PresencePLUS® P4 GEO Customer Workshop

PresencePLUS® P4 GEO Workshop Agenda Introduction to Machine Vision Technology Banner Vision Mission and Offering Setting up a P4 GEO Inspection Hardware GUI Navigation Trouble Shooting Best Practices for Applying the Geometric Count Tool Your Applications Q/A

Machine Vision Applications LOT 24 Machine Vision Applications Verification Presence/Absence Gauging/Measuring Orientation Flaw Detection Sorting LOT 24 LOT 24 X LOT 24 LOT 24 LOT 24 LOT 25

What is Machine Vision? Computerized Light Measurement to Error-Proof Production Processes

Camera CCD – Charged Coupled Device Pixel – Picture Element Image Sensor 128 Pixels 100 Pixels 1/3" CCD Array 12,800 Pixels

The Image is Converted to Pixels 640 x 480 image

Convert Signal to Gray Scale Voltage = 1.0 Voltage = 0 Voltage = .5 CCD Volts Black = 0 Brightest = 255 Mid Gray = 128 Gray Scale

Lighting Control is Critical Low Angle Directional Backlight Dome Light On-Axis We could easily have an entire seminar on just lighting—creating contrast. But we’re not going to do that today. At the start of your application solving process, contact your local Banner rep for help in selecting the illumination technique that will work best. Ring Light

What Are You Trying to Maximize When You Apply a Vision Sensor? CONTRAST ‘Good’ Condition ‘Bad’ Condition

Banner Vision Division Make Machine Vision Technology Affordable and Practical for Routine Factory Floor Inspections Performance – Reliably Solve Inspections Ease of Use Value

Banner: More Sensors, More Solutions

PresencePLUS® Vision Sensor Line Introduced in 2000 PresencePLUS® Pixel-Counting Sensor PresencePLUS®Pro Full-Function Vision Sensor PresencePLUS® P4 GEO Single-Function Sensor

Setting Up an Inspection PresencePLUS® P4 GEO Setting Up an Inspection

PresencePLUS® P4 Hardware NTSC Connector for Live Video 10/100 Ethernet PICO Connector for Banner LED Light – 24V dc and Strobe Control 12-Wire Power and I/O Cable

P4 Platform Connections 10­30V dc 4 Discrete I/O User Defined (input or output) User Programmable (PNP or NPN) 10/100 Ethernet & Serial Interfaces 10 Ethernet Ports 1 RS­232 Port Pico Connector on Sensor Provides Power for Light Source and has Connection for Strobe Control Output

PresencePLUS® P4 Wiring 1 2 3 4 5 6 7 8 9 10 11 12 RS­232 TX Output Remote Teach Input Product Change Input External Trigger Input I/O #1 In/Out I/O #2 In/Out I/O #3 In/Out I/O #4 In/Out RS­232 RX Output RS­232 Ground Output DC Common Input 10­30V dc Input

PresencePLUS® P4 GEO Indicators Bi-Colored Status Indicators Green = PASS Red = FAIL Green = POWER Red = ERROR Green = READY Yellow = TRIGGER Lens Standard C-Mount Housing Black Anodized Aluminum IP20 Environmental Rating

Install the GUI Software on Your PC Load the PC Software Using the Automatic Installer on the CD ROM PresencePLUS 2.0.1 Works in 9 Major Languages and on All PresencePLUS Sensors Free Updates Available on bannerengineering.com

Step 1 Check the Hardware Connection The Yellow LED on the Back of the Sensor Should be On If Yellow LED is off check cable connections, status of Ethernet port on the PC and power supplied to the P4 Sensor Network Troubleshooting Left Yellow LED - Physical link, wiring is OK Right Green LED - Blinks Green - Network Traffic - TCP / IP Data is being exchanged. When the green light goes on, you aren’t troubleshooting anymore.

