Banner PresencePLUS P4 User Manual

PresencePLUS
User's Manual
®
P4 AREA/AREA 1.3
Banner Engineering Corp.
P/N 125439 rev. D — 2009R2

Table of Contents

1. Product Support and Maintenance...................................................................7
2. System Description ...........................................................................................9
2.1 P4 Vision Sensors..................................................................................................................9
2.1.1 Typical P4 Vision Application........................................................................................9
2.1.2 PresencePLUS®P4 Components..............................................................................10
2.1.3 P4 Cable Connections................................................................................................11
2.2 Software Overview................................................................................................................12
2.2.1 Main Menu Toolbar ....................................................................................................13
2.2.2 Image Window............................................................................................................14
2.2.3 Navigation/Results Window........................................................................................15
2.2.4 Configuration Window................................................................................................17
2.2.5 Status Window............................................................................................................17
3. Getting Started.................................................................................................19
3.1 Installing the PresencePLUS Software.................................................................................19
3.1.1 Installing the Software................................................................................................19
3.1.2 Starting Up the Software............................................................................................19
3.2 Typical Setup and Startup Sequence...................................................................................24
3.3 Startup and Troubleshooting................................................................................................24
3.3.1 General Troubleshooting............................................................................................25
3.4 Setting Up Hardware Parameters.........................................................................................26
3.5 Building an Inspection...........................................................................................................26
4. Setup.................................................................................................................29
4.1 Setup Screen........................................................................................................................29
4.2 Capturing a Reference Image..............................................................................................29
4.3 Focus Tab.............................................................................................................................29
4.3.1 Reference Image Source...........................................................................................30
4.3.2 Focus Value................................................................................................................31
4.3.3 Auto Exposure............................................................................................................31
4.4 Trigger Tab............................................................................................................................32
4.4.1 Trigger Settings..........................................................................................................33
4.4.2 Resolution...................................................................................................................34
4.5 Advanced Tab.......................................................................................................................34
5. Tools Screen ....................................................................................................37
5.1 Overview...............................................................................................................................37
5.2 Typical Build/Modify Procedure............................................................................................38
5.2.1 Choosing a Tool..........................................................................................................38
5.2.2 Adding a Tool..............................................................................................................38
5.2.3 Adding a Test Tool......................................................................................................38
5.2.4 Renaming Tools..........................................................................................................38
5.2.5 Removing a Tool.........................................................................................................39
5.3 Quick Teach..........................................................................................................................39
5.4 Load Tab...............................................................................................................................39
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5.4.1 Flexible Inspection Loading........................................................................................40
5.4.2 Inspection Storage Capacity......................................................................................41
5.4.3 Opening an Inspection from the Sensor or a Library..................................................42
6. System Setup Window Overview....................................................................45
6.1 Sensor Select Tab.................................................................................................................46
6.1.1 Change Sensor IP Address........................................................................................48
6.1.2 PC (GUI) to Sensor Connection Setup.......................................................................49
6.1.3 IP Address History......................................................................................................50
6.2 Communication Tab..............................................................................................................51
6.2.1 Communication Setup................................................................................................52
6.2.2 Remote Command Channel Configuration ...............................................................56
6.2.3 PresencePLUS/Kawasaki Vision Guidance and Inspection.......................................65
6.2.4 Using Custom_ASCII to Communicate with an External Device Over Ethernet........81
6.3 P4 Input/Output Tab..............................................................................................................82
6.4 Strobe Tab............................................................................................................................84
6.4.1 Strobe Width...............................................................................................................84
6.4.2 Level...........................................................................................................................85
6.5 Units Tab...............................................................................................................................85
6.6 Reset Tab..............................................................................................................................86
6.7 Start-Up Inspection Tab........................................................................................................87
6.8 NTSC Tab.............................................................................................................................89
6.9 Language Tab.......................................................................................................................90
6.10 Tools Configuration.............................................................................................................91
6.10.1 Standard Mode.........................................................................................................92
6.10.2 Enhanced Mode.......................................................................................................92
6.10.3 Custom Mode...........................................................................................................92
6.10.4 Tool Licensing...........................................................................................................92
7. PresencePLUS Software Tools.......................................................................95
7.1 ROI Types.............................................................................................................................95
7.1.1 Linear ROI..................................................................................................................95
7.1.2 Area ROI.....................................................................................................................95
7.1.3 Search ROI.................................................................................................................96
7.2 Location Tools.......................................................................................................................96
7.2.1 Locate Tool.................................................................................................................96
7.3 Vision Gray Scale Tools......................................................................................................103
7.3.1 Average Gray Scale Tool..........................................................................................104
7.3.2 Blob Detect Tool.......................................................................................................107
7.4 Analysis Tools.....................................................................................................................119
7.4.1 Communication Tool.................................................................................................120
7.4.2 Math Tool..................................................................................................................136
7.4.3 Measure Tool............................................................................................................141
7.4.4 Test Tool...................................................................................................................162
8. Communication Tool Setup...........................................................................183
8.1 Ethernet Connection...........................................................................................................183
8.2 Serial Connection...............................................................................................................185
8.3 Overview of Testing the Communication Tool.....................................................................186
8.4 Detailed Steps for Testing the Communication Tool...........................................................187
8.4.1 Testing Ethernet Communications............................................................................187
8.4.2 Testing Serial Communications................................................................................187
8.5 Troubleshooting Ethernet Connections..............................................................................188
8.6 Troubleshooting Serial Connections...................................................................................188
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8.7 Remote Command Channel Configuration ........................................................................189
8.7.1 Remote Command Set ............................................................................................189
8.7.2 RCC Return Values..................................................................................................192
8.7.3 Frame Tag Numbers ................................................................................................193
8.7.4 Command Processing .............................................................................................194
8.7.5 RCC Log ..................................................................................................................194
8.7.6 Frame and Field Delimiters......................................................................................195
9. Teach...............................................................................................................197
9.1 Quick Teach........................................................................................................................197
9.2 Teach..................................................................................................................................197
9.3 Teach Screen......................................................................................................................198
9.3.1 Teaching an Inspection.............................................................................................198
9.4 Remote Teach.....................................................................................................................200
9.4.1 Understanding Remote Teach..................................................................................200
9.4.2 Remotely Teaching a Tool........................................................................................201
9.4.3 Timing Sequence......................................................................................................201
9.4.4 Remote Teach Results.............................................................................................202
10. Run Screen...................................................................................................203
10.1 Selected Inspection..........................................................................................................204
10.2 Display..............................................................................................................................204
10.3 Capture Control................................................................................................................205
10.4 Results..............................................................................................................................205
10.5 Inputs................................................................................................................................206
10.6 Outputs.............................................................................................................................206
10.7 Product Select..................................................................................................................207
10.8 System..............................................................................................................................207
10.9 Start/Stop..........................................................................................................................207
10.10 Select Tab.......................................................................................................................207
10.11 Log Tab...........................................................................................................................209
10.12 Run Results....................................................................................................................211
10.13 Run Player/Recorder......................................................................................................213
10.13.1 Record..................................................................................................................215
10.13.2 Playback...............................................................................................................217
11. Product Change............................................................................................221
11.1 Product Change Specifications.........................................................................................221
11.2 Product Select Input Specifications..................................................................................222
12. P4 Product Change and Product Select Timing........................................223
12.1 One Pulse Set Overview...................................................................................................223
12.1.1 Product Select in One-Pulse Configuration............................................................224
12.2 Three Pulse Set Overview................................................................................................225
12.2.1 Product Select in Three-Pulse Configuration.........................................................225
13. Saving Inspections.......................................................................................227
13.1 Saving Inspections to a Vision Sensor.............................................................................228
13.2 Saving Inspections to a PC or Network Drive...................................................................230
14. Backing Up and Restoring Vision Sensor Data.........................................231
14.1 Backing up Vision Sensor Data........................................................................................231
14.2 Restoring Vision Sensor Data...........................................................................................235
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15. Dimensions and Specifications..................................................................239
15.1 Sensor Dimensions...........................................................................................................239
15.1.1 Right-Angle Sensor Dimensions............................................................................239
15.1.2 Right-Angle Sensor Mounting Bracket Dimensions...............................................239
15.1.3 In-Line Sensor Dimensions....................................................................................240
15.1.4 In-Line Sensor Mounting Bracket Dimensions.......................................................240
15.2 Sensor Specifications.......................................................................................................241
15.3 Monitor Specifications - 9" CRT........................................................................................243
15.4 Monitor Specifications - Flat Panel 8" LCD Color.............................................................243
15.5 Ethernet Communication Specifications...........................................................................244
15.6 Serial Port Communication Specifications........................................................................245
..............................................................................................................................247
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Product Support and Maintenance

This section provides general Banner resources and specific documentation for installers and operators of this PresencePLUS Vision Sensor.
Attention: Not to be Used for Personal Protection.
Never use these products as sensing devices for personel protection. Doing so could lead to serious injury or death.
These sensors do NOT include the self-checking redundant circuitry necessary to allow their use in personnel safety applications. A sensor failure or malfunction can cause either an energized or de-energized sensor output condition. Consult your current Banner Safety Products catalog for safety products which meet OSHA, ANSI, and IEC standards for personnel protection.

1.1 Product Support

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Banner provides the following resources for quickly setting up and operating the sensor.
Documentation
Online Help
The PresencePLUS online help is available from the from the Help menu item within the PresencePLUS software. You can also get targeted help while on any system tab or dialog by pressing the <F1> key.
PDF Documentation
The PresencePLUS Sensor documentation is available in a convenient printable format (PDF) on the installation CD or on the Banner Web site
Banner Website
The most current PresencePLUS information, documentation, and software updates are available at the following Banner website page:
www.bannerengineering.com
Warranty Service
The PresencePLUS Vision Sensor is designed for reliability. Do not open the housing; it contains no field-replaceable components. If repair is necessary, do not attempt to repair the sensor yourself; return the unit to the factory. Should it become necessary to return a sensor to the factory, please do the following:
1. Contact the Banner Factory Application Engineering group at the address or numbers listed below. They will attempt to trouble shoot the system from your description of the problem. If they conclude that a component is defective, they will issue an RMA (Return Merchandise Authorization) number for your paperwork and give you the proper shipping address.
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2. Pack the sensor carefully. Damage which occurs during return shipping is not covered by warranty.
Factory Support
Call, e-mail, fax, or write your local Banner representative or a Banner Applications Engineer for support. Applications Engineers are available from 8:00 A.M. to 5:00 P.M. Central Time, Monday through Friday, excluding holidays.
Phone
Local: 763.544.3164
Toll Free: 1.888.3.SENSOR (1.888.373.6767)
763.544.3213Fax
sensors@bannerengineering.comE-mail
Address
To help Banner better assist you, be ready to provide the following information:
Banner Engineering Corp.
9714 10th Avenue North, Minneapolis, MN 55441 USA
• PresencePLUS software version (to find version number, click Help in the Main Menu toolbar and
choose About)
• Operating system of your PC
• Sensor Model Number and Date Code. Model Number is on top of Sensor, Date Code is either on
the bottom or the side
• Exact wording of any messages that appeared on your screen
• A description of what you were doing and what happened
• A description of how you tried to solve the problem

1.2 Maintenance

Maintenance tasks include keeping the hardware free of dust and dirt and possibly updating the PresencePLUS software as new versions become available.
Cleaning the Sensor
Regularly remove any dust or dirt from the Sensor using a soft cloth. If needed, slightly dampen the cloth with a weak solution of neutral detergent. Avoid getting dirt on the imager (the area behind the lens). If the imager is dirty, use anti-static compressed air to blow off the dust.
Cleaning the Lens
Regularly remove dust, dirt, or fingerprints from the lens. Use anti-static compressed air to blow off dust. If necessary, use a lens cloth and lens cleaner or window cleaner to wipe off remaining debris.
Do not use any other chemicals for cleaning.
Updating the PresencePLUS Software
The current version of PresencePLUS software is available for download from the Banner website. See Banner Website for the software downloads link.
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System Description

The PresencePLUS ProII and P4 sensor families are easy-to-use camera systems with advanced visual inspection capability. With minimal knowledge of vision systems, a user can quickly set up a PresencePLUS ProII or P4 and run an inspection that tests products accurately, rejecting bad products on a production line.
Inspections are set up using a personal computer (PC). A digital camera inside the Vision sensor captures images, and the sensor software analyzes the images using one or more Vision tools to pass or fail the product. The PC is not required for running inspections after the inspection files have been stored in the sensor’s memory.
Inspection setup involves focusing the camera and selecting the appropriate Location, Vision, and Analysis tools. The full range of inspection tolerances can be established either automatically or manually. The automatic Teach function eliminates the iterative process of determining correct tolerances.
The PresencePLUS ProII and P4 Sensor families accommodate both translational and rotational variation. Parts moving down a production line or web need not be oriented in exactly the same way.
The Sensor is easy to operate, with both basic and advanced options. New users can follow the guided Setup sequence. Advanced users can override automatic settings and create highly customized inspections.

