "Referencing". Please note that the object in the recorded image also has the reference measurements. 66

67 14 Parameter Code Window Barcodes can be checked with windows for code control (barcodes, pharmacodes, batch codes). Barcodes can be read in horizontal or vertical directions, or omnidirectionally. This is controlled with the value for code size as well as the geometry of the control window. Parameters of BARCODE Windows Window Name CODE >>NEXT>> Search Area 250/190/100/ Omnidirectional:On Code Type Pharmacode QZone:0 --- Pharmacode binary L->R --- X Threshold / Color #AUTO# #AUTO# --- Size #AUTO# Attempts:1 --- Finder 0 0/0 --- Filter Delete:0 Connect:4 Noise reduction: Off Contrast 0 Attempts:1 --- Learn All Barcodes Quality check OFF Code Syntax: CTRLC ON Scans Min. / Steps Compare / Dyn.Code ON OFF --- Search area PX, PY, DX, DY By choosing this parameter, the control window's size and position can be changed. The values displayed here describe the coordinates of the control window in which the barcode will be searched for. Omnidirectional ON/OFF If Omnidirectional is switched on, the camera is able to read a barcode on any rotated position. Some additional parameters as Threshold, Color and Size will appear in this mode. Please switch on only when necessary, because Omnidirectional reading isn t possible in some cases. QZone, checking the quiet zone A test can be allowed for the minimum width of the quiet zone on the left and right border of the code window. If the quiet zone is too small, the code will be indicated as invalid; the standards for most codes indicate a quiet zone of at least 10x the width of the smallest module; if the code is tested for adherence to these values, a '10' is to be entered. If a '0' is entered as a value, no test is undertaken. For quality control of a printed barcode, this function is recommended to be used together with the function minimum number of positive scans, and to set a minimum number of code height/4. Scans with false quiet zones are marked in the reading window; red lines indicate a disrupted quiet zone, blue lines an error-free range. 67

68 Checking the quiet zones is only possible at this time with static codes, for omnidirectional code reading, the QZone displays a value which is added to the length of the codes, and makes it possible to have a quiet zone for the reliable reading of codes. The default value is 10, and means that the code found has been lengthened by 10 pixels. Code Type The type of barcode is set under code type. This can also be changed later. The currently legible code types are found at general in Appendix smart camera code types. The code type can be analyzed by specifying the reference codes, and is then entered into the product. Code Type dependent settings: Pharmacode For pharma codes, the decoding of the reference codes can have additional decimals or binary settings. Binary (Pharmacode): 1=thin bar, 2=thick bar; Trinary (2-track -Pharmacode): 0=bar below, 1=bar above, 2=bar above and below; Decimal: Decimal value; PDF417 A PDF417 Code has some special properties as the Number of Rows and Lines and the Level for Error Correction (ECC). Those can be manually defined (but they can also be automatically detected) Furthermore the camera has an ECC Mode option which can be turned off to prevent the camera from using the Error Correction Data inside the code. If the Decoding is turned off completely, the camera will only count the readable Code words and return this as the number of positive scans. L->R / R-> L ; U->D / D->U - Direction If a Pharmacode, a two-track Pharmacode or a PDF417 is chosen as a code type, the reading direction can be set here. Threshold [for omnidirectional reading] The gray value threshold is shown in this window for omnidirectional reading to find the barcode. The value can be taught. If the value is at #AUTO#, then the camera tries to automatically determine this value, and then enters the value found into the product. Color [for omnidirect. reading] Here a setting is made which searches for a code which is black on white or white on black. Size [for omnidirect. reading] The size and print color of the code can be set in this window, with omnidirectional code reading, it constructs an important value to find the code within the control window. If the value is at #AUTO#, then the camera tries to automatically determine this value, and then enters the value found into the product. Note: With omnidirectional reading of pharmacodes, the code size must necessarily be taught. Attempts (1,3,5,7) [for omnidirectional reading] The number of tries to search for the barcode with omnidirectional code reading can be set here; if the code is not found in the first attempt, then the code search will be repeated with changed threshold values and filter settings. Finder [for omnidirectional Reading and pharma code] Additional information must be configured to find the pharmacode with omnidirectional code reading, because pharma codes possess identifiers for the start or end, such additional information is needed in order to determine the reading direction of the pharmacode. 68

69 In addition, the size of the codes must be learned: Then the range can be established in which the additional information is searched for: The size of the search area and the number values found are entered as parameters in the product. Filter: Delete points, Connect points [for omnidirectional. reading] These parameters are important to find the barcodes with omnidirectional code reading, with codes with large gaps, a large filter value is needed with connect points, small codes with small distances to disrupting objects need a smaller filter value. The behavior of the filters can be analyzed with the diagnostic function. [Menu]-> Service -> Diagnostic -> Data Matrix: Display binary image check. 69

70 Filter: Noise Reduction This filter is suppressing noisy background when switched on. Improves the image quality in colored background. Can be used for smoothing of holes in bars. Should not be used, if structures are extremely fine. Contrast The contrast value is related to the contrast between the code and the background. A small value is set for low ( poor ) contrast, a larger value accordingly for a high contrast. The value range is from 1 to 255. Undesired contrast in the background can be grayed out, or the sensitivity increased with the contrast value. The contrast can also be automatically taught if the respective option is chosen to set or change the code window. Contrast: Attempts (1,3,5,7) Camera is trying to read the code with up to 7 different contrast settings. This can be useful, when illumination or contrast conditions are inconstant during production. Learn: Code 39, Int2/5, Code 128 These are the predefined code types, which will be used for automatic code learning. Learn: 11 Here one can choose whether contrast and reference codes are automatically taught, or should be set manually. Manual [X] Reference code [_] Reference code [X] Reference code [_] Reference code [X] Reference code [_] Reference code [X] Reference code [_] Contrast [X] Contrast [X] Contrast [_] Contrast [_] Contrast [X] Contrast [X] Contrast The setting determines which parameters can be learned automatically with the new reference code function. 70