Step 2 Change the IP Address of the PC Set the PC Subnet to match the factory default address of the PresencePLUS sensor IP Address 192.168.0.2 Subnet Mask 255.255.255.0 We have all set up our demo units to talk to the pro, so we’ve seen this dialog box. Think of the extended network prefix as the “area code” and the host address as the “local seven digit number”, or the extension

Getting to the TCP/IP Properties Window Takes a Few Steps Have Setup and Configuration notes has handouts. Setup and Configuration Notes for Changing the IP Address for Each Windows Operating System in your Workshop Binder

PresencePLUS® Software

PresencePLUS® GUI Configuration Window 7 Buttons – No Pull-Down Menus to Hunt Through Toggle-Switch Icons Demonstrate the P+ GUI live—hide these slides Image Window Results Window Status Bar

Status Bar Value: 31 [615, 436] 1:1 Cursor Position Gray Scale Value Cursor Position Address Current Displayed Image Resolution (compression) Demonstrate the P+ GUI live—hide these slides

Delete Selected Tool and All Subsequent Tools Toggle Switch Icons Zoom (left click zoom in right click zoom out) Shows Selected Tool ROI/ ”A” Shows all Tools ROIs Demonstrate the P+ GUI live—hide these slides Delete Selected Tool and All Subsequent Tools Expand Window Delete Selected Tool

The System Tab Demonstrate the P+ GUI live—hide these slides

I/O Options – Function General Input (default) General Output (tie to TEST tool results) Pass (latch only) Fail (latch only) System Error (latch only) Ready (latch only) Product Select (use in conjunction with the orange product change line)

Input Options Trigger, Remote Teach, Product Change and General Input NPN (Current Sourcing, Default Setting) PNP (Current Sinking)

General Output 150 mA – Use a Relay if Trying to Connect to Solenoid or other Device with a Load Above 150 mA Electrical: Current Sinking/NPN (default) or Current Sourcing/PNP Normally: Open (default) or Closed Output Delay: 0 (default) – 10,000 ms Output Duration: Latched (default) or Pulsed from 1-10,000 ms

Output Options Pass, Fail, System Error, Ready System Outputs Will Stay the Same with Every Inspection Only Latched and No Delay Everything Else is Configurable For Best Engineering Practices Monitor to the Ready (not busy) Output If Using Pass or Fail Outputs, Monitor a Ready Output to Insure Inspections are Continuing to Operate

Latched Output ON OFF Pass Output Inspect Idle Sensors Status Pass Fail

Strobe If Exposure Time is < 1 ms Configure Strobe Tab to “On” (Default)

Steps For Creating an Inspection SETUP – Position, Focus and Adjust Lighting to Create Reference Image Add To: Find the Part – Location Tool (rarely used) Analyze the Part – Geometric Count Tool Measure the Part – Measure Tool Set / Criteria Test Tool (required) TOOLS TEACH Automatically Configure Values for Good Parts (optional) RUN The Inspection

Setup Screen

Get an Image Focus Tab Trigger Type Focus Image Brightness Resolution

Get an Image – Trigger Continuous – The PresencePLUS Pro Software will Trigger the Camera to Snap Pictures as Fast as Possible External – The Camera Waits for an Electrical Signal from the Trigger Input to Snap a Picture Manual – The Camera Waits for the Manual Button on the Software to be Clicked to Snap a Picture Off – The Camera will Not Acquire Images

Get an Image Focus The Focus Number Represents the Image’s Contrast Level High Contrast – Higher Focus Number Low Contrast – Lower Focus Number Turn the Lens Focus Adjustment Ring as the Focus Number Increases; Turn the Ring the other Direction when the Focus Number Starts to Decrease

Get an Image – Image Intensity Exposure Time (electronic shutter) The Amount of Time the CCD Image Chip is Exposed to Light .01 ms to 20.47 ms Gain – Electronically Boosting the Light (and the Noise) Sensed by the CMOS Imager Use Auto Exposure; Tweak, if Necessary

Get an Image – Exposure Time Determines the Amount of Light Needed for an Inspection Determines How Fast a Part can Move Past the Camera While an Image is Being Captured For Moving Targets Minimize Exposure Time by Opening the Aperture and Increasing the Gain For Indexed Targets Leave the Gain at 20 and Adjust Exposure for the Light Needed for Adequate Contrast

Affecting Blur 2 ms 5 ms 1 ms 10 ms

Blur Calculation Example Pixel Blur = 640 Pixels X Exp. (ms) X speed (in/sec) FOV (in) X 1000 (ms/in) Part is 4 inches wide and is moving at 40 in/sec (200 ft/min). The exposure time is 1 ms. Pixel Blur = 640 Pixels X 1 (ms) X 40 (in/sec) 4 (in) X 1000 (ms/in) = 6.4 Pixels At 1 ms There is a 6 Pixel Blur!