2.1 P4 Vision Sensors

2.1.1 Typical P4 Vision Application

A typical PresencePLUS P4 application is shown below.
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In the application shown above, as each plastic formed part comes past the Vision sensor, an inspection is performed. If the part is not shaped correctly as shown here, the inspection fails.

2.1.2 PresencePLUS®P4 Components

The PresencePLUS P4 system consists of the Sensor and a PC with PresencePLUS software and the appropriate connections. The Sensor requires lighting and a trigger device, and an optional video monitor can be connected.
Note: The trigger device can be any 10-30V dc photoelectric sensor (PNP or NPN) or a device with a similar output.
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2.1.3 P4 Cable Connections

System Description7/2009
or Switch
STP07 — 2.1 m (7')
P/N 000000
Note: The sensor power must be 24V dc ± 10% if a light source is powered by the sensor.
Monitor Cable (to Video Monitor, optional)Crossover Ethernet Cable (to PC Ethernet Port)*
BNC06 —2 m (6')STPX07 — 2.1 m (7')
BNC15 — 5 m (15')STPX25 — 7.6 m (25')
BNC30 — 9 m (30')or
Serial Cable (to PC serial Port)*Standard Ethernet Cable (to PC via Network Hub
DB9P06 — 2 m (6')
DB9P15 — 5 m (15')
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STP25 — 7.6 m (25') DB9P30 — 9 m (30')
*The Sensor can be connected to the PC via a serial cable or an Ethernet network; Ethernet provides faster communication.
DirectionDescriptionWire ColorPin #
OutputRS-232 TX**Yellow1
InputRemote TeachGray2
InputProduct ChangeOrange3
InputExternal TriggerPink4
In/OutDiscrete I/O #1Black5
In/OutDiscrete I/O #2Red6
In/OutDiscrete I/O #3White7
In/OutDiscrete I/O #4Light Blue8
InputRS-232 RX**Violet9
OutputRS-232 Signal Ground**Green10
** These three wires make up the RS-232 serial connection.
Note: All unused inputs and outputs should be connected to ground if configured as PNP, and connected to +24V dc if configured as NPN. Serial input pins should be connected to ground.

2.2 Software Overview

The PresencePLUS application window is shown below.
InputCommon (Signal Ground)Blue11
Input10-30V dcBrown12
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2.2.1 Main Menu Toolbar

Use the Main Menu toolbar to navigate between the Sensor options. Proceeding from left to right, the buttons in the Main Menu toolbar step through the process of creating and controlling an inspection. Each button is explained in the illustration below and in the table that follows.
The following table describes the screen associated with each button in the Main Menu.
Inspection-Specific Screens
Setup
Tools
Teach
System
Set up the camera, lens, trigger, and lighting to acquire images. Create a reference image to be used later.
Add tools to an inspection. Build the inspection from scratch, or load tools from a previous inspection file saved on the controller or a PC.
Teach the Sensor good products. This screen automatically configures the parameters chosen in the Tools screen.
Choose which inspection file the Sensor will run, and view the results of the inspectionRun
System-Wide Screens
Set up the discrete inputs and outputs and communication configuration. This screen also has the Sensor diagnostic tools.
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Name the current inspection files and save them to the controller or a PC for future use.Save
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Inspection-Specific Screens
Call the Help window or the About window.Help

2.2.2 Image Window

The Image window, on the left side of the screen, displays images acquired from the camera or the reference image that is set for the current inspection. The toolbar buttons in the Image window are explained below.
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Note: The reference image is used as a template for developing an inspection; it establishes the initial values for the Vision tools. The reference image also is used by Quick Teach.
DescriptionIcon
Zoom -- toggles zoom control. When enabled, click on the image window to zoom
in and right-click to zoom out. This button is active when an image is displayed in the Image window.
Expand Image -- toggles the size of the Image window between maximum and minimum.
Selected ROI / ALL ROIs -- toggles between the currently S elected Region of Interest (ROI) and A ll ROIs.
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2.2.3 Navigation/Results Window

The Navigation/Results window, at the bottom of the screen, displays tool navigation buttons or inspection results files.
Navigation Buttons
Clicking on the Tools button in the Main Menu toolbar brings up the tool navigation buttons in the Navigation/Results window. When setting up or using tools, click on any tool navigation button to get the corresponding tab in the Configuration window.
Tool nameLOCATE_1 (or BLOB_1)
AbsoluteA
RelativeR
Tool typeLocate (or Blob)
Absolute and Relative Tools
An absolute tool’s Region of Interest (ROI) does not move in the image window. A relative tool shifts the ROI from the previous tool, relative to the position of the part.
The Location tools (for example, Locate) track parts in the Image window, and the Vision tools that follow (for example, Average Gray Scale and Blob Detect) are relative. A Vision tool that precedes all Location tools will be absolute. Rules governing whether a tool is absolute or relative are as follows:
• The first Location tool is always absolute.
• All tools following a Location tool are relative to that tool unless they are made absolute themselves, in which
case the chain is broken, and a new chain is started.
• For a Vision tool to be absolute, it must be placed before any Location tools.
Navigation/Results Toolbar Buttons
Using the Navigation/Results toolbar buttons, the Navigation/Results window size can be set, and tools can be deleted.
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DescriptionIcon
Expand Results -- toggles the size of the Navigation/Results window between
maximum and minimum.
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DescriptionIcon
Delete Selected Tool -- deletes the selected tool from the current inspection.
Delete Selected Tools -- deletes the selected tool and all the tools to the
right of the selected tool.
Copy Selected Tool -- clones the selected tool.
Expand Button
Clicking on the Expand button ( ) toggles the size of the Navigation/Results window to accommodate an expanded list of inspection results files, as shown below.
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2.2.4 Configuration Window

The Configuration window, on the right side of the screen, displays the currently selected options with multiple tabs. Clicking the Setup, Tools, Teach, Run, System, Save, or Help buttons on the Main Menu toolbar changes the contents of the Configuration window accordingly.

2.2.5 Status Window

The Status window, shown below, provides the following Sensor feedback.
The following table provides descriptions of each region in the Status window:
DescriptionRegion
Connection info -- current sensor to which the PC is
connected.
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DescriptionRegion
Image update completion -- progress bar shows
relative image update completion when an image is being transferred from the camera to the PC (this flickers, and is next to Connection: Sensor
192.168.0.1).
Current zoom value - works with the Zoom icon (magnifying glass).
Current grayscale value -- the 0-255 gray scale value of the pixel under the cursor.
Cursor position -- displays the x, y coordinates of the pixel under the cursor relative to the upper-left corner (origin, which is 0,0) of the field of view. Note that you must have the mouse pointer hovering over the image to get this information, otherwise, it displays
(-1,-1).
Current image display resolution -- displays the user-specified value, which can be from 1:1 to 64:1. Note that this does not affect how the sensor operates; it only affects sensor-to-GUI image communication speed, and is more useful when using Serial communication.
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Getting Started

This section begins with some Vision basics, then provides a brief overview of how to install the software, and the general steps to creating an inspection.

3.1 Installing the PresencePLUS Software

The PresencePLUS software CD includes the sensor software and this documentation.

3.1.1 Installing the Software

To install the PresencePLUS software:
1. Close all active programs.
2.
Make sure that no previous installations of PresencePLUS are installed.
3.
Insert the PresencePLUS CD into the CD ROM drive of the personal computer. If you have auto-start enabled, the CD should automatically start. If it doesn't start --
a. Double-click on the My Computer icon on the desktop. b. Double-click on the CD Drive in the list that appears. c. Double-click on the PresencePLUS autorun file.
4. When the Install screen appears, click PresencePLUS PC Software.
5. Follow the instructions on the screen.
6. When the installation completes, reboot the PC.

3.1.2 Starting Up the Software

1. Power up the PC.
2.
Install the software if it has not been installed. The installation screen of the PresencePLUS Pro software CD is shown below.
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Note: The following instructions assume you are installing the software on Windows XP.
3. If using an Ethernet communication cable, configure the IP address as follows:
a. Open Network Properties on the PC (right-click on the Network Neighborhood icon).
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b. On the Local Area Connection, right-click on Properties.
Getting Started7/2009
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Note: The PC in the example above has a second network card which is used to connect to the camera so it is using Local Area Connection 2.
c. In the dialog, click on Internet Protocol (TCP/IP) and click the Properties button.
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4. In the Internet Protocol (TCP/IP) Properties dialog, select Use the following IP address and make sure that the the IP address is 192.168.0.2, and the subnet mask is 255.255.255.0.
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5. Start the sofware.
6. Upon initial startup, the software communication is not configured, and the following error message is displayed.
7. Click Yes to open the Communication screen.
8. Establish communications as follows:
Ethernet Connection
1. When the software is started for the first time, the IP address is "Localhost." Choose Ethernet (RJ 45).
2. Change the IP address to 192.168.0.1 (default IP address of the sensor).
3. Click OK.
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3.2 Typical Setup and Startup Sequence

The following subsections proceed through a typical Sensor setup and startup sequence
1. Connect and power up the hardware.
2. Start up the software.
3. Set up hardware parameters.
4. Build and run an inspection.
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3.3 Startup and Troubleshooting

The following explains how to verify connections and start the PresencePLUS software.
1. Verify cable connections.
• The sensor is connected to a PC with an Ethernet crossover cable ofr a serial cable.
• The monitor, if used, is connected to the sensor's video port.
2. Thread the lens onto the sensor.
3. Verify electrical connections.
• +V is connected to Pin 12, brown were, 10-30V dc (24V dc ± 10% if a light is powered by the sensor).
• -V is connected to Pin 11, blue wire (dc common).
• The trigger device is connected to Pin 4 (pink wire, Trigger In).
• Any additional connections are made as required.
4. Verify power. Ensure that the sensor is powered by 10-30V dc (24V dc ± 10% if a light is powered by the sensor).
5. Verify PC configuration.
Ethernet connection: IP address of PC is 192.168.0.2.
Serial connection: A dial-up network has been established, and the network is a point-to-point
protocol (PPP).
6. Power up the hardware and verify that the Error LED turns off.
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During powerup, all the sensor LEDs illuminate for 15 to 20 seconds.
• After the Red Error LED turns OFF, verify that the Green power LED is flashing.
7. Launch the Software.
• Click Start > PresencePLUS to start the program.
• If the sensor has a different IP address than the default address (192.168.0.1), or if it is connected
through a serial connection, the following error message will display:
Sensor not found on specified IP address 192.168.0.1.
Do you want to try another IP address?
• Click Yes to access the System Setup window.
• Click on the Sensor select tab, and change the conection setup as follows:
Ethernet Connection --
1. Select Ethernet (RJ45) in the drop-down menu.
2. Change the IP address to the address of the sensor to which the PC is connected.
3. Click OK.
Serial Connection --
1. Select PC Serial in the drop-down menu.
2. Click OK.