71 Note: Because reference codes are for the most part sent from the pilot, the camera in normal operation can be easily used manually with Teach-in set to manual. Print quality (ISO15416) Here, the Quality Control of the Barcode reading can be activated and configured. The quality analysis corresponds to ISO Print quality (ISO15416) C Off / A / B / C / D / F Quality Parameters Quality check / Grading Note: The correct code analysis depends on an accurate adjustment of the camera; the aperture of the camera must be configured accurately by means of calibration cards. Any later changes such as illumination, distance, focal length or contamination change the reliability of the quality analysis. The grading classes ABCDF correspond to the proposals of the ISO Class F is classified as no longer readable. At this point the minimum quality class that has to be reached by a barcode, to be evaluated as a Good Product, can be set. Quality Parameters Configuration of possible parameters for the classification of a code is made here. All seven parameters must be set for an analysis according to ISO Code Syntax CTRLC ON (default): Camera will read and transfer all control character. CTRLC OFF: When CTRLC OFF is set, a control character like value 102 ( ]C1 ) will be hidden in the current code. GS1: If GS1 is set, then a code must start with a decimal value 102, which during decoding will be converted to the character sequence ]C1. This setting helps distinguish a GS1-compliant code from a code that is merely similarly decoded. 71

72 Scans, minimum numbers of positive scans This inputs how many scans must be positive so that the code can be assessed as GOOD. Image from production run: Barcode with 27 positive scans. Minimum number is 6. With CC-A-Code, the minimum number of positive scans is given for how many rows of stacked code must be present at a minimum. Image from production run: CC-A-Code with two columns and 6 rows. The minimum number of positive scans is six. Scan Steps (distance of the individual readings) Code reading by the camera is carried out similar to a laser scanner. Individual rows of the code are read. The reading frequency of the codes can be set using the parameter scan distance. The adjustable step width is 1-10 rows. As a default here, '2' is set; for very small codes, one can set '1,' for large codes, greater values can be set in order to save calculating time. Reference - Actual Comparison The way the reference/actual comparison is performed is defined here. The possibilities are as follows: 0 = Good signal for a positive reference/actual comparison 1 = Machine stops for an incorrect code 1) 2 = NO positive reference/actual comparison The reference/actual comparison is adjusted for each defined code window. 1) If the Function 1 is activated and if the code is incorrect, the active signal of the camera will be reset and the message Wrong Code will be displayed. Dynamic Reference Code In order to check a continuous barcode, the reference code of the camera must be changed too. With the Dynamic reference code setting, the camera can adjust the reference code. For doing so, various settings can be input in the camera menu item New Reference Code : Correction = New Format = Pre-specification of the next reference characters (reference codes). The first code for which the check is to start must be entered. Specify a new counting system: Input unchanging characters, next counter reading, minimum counter reading, maximum counter reading, counting direction (up, down) for counters and interval for counters. 72

73 15 Barcode Quality Control Referring to ISO/IEC The bar coding technology is based on the recognition of samples, which are encoded in bars and gaps with different widths. The translation of numbers and characters into bars and gaps is defined for every code type in its on guideline. If a barcode shall fulfill its purpose, it has to be decodable reliably at the place, where it will be used. The standard ISO/IEC is a basis for the classification of the quality of 1D codes, related to specific demands on the reading process. The print quality control with a PCE Smart Camera can only be an approximation to the standard, because the control conditions of the standard are adjusted for an Offline-Inspection, the PCE SMC instead is an Inline- Inspection system. Various adverse conditions for inline inspection (e.g., position tolerances, aberrant lighting, limited analysis time, etc.) may result in a difference of one grading class between inline inspection and offline inspection. The viewing direction of the camera as well as any additional lighting can also affect the grading results! 15.1 Classification of a 1D Barcode The classification of the quality of a barcode divides into the classes A (best) to F (worst). Good Quality Bad Numeric Letter A B C D F Note: Class E will not be used for classification! The class of a 1D barcode is determined from the classes of 10 different lines inside the code. This means, that every one of these lines will be evaluated. If a line has been decoded successfully, afterwards its quality will be checked by the usage of a number of parameters. The quality class of the line arises from the class of the worst rated parameter. If, for example, 5 parameters are rated A, but 1 is only rated C, the result class of this line will be C. The total class of the barcode is the average value over the 10 result classes from the 10 analyzed lines. 73

74 Parameters of Classification In the following the parameters, which have to be checked in order to fulfill ISO/IEC 15416, are described. Image 2 shows a grey value profile or reflection profile of one line of the code, shown in image 1. In this profile some of the parameters, which have to be analyzed, are shown. Image 1: Original barcode image Quiet zone min. Adjacencycontrast Defect max. Grey Gaps Quiet zone Global Threshold min. Grey Bars Image 2: Grey value profile for one line through the barcode Decode [DEC] The classification of a Barcode Scanline can only be done, if the decoding was possible with the reference decoding algorithm. This means that the code data has to be readable and the checksum (if applicable) has to be correct. Also the Quiet Zone will be checked. Note: If decoding of the barcode is possible, but the quality analysis claims a bad Decode-parameter, this suggests a Quiet Zone which is too small. If Omnidirectional Reading is deactivated: Make sure that the Control Window is set big enough to contain the whole Code and its Quiet Zone. If Omnidirectional Reading is activated: Increase the parameter QZone in the CODE-Window parameter table step-by-step if required Make sure, there are no other graphics/texts on the product inside of the codes Quiet Zone. 74

75 Symbol Contrast [SC] The Symbol Contrast indicates the maximum difference of reflection in the barcode. Through the whole Barcode including its Quiet Zone the minimum and maximum reflection values are searched. Adjacency Contrast [ECmin] The Adjacency Contrast or Edge Contrast is the reflection difference between 2 adjacent elements. Every bar or gap is an element. The minimum of these contrast values which are found in the barcode will set this parameter. This value is checked to make sure that a good contrast is not only available between the maximum and minimum brightness of the code, but also between every bar and gap Modulation [MOD] The Modulation is the ration from the Adjacency Contrast to the Symbol Contrast. An Adjacency Contrast near the Symbol Contrast means that the Contrast is constant and will result in a better Modulation value. Minimal Reflection [Rmin] The Minimal Reflection is the lowest reflection value in the whole barcode. According to ISO/IEC 15416, it may not be greater than the half of the maximum Reflection. This parameter shall make sure, that there is enough difference between the brightness of bars and gaps. Defects [Def] Defects are irregularities within spaces and bars. If there are interfering elements in the spaces or scratches in the bars, the code indicates defects at these places. Defects are identified in the whole barcode including its Quiet Zone. Decodability [V] The decodability of a barcode is an indicator of its printing accuracy in relation to the dimensions specified by its standard decoding algorithm. It is calculated on basis of different reference decoding algorithms depending on the code type. "Dimensions" refers to the widths of the elements and their relationship to one another. Inconsistent widths of bars and gaps in the barcode will result in a lower decodability. This Parameter uses different calculations for 2-width-codes (Interleaved 2/5, Code39) and multi-width-codes (Code128, EAN13). 75