Exposure Time Calculation Maximum Exposure Time (ms) = FOV (inches) X 1000 (ms/sec) 640 Pixels X Speed (inches/sec) Part is Moving at 200 Ft/Min and is 4 Inches Wide Maximum Exposure Time (ms) = 4 (inches) X 1000 (ms/sec) 640 Pixels X 40 (inches/sec) = .16 ms

Tools Screen Tool Overview

Location Tools Not Required for Typical P4 GEO Inspection Useful for Positioning ROI When Using Remote Teach Function Locate Combined with a Smaller Geometric Count Search Area will Speed Inspection Time Compensates for Translational and Rotational Movement of the Inspection Target Used to Move Regions of Interest (ROIs) that Follow the Location Tool Two Types Geometric Find Locate

Vision Tool – Geometric Count The Geometric Count Tool Searches For Matching Patterns Workhorse of the P4 GEO Sensor

Measure Tool Measure Tool is Used to Measure the Distance Between the Center of Patterns, Edges Found with the Locate Tool or the Sensor’s Origin The Absolute Distance as well as the Horizontal (x) or Vertical (y) Distance in Pixels is Found

Test Tools Evaluates Results of Selected Vision and Analysis Tools Activates Outputs Determines Tolerances for when an Inspection Passes or Fails Performs Logical Operations At Least 1 Test Tool is Required for an Inspection

Communications Use the Test Tool to Configure Discrete Outputs (Black, Red, White and Light Blue Wires) Use the Communications Tool to Send any Inspection Information out the Ethernet Port and/or the RS232 Serial Port

Geometric Count Tool

Geometric Count Tool – ROI Selection Chose a Rectangular, Elliptical or Circular ROI

Geometric Count Tool Add Masks (Optional) Mask any Area of the Geometric Count ROI that is NOT a Critical Pattern Feature Add up to Eight Masks

Test Tool

Test Tool Configuration Four Inputs Configured as Either: Geometric Count Tools Measure Tools External Inputs Previous Test Tools Logically Tie the Inputs Together Turn on Outputs

Test Results The Results Can be Used: As an Input to Another Test To Turn on an Output To Contribute to Passing or Failing an Inspection Or All of the Above

Quick Teach

Quick Teach Populates Test Tool Input Tabs with Values Such that the Reference Image will Pass In a Typical P4 GEO Inspection, Quick Teach Fills in the Geometric Pattern Count Input of the Test Tool with a Min 1 and a Max 1

Run (Run Screen) But First . . .

Save In-Between Quick Teach and Run Save the Inspection on the Controller

Run Select the Inspection Start/Stop the Inspection Choose Inspection Capture Method Set Fail Capture Time on NTSC Video Monitor Clear Inspection Count View Discrete I/O View Results

Run – Results Screen Inspection Parameters Camera Trigger Run Parameters Tool Inputs and Results Test Tool Inputs and Results

Expand Test Tool to See More Run – Results Screen Expand Test Tool to See More

Run – The Inspmgr View Sensor Response Time Includes Compete Inspection Time from Trigger Initiation to Output

Lab 1 – WORLD-BEAM® Targets Goal Build a Basic Inspection Quick Teach Inspection Save Inspection Run Inspection and View Results

Update P4 GEO On­the­Fly Remote Teach Update P4 GEO On­the­Fly

Two Flavors of Remote Teach the Pattern the Quantity

Remote Teach – Tools Affected RT Affects Pattern RT Affects Min/Max

Remote Teach Timing Diagram Existing Inspection Occurs Here Remote Teach Occurs Here New Inspection Occurs Here New Target Must in Place Remote Teach is Activated Trigger Ready Remote Teach