3.3.1 General Troubleshooting

The following table describes solutions to the most common problems in using the PresencePLUS software. For further assistance, contact Banner Engineering.
Cause/SolutionProblem
• Green Power LED on sensor is not ON.
• Interface cannot connect to the sensor.
• No image on the monitor.
• No image on PC or monitor.
• Green Ready LED on sensor is OFF.
• The software seems to be working correctly, but the image is missing.
• Error message "Failed to capture a full-resolution image. Please try again."
• Image is frozen on the PC and monitor.
• Green Ready LED on sensor is OFF
Sensor not getting enough power.
• Check the connection to the power supply.
Run display set to "None"
• Ensure that the sensor is receiving trigger signals.
Sensor not receiving triggers
• If the connections are secure, call a Banner Applications Engineer.
Software restart needed or there are loose connections.
• Restart the PresencePLUS software.
• Check all connections.
• If a software restart does not correct the problem and the connections are secure, call a Banner Applications Engineer.
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Cause/SolutionProblem
• Error message "Failed to capture a full-resolution image. Please try again." • Reconnect the cable.
Image is frozen on PC, but image on monitor updates properly.Image is frozen on PC, but image on monitor updates properly.
• Indicator lights on RJ-45 port are OFF.
• Focus number does not update.
• QuickStart fails.
• Errors when saving inspections to the sensor.
Error code is displayed on PC.
Ethernet connection lost.
Check the cable for breaks, then power down and back up.
• Replace the cable.
• Attempt to close and reopen PresencePLUS software.
• If none of these actions fix the problem, call a Banner Applications Engineer.
FTP communications is blocked.
• Disable TCP/IP Firewall software on the PC.
A list of error codes and potential causes and solutions are available in the main help.

3.4 Setting Up Hardware Parameters

If the Sensor is being run for the first time, or if changes have been made to the hardware, then you may need to set or modify hardware parameters.
1. Click on System in the Main Menu toolbar.
2. Configure the Trigger parameter according to the trigger device being used. For example, if using the QS18V6ND as the trigger device, then select NPN.
3. Configure the six discrete inputs/outputs.
4. If the controller triggers a strobe light source, set the strobe trigger options.
5. If using the product select, configure the product select and product change lines to be NPN or PNP as required.
6. Click on Setup in the Main Menu toolbar, select Trigger tab, and configure the remaining parameters:
• Polarity
• Minimum Trigger Width
• Trigger delay
• Trigger Divide

3.5 Building an Inspection

The automatic screen sequence starts with the Setup screen, hich results from the first button (Setup) in the Main Menu toolbar. Subsequent screens are shown below in the Main Menu toolbar layout.
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1. Setup screen:
a. Set up the camera, lens, and lighting. b. Choose trigger option Continuous for a live image. c. Click Auto-exposure to adjust the image brightness. d. Focus the lens by turning the lens focusing ring until the focus value is maximized. e. When the desired image is shown, click Next to proceed to the Tools screen.
2. Tools screen:
Getting Started7/2009
a. Add Location tool(s) to find the target to adjust the Regions of Interest (ROI) for translational and rotational
changes. b. Required: Add Vision tool(s) to inspect the part. c. Add Measure tools(s) to create distance measurements from points found. d. Required: Add Test tool(s) to set the Pass/Fail criteria (Vision and Measure tools are inputs to the Test
tool). e. Click Quick Teach to automatically set all the selected parameters in the Test tool and to proceed to
the Run screen, or click Next to proceed to the Teach screen and to teach a sample set of good products.
Note: To keep specific, user-defined parameters in a Test tool, skip Teach and go directly to Run.
3. Teach screen:
The Teach screen automatically configures the parameters chosen in the Tools screen.
a. Chooose the sample size. b. Click Start. c. Trigger the controller with the external trigger device. d. Click Stop.
Note: Before entering Run, save inspection file to one of the memory locations on the controller.
e. Click Next to proceed to the Run screen.
4. Run screen:
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Note: Save a backup copy of the inspection to the host PC.
Select an inspection fo run, and review the results of the inspection.
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To select an inspection (in the Select tab), enable Software Override, and select the inspection file from
the list of stored inspections on the camera.
• An alternate method is to use Hardware input to select an inspection via discrete inputs to the controller.
5. Begin inspection:
To begin inspecting, click the Start button in the Run screen.
7/2009Getting Started
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Setup

4.1 Setup Screen

The Vision sensor has two modes: running and idle. If the sensor is idle when you start up the PresencePLUS software while your PC is connected, the software starts in the Setup screen. If the sensor is running, then the software starts in the Run screen.

4.2 Capturing a Reference Image

The reference image is used as a template for developing an inspection. The Vision tools use this image to acquire the critical information needed for the inspection.
Acquiring a quality image is crucial for a successful inspection. A quality image shows a measurable and repeatable difference between good products (which pass inspection) and bad products (which fail inspection). Most commonly, what determines the quality of the image is the illumination.
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4.3 Focus Tab

The Focus tab on the Setup screen is used to:
Reference Image Source4.3.1 Reference Image Source on page 30
Focus Value4.3.2 Focus Value on page 31
Auto Exposure4.3.3 Auto Exposure on page 31
Focus tab
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4.3.1 Reference Image Source

Before capturing an image, you need to determine what will trigger the Sensor to capture and image.
The Sensor can be triggered to capture an image in one of the following ways.
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DescriptionTrigger Option
The sensor will update continuously in Setup mode.Continuous
External
Manual
From Disk
Images are acquired only in reponse to a signal from an external source as configured on the Trigger tab. Choose External if the part will be moving during the inspection to capture an image with the same conditions as the inspection conditions.
Images are acquired only then the Trigger button is clicked. The Trigger button is grayed out when any trigger option other than Manual is selected.
If you check this option, the a Trigger button allows you to browse for an image to load from disk.
Note: The trigger options described above are used only in the Setup routine. Note, though, that Run mode does require an external trigger.

4.3.2 Focus Value

The Focus value on the Focus tab is a number between 1 and 255.
To focus the lens, place the target object so that the area to be focused appears on the center of the displayed image. You can use the image on the PC to determine when the image is sharp enough, or you can use this Focus value as a guide. Turn the focus ring on the lens until the Focus value is at the highest possible number between 1 and 255. Note there is no optimal value for this number, but it can be used as a guide if setting up more than one camera focused on the same target.

4.3.3 Auto Exposure

When you click Start in Auto Exposure, the exposure time and gain are optimized for the current inspection and the Status field provides feedback.
DescriptionField
The following are status possibilities:Status
Not running -- Auto exposure has not been activated since entering this screen.
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DescriptionField
Running -- Auto exposure is currently running.
Finished -- Auto exposure has run and is complete.
Image too dark -- Auto exposure could not brighten the image enough. Add more light to the inspection, or increase the exposure manually.
Image too bright -- Auto exposure could not darken the image enough. Remove light to the inspection, or decrease the exposure manually.
Exposure Time
Gain
Exposure time is the amount of time the camera allows light to energize the image chip. Increasing the exposure time (that is, moving the slider to the right) allows more light to energize the image chip, which brightens the image.
Gain is an electronic boost to the image signal. Increasing gain (that is, moving the slider to the right) increases image brightness without increasing exposure time.
Note: Gain brightens both the light pixels and dark pixels. High gain values will make the image appear grainy.

4.4 Trigger Tab

An external trigger is used to tell the Sensor when to capture an image. You can modify the validity and timing of the trigger by setting the parameters on the Trigger tab.
Note: Parameters set in the Trigger tab are stored in the inspection file and can be different for each inspection.
Trigger tab
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4.4.1 Trigger Settings

Trigger Divide (range: 1-10,000 triggers)
Trigger Delay (range: 0-8,000 ms)
Minimum Trigger Width (range: 1-8,000 ms)
Polarity
DescriptionField
Sets the sequence of valid triggers. If set to 1, an image is captured in response to every valid trigger; if set to 2, and image is captured in response to every second valid trigger, and so on.
Fixed time (ms) from the instant the Sensor receives a valid trigger to the instant the Sensor captures the image.
Eliminates unwanted triggers by accepting triggers only if they are above a specified duration.
Choose Leading Edge to capture images at the leading edge of a trigger signal. Choose Trailing Edge to capture images at the trailing edge of the trigger signal.
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7/2009Setup

4.4.2 Resolution

Increases or decreases the resolution on the displayed image. A lower resolution will have a faster PC update. The resolution does not change the inspection. Resolution options are 1:1, 4:1, 16:1, and 64:1.

4.5 Advanced Tab

The Advanced tab on the Setup screen allows you to adjust the field of view (FOV). The FOV is the image area at the focal plane of a camera.
You can use the maximum FOV or adjust the FOV to improve performance. The FOV dimensions are shown in the Advanced tab.
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Default Mode
Maximum and adjusted FOV
The FOV is denoted by the green box surrounding the image in the Setup screen. The maximum FOV is shown below.
The Default Mode determines whether to use the Current FOV or Maximum FOV by default.
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To improve performance, reduce the size of the FOV either vertically, horizontally, or both, as shown below.
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Tools Screen

5.1 Overview

Using the Tools screen, the user establishes the inspections that the Sensor will execute. Three sources of inspections are available:
1. Building an inspection from scratch is the typical method of establishing an inspection. The Tools screen is designed to aid the user in building an inspection. A typical inspection consists of Location Tools, followed by Vision Tools, Analysis Tools, and finally (if required) the Communication Tool. The Tools screen, shown below, supports this inspection organization.
2. Existing inspections can be obtained from the sensor (with or without the reference image) for execution or modification. This method is very useful if the user has an existing inspection on the controller and needs to make modifications to establish a new inspection.
3. Existing inspections also can be obtained from host resources using the Library. In this case, the sources of the inspections are the host’s hard drive or network resources. This method provides access to an unlimited number of existing inspections (with or without the reference image) for execution or modification.
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5.2 Typical Build/Modify Procedure

5.2.1 Choosing a Tool

To choose the right tools for an inspection, consider the tool's parameters and result options:
• Parameters are selected inputs for each tool (for example, relative threshold).
• Results are the information returned from the tool after it has executed.
Some tools perform evaluations, while others provide positional data for the tools that follow. Test tools evaluate, combine, or compare the results of other tools and determine a Pass-or-Fail judgment.
Note: Test tool must be chosen to evaluate the results of each tool or set of tools.

5.2.2 Adding a Tool

The following steps provide an overview for setting up tools in an inspection. Steps not available for some of the Location or Analysis tools are noted.
7/2009Tools Screen
1. Click the button of the tool to be added to the inspection.
2. Rename the tool.
3. Draw the ROI (not available for Analysis tools).
4. Set Input options to indicate the expected results (not available for the Test tool).
5. Add a Test tool.
6. Configure the Test tool inputs and, if desired, configure the desired results.
7. Set the judgment tolerances in one of three ways:
• Use Quick Teach.
• Use Teach.
• Manually set the judgment tolerances.