76 15.2 Configuration of Quality Control Calibration of the camera for barcode quality control reasons For barcode quality control reasons the camera must be calibrated in advance. An adequate calibration is essential for the correct evaluation of the quality. Please refer to the instructions in chapter 18.2 Camera Calibration for Data Matrix Quality Control Reasons. Maybe you will have to create a new temporary product with a data matrix control window, in order to perform the calibration. Usage of the Barcode Quality Control A Minimum-Quality-Class has to be chosen. If the printing of a barcode does not achieve this Minimum-Quality- Class, it will be rated as a Bad-Product. For example, if the class B was chosen, the printing of a code has to receive class A or B, to be rated as a Good-Product. Furthermore, single parameters can be specifically excluded from the print quality analysis. The quality control can be activated in the parameter table for CODE windows (see chapter 11 Parameter code window). It is recommended to use the omni-directional reading with the quality control if possible, to improve the code finding and the reliability of the quality analysis. Note: The print quality control is currently only available for barcodes of the type Code128. In production, the result of the quality analysis of the present barcode will be shown inside the CODE-Window. Structure of the result view: Grade: C (2.2) (MOD) Grade: Grading-Class (numerical Class) (worst average Parameter) Additional display of parameters: The parameter view shows the average quality of all line readings for each parameter. See chapter 9 Service Menu (p. 37). Note: By activating the view, the cameras calculation time possibly increases. 76

77 16 Pixel Window Parameters By using a pixel window, sizes of the black and white areas will be measured. In this way, the presence of a label or printing can be verified very easily, for example: For one control window two limit values always have to be set, the upper and the lower tolerance value. If the camera is in the production run, and the actual measuring value lies within the two tolerances, the object is then assessed as good. Below and above the tolerance values the object is bad. If the camera works with large tolerances, the system controls the presence. If the plus and minus tolerance is kept small the camera is able to carry out measurements. The operator can choose whether the tolerance values are to relate to a black or white area. In addition, the operator can decide whether the measuring values and tolerances are to be absolute or relative. The inspection principle Area measurement is the same for both measurements. During the pixel inspection, the first window is given the name Pix0. This is displayed in the top left corner of the window. The other pixel windows are given the names Pix1, Pix2, etc. Up to twelve different pixel windows can be set and thus up to twelve different features can be verified on an object. When the first window has been set, press the Enter button to save the settings. Presence control (absolute measurement) For the absolute measurement, the black area e.g. is displayed as a measured pixel number. If the area to be inspected is enlarged, the number of pixels is then greater. If the size of the black area is reduced, the number of pixels measured is smaller. The plus tolerances and the minus tolerances are entered as a pixel number; the display for the actual value is shown in the production mode as a pixel number. The measurement of an area does not depend on the size of the control window. Examples: Pixel number =1000 (reference value) Pixel number =500 Pixel number =2000 Print control (relative measurement) For the relative setting, the size of an area (reference area) is taught in and set as 100%. The following measurements can be smaller than 100% if, e.g. the printed area is missing, or greater than 100% if, e.g. there is too much print. The input of the plus and minus tolerance and the display of the measuring values is given as a percentage value. Examples: Measuring value =100% (reference value) Measuring value =50% Measuring value =200% Note: The pixel windows are to be set as described in the section Camera start-up with OCV windows. 77

78 Changing an existing product with pixel windows If for example, after a change in format, the window position is no longer correct or only the tolerances have to be changed, this can be changed quickly and easily in the parameter table. Starting at the main menu the sub-menu, Change product > Parameters PIXEL window can be called up. A table appears there with all the pixel inspection parameters. Here the size and position of each window can be changed, the grey threshold aligned or the tolerances modified. Parameter table Windows PX, PY, DX, DY The parameters Px, Py, Dx and Dy give the coordinates of the control window. The size and position of the window can thereby be documented and, if necessary, reproduced. If the black cursor is positioned on one of the values and the Enter key is pressed, the yellow control window appears in the following step for processing. The size and position can be changed using the line keys. Grey threshold The contrast value Grey threshold should be set for each window such that the object appears black and the background is shown in white without any black points. If the inspection is inverted, the background should be an even black and the object an even white. Object color Here it is possible to choose whether the tolerances are related to the white or black areas. Minimum, maximum tolerance For one control window two limit values always have to be set, the upper and the lower tolerance value. For the absolute measurement, the entry is given as a pixel number and for the relative measurement as a percentage value. (see absolute, relative measurement above). Mode The relative or absolute measurement can be selected as the mode. The absolute measurement is called presence control (mode0) and the relative measurement, Print control. The absolute measurement supplies the pixel number. (Mode 0) The relative measurement supplies a percentage value in respect to the teach-in object. (Mode 1) Contrast Here a filter can be activated for improving the contrast. This is beneficial for poorly contrasting images, or images that are illuminated unevenly. Pixels supplying contrast values that are smaller than the settable minimum value, are set to the background (background = black, if object color = bright pixels is activated; background = white, if object color = dark pixels is activated). The evaluation time is longer if the contrast filter is switched on. Send result Here, the output of the reading result via the interface RS232 can be switched on and off. 78