Change From One Inspection to Another On­the­Fly Product Change Change From One Inspection to Another On­the­Fly

This Pulse Would Not be Counted Product Change Timing Product Change Input (Pin 3) Start Counting Pulses on Product Select Line Pulse this Line to Increment Inspection Address Stop Counting Pulses on Product Select Line This Pulse Would Not be Counted Product Select Input (Pin 5, 6, 7, or 8) Example: The Sensor will Stop Executing the Inspection it is Currently Running, Go to Address Number 4, Load the Inspection at Location 4, Enter RUN Mode, Execute the Inspection on the Next Valid Trigger Sensor Should be in Ready Mode and not Running an Inspection When Making a Product Change Request

Geometric Count Tool How it Works Best Practices for Configuring

Tools Menu

Intelligent Edge Extraction P4 Tool Screen Shot Geometric Count Tool Intelligent Edge Extraction

360o Rotation = OK

Occluded Object = OK

Overlapping Objects = OK

Multiple Targets = OK

ROIs Outside of FOV = OK

Changing Light Levels …

… = OK

Pattern ROI Search ROI

Input Tab Establish Geometric Count Tool

Advanced Tab Increase or Decrease Pattern Rotation Change to More Exact Pattern Match

Geometric Count Defaults = Forgiving Application May Require a More Discerning Search; Use Extra Edges and Missing Edges Filter Example: Look at Date/Lot Code on Container to Determine: Presence/Absence vs. Date/Lot Code Being Correct

Good Product Passes Geometric Count Default Settings

Geometric Count Default Settings Different Product Passes

Geometric Count Default Settings Different Product Passes

What If Customer Wants to Make the Inspect for an Exact Pattern Match? Previous Application did Determine Presence/ Absence Correctly Minimum Acceptance Level Adjustment will Not Fail Bad Products Must Go into Advanced Tab

Lot Date Code Application Turn on Extra Edges Turn on Missing Edges

Geometric Count Configured To Check for Extra and Missing Edges Good Product Passes

Geometric Count Configured To Check for Extra and Missing Edges Different Product Fails Missing Edges

Geometric Count Configured To Check for Extra and Missing Edges Different Product Fails Extra Edges

Methods to Speed Inspection Increase ROI Size (red box) to Include More Edge Content Reduce Edge Content outside the Pattern Area of the FOV (Field of View) Reduce Rotation Range Reduce Search Area ROI (yellow box)

Lab 2 – Date Code Targets Learn How Remote Teach Works Learn How to use Extra and Missing Edges for a More Exacting Inspection Learn How ROI Content, Rotation Range, and Search Area Size Affect Inspection Speed

Using the Log Tab to Trouble-Shoot Inspection Logging Using the Log Tab to Trouble-Shoot

Log Options Default None, Image Enable Unchecked Chose Pass, Fail, Any Or to Troubleshoot Remote Teach Choose RT or RT Fail Select Strategy 1st 10 Inspections Last 10 Inspections First 5 and Last 5

Obtain Images and View Results Shows Image and Inspection Results for All Logged Inspections Can Save to PC or Load Saved Inspections From the PC

Teach How Teach Works

Teach Trigger Good Products Test Tool Parameter Windows will Expand so that all Taught Products will Pass Teach Never Narrows Test Tool Parameter Windows Teach Overwrites Any Values (including manually entered values) Best Practices – Use Teach Than in Run Verify Best Bad Products Fail If Required, Tweak Test Tools Manually

Locate Tools

Most P4 GEO Applications Require No Locate Tool Two Instances to Use a Locate Tool: Increase Speed Decrease Geometric Count Search ROI Place Search Window in Accordance with a Located Edge Feature Place Geometric Count ROI During Remote Teach Locate Tool Executes Prior to Remote Teaching of Geometric Count Tool Geometric Count ROI Placed in Reference to Target Feature For Consistency

Locate Tool: Part Moves but is Still Good Finds the Edge and Adjusts Subsequent Vision Tool ROIs Good Part