5.2.3 Adding a Test Tool

The following steps provide an overview for adding a Test tool to an inspection.
1. Add a Test tool.
2. Configure the Test tool inputs.
3. Set the judgment tolerances.

5.2.4 Renaming Tools

The default name of each tool can be edited or replaced (examples: GS_1, TT_2). Each name must be unique.
To edit the tool name, click on the Name field (double-click to select the entire name), and type to change or replace the name.
• Enter up to 49 characters; only alphanumeric characters and underscores are valid.
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• The button in the Navigation/Results window that appears will show the first nine characters after
exiting the tool.

5.2.5 Removing a Tool

To remove a tool:
1. Choose the tool to be removed in the Navigation/Results window.
2. Click the Delete button in the lower-left corner of the screen.

5.3 Quick Teach

Quick Teach provides the fastest and easiest method of establishing an inspection. Quick Teach will use the reference image to establish Pass/Fail parameters of the Test tools.
Quick Teach does the following:
• Executes the inspection on the reference image.
• “Learns” the results of the Vision tools.
• Applies the applicable tolerances (user-determined, but default is 10%) to the selected parameters
in the Test tool (these parameters determine the Pass/Fail criteria for each Test tool within the inspection).
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Note: Quick Teach discards any manually-entered values in the Test tool. Manually-entered values must be entered after Quick Teach has been performed, or they will be lost.
Click Quick Teach to:
• Run all the tools.
• Calculate the measurements.
• Add a percentage of tolerance around taught values.
• Save the inspection to the controller.
• Go to Run.

5.4 Load Tab

The Load provides a way to load a saved inspection and a reference image.
Load Tab
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5.4.1 Flexible Inspection Loading

Release 2009R1B introduces a more flexible inspection loading capability that allows most inspections created by any PresencePLUS vision sensor to be loaded through the PresencePLUS software even if connected to a different type of PresencePLUS vision sensor. This means that you can now load, for example, an inspection created by an OMNI 1.3 into PresencePLUS software connected to a standard OMNI. Prior to Release 2009R1B, inspections could only be loaded into PresencePLUS software that was connected to the same type of PresencePLUS vision sensor that had created the inspection. In other words, a ProII camera could only load inspections created by another ProII camera, and an OMNI could only load an inspection saved from another OMNI, etc.
Note: The one limitation that still exists occurs when trying to load an inspection that uses a tool that is unavailable (or unlicensed) for the currently connected sensor (for example, attempting to load to an inspection that uses a Geometric Count tool to a PresencePLUS AREA sensor will not work because the Geometric Count tool is not supported on the AREA sensor).
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Inspection Source
Color sensor (for example, a Color OMNI)
Grayscale sensor (for example, a standard OMNI)
High Resolution (1.3) sensor (for example, an AREA 1.3 sensor
Destination
Standard grayscale sensor (for example, a standard OMNI)
Color sensor (for example, a Color OMNI)
Standard VGA sensor (for example, a standard AREA sensor)
ResultInspection
image color has changed and the inspection loads
image color has changed and the inspection loads
A dialog indicates that the image/FOV has been adjusted and the image loads the image into the upper-left of the FOV.
) Note that the image may be
cropped at the right and/or bottom and ROIs may be outside the image area
Standard VGA sensor (for example, a standard AREA
High Resolution (1.3) sensor (for example, an AREA 1.3 sensor)
A dialog indicates that the FOV has been adjusted and the inspection loads with the image centered in the FOV
sensor)
Sensor with 6 I/O (for example, a
Sensor with 4 I/O (for example, an OMNI)
inspection uses I/Os not
ProII) available on the sensor and
the inspection loads
Possible Inspection Modifications
None requiredA dialog indicates that the
None requiredA dialog indicates that the
Reposition image, adjust ROIs and tools in the FOV, and possibly acquire a new reference image
Possibly acquire a new reference image
Adjust I/O as appropriateA dialog indicates that the
Sensor that supports a larger maximum trigger delay, trigger width, NTSC fail/hold time, or exposure time (for example, a ProII maximum
Sensor that supports a smaller maximum trigger delay, trigger width, NTSC fail/hold time, or exposure time (for example, a standard OMNI maximum trigger delay set to 8000 ms)
A dialog indicates that the timing was adjusted and the inspection loads with the timing(s) adjusted to the maximum time allowed on that sensor
Retest and modify timings as appropriate, and possibly acquire a new reference image
trigger delay set to 10000 ms)

5.4.2 Inspection Storage Capacity

The INS file format allows for the storage of inspection files onboard every sensor. The table below shows the storage capacity for the various Vision sensors. Stored inspections can be modified, run, or deleted on the sensor.
Number of INS FilesINS Storage MemorySensor Type
Number of INS files without Reference Images*
99918864MBPro II
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7/2009Tools Screen
Number of INS FilesINS Storage MemorySensor Type
*Not saving a reference image with the inspection frees up a lot of room onboard the sensor. However, inspections that include any of the following tools require a reference image to be saved:
Number of INS files without Reference Images*
99916064MBPro II Color
500+1508MBArea/GEO/Edge
9998532MBOMNI
9997232MBOMNI Color
9994464MBPro II 1.3
9994464MBOMNI 1.3
400+8BCR
9992032GEO/Edge/Area/BCR 1.3
• Geometric Find
• Geometric Count
• Pattern Find
• Pattern Count
• Color Match
• Color BLOB

5.4.3 Opening an Inspection from the Sensor or a Library

Inspections can be stored on the sensor or to a libary of inspections stored on a PC or network drive. To select and open an inspection from the sensor or a library:
1. Click the Load tab.
2. From the Load from drop-down list, select the Sensor or a location on a PC or Network.
3. Select the desired inspection.
4. Click the Load button.
The tools from the selected inspection populate the Navigation/Results window. At this point, all tools in the inspection can be modified. If new tools are to be added, simply select the tool in the Tool screen. If tools are to be deleted, select the tool and click the Delete icon.
Note: If you want to see the the image stored with the inspection, check the Load reference image box.
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6

System Setup Window Overview

To access the System Setup window, click the System button in the Main Menu toolbar on the applcation window.
To clear changes, click Cancel. To save changes and exit the System Setup window, click OK.
To exit the System Setup window without changes, click the X in the upper-right corner of the window.
Note: To make changes to the sensor selections, an inspection must not be running. To stop a running inspection, click the Stop button in the Run tab. To save changes, click OK before exiting the tab or closing the window.
The System Setup Window includes the following tabs:
Sensor Select Tab6.1 Sensor Select Tab on page 46
Communication Tab6.2 Communication Tab on page 51
Input/Output Tab
Strobe Tab6.4 Strobe Tab on page 84
Units Tab6.5 Units Tab on page 85
Reset Tab6.6 Reset Tab on page 86
Start-Up Inspection Tab6.7 Start-Up Inspection Tab on page 87
NTSC Tab6.8 NTSC Tab on page 89
Language Tab6.9 Language Tab on page 90
Tools Configuration6.10 Tools Configuration on page 91
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System Setup Window
P4 System Setup Window
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6.1 Sensor Select Tab

Use the Sensor Select tab to establish the Sensor connection with the PC.
Note: An option box to open the Sensor Select tab is automatically displayed if the Sensor either is not connected or is connected but with the wrong IP Address selected.
Sensor Neighborhood Fields
The Sensor Neighborhood will list sensors in your environment. The following describes the fields in the Sensor Neighborhood.
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DescriptionField
Available
If the Icon is green (Yes), the sensor is available; if yellow, a connection can't be established for some reason; if red (No), the sensor is not available.
Note: The sensor to which you are currently connected will sho up as unavailable (red icon).
The name of the sensor.Name
The IP address assigned to the sensor.IP Address
The sensor model and type.Product ID
The sensor version.Sensor Version
Indicates whether the sensor is running or not.Running
Inspection
Indicates whether there is an error condition associated with the sensor.Error
The MAC address of the sensor.MAC
PC (GUI) to Sensor Connection Setup
This selection is used to configure the communication link between the GUI (Graphical User Interface) and the sensor. There are two possible selections, Ethernet (RJ45) and Serial:
Ethernet (RJ45)
This selection will configure the GUI to communicate with the sensor using the Ethernet (RJ45) connection. To establish communication you must enter the IP address of the sensor you would like to communicate with into the "Connection IP Address" edit box or select the desired Sensor from the Sensor Neighborhood results. Then, click on the "OK" button to connect.
Serial
This selection will configure the GUI to communicate with a sensor via the Serial connection. To establish communication you must first start Dial-Up Networking (DUN) on the PC. Then, click on the "OK" button to connect.
Sensor Select Tab
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6.1.1 Change Sensor IP Address

To change a sensor's IP address:
1. Select the sensor in the Sensor Neighborhood
2. Click the Change Sensor IP Address button.
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3. Click Next
4. Enter an appropriate sensor name in the New Sensor Name field.
5. Click Finish.

6.1.2 PC (GUI) to Sensor Connection Setup

Use this field to select whether the Sensor will communicate via the Ethernet port or a serial connection.
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• If you select Ethernet (RJ 45), the Connection IP Address shows the IP address for which the
software is looking. Initially, the IP address should be 192.168.0.1, the default IP address of the sensor.
• If you select Serial, the IP address is not applicable.

6.1.3 IP Address History

Use this button to view previous IP Addresses and Subnet Masks.
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6.2 Communication Tab

The Communication tab is used to configure:
• General Communication Setup
• Remote Command Configuration (RCC)
Communication Tab
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6.2.1 Communication Setup

Banner Vision sensors support the following communication options:
• Ethernet Sockets 1-10
• Serial 1
• Industrial Ethernet
Ethernet Connection
In order to establish an Ethernet connection , the external device must be directed to the correct IP address and the correct TCP port. In TCP/IP protocol, a TCP port number is used with the IP address to identify a specific path or socket. The sensor has sockets 1 to 10, and can send out unique sets of data to 10 different devices.
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Valid user TCP/IP port numbers are in the range of 1024 through 65535. The PresencePLUS GUI provides automatic notification if you attempt to use a reserved port.
To view an Ethernet connection:
1. Click on the System button in the Main Menu toolbar to bring up the System Setup window.
2. Click on the Communication tab.
3. Choose a connection from the fixed Connection drop-down list of the Communication Tool Setup field.
Each Ethernet socket has a unique TCP port number as shown below
Note: The following addresses are defaults.
PortDefault IP AddressSocket
20000192.168.0.11
20001192.168.0.12
20002192.168.0.13
20003192.168.0.14
20004192.168.0.15
20005192.168.0.16
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PortDefault IP AddressSocket
20006192.168.0.17
20007192.168.0.18
20008192.168.0.19
20009192.168.0.110
Serial Connection
The sensor has a single serial connection that you can configure, Serial 1:
• Serial 1 is the DB-9 connector.
Note: The Pro has 2 serial connections. Serial 2 in the dropdown list is to support those sensors.
The sensor has one serial connection that can be configured: Serial 1 is pins 1, 9, and 10. Set up the serial communication options to match the receiving device. The following table shows the configuration options:
Default SettingAttribute
115200Baud Rate
8Data Bits
NoneParity
1Stop Bit
NoneFlow Control
To setup a serial connection:
1. Click on the System button in the Main Menu toolbar to bring up the System Setup window.
2. Click on the Communication tab.
3. Choose Serial 1 from the Connection drop-down list of the Communication Tool Setup field.
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Note:
Because there is no flow control for the serial connections, the sensor wil not detect or log a lost or broken connection
Industrial Ethernet
Protocol
Protocol selects which Industrial Ethernet protocol is being used. This changes the string format and the word/register values reported in the PLC Map.
32 bit Format
32 bit Format determines how 32 bit integers and floating point values are stored in sequential 16 bit registers (words) - least significant word first (LSW-MSW) or most significant word first (MSW-LSW).
Character String Order
For Modbus/TCP and PCCC protocols, characters in the string can be packed into registers according to either the Standard String format or the ControlLogix Format1:
• Standard String Format is used when the Character String Order option is set to “High Byte – Low
Byte” selection.
Please note that the length of the string is stored in one 16-bit register:
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• ControlLogix packing format is used to store characters into registers when the Character String
Order option is set to “Low Byte – High Byte” selection.
Please note that in this particular case, the length of the string is still stored in one 16-bit register, and only the order of characters in each 16-bit register follows the ControlLogix format:

6.2.2 Remote Command Channel Configuration

This section describes the commands that are supported to communicate with a Vision sensor. All commands are case-insensitive
Remote Command Set
All RCC commands are case-insensitive. Valid characters for commands are 7-bit ASCII alphabetic or numeric characters (A-Z, a-z, 0-9), dash (-) and underscore (_).
All commands have the following structure:
ACTiON OBJECT_IDENTIFIER QUALIFIER(S)
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ACTION is an operation the user intends to perform on the OBJECT_IDENTIFIER. There are three possible actions available:
• GET — used to retrieve information associated with the named object. This information can be a
Boolean value, and unsigned or signed number, a string or, for complex objects like the Communications tool, a field-delimited record that includes other data types.
• SET — used to assign a value to a named object.
• EXEC — used to execute a pre-defined functional object or activity in the sensor. Activities may
take object identifiers as parameter qualifiers.
The table below identifies objects that are supported in the current RCC release, their identifiers, and the corresponding actions that they will support. Items highlighted in bold are command keywords. Flag objects are appended with the FLG suffix, status objects are appended with the STS suffix, and counters are appended with the CNT suffix.
System Object, Component, or Activity
Change
Flag Reset
Object or Activity Identifier
Support Actions
EXECPRODCHANGEProduct
EXECRESETCounter or
Required Qualifiers
NoneEXECTRIGGERTrigger
Numeric Inspection ID
or
PASSFAILCNT
or
MISSTRIGCNT
Qualifiers
Timeout (msec)
or
NOWAIT
Timeout (msec)
or
NOWAIT
NoneSYSERRFLG
CommentsOptional
If no qualifiers are specified, a 30 second timeout is used.
By default, a 30 second timeout is used.
Reset either the System Error Flag, Pass and Fail counters, or Missing Trigger count.
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NoneEXECRTEACHRemote Teach
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TRIGGER or TRIGGER
Enables remote teach. If no qualifiers areNOWAIT or specified,TRIGGER remote teachTimeout
(msec) will occur on the
next trigger. If TRIGGER qualifier is specified, remote teach will occur
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System Object, Component, or Activity
Object or Activity Identifier
Support Actions
Required Qualifiers
CommentsOptional
Qualifiers
immediately, and the command will block until a default 30-second timeout expires. If TRIGGER NOWAIT is specified, remote teach will occur immediately, and the command will return right away. If a timeout value is specified, the command will block until the specified timeout expires.
NoneNoneGETONLINESTSOnline Status
Retrieve the sensor online status.
NoneNoneGETREADYFLGReady State
Returns 1 if the camera is ready, 0 otherwise
NoneNoneGETINSPNUMCurrent
Inspection
Retrieve currently
Number running
inspection
Retrieve comm tool results, either by specifying its
Tool Results
NoneGETCOMMTOOLCommunications
CommTool Numberor CommTool Name
sequential number in the inspection
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System Object, Component, or Activity
Object or Activity Identifier
Support Actions
Required Qualifiers
Qualifiers
NoneNoneGETPASSFAILFLGPass/Fail flag
NoneNoneGETSYSERRFLGSystem Error
NoneNoneGETFRAMENUMFrame Number
CommentsOptional
(1,2,..,n) or by specifying its name. By default, data for the first comm tool will be retrieved.
Retrieve the value of the Pass/Fail flag ­1 if pass, 0 if fail
Retrieve the value of the System Error ­either 0 or 1
Retrieve the current frame number
Count
Count
NoneNoneGETPASSCNTPass Count
Retrieve the pass count
NoneNoneGETFAILCNTFail Count
Retreive the failed count
NoneNoneGETITERCNTIteration Count
Retrieve the Iteration Count
NoneNoneGETSYSERRCNTSystem Error
Retrieve the system error count
NoneNoneGETMISSTRIGCNTMissed Trigger
Retrieve the missed trigger count
GETIOSTSI/O Line Status
NoneI/O line id, numeric, either 1 through 4 or 1
Retrieve the cached status of the I/O line
through 6
NoneGETGAINGain
Retrieve the gain
Set the gainNonePositive IntegerSETGAINGain
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System Object, Component, or Activity
Tag
Tag
Tag
Object or Activity Identifier
Support Actions
Required Qualifiers
Qualifiers
NoneGETEXPOSUREExposure
NonePositive NumberSETEXPOSUREExposure
NoneENABLESETFRAMETAGFrame Number
NoneDISABLESETFRAMETAGFrame Number
NoneNoneGETFRAMETAGFrame Number
CommentsOptional
Retrieve the camera exposure
Get the camera exposure
Enables frame number as command acceptance indicator
Disables frame number as command acceptance indicator
Retrieve the status of the frame tag indicator
Coordinate tool
Commands
set coordtool tool_name|tool_number x\y|angle
get coordtool tool_name|tool_number x\y|angle
Math tool and the Remote Command Channel
Commands
set mathtool tool_name|tool_number operand_1|operand_2
get mathtool tool_name|tool_number operand_1|operand_2
String tool
Commands
DescriptionSyntax
Returns the specified Coordinate tool output.
Gets the value
DescriptionSyntax
Sets the specified tool operand, if it is a constant. Value should be a floating number.
Gets the value of the specified tool operand, if it is a constant.
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DescriptionSyntax
set stringtool tool_name|tool_number operand_1|operand_2
get stringtool tool_name|tool_number operand_1|operand_2
OCV Tool and the Remote Command Channel
Commands
set ocvtool tool_name|tool_number exp_string value|
get ocvtool tool_name|tool_number exp_string
RCC Return Values
RCC return values are numeric, and are listed below:
Sets the specified tool operand, if it is a constant. Value should be a quoted string (see
Character Strings 6.2.2.6.1 Character Strings
on page 196).
Gets the value of the specified tool operand, if it is a constant.
DescriptionSyntax
Sets the expected string, if it is a constant. The Value should be a quoted string containing printable ASCII characters (see Character
Strings 6.2.2.6.1 Character Strings on page
196).
Gets the value of the exptected string.
• 0 - command accepted. This return code is generated when a valid SET, GET, and EXEC command has been completely handled by the sensor. It may be followed by a command-specific return value or a completion code.
If the frame tag is enabled, the current frame number will be returned instead of 0 as command acceptance indicator.
• -100 - Invalid command entered by the user.
• Trigger and Product Change error codes:
• -201 - Product change command attempted in the middle of the inspection
• -202 – Trigger command attempted in the middle of product change
• -203 – Trigger command is attempted when the inspection is not executing (sensor is idle)
• -204 – Specified inspection slot is out of range
• -205 – Trigger command attempted in the middle of the inspection
• -206 – Product change command attempted in the middle of a product change
• -207 – Product change command attempted while the sensor is in the Teach mode
• -208 – Product change attempted when the GUI is connected, and the inspection is not executing
• Comm tool error codes
• -301 – get/set tool command attempted while the inspection is not executing
• -302 – get command issued before inspection is triggered for the first time – tool results unavailable
• -303 – get/set tool command attempted in the middle of the inspection
• -304 – get/set tool command attempted in the middle of the product change
• -305 – Tool specified in get/set command not found in the inspection
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• -306 – Requested comm tool is not configured for RCC
• -307 - Tool executed with an error or did not execute
• -308 - Specified tool operand is not a constant, and cannot be modified
• Reset command error codes
• -401 – Reset command attempted in the middle of the inspection
• -402 – Reset command attempted in the middle of the product change
• -500 – RCC commands are not accepted because the sensor is in the Playback mode
• Timeout error codes
• -600 – Product change timeout occurred
• -601 – Trigger timeout occurred
• -700 – Specified value is out of range
• -701 – Set Gain command attempted when the GUI is connected and the inspection is not executing
• -702 – Set Exposure command attempted when the GUI is connected and the inspection is not executing
• -800 – Product Change, Trigger or Get Commtool command attempted when either Product Change or Trigger Command timeout occurred, but the operation has not yet completed.
Frame Tag Numbers
RCC provides user with a debug facility that allows users to correlate command completion with current frame numbers. This facility is enabled by issuing a SET FRAMETAG ENABLE command. This command will cause RCC to send the current frame number as the command acceptance code. This will allow users to track when each command was issued, and which frame it applies to.
For EXEC TRIGGER command, returned number will be the frame number at the completion of the inspection execution.
For EXEC TRIGGER command, returned number will be the frame number at the completion of the inspection execution.
For all other commands, the returned number is the current frame number.
Command Processing
RCC commands are interpreted in the context of the running PPVS system. Due to the constantly changing system state caused either by external action or by previous RCC commands, certain rules are imposed on RCC command acceptance and processing. Please note that command acceptance does not constitute successful completion of the command.
1. EXEC TRIGGER command can be successfully accepted under the following conditions:
• Inspection is Executing and is Ready
2. EXEC PRODCHANGE command can be successfully accepted under the following conditions:
• Sensor is idle (inspection is not loaded), and the GUI is not connected
• Inspection is Executing and is Ready
• Sensor was previously product changed to an invalid slot
3. EXEC RESET command can be successfully accepted under the following conditions:
• Sensor is idle (inspection is not loaded)
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• Inspection is Executing and is Ready
4. SET GAIN or SET EXPOSURE commands can be successfully accepted under the following
conditions:
• Inspection is Executing and is Ready
5. GET status, counter or flag commands can be accepted at any time. If issued when inspection is
Executing but is not Ready, these values may change as the inspection is executing.
6. GET COMMTOOL command can be successfully accepted if the inspection has been loaded.
However, RCC may not have valid data until the inspection has been triggered (executed) at least once.
Commands with timeouts, such as EXEC TRIGGER and EXEC PRODCHANGE, will block processing of additional commands while they are executing if they are invoked without the NOWAIT option. Additional commands that are issued while processing is blocked will be queued, and will be processed in the order that they were received when the blocking command finishes its execution.
When blocking commands, such as EXEC TRIGGER and EXEC PRODCHANGE, are invoked with the NOWAIT option, GET commands that retrieve flags and status are accepted for processing. All other commands are rejected with an appropriate error code.
RCC Log
RCC Log allows users to monitor and troubleshoot communication inputs and outputs.
Log consists of a circular buffer with up to 400 entries. These entries can be one of three types:
• IN – characters received in the input stream
CMD – commands that were extracted after the frame start and frame end delimiters have been received
• OUT – formatted command output, with frame delimiters already included.
Log entries are time stamped with system time and sorted in the order they were received.
Non-displayable ASCII characters are shown in the ASCII Hex string form. The ASCII Hex strings are preceded by character sequence “\x” (backslash-lower-case-x). The ASCII Hex string will always be two characters long. For example, NULL will be converted to “\x00”, and carriage return will be converted to “\x0D”. To represent ASCII Hex digits, only upper case letters, A-F, are used.
Sample RCC log is given below:
0000000118.116 IN e
0000000118.116 IN x
0000000118.116 IN e
0000000118.116 IN c
0000000118.116 IN
0000000118.116 IN t
0000000118.116 IN r
0000000118.116 IN i
0000000118.116 IN g
0000000118.116 IN g
0000000118.116 IN e
0000000118.116 IN r
0000000118.116 IN \x0D
0000000118.116 IN \x0A
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0000000118.116 CMD exec trigger
0000000118.483 OUT 0\x0D\x0A
In this example, command exec trigger was sent to RCC interface. The interface was configured to use no start frame delimiter, and carriage return (\x0D) and line feed (\x0A) as frame delimiters. As soon as valid frame delimiters were received, the command exec trigger was sent for processing, and the command response was sent back after inspection finished executing.
Frame and Field Delimiters
The PresencePLUS GUI includes a drop-down list of Frame delimiters as follows:
<none> for no delimiter
\r for carriage return (<CR>)
\n for line feed (LF)
\r\n for carriage return followed by a line feed (CR-LF)
\n\r for line feed followed by a carriage return (LF-CR)
In addition to the above field delimiters, you can enter other delimiter types keeping in mind the following:
• ASCII hex format can be used as a delimiter
• a NULL character can be used as a delimiter (specified in ASCII hex format)
• Frame delimiters can be multi-character sequences up to 20 characters long
The PresencePLUS GUI includes a drop-down list of Field delimiters as follows:
<none> for no delimiter
• , for comma
• ; for semi-colon
• : for colon
<SPC> for space
\t for tab
In addition to the above field delimiters, you can enter other delimiter types keeping in mind the following:
• ASCII hex format can be used as a delimiter
• a NULL character can be used as a delimiter (specified in ASCII hex format)
• Field delimiters can be multi-character sequences up to 10 characters long
Character Strings
Communications Tool configured for Barcode or String Tool output may produce strings that contain non-printable ASCII characters, such as carriage returns, line feeds, and characters in the upper ASCII range.
To output these strings, the following encoding rules are used:
• Tool output strings will be enclosed in double quote characters, “.
• Any non-printable ASCII character, including NULL, will be converted to its ASCII Hex equivalent. The ASCII Hex string will be preceded by character sequence “\x” (backslash-lower-case-x). The ASCII Hex string will always be two characters long. For example, NULL will be converted to “\x00”, and carriage return will be converted to “\x0D”. To represent ASCII Hex digits, only upper case letters, A-F, will be used.
• Any backslash encountered in the Barcode or String Tool data will be converted to its ASCII Hex equivalent, “\x5C”.
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• Any double quote encountered in the Barcode or String Tool will be converted to its ASCII Hex equivalent, “\x22”.
For RCC input strings, the formatting rules are expanded to accommodate readability as follows:
• Carriage return can be specified as character sequence "\r" (backslash-r).
• Line feed can be specified as character sequence "\n" (backslash-n).
• Double quote can be specified as character sequence "\"" (backslash-doublequote).
• Backslah can be specified as character sequence "\\" (backslash-backslash).
• tab can be specified as character sequence "\t" (backslash-t).
• Embedded NULLL characters are not allowed.