79 17 Data Matrix Window Parameters In a DM window a Data matrix code (ECC200) or an EAN Data matrix is inspected. The code content is read by the camera and compared with the reference code. If they agree, the good signal is given. The quadratic code can be read in any position (omni directional), i.e. the code can be turned at any angle within 360. Currently there is no omni directional reading at rectangular code possible, but only in the orientations of 0, 90, 180 and 270 with a tipping up to 30. The camera can also send the read content of the code on the serial interface without a comparison. With Main menu > Change product > Parameter Data matrix window any necessary setting can be made by the operator. Further information about Data matrix Code sizes with preset content can be found in the appendix "Size/Data Comparison Chart". Parameter Data Matrix CODE Control DM0 ON Calibration >>NEXT>> X Searching area Code size/module number 136x135 px² 14x14 mod² MultiCode(Amount/Int./Tol.) #1 100% 300% --- Ori/Col #AUTO# Black GW threshold Search: 102 Code: 102 Attempts:1 --- Code Syntax/Code to RS232 CTRLC ON OFF Dot-Code OFF Max. Distortion/Grid 0 Grid: 20% Print quality ON C,40% Minimum Learn Code/Compare 4: 1111 ON Filter: Erase/Dilat Dynamic Code OFF OCV Reference OFF Calibrate This function starts code reading of a Data Matrix Code in the presented search area. It will help you adjusting the camera for Data Matrix print quality inspection. Searching area The search area stipulates the position and size of the control window using four coordinates. Code size The code size provides the camera with information telling it how large the code is printed, or seen by the camera. This is given using two size coordinates. Module number The number of modules states the number of modules the code consists of, e.g. 14x14 modules. At present, the camera can inspect quadratic codes from 10x10 to 144x144 and rectangular codes with 8x18, 8x32, 12x26, 12x36, 16x36 and 16x48 modules. Using the Auto function, the camera can automatically determine the number of modules and read the code. 79

80 MultiCode - Code Amount Sets the number of codes inside of the DM window. This way multiple Codes can be found and read in one single DM window. All codes will be evaluated separately. Only if the adjusted number of codes was found and every code was evaluated positively, the DM window will state a good reading. Please note that there is only one reference code per DM window so that all Codes inside must have the same content if the Comparison is set to ON. MultiCode - Search Intensity If the camera is finding other objects inside of the window (which have the appearance of the searched DM Code), it may not find the real DM Code objects. In this case the Search Intensity can be increased. The system will then try to find and read additional objects, under which the DM Codes should be. A higher value will increase calculation time. MultiCode - Match Tolerance If the DM codes inside the window have high deviations in their shape, this value may be increased to find them. If the camera is trying to decode other objects which are no DM Codes but have a slightly similar shape, this value may be reduced, to ignore those objects. A smaller value will reduce calculation time. (Use this when working with multiple Attempts.) Ori / Col The Orientation parameter (Ori) stands for the position of the L-finder in the code. Different positions or Auto can be preset for the camera. The Color parameter (Col) states whether the code has been printed in black or white, i.e. black on a white background or white on a black background. GW threshold The grey value or contrast threshold appears in the list with three parameters. Grey value 1 Search defines the contrast for finding the code and for distinguishing it from any other additional print and the background. Grey value 2 Code is used for code reading. By using the adjustment Attempts a multiple evaluation can be set. The quantity of trials can be chosen between 1, 3 and 7. The standard adjustment is 3. Code to RS232 (option) If this function is activated, the camera sends the code content via the RS232, for example, to a PC. Code Syntax CTRLC ON (default): Camera will read and transfer all control character. CTRLC OFF: When CTRLC OFF is set, a control character like value 232 ( ]d2 ) will be hidden in the current code. GS1: If GS1 is set, then a code must start with a decimal value 232, which during decoding will be converted to the character sequence ]d2. This setting helps distinguish a GS1-compliant code from a code that is merely similarly decoded. PPN: If PPN is set, then a code must start with a decimal value 237, which during decoding will be converted to the character sequence [)>06. This setting helps distinguish a PPN compliant code from a code that is merely similarly decoded. 80

81 Dot-Code Printing a data matrix code with an inkjet printer results in the creation of round or circular modules. An ideal printed module, however, should be square. The camera has various filter functions so that such codes can also be read accurately. In the software, the user can specify whether a dot (module) = a gap is printed. Or whether a module smaller or larger than a gap is printed. With this function, several dots per module are used for analysis. Max. Distortion / Grid In order for the code reading to be less sensitive to printing errors, a setting can be allowed that permits the code to be read with a trapeze-shaped deformation. The value given by the grid parameter determines the deviation of a module from the ideal place in the grid. Print quality Quality control of the Data matrix reading can be activated and configured. The quality analysis corresponds to ISO ON/OFF Grading L-Finder Quality Parameters Search for quality Print quality ON C,30% Minimal Grading The grading classes ABCDF correspond to the proposals of the ISO15415, class F is classified as no longer readable. L-Finder Damage L-Finder Damage is an additional parameter that only evaluates the modules in "L". The percentage value refers to individual modules in the L-finder and sets the maximum number of pixels in a module that might be missing. Quality Parameters 81

82 Configuration of possible parameters for the classification of a code is made here. The seven first parameters must be set for an analysis according to ISO Search for quality Classification of the code quality depends on the internal settings during the reading. During the setting Minimal the reading will be accepted with the first readable and valid quality. During the setting Maximal the parameters will be varied until a result with the utmost quality is reached. For pure control reasons the timesaving function Minimal is sufficient. For quality classifications (e.g. during configuration) the function Maximal is recommended. Note: The correct code analysis depends on an accurate adjustment of the camera; the aperture of the camera must be configured accurately by means of calibration cards. Any later changes such as illumination, distance, focal length or contamination change the reliability of the quality analysis. Teach-in code The following parameters can be set manually by the operator or determined automatically by the camera: threshold value (grey), code size (print size), reference code and number of modules. The selection is made using a table. 0 [_] Threshold [_] Size [_] Reference code [_] No. modules 1 [X] Threshold [X] Size [_] Reference code [_] No. modules 2 [X] Threshold [X] Size [X] Reference code [_] No. modules 3 [X] Threshold [X] Size [_] Reference code [X] No. modules 4 [X] Threshold [X] Size [X] Reference code [X] No. modules Comparison As standard the camera offers the good signal of the machine control. It can then be shown whether the correct code or no code has been read. With the comparison setting, the camera can also indicate when an incorrect code has been read. For this purpose the camera ready signal (SR) is either set or not set. Filter: If for example there are disruptive ink splashes in the background of the code, the Erase filter function can be used. The Dilat filter function is helpful if the code is printed with large gaps. The standard value is 3, but it can be lowered to 2 or 1 if interferences in the vicinity of the data matrix code are causing code recognition problems. For codes with small modules, large gaps, and defective finders, increasing the value may help. This can be checked with the Diagnostics: Data Matrix Binary Image function. Dynamic Code Here a counter for the reference code can be activated. It will count up or count down with each trigger. The counter can be configured as follows: - dynamic reference code ON /OFF - start counting with first proper reading : The counter only starts after the first proper reading. 82