Locate – Configuration Threshold Type Threshold Level Polarity ROI Width Smooth Filter Minimum Width Sample Rate

Locate – Configuration Threshold Types Absolute Threshold Relative Threshold Edge Strength

Locate – Configuration Relative Threshold An Edge is Found When the ROI Detects Pixels That Pass a Gray Scale Percent Locate Only Uses the First Edge ROI Profile Threshold Edges =

Locate – Configuration Relative Threshold Advantages Tolerant to Light Fluctuations Between Inspection Disadvantage Can Find False Edges

False Edge Example

Locate – Configuration Threshold Level This Option Moves the Threshold Level (the green line on the graph)

Locate – Configuration Polarity Options Bright to Dark Dark to Bright ALL

Locate – Configuration Enable Rotation Activates the Edge Angle Calculation The Position of the ROIs That Follow will Adjust for Both Translation and Rotation Enable Rotation Requires an ROI Width of 13 A Width of 21 or Greater is Recommended

Locate Results Results Used by Test Tool None Results Used by the Measure Tool First Edge Found Must be Used in Conjunction with Another Vision Tool

PresencePLUS® Communications

Networking Basics What is a Network? An Interconnected or Interrelated Chain, Group, or System Two Common Networks Are: World Wide Web Telephone System

Converter Voice/Electric Signal Networking Basics Components of a Network – Telephone Converter Voice/Electric Signal Application Voice Voice Converter Physical Medium

Networking Basics Components of a Network – Ethernet PC Software Pro Cat 5e Cable Ethernet Port Ethernet Card A B C PC Data Collection P+Pro PC Software Pro Software

Networking Basics How Does the PC Find the Pro? Through the TCP/IP Address What is TCP/IP? Transmission Control Protocol/Internet Protocol A Set of Software Standards to Establish Communications Between Two Computers

The Telephone Address System Phone Numbers (xxx) xxx-xxxx To Connect to the Vision Phone: Call 001.763.544.3164 ext. 3067 Vision Extension 3067 Banner 544.3164 Country Code 001 Area Code 763

The Network Address System IP Address xxx.xxx.xxx.xxx To Email to the Vision Computer: 192.168.104 Port 110 Vision Network 192.168.0. POP3 Mail 110 Vision Computer 104

Networking Basics When We Set up the TCP/ IP Setting on a Computer, We Need to Know Two Things: IP Address Subnet Mask Subnet Mask is Used to Separate the Two Parts of the IP Address, the Extended Network Prefix and the Host Address

Subnet Mask Most Common Subnet Values 255, Used to Indicate the Static Network Numbers 0, Used to Indicate the Variable Host (PC) Numbers

Subnet Mask The Subnet Mask Determines the Maximum Number of Devices per Network Network Size Subnet Computer A Computer B Computer C Computer D 255 Nodes 255.255.255.0 192.168.0.11 192.168.0.121 192.168.0.5 192.168.0.240 65000 Nodes 255.255.0.0 192.168.1.11 192.168.23.11 192.168.0.35 192.168.23.2

Pro Communications Ports PC 192.168.0.104 Data Collection 192.168.0.2 P+Pro 192.168.0.1 A B C Port 20000 Port 23 GUI Port Comm Port

Ethernet TCP/IP and Serial Communication Port(s)

Communication Tool Steps Create an Inspection Add a Communication Tool Choose the Vision Tool With the Data Choose the Specific Data to Send Choose Which Port to Send it Through Choose How to Format the Message

Choose the Vision Tool

Select the Data Order of the Data – Left to Right, Top to Bottom

Choose the Port

Format the String Delimiters , : ; space <cr> <lf> <cr-lf> <lf-cr> Start String, End String Enable Labels

PC Programs to Display Data Telnet Start -> Run -> [IP address] [port] [192.168.0.1] [20000]

PC Programs to Display Data HyperTerminal Start New Session Choose Icon Winsock (TCP/IP) Host Address 192.168.0.1 Port 20000

PresencePLUS® P4 GEO Customer Workshop