6.2.3 PresencePLUS/Kawasaki Vision Guidance and Inspection

Integrating Banner Vision Sensors with Kawasaki Robot Controllers
Quick Start
This document describes how to integrate a Banner PresencePLUS sensor with Kawasaki Robot Controllers, and:
includes instructions for establishing communications between the PresencePLUS sensor and a Kawasaki Robot Controller
describes how to set up a sample PresencePLUS vision inspection
• provides a sample Kawasaki AS Language program
Below is a quick overview of the procedure for integrating PresencePLUS sensors with Kawasaki Robot Controllers and, where noted, more details are provided in the document subsections.
Tasks to CompleteMain Steps
Establish communication between the PresencePLUS sensor and the Kawasaki Robot Controller. See
Establishing Sensor/Robot Communication 6.2.3.3 Establishing Sensor/Robot
1.
Install and physically connect a Banner PresencePLUS Vision Sensor to a Kawasaki controller.
2.
Configure PresencePLUS and Kawasaki controller IP addresses.
3.
Configure the PresencePLUS Remote Command Channel.
Communication on page 67
Create and save a PresencePLUS Inspection. See Creating the
PresencePLUS Inspection 6.2.3.4 Creating the PresencePLUS Inspection on page 69 for more
details.
1. Create a new inspection and configure Vision tools to produce the desired part location data that outputs it to the RCC interface. The sample inspection described in this document:
• Locates a part
• Tests for presence of the part
• Outputs X, Y, and Rotation about the Z-axis offsets
2. Save and then start the inspection.
Program the Kawasaki controller to connect and issue commands to the PresencePLUS sensor . A
sample AS program is provided to
get you started.
1. Load the sample AS Language program onto robot controller.
The sample program implements the following actions:
• Connects to the RCC.
• Triggers vision sensor and wait for inspection to complete.
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Tasks to CompleteMain Steps
• Determines pass/fail condition of the inspection.
• Gets the X, Y, and Rotation about Z-axis offsets.
• Closes the connection to the RCC.
2. Run program.
Note: The IP address and port number within the sample AS Language program must be modified to match the IP address and port number of the PresencePLUS sensor.
Overview
The PresencePLUS ProII and P4 sensor families are cost-effective, easy-to-use camera systems with advanced visual inspection capability. Where other vision systems can be difficult to configure, the PresencePLUS software is straight-forward. This enables users with minimal experience with vision systems to quickly set an inspection that inspects and accurately determines product position, and to integrate the PresencePLUS system into their environment.
To facilitate the implementation of Presence PLUS Vision Sensors with robots to provide vision guidance and/or product quality tests on a production line, Presence PLUS supports a user-configurable, ASCII-based, TCP /IP communications interface called the Remote Command Channel. The RCC supports a Kawasaki protocol specifically designed to communicate with Kawasaki C/D/D+ robot controllers.
Summary of Remote Command Channel Features
The RCC within the Banner PresencePLUS Sensor is configured as a Server device. This means that it does not initiate connections on its own, but instead waits for a client (robot controller) to connect to it. The PresencePLUS Remote Command Channel (RCC) supports the following features:
• Triggering the sensor and performing product changes
• Checking sensor status, such as pass, fail, and I/O line state
• Retrieving tool results, and sensor counters including pass/fail
• User-defined frame (command) delimiters and output field separators
• Logging input and output data to assist with RCC/MMI debugging
Prerequisites Kawasaki Robot
This procedure assumes that you are using an Ethernet-enabled Kawasaki robot controller configuration such as:
• Kawasaki C Series Controller with a 1HA Ethernet board option
• Kawasaki D Series Controller with a 1KN or 1QN Ethernet board option
• Kawasaki D+ Series Controller with an integrated 1RA Ethernet board
Related Documentation
For more information relating to Banner's Vision Sensors and Kawasaki Robot Controllers, refer to the following sources:
• Kawasaki Robot TCP/IP Function Instruction Manual
• Kawasaki D Series Controller AS Language Reference Manual
PresencePLUS electronic Help
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Establishing Sensor/Robot Communication
Main Tasks to CompleteStep 1
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Install and connect a PresencePLUS Vision Sensor
Configure PresencePLUS Ethernet ports: The
PresencePLUS Sensor supports user-assignable TCP /IP ports. This assignment is
1.
Install Banner PresencePLUS Vision Sensor version 2009R1B or later.
2. Connect the Vision Sensor using one of the following approaches:
• connect to an existing Ethernet network via a switch or hub using a straight-through Ethernet cable with RJ45 connectors
• connect directly to the Kawasaki controller using a cross-over Ethernet cable with RJ45 connectors.
3.
Configure both the PresencePLUS sensor and the Kawasaki controller with static IP addresses.
Main Tasks to CompleteStep 2
1. Start the PresencePLUS software.
2. Connect to the sensor.
3.
Click on the System button in the upper right corner of the PresencePLUS GUI to display the System Setup screen.
4. Click on the Communication tab to display the Communication configuration dialog.
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performed from the System Setup Dialog, Communications tab
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Main Tasks to CompleteStep 2
The default Ethernet port assignments are from 20000 to 20009.
Note: Valid user TCP/IP port numbers for PresencePLUS sensors are in the range of 1024 through 65535. The PresencePLUS GUI will provide automatic notification if an attempt to use a reserved port is made. Any changes to the port assignment must be reflected in the AS Language program included in this document .
Main Tasks to CompleteStep 3
Configure the PresencePLUS Remote Command Channel (RCC)
1. Click on the RCC Protocol drop-down menu, and select "Kawasaki" from the menu. The default protocol configuration for Kawasaki robot is displayed.
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Main Tasks to CompleteStep 3
2. Click the OK button to accept the configuration.
Kawasaki Protocol Defaults
The default Kawasaki protocol configuration parameters are:
• Ethernet Socket 1 configured for TCP/IP Port 20000 as the communications channel
• No Frame Start (Command Start) delimiter
• Carriage Return/Line Feed as Frame End (Command End) delimiter
• Space as the input command field separator
• Comma as the output field separator.
Note: You can adjust each of these parameters as necessary, but corresponding adjustments will have to be made to the sample AS Language program provided to enable successful communication.
Creating the PresencePLUS Inspection
Enable the Coordinate Tool in
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Main Tasks to CompleteStep 1
1.
Click the System button in the upper-right corner of the PresencePLUS GUI.
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Main Tasks to CompleteStep 1
the Tool Configuration dialog.
2. Select the Tools Configuration tab.
3. Scroll down to the Coordinate Tool, and then select the checkbox next to it, as shown below.
4. Click the OK button to close the Tool Configuration dialog.
Create a New Inspection using
Setup.
Add a Geometric Find tool to locate
Main Tasks to CompleteStep 2
1.
In the PresencePLUS GUI, create a new inspection by pressing the Setup button in the upper-left corner of the GUI.
2. Capture an image of the part to locate.
3. Press the Goto Tools button in the lower-right corner of the Setup tab.
Main Tasks to CompleteStep 3
1.
In the PresencePLUS GUI, click the Location Tools tab.
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the part within the field-of-view.
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Main Tasks to CompleteStep 3
2. Click the Geomtric Find button.
3. Draw the tool ROI (Region of Interest) to select the image feature of interest as shown below.
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4. Click the Apply button to accept the ROI.
5. Click the Next button to return to the Tools menu.
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Main Tasks to CompleteStep 4
Add a Coordinate tool to provide
locational data for the Robot.
1.
In the PresencePLUS GUI, click the Analysis Tools tab.
2. Click the Coordinate tool button to create a Coordinate tool.
3. Select Offset Only from the Tool List Filter drop-down menu.
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4. Click the Next button to return to the Tools menu.
Note: The X, Y and Rotation selections will default to GF_1.
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Main Tasks to CompleteStep 5
Add a Test tool to
receive a positive confirmation that the inspection ran successfully; that is, the part was found.
1.
In the PresencePLUS GUI, click the Analysis Tools tab.
2. Click the Test tool button.
3. Select Coordinate Tool (COORD_1) from the Input 1 drop-down list.
4. Click on the Coordinate Tool (COORD_1) tab and make sure that the checkmark next to the X-Coordinate value checked. Enter 0 (zero) in the Min column and a large number (e.g., 1000) in the Max column.
Note: These settings will cause the Test tool to pass all resulting X values, but fail if the X value is invalid (that is, if the part is not found).
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5. Uncheck other values.
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Main Tasks to CompleteStep 5
6. Click the Back button.
7. Cleck the Next button to exit the Test Tool configuration.
Main Tasks to CompleteStep 6
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Save and Start Inspection
In the PresencePLUS GUI, click the Go To Run button. When prompted to save the inspection:
1. Enter a name in the Inspection Name field.
2. Click on the Save button.
3. Once the inspection is saved, click the Start button to start the inspection.