83 Example: ABCDEF left start digit of the counter (first digit is 0): 6 - number of counting digits: 9 - Increment and counting direction: -1 Dynamic Code ON ON 6\9\1 --- In this example the reference code after the next trigger would look as following: ABCDEF Note: In operation with the PLM software, the reference codes are specified by PLM. Dynamic reference codes may not be used in this operating mode. OCV Reference These parameters define a function which enables an adjustable part of the read data matrix code to be used as the reference code of an OCV/OCR window. A wizard will ask for the necessary values one after the other and thus simplify input: Example: - First it will ask which the OCV/OCR window to use as the target for the operation. - Then it will ask for the start position in the Data Matrix reference code (There is a '0' position) - Then it will input the number of characters to transfer - Lastly, it will ask for the position in the target. (There is a '0' position and the target must have at least enough reference characters to accommodate the beginning of the transferred characters. The text Total--- was input as the reference code for OCV0. The setting in the parameter table looks like this: OCV Reference OCV0 6\7\ A calibration card with the text Pharmacontrol Electronic GmbH appears in front of the camera. Reading in the production mode results in the following reference code in the OCV0 window: Total control 83

84 18 Data Matrix Quality Control 18.1 Data Matrix Quality Control in Keeping with ISO/IEC To determine the code quality, 8 parameters are measured and the measurement results are assigned to classes ranging from A to F. Good Quality Bad Numeric Letter A B C D F The 8 parameters are: 1. Decode Code is legible or code is illegible. Result is A or F. 2. Symbol Contrast Difference between light and dark modules examined over the entire code. 3. Modulation Difference between light and dark modules relative to the individual code words. 4. Fixed Pattern Damage Damage in the search sample, frequency sample, and in the quiet zone. 5. Axial Nonuniformity Differences in the length of the X-axis relative to the Y-axis. 6. Grid Nonuniformity The greatest deviation of the actual position of the modules relative to the ideal position. 7. Unused error correction Number of blocks not used for error correction dy dx The worst parameter determines the quality rating of the code. 84

85 8. L -Finder Damage This parameter is not part of the ISO norm. It was established for detection of typical Ink Jet faults. The value gives the percentage of pixels that may be missing in an individual Module on the L-Finder. Note: The ISO/IEC standard covers offline inspection. At the present time there is no corresponding standard that covers inline inspection. Various adverse conditions for inline inspection (e.g., position tolerances, aberrant lighting, limited analysis time, etc.) may result in a difference of one grading class between inline inspection and offline inspection. Should a code rated as D by the offline verifier be rated as poor inline, the grading threshold must therefore be set to B in the Smart Camera menu (also see Data Matrix Inspection Type chapter). Laser labeling by removing color: Because the measured contrast is strongly dependent on the interplay of the varnish used with the lighting employed, it is possible that uniform results may not be achieved with different verifiers. The viewing direction of the camera as well as any additional lighting can also affect the grading results! 85

86 18.2 Camera Calibration for Data Matrix Quality Control Reasons For data matrix quality control reasons the camera must be adjusted strictly according to the instructions by means of a calibration card. A suitable calibration card can be ordered from PCE. Adequate calibration is essential for the correct evaluation of the quality. It is recommended that calibration should be checked every 3 months. Furthermore, if components (camera or illumination) are replaced or if the reading distance of the camera is changed, recalibration will be essential. In case the amount of DM codes evaluated as faulty during the production exceeds extensively, the calibration should be checked. Note: For all formats, it is important to use the same shutter value! For black ink-jet-print on white cartons, the following settings are recommended. Camera type - Standard; - High-Speed; - High Res; - High Res/High Speed; -Ultra-high Res/High Speed; Shutter [microseconds] Each calibration card is gauged at PCE. The ML (mean light) value is indicated on the card. Steps: 1.) Please select [menu] -> [service] -> [system parameter] -> [shutter speed] for checking the right shutter value. 2.) You can adjust the ML (mean light)-value when you select the function Calibration Please note a Data Matrix window has to be set to use this function. The function can be found under [Menu] -> edit product -> parameter data matrix -> Calibration Parameter Data Matrix CODE Control DM0 ON Calibrate >>CONTINUE>> X In this mode, the camera initially tries to recognize the data matrix code and then continuously displays the read values for ML as well as the quality parameters for the data matrix reading. 86

87 3.) Position the data matrix code on the calibration card in front of the camera, at the correct reading distance. Press [next] button for teaching-in the data matrix code. If there are no hits during setup, please check the parameter settings explained in chapter 15. The data matrix code should now be read continuously and the graphic evaluation of the quality analysis displayed. The following graphic should be displayed on the screen of the PLM PC: The displayed ML value must correspond to the value on the calibration card (+/-5). Please make sure that the measurements are made in exactly the same area of the image where you want to read the production code. 4.) Adjustment of illumination If the ML value varies, the illumination of the camera must be adjusted. In order to do so, open the M18x1 screw blocking access to the objective and turn the aperture ring from the outside with a suitable tool, e.g. a small pointed screwdriver, making sure not to alter the focus of the objective. Make sure that you don t change the focus of the lens. Focus Aperture Do not terminate the 'Calibration' function until you have successfully completed the process. Note: Some cameras might have an adjustable internal illumination. If the software detects the presence of an adjustable illumination, it will display a slider for manual adjustment of image brightness. Please do not try any brightness adjustment on the aperture of your camera. 87

88 19 QR Code Window Parameters In a QR window a QR (Quick Response) code can be inspected. The code content is read by the camera and compared with the reference code. If they match, the good signal is given. The quadratic code can be read in any orientation. The camera can also send the read content of the code on the serial interface without a comparison. With Main menu > Change product > Parameter QR window any necessary setting can be made by the operator. Parameter QR CODE Control QR0 ON --- Searching area Size Finder: 135x135 px² Modules: 14x14 mod² Color Black Threshold Search: 102 Code: 102 Attempts:1 --- Filter 1.Filter: 1 2.Filter: 0 Noise reduction:off Dot-Code OFF Code Syntax Symbology ID: OFF Learn Code/Compare 4: 1111 ON OCV Reference OFF Code to RS232 OFF X >>NEXT> > --- Searching area The search area defines the position and size of the control window in which the QR code will be detected. Size - Finder The Finder Size will help the camera finding the 3 Finder Elements which are part of every QR code and are important for recognition of size, position and orientation of the code. Size - Modules The number of modules states the number of modules the code consists of, e.g. 21x21 modules. Using the Auto function, the camera can automatically determine the number of modules during inspection and read the code. Color The Color parameter states whether the code has been printed in black or white, i.e. black on a white background or white on a black background. Threshold - Search The search threshold defines the contrast for finding the 3 finder elements of the code and for distinguishing them from any other additional print and the background. Threshold - Code The code threshold will be used for distinguishing the black and the white module in a QR code. Threshold - Attempts By using the adjustment Attempts, multiple evaluations with different threshold levels around the configured value can be activated. The quantity of attempts can be chosen between 1, 3 and 7. A higher value increases reading stability for poorly printed codes, but also increases time consumption for evaluation. 88

