1. PresencePLUS® P4 GEO Customer Workshop

2. 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

3. 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

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

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

6. The Image is Converted to Pixels
640 x 480 image

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

8. 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

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

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

11. Banner: More Sensors, More Solutions

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

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

14. 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

15. 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

16. PresencePLUS® P4 Wiring1 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

17. 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

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

19. 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.

20. 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
Subnet Mask
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

21. 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

22. PresencePLUS® Software

23. 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

24. 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

25. 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

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

27. 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)

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

29. 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

30. 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

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

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

33. 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

34. Setup Screen

35. Get an Image
Focus Tab
Trigger Type
Focus
Image Brightness
Resolution

36. 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

37. 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

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

39. 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

40. Affecting Blur
2 ms
5 ms
1 ms
10 ms

41. 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!

42. 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

43. Tools Screen
Tool Overview

44. 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

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

46. 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

47. 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

48. 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

49. Geometric Count Tool

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

51. 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

52. Test Tool

53. 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

54. 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

55. Quick Teach

56. 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

57. Run (Run Screen)
But First . . .

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

59. 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

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

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

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

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

64. Update P4 GEO On­the­Fly
Remote Teach
Update P4 GEO On­the­Fly

66. Two Flavors of Remote Teach
the Pattern
the Quantity

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

68. 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

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

70. 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

71. Geometric Count Tool
How it Works
Best Practices for Configuring

72. Tools Menu

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

74. 360o Rotation = OK

75. Occluded Object = OK

76. Overlapping Objects = OK

77. Multiple Targets = OK

78. ROIs Outside of FOV = OK

79. Changing Light Levels …

80. … = OK

81. Pattern ROI
Search ROI

82. Input Tab
Establish Geometric Count Tool

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

84. 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

85. Good Product Passes
Geometric Count Default Settings

86. Geometric Count Default Settings
Different Product Passes

87. Geometric Count Default Settings
Different Product Passes

88. 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

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

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

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

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

93. 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)

94. 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

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

96. 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

97. 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

98. Teach
How Teach Works

99. 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

100. Locate Tools

101. 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

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

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

104. Locate – Configuration
Threshold Types
Absolute Threshold
Relative Threshold
Edge Strength

105. 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 =

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

107. False Edge Example

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

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

110. 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

111. 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

112. PresencePLUS® Communications

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

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

115. 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

116. 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

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

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

119. 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

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

121. 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
65000 Nodes

122. Pro Communications PortsPC
Data Collection
P+Pro A B C
Port 20000
Port 23
GUI Port
Comm Port

123. Ethernet TCP/IP and Serial Communication Port(s)

124. 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

125. Choose the Vision Tool

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

127. Choose the Port

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

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

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

131. PresencePLUS® P4 GEO Customer Workshop