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PresencePLUS ® P4 GEO Customer Workshop. PresencePLUS ® P4 GEO Workshop Agenda Introduction to Machine Vision Technology Banner Vision Mission and Offering.

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Presentation on theme: "PresencePLUS ® P4 GEO Customer Workshop. PresencePLUS ® P4 GEO Workshop Agenda Introduction to Machine Vision Technology Banner Vision Mission and Offering."— Presentation transcript:

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

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

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

6 The Image is Converted to Pixels 640 x 480 image

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

8 Directional Backlight Low Angle On-Axis Ring Light Dome Light Lighting Control is Critical

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

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

11 Banner: More Sensors, More Solutions

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

13 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 Wiring RS­232 TXOutput Remote TeachInput Product ChangeInput External TriggerInput I/O #1In/Out I/O #2In/Out I/O #3In/Out I/O #4In/Out RS­232 RXOutput RS­232 Ground Output DC Common Input 10­30V dcInput

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

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

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

22 PresencePLUS ® Software

23 7 Buttons – No Pull-Down Menus to Hunt Through Status Bar Image Window Results Window Configuration Window Toggle-Switch Icons PresencePLUS ® GUI

24 Status Bar Cursor Position Address Current Displayed Image Resolution (compression) Cursor Position Gray Scale Value Value: 31[615, 436]1:1

25 Toggle Switch Icons Zoom (left click zoom in right click zoom out) Expand Window Shows Selected Tool ROI/ ”A” Shows all Tools ROIs Delete Selected Tool Delete Selected Tool and All Subsequent Tools

26 The System Tab

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 Trigger, Remote Teach, Product Change and General Input Input Options 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 Pass, Fail, System Error, Ready Output Options 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 Pass Fail

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

33 SETUP – Position, Focus and Adjust Lighting to Create Reference Image Steps For Creating an Inspection TEACH Automatically Configure Values for Good Parts (optional) RUN The Inspection 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

34 Setup Screen

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

36 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 – Trigger

37 Focus Get an Image 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 2 ms 5 ms 10 ms Affecting Blur 1 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. = 6.4 Pixels At 1 ms There is a 6 Pixel Blur! Pixel Blur = 640 Pixels X 1 (ms) X 40 (in/sec) 4 (in) X 1000 (ms/in)

42 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 Exposure Time Calculation

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 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 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 Remote Teach Update P4 GEO On­the­Fly

65

66 Two Flavors of Remote Teach Remote Teach the Pattern Remote Teach 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 Product Change Change From One Inspection to Another On­the­Fly

70 Product Change Timing 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 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)

71 Geometric Count Tool How it Works Best Practices for Configuring

72 Tools Menu

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

74 360 o 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 Example: –Look at Date/Lot Code on Container to Determine: Presence/Absence vs. Date/Lot Code Being Correct Application May Require a More Discerning Search; Use Extra Edges and Missing Edges Filter

85 Good Product Passes Geometric Count Default Settings

86 Different Product Passes Geometric Count Default Settings

87 Different Product Passes Geometric Count Default Settings

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

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

92 Different Product Fails Extra Edges Geometric Count Configured To Check for Extra and Missing 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 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 –1 st 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 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 Two Instances to Use a Locate Tool:

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

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

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

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

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

107 False Edge Example

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

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

110 Enable Rotation Locate – Configuration 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 Networking Basics Converter Voice/Electric Signal Physical Medium Application Voice Converter Voice Components of a Network – Telephone

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

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 Area Code 763 Banner Vision Extension 3067 To Connect to the Vision Phone: Call ext Country Code 001

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

119 Networking Basics –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 When We Set up the TCP/ IP Setting on a Computer, We Need to Know Two Things:

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

121 Subnet Mask 255 Nodes Network Size Subnet Computer A Computer B Computer C Computer D Nodes The Subnet Mask Determines the Maximum Number of Devices per Network

122 PC Data Collection P+Pro A B C Port Port 23 GUI Port Comm Port Pro Communications Ports

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 Start String, End String Enable Labels

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

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

131 PresencePLUS ® P4 GEO Customer Workshop


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