89 Filters If for example there are disruptive ink splashes in the background of the code, the first filter can be used with a negative value. This will reduce the disruption but also the size of the code modules. To regain the correct size of the modules, the second filter can be used with a positive value. Filters: off 1.Filter: -3 1.Filter: -3 & 2.Filter: +1 Filter: Noise Reduction This filter is suppressing noisy background when switched on. Please consider that this filter will have an impact on the time consumption of the evaluation. Dot-Code Printing a data QR code with an inkjet printer results in the creation of round or circular modules. An ideal printed module, however, should be square. The camera has various filter functions so that such codes can also be read accurately. In the software, the user can specify whether a dot (module) = a gap is printed. Or whether a module smaller or larger than a gap is printed. With this function, several dots per module are used for analysis. Code Syntax - Symbology ID The Symbology Identifier (e.g. ]Q3) is part of every QR code as it is defined by ISO/IEC In general this information is not returned by QR code readers. With this option the behavior of the camera can be defined. If this option is turned on the camera will add this identifier to the decoded content as a prefix. Teach-in code The following parameters can be set manually by the operator or determined automatically by the camera: threshold values, finder size, reference code and number of modules. 0 [_] Threshold [_] Size [_] Reference code [_] No. modules 1 [X] Threshold [X] Size [_] Reference code [_] No. modules 2 [X] Threshold [X] Size [X] Reference code [_] No. modules 3 [X] Threshold [X] Size [_] Reference code [X] No. modules 4 [X] Threshold [X] Size [X] Reference code [X] No. modules The marked elements will be automatically defined by the camera, when setting a new reference code in the main menu. Comparison By default camera releases a good signal to the machine control, when the decoded code matches the reference code. The camera provides an option here to stop the machine, as soon as it reads a wrong code. For this it will deactivate its system ready (SR) signal. A third option is to turn off comparison. Then the camera will evaluate every readable code as a positive result, independent from the code content. 89

90 OCV Reference These parameters define a function which enables an adjustable portion of the read data matrix code to be used as the reference code of an OCV/OCR window. A wizard will ask for the necessary values one after the other and thus simplify input: Example: - First it will ask which OCV/OCR window to use as the target for the operation. - Then it will ask for the start position in the QR reference code (There is a '0' position) - Then it will input the number of characters to transfer - Lastly, it will ask for the position in the target. (There is a '0' position and the target must have at least enough reference characters to accommodate the beginning of the transferred characters. The text Total--- was input as the reference code for OCV0. The setting in the parameter table looks like this: OCV Reference OCV0 6\7\ A calibration card with the text Pharmacontrol Electronic GmbH appears in front of the camera. Reading in the production mode results in the following reference code in the OCV0 window: Total control Code to RS232 (option) If this function is activated, the camera sends the code content via the RS232, for example, to a PC. 90

91 20 Code Aggregation The Aggregation Mode is an optional mode for Smart Cameras which are for example integrated into a Case Packer System. The Aggregation can be activated in the Parameter Table of a Barcode or DM Code window. When activated, the mode will be applied to all Barcode and DM Code windows of the current product. For the function of aggregation, the camera needs two signals from the machine or PLC: Primary Gate on Input1 Secondary Gate on Input2 The Primary Gate Signal must be high during the aggregation cycle and point out the end of this cycle with its falling flank. If applicable, the Secondary Gate must point out the end of a subset of codes from the current cycle. After each aggregation cycle the camera will send all aggregated codes to the PLM. The maximum amount of codes for one aggregation cycle (e.g. one packing case) is 500. Operating Modes The code aggregation can be activated in two different modes (the appropriate mode is depending on the type of the machine): Aggregation In this basic mode all code reading results (no matter if positive or negative) will be submitted to the PLM, this means unreadable codes will also be sent as part of the aggregation data in form of an error message (prefixed with #ERR ). In this operating mode, the Secondary Gate signal should be coupled [ ] with the Primary Gate signal physically. Trigger & Analysis Good Bad Good Good Secondary Gate Primary Gate Aggregate Aggregate Aggregate Aggregate Submit 91

92 Aggregation (partial rejection) If the aggregation system e.g. has a rejection system for a series of products (a layer or a row), a PLC may use the cameras result output to reject a series if at least one code of it was unreadable. As the Codes from this series then should not be part of the aggregated data, the camera has this operating mode in which it will discard these codes (all codes of a series with at least one bad reading). A series of codes is defined by the Secondary Gate. Trigger & Analysis Good Bad Good Good Secondary Gate Ignore Primary Gate Aggregate Aggregate Submit 92