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Kawasaki AS Language Sample
This sample AS Language code snippet will assist with the integration of a Banner PresencePLUS Vision Sensor and a Kawasaki C/D/D+ Series Robot Controller.
In this example, the Banner Remote Command Channel (RCC) has been configured to use the Kawasaki RCC Protocol with Ethernet Socket 1, all other settings are default (TCP port 20000, command and response frame start delimiter is empty string (<none>) with an end delimiter of carriage return-linefeed (\r\n), and the field output delimiter is comma (,).
This example assumes that a Banner PresencePLUS inspection that produces X, Y and Angle offsets has been loaded into the PresencePLUS Vision Sensor and has been started with the PresencePLUS GUI. These offsets will then be obtained and stored in the following variables:
• X_offset is the offset (in units set in camera) along the horizontal axis of the image, increases to the right
• Y_offset is the offset (in units set in camera) along the vertical axis of the image, increases downward
• Rz_offset is the angular offset (in degrees) about the Z-axis, increases clockwise
This program implements the following actions:
1. Connect to the RCC.
2. Issue EXEC TRIGGER and wait for inspection to complete.
3. Determine pass/fail condition of the inspection.
4. Get the X, Y, and Rotation about Z-axis offsets.
5. Close the connection to the RCC.
If any failure occurs, such as a TCP communications failure or a RCC command error, then the connection to the RCC will be severed within this example program.
.PROGRAM banner_vision() ; Global variables $cmd_del = $CHR(13)+$CHR(10) $coord_del = "," tcp_sock_id = -1 ; TCP/IP socket id for the camera
; Local variables .ret_val = -1 .$cmd_str = "" ; Used for commands to camera .$rcv_str = "" ; Used for incoming data from camera .$rsp_str = "" ; Used for response parsing from camera
; ; Open TCP socket and connect to RCC ;
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CALL tcp_open(.ret_val, 20000) IF .ret_val < 0 THEN PRINT "Unable to connect to RCC" RETURN END
; ; Trigger the camera and wait for the inspection to complete ;
; Send Trigger to camera and wait for the inspection to complete .$cmd_str = "EXEC TRIGGER"+$cmd_del CALL tcp_send(.ret_val, .$cmd_str) IF .ret_val < 0 GOTO tcp_error
; Read command response from camera .$rcv_str = "" CALL tcp_recv(.ret_val, .$rcv_str) IF .ret_val < 0 GOTO tcp_error
; Decode command response - a response of zero indicates that ; the command was accepted for processing, a negative value ; indicates that an error has occurred. .$rsp_str = $DECODE(.$rcv_str, $cmd_del, 0) .ret_val = VAL(.$rsp_str) IF .ret_val < 0 GOTO cmd_error ; Trigger failed
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; ; Determine whether the inspection passed or failed ;
; Send command to camera to determine if the inspection passed ; the inspection and found the desired part .$cmd_str = "GET PASSFAILFLG"+$cmd_del CALL tcp_send(.ret_val,.$cmd_str) IF .ret_val < 0 GOTO tcp_error
; Read command response from camera .$rcv_str = "" CALL tcp_recv(.ret_val, .$rcv_str) IF .ret_val < 0 GOTO tcp_error ; Get command failed
; Decode command response .$rsp_str = $DECODE(.$rcv_str, $cmd_del, 0) .ret_val = VAL(.$rsp_str) IF .ret_val < 0 GOTO cmd_error ; Get Pass/Fail failed $temp = $DECODE(.$rcv_str, $cmd_del, 1) ; Remove frame delimiter
; Decode the Pass/Fail status data returned by the Get command .$rsp_str = $DECODE(.$rcv_str, $coord_del, 0) .passfail = VAL(.$rsp_str) IF .passfail <> 1 GOTO notfnd_error
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; ; Obtain the X, Y, and Rz offset data ;
; Send command to camera to acquire the Communication Tool ; result data .$cmd_str = "GET COORDTOOL"+$cmd_del CALL tcp_send(.ret_val,.$cmd_str) IF .ret_val < 0 GOTO tcp_error
; Read command response from camera .$rcv_str = "" CALL tcp_recv(.ret_val, .$rcv_str) IF .ret_val < 0 GOTO tcp_error
; Decode command response .$rsp_str = $DECODE(.$rcv_str, $cmd_del, 0) .ret_val = VAL(.$rsp_str) IF .ret_val < 0 GOTO cmd_error ; Get Commtool failed
$temp = $DECODE(.$rcv_str, $cmd_del, 1) ; Remove frame delimiter
; Decode the X offset data .$rsp_str = $DECODE(.$rcv_str, $coord_del, 0) X_offset = VAL(.$rsp_str) $temp = $DECODE(.$rcv_str, $coord_del, 1) ; Remove field delimiter
; Decode the Y offset data .$rsp_str = $DECODE(.$rcv_str, $coord_del, 0) Y_offset = VAL(.$rsp_str) $temp = $DECODE(.$rcv_str, $coord_del, 1) ; Remove field delimiter
;Decode the Rz offset data -- rotation about the Z axis .$rsp_str = $DECODE(.$rcv_str, $coord_del, 0) O_offset = VAL(.$rsp_str) $temp = $DECODE(.$rcv_str, $coord_del, 1) ; Remove field delimiter
; ; Handle new coordinate offsets ; PRINT X_offset, Y_offset, Rz_offset POINT pick = frame1+TRANS(X_offset, Y_offset, ,Rz_offset) HOME LAPPRO pick,100 LMOVE pick CLAMP 1 LDEPART 100 HOME
; Part not found error notfnd_error: PRINT "The part was not found" GOTO all_done
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; TCP error tcp_error: PRINT "Error during send or receive via TCP:", .ret_val GOTO all_done
; RCC Command error cmd_error: PRINT "Error during command to camera:", .ret_val GOTO all_done
; Done with program all_done: CALL tcp_close .END
; ; Open a TCP connection to the RCC using specified TCP port number ; .PROGRAM tcp_open(.ret_val, .port)
.ret_val = 0 ; Initialize the return value .retry_count = 0 ; Initialize the retry count
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; Set the IP address to 192.168.0.1 ip[1] = 192 ip[2] = 168 ip[3] = 0 ip[4] = 1
connect:
; Connect to the RCC port TCP_CONNECT tcp_sock_id, .port, ip[1]
; Check whether connection was established IF tcp_sock_id < 0 THEN IF .retry_count >= 5 THEN ; Number of retries exceeds 5, exit with error PRINT "Unable to establish connection with camera" .ret_val = -1 GOTO connect_error ELSE ; Increment the retry count and try again .retry_count = .retry_count + 1 PRINT "TCP_CONNECT error – attempt #", .retry_count GOTO connect END ELSE PRINT "Established connection, socket id = ", tcp_sock_id END
; Error occurred during connection attempt(s)
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connect_error: RETURN
.END
; ; Close the TCP connection ; .PROGRAM tcp_close()
.ret_val = 0 ; Initialize the return value
TCP_CLOSE .ret_val, tcp_sock_id
; Check for errors IF (.ret_val < 0) THEN PRINT "Unable to close TCP connection, error id = ", .ret_val ELSE PRINT "TCP Connection has been closed" END .END
; ; Receive data over TCP connection ; .PROGRAM tcp_recv(.ret_val, .$receive) .ret_val = 0 ; Initialize the return value .error_return = -99 ; Return value from TCP_RECV .timeout_recv = 60 ; Timeout of 60 seconds .max_recv_len = 255 ; Maximum length of single string element .$receive = "" ; Empty the return string .num_elem_recv = 0 ; Number of elements received
; Read the TCP socket TCP_RECV .error_return, tcp_sock_id, .$recv_buf[1], .num_elem_recv, .timeout_recv, .max_recv_len
; Process data IF .error_return < 0 THEN PRINT "Error receiving data, TCP_RECV error #", .error_return .ret_val = -1 ELSE IF .num_elem_recv > 0 THEN
; Ensure the combined return string element lengths do ; not exceed 255 (maximum allowed length of string) – the ; multiplication allows .max_recv_len to be less than 255 IF .num_elem_recv * .max_recv_len <= 255 THEN
; Copy all of the received elements into output buffer FOR .j = 1 TO .num_elem_recv .$receive = .$receive+.$recv_buf[.j] END
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ELSE PRINT "Received string too long" .ret_val = -1 END ELSE PRINT "Invalid number of elements received" .ret_val = -1 END END .END
; ; Send data over the TCP connection ; .PROGRAM tcp_send(.ret_val, .$data)
.ret_val = 0 ; Initialize function return code .$send_buf[1] = .$data ; Data to send .buf_num = 1 ; Number of array elements .send_timeout = 60 ; send timeout .error_return = 0 ; send error return code
TCP_SEND .error_return, tcp_sock_id, .$send_buf[1], .buf_num, send_timeout
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IF .error_return < 0 THEN .ret_val = -1 PRINT "TCP SEND error in SEND, error = ", .error_return END .END
PresencePLUS Communication Testing
The RCC interface is not a true Telnet interface, although you can use Telnet to test it. Some of the control keys, such as Back Space and Delete will not cause mistyped characters to be erased. Instead, they will be passed on and consumed by the RCC interface. Other control characters will also be consumed by the interface without the usual Telnet actions.
However, you can test the RCC connection by using a Telnet application to connect to the sensor using the port that you configured for the RCC (20000 by default). To function correctly, you must set the Newline transmit value within the Telnet application to be the same as the Command Line End delimiter that you selected in the RCC configuration menu (Carriage Return/Line Feed by default).
After you have successfully connected to the RCC, you can enter RCC commands and observe responses. For example, you can enter get onlinests to retrieve the online status of the sensor. Another example is you can type in the command exec trigger , this will result in the sensor to be triggered, the inspection will be executed, and you should see the inspection output in the GUI. For a complete list of RCC commands and return codes, please refer to the PresencePLUS electronic documentation - accessible through the PresencePLUS GUI.
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6.2.4 Using Custom_ASCII to Communicate with an External Device Over Ethernet

To select Custom_ASCII, click on the RCC Protocol pull-down menu, and select Custom_ASCII from the menu. The protocol configuration for Custom_ASCII is displayed as shown below. The default protocol configuration parameters are:
• Ethernet Socket 1 configured for TCP/IP 20000 as the communications channel
• No Frame Start (Command Start) Delimiter — <none>
• Carriage Return/Line Feed as Frame End (Command End) Delimiter — \r\n
• Comma as the Output Delimiter for the Field Definition — ,
• Space as the Input Delimiter for the Field Definition — <SPC>
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6.3 P4 Input/Output Tab