93 21 Appendix 21.1 Error Messages and Error Recovery Error message Error recovery System fails to start: Switch system off and on again. Check connection leads. System cannot be operated using the mini keyboard: LAN connection OK? Switch system off and on again. Has the IP address been configured correctly? System cannot be operated from the PC: Has the correct port on the PC been selected? Network hardware hub, switch and cabling correct? Firewall in PC active? System fails to take a photo: Check the trigger signal. The photo is blurred: Check the distance between the camera and the object. Good characters are mistaken for errors: Check character set, if necessary, conduct new character teach-in. Characters in the character set are not readable: Avoid reflections, new character teach-in. Control window or measuring lines wrongly positioned. Reset window. Brightness of background is not even. Incorrect readings in the production run Reduce reflections. for the optical character verification: Protect against any external light. Check references entered. Train characters. Incorrect readings at high speed: Reduce machine clock speed. Check whether trigger signal bounces. No window set! One window has to be set. Characters not found in the memory! Teach-in character. No teach-in for character! Teach-in character. Please teach-in the character set first! Teach-in character. Please take photo first! Take live photo. Reference code is not permissible! Change reference code. Too many different characters! Enter correct number of characters. For dynamic reference code, teach-in compulsory for all digits! Teach-in the characters 0, 1, 2, 3, 4, 5, 6, 7, 8 and 9.!! Password is incorrect!! Enter correct password. Passwords are not identical The second new password must agree with the first.! Character set memory is empty! In the OCV mode the characters must be taught in first.! Character set memory is full! No more characters can be taught in. To teach-in new characters, old characters first have to be deleted. The number of characters entered does not agree with the number Incorrect number of characters! Characters found: of taught-in characters. Enter correct number of characters or repeat the procedure. Error when loading the device data The default settings are No data is available in the camera. Error message only occurs when switching on for the first time. used < >!!!! Flash memory is full!!!! Flash memory is full, delete characters not required.!!!! Error Flash memory!!!! Data could not be stored. Memory is full or an error has occurred. Repeat memory procedure or delete old characters. Error when loading the product! < > Repeat loading, or product is not available. Error when initializing the Error message cannot be influenced. main FDC < >. Press Quit on the screen. You may have to remove all products Statistic Buffer full for [IP] between the Master and Slave Camera because their statistic data will be lost. Statistic not sent. Camera was not able to send Statistic data to PLM before next trigger. Press Quit on the Screen and check speed limitations. Time OUT: evaluation was stopped, because time reached the!to! defined Time Out value. See also chapter System Parameters/ Time Out E01 Missing character in reference code -. Object width out of tolerance. See also chapter Parameters of OCV / TIN Windows/ Control. and 1000 Character height is out of tolerance. See also chapter Change 93

94 ERROR: SENSOR1 (PRODUCT DISTANCE) ERROR: SENSOR2 (UNEXPECTED SIGNAL) ERROR: SENSOR3 (NOT EJECTED) ERROR: SENSOR3 TIMEOUT (WRONG EJECTED) scaling tolerance / scaling tolerance Description: Too many triggers on Sensor1 (product distance not ok/too small or sensor error). Solution: Check object distance and adjustment of Sensor1. Description: Solution: Description: Solution: Description: Solution: Too many triggers on Sensor2 (sensor error, failure of Sensor1). Check operation of Sensor1 and adjustment of Sensor2. If product was faulty, but was not ejected and passed Sensor3. Check ejection system and and timings. Product passed Sensor1 and result was good, but camera received no signal from Sensor3 within the defined time frame. Check ejection system and timings and operation of Sensor3. Description: Product passed Sensor1 but camera received no ERROR: SENSOR2 TIMEOUT" signal from Sensor2 within the defined counter check time frame. Solution: Check operation of Sensor2 and timings. ERROR: NO REFERENCE DATA RECEIVED Description: Camera not received new data before next trigger; see chapter System parameter/reference data receive check; Solution: make sure that data will be send from external or switch off control; No connection to image server Description: Camera is missing an external FTP server for storing failed images. Solution: start FTP server or switch off function storing failed images. If the error cannot be remedied in this way, please call the Customer Service. 94

95 21.2 Maintenance The device has been specially designed for industrial requirements. As a result, reliable operation is guaranteed under the normal conditions existing in production plants, provided that trained personnel have installed the device. For perfect operation, it is necessary to clean the glass plate of the camera housing at regular intervals. For cleaning, only use the cleaning cloths and agents intended specially for this purpose. Note: The device itself has no mechanical wearing parts and therefore requires no maintenance. If a Grading according to ISO for DM or ISO for other Code types shall be performed a calibration described in chapter 18.2 Camera Calibration for Data Matrix Quality Control Reasons Further Documents The following table shows further documents available for Smart Cameras. Further Documents SMC 3 Hardware Documentation JDatatrans Software Manual Patch Panel 3 Manual SMC 3-Series Datasheets Describes the functionally and handling of camera Hardware. Describes the functionally and handling of the service tool JDatatrans which is running on a PC. Describes how to connect the camera cables to the patch panel and a switching cabinet and shows the wire and pin assignment. The datasheets for SMC 3 cameras shows properties of cameras in compact form. 95

96 21.4 Adjusting the Focus / Reading Distance The following description can be used to check if the image sharpness displayed by the PLM or the SMC Client corresponds to the expected image quality or if the image sharpness needs to be readjusted after setting the reading distance desired. After adjusting the Focus and the Image brightness change the quality of image transfer back to the pre-set value of 2 or turn off the Zoom mode. Setting the quality of image transfer too high can increase the processing time during production by more than 10 ms. Standard cameras have a reading distance of 89 mm; as a general rule the reading distances are set during the installation of the system. If the reading distance changes, the focus have to be adjusted manually. Note: Some cameras might have an adjustable lens, if the software detects the presence of an adjustable lens, it will display the buttons Focus and Autofocus on the menu for Optical Settings. Please make all the adjustments by software using the Focus or Autofocus function. Instruction to adjust the focus: 1. Increase the size of the details displayed either by turning on the Zoom mode in the Main Menu or by switching image quality to 1 in Service Image configuration - image transfer. 2. Then switch the camera to the Live image mode. 3. Now adjust the distance between the object and the camera until the image displayed on the screen corresponds to the size desired. 4. Loosen the screws of the lid, which closes the opening to the lens, and turn the ring for the focal distance from the outside using a suitable tool such as a small pointed screwdriver until you see a clear, sharp image on the screen. Make sure that you did not accidentally change the f-stop. Focus Aperture 5. Change the quality of image transfer back to the pre-set value of 2 or turn off the Zoom mode. Setting the quality of image transfer too high can increase the processing time during production by more than 10 ms. 96

97 22 Specifications for OCR/OCV Control 22.1 Font Font type In principle the camera can check almost any font type. But because the characters in certain fonts can be hard to distinguish, we recommend using OCR-A (ISO ) or OCR-B (ISO ) font. Character spacing There should be a space of at least one line width perpendicular to the reading direction between characters. Font size The smallest possible font size depends on the size set for the field of view and on the camera resolution. Cameras are set to a minimum font size of 2 mm by default. Font color The camera can check either light font on a dark background or dark font on a light background. The contrast between the characters and the background should be as high as possible. Black font on a white background is ideal, whereas yellow font on a white background, for example, is problematic. The contrast can also be enhanced by using application-specific lighting. The character background should be uniform. Printing technique Stamp, hot stamp, block, thermal transfer, laser, and also inkjet and UV print can be read. A special UV light source is required for UV ink. For laser and inkjet print, there are filters in the software for connecting the individual dots. 97

98 22.2 Permissible Characters for OCR/OCV Control Unicode Character Unicode Character Unicode Character 0020 SPACE (not checked) 0043 C 0065 e 0021! (not valid) 0044 D 0066 f 0022 " 0045 E 0067 g 0023 # 0046 F 0068 h 0024 $ 0047 G 0069 i 0025 % 0048 H 006A j 0026 & 0049 I 006B k 0027 ' 004A J 006C l 0028 ( 004B K 006D m 0029 ) 004C L 006E n 002A * (not checked) 004D M 006F o 002B + 004E N 0070 p 002C, 004F O 0071 q 002D P 0072 r 002E Q 0073 s 002F / 0052 R 0074 t S 0075 u T 0076 v U 0077 w V 0078 x W 0079 y X 007A z Y 007B { A Z 007C B [ 007D } C \ 007E ~ 003A : 005D ] 00a3 003B ; 005E ^ 00c4 Ä 003C < 005F _ 00d6 Ö 003D = 0060 ` 00dc Ü 003E > 0061 a 00df ß 003F? (not valid) 0062 b 00e4 ä 0063 c 00f6 ö 0041 A 0064 d 00fc ü 0042 B 20ac 98

99 Cyrillic character: Unicode Character Unicode Character 0401 Ё 0432 в 0404 Ɣ 0433 г 0407 Ɨ 0434 д 0410 А 0435 е 0411 Б 0436 ж 0412 В 0437 з 0413 Г 0438 и 0414 Д 0439 Й 0415 Е 043A к 0416 Ж 043B л 0417 З 043C м 0418 И 043D н 0419 Й 043E о 041A К 043F п 041B Л 0440 р 041C М 0441 с 041D Н 0442 т 041E О 0443 у 041F П 0444 ф 0420 Р 0445 х 0421 С 0446 Ц 0422 Т 0447 ч 0423 У 0448 ш 0424 Ф 0449 щ 0425 Х 044A ъ 0426 Ц 044B ы 0427 Ч 044C ь 0428 Ш 044D э 0429 Щ 044E ю 042A Ъ 044F я 042B Ы 0451 ё 042C Ь 0454 Dž 042D Э 0457 Lj 042E Ю 0490 Ǫ 042F Я 0491 ǫ 0430 а 0431 б Note: The characters listed above can be taught -in or entered as reference characters respectively. The ability to differentiate the characters from each other depends amongst others on the font type and the features of the respective characters. SPACE (u0020) can be entered as reference character, however it will not be checked. * (u002a) is used as replacement character.! (u0021) and? (u003f) are used as control characters. 99

100 23 Readable Code Types Pharmacode 2-Track Pharmacode Code-39 Code-32 Interleaved 2 of 5 Code128 GS1-128 (EAN.UCC 128) 10 0

101 UPC_A EAN-13 EAN-8 Codabar Data Matrix (ECC 200) GS1 Data Matrix EAN Data Matrix PPN Code Data Matrix QR Code GS1-DataBar (before RSS14) 10 1

102 GS1-DataBar Truncated GS1-DataBar Stacked GS1-DataBar Limited EAN.UCC Composite (CCA) PDF417 (ECC Level 0 6) Compact PDF417 (truncated) (ECC Level 0 6) GS1-DataBar has been named as RSS14 before. EAN.UCC Composite (CCA-Code) does apply only in connection with GS1-DataBar. In this case a control window has to be set for both codes. 10 2

103 10 3

104 24 Index A Accept error images Adjusting image sharpness Alias Applications for optical character verification... 5 Assignment for the System Plugs... 7 Autofocus B Black on white Brightness compensation Brightness correction C Calibrate... 67, 74, 84, 85 Change character set Change Product Character Check quantity Clock overflow Code... 8, 70, 77, 87 Code Type Code types Code-Control Colour Inverted Configure Connection... 5 Connectivity... 6 Contrast D Data... 67, 76 Data Matrix Mode... 8 Delete counter Diagnosis Diagnosis value Dimmer Direction Display error images Disruptive pixels Distinguishing periods and hyphens Dot-code... 69, 77 Dynamic E Empty line pixels Error messages Error recovery External Illumination... 7 F Filter... 57, 71, 77 Finder Focus Font Fonts G Gap General Instructions... 4 Geometry Good outputs Good signal Grading... 59, 69, 72 Grey... 19, 66, 68, 76 Grey threshold measuring arrows Grey threshold windows Grid GS1-Test... 59, 68 H Hardware... 5 I I/O configuration I/O-Cable... 7 Identifier Image transfer quality Ink-Jet-Filter Installation and start-up... 4 Intended use... 4 Interspaces Inverse... 66, 68, 76 Inverse Filter ISO , 69 K Key assignments L Language Learn character group Link M Maintenance Maximum character size Menu Overview Menu selection Minimum character size Mirror Module... 67, 68, 76 N Noise pixels Noise Reduction... 52, 58, 77 Number O OCR... 8 OCR-Parameter OCV... 8, 71, 78 OCV-Parameter omnidirectional

105 Operation Optical Character Verification Optical Character Verification Service Optical Settings P Pass- and search tolerance Passwords Pixel... 8, 22, 65 Place holder Position Product administration Q Quiet zone QZone R Reading direction Reference Reflection Reflection correction S Safety measures... 4 Save counters Service Menu Setting Setting control window Show character set Show Font Shutter Size Size tolerance Start-Up... 13, 14, 15 Statistics switch off Switching off the camera System cable... 7 System parameters T Teach-In Mode... 8 Technical Specifications Time Out TIN-Parameter Train characters Transport... 4 Turn Type... 8, 9 U User User administration V Valid Virtual Keyboard W White on black Wildcard Window name OCR... 47, 54 Z Zoom

106

107 For more information Pharmacontrol Electronic GmbH Gernsheimer Strasse Zwingenberg, Germany Tel Fax Subject to technical changes. Pharmacontrol Electronic GmbH 05/2017 Optical Character / Code Verification - OCV User Manual - Document Version A