Use this tab to set t he functionality of the four programmable I/O connections.
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Inputs and Outputs
I/O 1 through 4 in the I/O column correspond to Pins 5 through 8 in the Pin # column.I/O, Pin #,
Function
Options from the drop-down list are:
General Input: Input to the sensor.
General Ouput: Output from the sensor that can be selected in a Test tool.
Pass: Active when the entire nspection passes.
Fail: Active when the inspection fails.
System Error: Active when a system error occurs.
Ready: Active when the sensor is ready to accept another trigger.
Product Select: Used in conjunction with Product Change to select inspection locations at which to begin execution.
Open/Closed
You can select Trigger, Product Change, Remote Teach, and Discrete inputs and outputs as eith NPN (current sourcing) or PNP (current sinking). Once NPN or PNP is selected, all inputs and outpus are either NPN or PNP.
Select the state (open or closed) that the output will take when not active.Normally
Normally Open: The output becomes active when the logic condition controlling the output becomes True.
Normally Closed: The output becomes inactive when the logic condition controlling the output becomes True.
Output Delay
Output Duration
Output Delay is the time from a trigger to start an inspection until the Sensor output turns ON. It is available only for general outputs.
Note: If processing time is longer than the output delay, the output will become active immediately after the processing is finished.
This option is available only for the general outputs; the other outputs (Pass, Fail, System Error, and Ready) are latched only.
Latched: Active until the condition changes.
Time: Active for a specific length of time.
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ON OFF
OFF
ON
Trigger
Output
Output DurationProcessing Time
Delay Latched
Input/Ouput Tab
P4 Input/Output Tab
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6.4 Strobe Tab

Use the Strobe tab to set the strobe signal for a strobed light source. The strobe signal is a +5V dc TTL signal.
Fields in the System Setup window's Strobe tab are described below:
Strobe Tab
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6.4.1 Strobe Width

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DescriptionStrobe Width Option
The strobe output never becomes active (light off).Off
The strobe output remains active (light on).On
Exposure Duration
Time Duration
The strobe output is active only while the sensor is acquiring an image. This is the default.
Sets the duration for active strobe output from the initial valid trigger (minimum pulse width has been satisfied) to the end of the duration. The range is from 0 to 4,000 ms.

6.4.2 Level

Active Low -- When given a 0V dc signal, it turns on. This is the default.
Active High -- When given a +5V dc signal, it turns on.

6.5 Units Tab

Use the Units tab to scale pixels to Engineering units (inches, millimeters, centimeters, etc.) as shown in Units tab shown below. To scale pixels, folow the instruction
Units Tab
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6.6 Reset Tab

Use the Reset tab to read sensor error codes, clear system errors and reestablish Sensor communications.
DescriptionOption
Click to clear the sensor's Red Error LED.Reset Error Flag
Click to clear the error log.Reset Error Log
System Reset
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Click to reboot the Sensor. (This is a system reboot and will take several seconds).
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DescriptionOption
Get Error Log
Reset Tab
Click to display the System Log icon in the Navigation/Results window. The System Log records information about all system failures (such as communication errors between the PC and the Sensor).

6.7 Start-Up Inspection Tab

The options on the Start-Up Inspection tab:
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• Click on Setup Mode if you want the camera to start in Setup Mode after it is powered down.
• Click on Inspection Name, and select an inspection from the drop-down list to have the sensor start up to run.
Start-Up Inspection Tab
P4 Start-Up Inspection Tab
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6.8 NTSC Tab

The Zoom Level adjustment on the NTSC tab is availalble only for single function, low-resolution sensors such as the Area and Geo. From the drop-down list, select the desired zoom level as it will appear on the optional NTSC video monitor that you can attach to the sensor. The default is 4:1.
NTSC Tab
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6.9 Language Tab

In the Languages tab, click on the down arrow for a drop-down list of the languages installed from the PresencePLUS software CD.
Click on the desired language, then click Apply. At the next start-up, the PresencePLUS software will use the selected language.
To save changes and exit the System Setup window, click OK. To exit the System Setup window without making any changes, click the X in the upper-right hand corner of the window.
Language Tab
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6.10 Tools Configuration

Tool Configuration provides the ability to customize the Tools page within the PresencePLUS software. Entire tools, or their enhanced features, can optionally be displayed or hidden. This provides the ability to configure the system to better support your application, thus further simplifying the creation and modification of inspections.
To assist with the customization, the list of tools for the connected sensor is displayed in a tree view. In this tree view, all tools which have a check mark are available for use in the inspection, and all tools that are unchecked are hidden. Similarly, a tool's enhanced feature will be available if checked, and unavailable if unchecked.
Tools Configuration
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6.10.1 Standard Mode

Choose this option to reset all tool configuration settings for the connected sensor to the factory defaults.

6.10.2 Enhanced Mode

Choose this option to enable all tools and all tool's enhanced features for the connected sensor.

6.10.3 Custom Mode

Choose this mode to customize the tools configuration settings within the tree view. This mode is automatically selected when changes are made to the tree view.
The Tool Configuration settings will only affect the sensor that the PresencePLUS software is connected ­these settings are stored with the sensor. Therefore, if the PresencePLUS software connects to a different sensor, then that sensor's tool configuration will be reflected within the PresencePLUS software.
This feature is available when connected to sensors with 2008R1 or newer versions of firmware.

6.10.4 Tool Licensing

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Some tools (e.g., barcode and OCR/OCV) require a license to be registered within the sensor before they can be activated. To purchase a license key, contact Banner with the following information:
- MAC address of the sensor you wish to license
- Product Type of the sensor
- The tool(s) you wish to purchase licenses
- Your company information
- An e-mail address to receive the Key
Please use caution when providing this information, as a license issued for one sensor cannot be registered on a different sensor.
After receiving a license key, you may register the license key using two different methods:
Method 1 - Use the Firmware Updater (recommended)
- Run the Firmware Updater - version 2.0.4 (2008R1) or newer
- Select the 'Licensing' tab
- Connect to the sensor with the MAC address used for key
- Enter the license key received for the sensor - or browse for the license file
- Click on the 'Register' button
- If necessary, select the 'Update' tab and update the firmware to the latest version
Method 2 - Use the PresencePLUS GUI software
(Use this method if sensor has latest version of firmware)
- Start the PresencePLUS software - version 3.2.0 (2008R1) or newer
- Connect to the sensor with the MAC address used for key
- Click 'System' on the title bar and then select the 'Tool Configuration' tab
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- Select the tool to activate
- Enter the license key received for the sensor
- Click on the 'Register' button
To view licenses currently registered within the sensor, click the 'Help' button on the title bar and select 'About' from the menu. The licenses are also displayed next to the product name in the title bar.
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PresencePLUS Software Tools

7.1 ROI Types

ROI types include Area, Search, and Linear.

7.1.1 Linear ROI

Linear ROIs are used by tools that scan along a defined line in a defined direction. Data are averaged along a linear ROI wider than 1 pixel to provide accurate test results. You can adjust the ROI width in increments of 4; that is, 1, 5, 9, 13, and so on. The ROI is widened symmetrically.
Note: Widening an ROI provides an average value/location, which results in improved repeatability.
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7.1.2 Area ROI

An Area ROI can be rectangular, elliptical, or circular. Click on Draw ROI in the input tab to expand the list of ROI shapes from which to select. The shapes are shown below.
Note: An Area ROI can be as large as the entire Field of View (FOV).
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7.1.3 Search ROI

Geometric Find, Geometric Count, Pattern Find, and Pattern Count ROIs, like Area ROIs, can be rectangular, elliptical, or circular; however, these ROIs are also bounded by a Search ROI. The Search ROI is indicated by a yellow box that is always rectanagular and, by default, is 20% to 30% larger than the Area ROI, which is red.

7.2 Location Tools

7.2.1 Locate Tool

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The Locate tool locates the position of a target in a field of view. This tool finds and marks position of the first edge along the ROI line. Typically, tools, including additional Locate tools that follow, are relative to this point. Additionally, the software can calculate the angle at which the Locate tool intersects the feature's edge and rotates following tools Regions of Interest (ROIs) accordingly.
Usage
The Locate tool is used to align and position Vision tools consistently over the feature of interest.
Fields
The following are fields on the Locate tool Input tab:
Threshold Type7.2.1.2 Threshold Type on page 98
Filters7.2.1.3 Filters on page 100
Results7.2.1.4 Results on page 101
Select7.2.1.5 Select on page 101
Supported Platforms
ProII Color
1.3
OMNI ColorProII/ProII
1.3
AREA/AREA1.3OMNI/OMNI
EDGE/EDGE
1.3
GEO/GEO
1.3
BCR/BCR
1.3
YesYesYesYesYesYesYesYes
Locate Tool Tabs
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Adding a Locate Tool
To add a Locate tool to an inspection:
1. Click the button of the tool to be added to the inspection.
2. If desired, rename the tool.
3. Draw an ROI.
DescriptionField/Button
Use this field to rename the tool. The default is tool_name_1, tool_name_2, and so on, where the default tool_name depends on the tool being created (for example, locate, edge or the like). The name can have only alphanumeric characters and underscores with no spaces.
Click this button to add an ROI to an image.
Click this button to remove an ROI from an image.
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Threshold Type
The threshold is used to mark the gray scale transition point. The tool marks the edge when the pixel intensity crosses the threshold level. From the dropdown list, select one of the following:
• Relative
• Absolute
• Edge Strength
Relative Threshold
Relative threshold is the default, and it finds an edge at a relative pixel intensity. The brightest gray scale level is 100% and the darkest is 0%. While Relative threshold is more tolerant of light fluctuations between inspections than other transition types, it may find false edges.
Percent
Polarity
Edge Profile Graph
DescriptionField/Graph
Percent is displayed when the Type is Relative. Choose the percentage value at which the edge should be marked.
Bright to Dark finds edges that start above the threshold value and cross below the threshold value.
Dark to Bright finds edges that start below the threshold value and cross above the threshold value.
Bright or Dark finds any edge.
In the Edge Profile graph displayed when the Relative threshold is selected, the red line shows the percentage pixel intensity relative to the green threshold line. The threshold line will move up or down with the percent value.
Absolute Threshold
Absolute threshold finds an edge at a specific gray scale level. While Absolute threshold is less likely to find a false edge than Relative Threshold, it may miss edges if the light level changes between inspections.
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DescriptionField/Graph
Value
Polarity
Edge Profile Graph
Value is displayed when Type is Absolute. Enter a specific gray scale value from 0 to 255.
Bright to Dark finds edges that start above the threshold value and cross below the threshold value.
Dark to Bright finds edges that start below the threshold value and cross above the threshold value.
Bright or Dark finds any edge.
In the Edge Profile graph displayed when the Absolute threshold is selected, the red line shows the percentage pixel intensity relative to the green threshold line. The threshold line will move up or down with the percent value.
Edge Strength
Edge strength measures the rate of change of grayscale values and needs sharply-defined transitions. Edge strength is more tolerant of gradual changes in light levels across the tool than other transition types and it will filter out weak or gradual edges.
DescriptionField
Enter an edge bandwidth value from 1 to 255.Edge
Polarity
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Bright to Dark finds edges that start above the threshold value and cross below the threshold value.
Dark to Bright finds edges that start below the threshold value and cross above the threshold value.
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DescriptionField
Bright or Dark finds any edge.
Graph Tab
When Edge Strength is selected in the Input tab, the software displays the Graph tab. This tab provides similar information to the Input tab, but displays separate Edge Profile and Edge Strength graphs for easier viewing.
The Edge Profile graph represents the absolute gray scale level across the tool ROI.
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Filters
The Edge Strength graph represents the change in gray scale along the tool ROI. Edge Strength detects an edge when the rate of change (solid red line on the graph) crosses the selected intensity change amount (dashed green lines on the screen).
A bright-to-dark transition has a negative edge strength value, and a dark-to-bright transition has a positive edge strength value. When the Edge Strength level is adjusted, both the negative and positive green dotted lines will adjust together.
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