VE Series Smart Camera
191666
Instruction Manual
Original Instructions
191666 Rev. B
31 October 2016
©
Banner Engineering Corp. All rights reserved
VE Series Smart Camera
Contents
1 Product Description .......................................................................................................
1.1 Models ....................................................................................................................................6
2 Overview ....................................................................................................................... 7
2.1 Features .................................................................................................................................. 7
2.1.1 Display ......................................................................................................................... 7
2.1.2 Indicators ......................................................................................................................7
2.1.3 Buttons .........................................................................................................................7
2.2 Vision Manager Software ...........................................................................................................8
3 Specifications and Requirements ...................................................................................9
3.1 Specifications .......................................................................................................................... 9
3.2 PC Requirements ...................................................................................................................... 9
3.3 Dimensions ........................................................................................................................... 10
3.4 Banner Engineering Corp. Software Copyright Notice ....................................................................11
4 Installation Instructions ..............................................................................................12
4.1 Install the Accessories .............................................................................................................12
4.2 Mount the Sensor ...................................................................................................................12
4.3 Connect the Cables .................................................................................................................12
4.3.1 Wiring Diagrams ............................................................................................................13
4.4 Install the Software .................................................................................................................15
5 Getting Started ............................................................................................................ 16
5.1 Connect to the Sensor .............................................................................................................16
5.2 Acquire a Good Image .............................................................................................................16
5.3 Set Up an Inspection .............................................................................................................. 17
5.3.1 Add a Tool ...................................................................................................................17
5.3.2 Rename a Tool .............................................................................................................18
5.3.3 Name an Inspection ......................................................................................................19
5.3.4 Save an Inspection to a Computer, Network Drive, or Storage Device ...................................19
5.3.5 Modify a Currently Running Inspection .............................................................................19
5.3.6 Copy a Tool ................................................................................................................. 20
5.3.7 Delete a Tool ................................................................................................................20
5.3.8 Delete a Tool and All Tools After It ..................................................................................20
5.3.9 Delete an Inspection ..................................................................................................... 20
5.4 Configure the Discrete I/O .......................................................................................................21
6 Vision Manager Workspace ..........................................................................................22
6.1 Home Screen .........................................................................................................................22
6.1.1 Sensor Neighborhood .....................................................................................................22
6.1.2 Sensor Maintenance .......................................................................................................24
6.1.3 Emulators ....................................................................................................................25
6.1.4 About ...........................................................................................................................26
6.2 Sensor Screen ....................................................................................................................... 26
6.2.1 Image Pane Parameters .................................................................................................26
6.2.2 Summary Pane .............................................................................................................27
6.2.3 Tools & Results .............................................................................................................28
6.2.4 Tools Only .................................................................................................................... 28
6.2.5 All Results ................................................................................................................... 29
6.3 Inspection Logs Screen ........................................................................................................... 30
6.3.1 Log Sources .................................................................................................................30
6.3.2 Loaded Logs .................................................................................................................31
6.4 Inspection Management Screen ................................................................................................31
6.4.1 Manage .......................................................................................................................32
6.4.2 Transfer ...................................................................................................................... 33
6.5 System Settings Screen .......................................................................................................... 34
6.5.1 Sensor Info ...................................................................................................................34
6.5.2 Discrete I/O .................................................................................................................34
6.5.3 Communications ...........................................................................................................36
6.5.4 Logs ........................................................................................................................... 39
6.5.5 Units ............................................................................................................................41
6.5.6 System Reset ...............................................................................................................44
7 Using the Camera Tool .................................................................................................45
7.1 Imager ................................................................................................................................. 45
7.2 Trigger ..................................................................................................................................46
7.3 Focus Information .................................................................................................................. 47
7.4 External Strobe ......................................................................................................................47
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VE Series Smart Camera
7.5 Camera Tool: Results ..............................................................................................................48
8 Using the Inspection Tools: Vision Tools ......................................................................
8.1 Average Gray Tool ..................................................................................................................49
8.1.1 Average Gray Tool: Input Parameters ...............................................................................49
8.1.2 Average Gray Tool: Test Parameters ............................................................................... 51
8.1.3 Average Gray Tool: Results ............................................................................................52
8.1.4 Using the Average Gray Tool ..........................................................................................52
8.2 Bead Tool ..............................................................................................................................53
8.2.1 Bead Tool: Input Parameters ..........................................................................................53
8.2.2 Bead Tool: Test Parameters ........................................................................................... 58
8.2.3 Bead Tool: Results ........................................................................................................58
8.2.4 Bead Tool: Adjust the ROI ..............................................................................................59
8.2.5 Using the Bead Tool ......................................................................................................61
8.3 Blemish Tool ..........................................................................................................................63
8.3.1 Blemish Tool: Input Parameters ......................................................................................64
8.3.2 Blemish Tool: Test Parameters ....................................................................................... 66
8.3.3 Blemish Tool: Results ....................................................................................................67
8.3.4 Using the Blemish Tool ..................................................................................................67
8.4 Blob Tool ...............................................................................................................................68
8.4.1 Blob Tool: Input Parameters ...........................................................................................68
8.4.2 Blob Tool: Test Parameters ............................................................................................ 72
8.4.3 Blob Tool: Results .........................................................................................................73
8.4.4 Using the Blob Tool .......................................................................................................76
8.5 Edge Tool ..............................................................................................................................79
8.5.1 Edge Tool: Input Parameters ..........................................................................................79
8.5.2 Edge Tool: Test Parameters ........................................................................................... 85
8.5.3 Edge Tool: Results ........................................................................................................85
8.5.4 Using the Edge and Measure Tools ..................................................................................86
8.6 Locate Tool ............................................................................................................................87
8.6.1 Locate Tool: Input Parameters ........................................................................................88
8.6.2 Locate Tool: Test Parameters ......................................................................................... 94
8.6.3 Locate Tool: Results ......................................................................................................94
8.6.4 Using the Locate Tool ....................................................................................................95
8.7 Match Tool ............................................................................................................................ 98
8.7.1 Match Tool: Input Parameters ........................................................................................ 98
8.7.2 Match Tool: Test Parameters ........................................................................................ 102
8.7.3 Match Tool: Results .....................................................................................................103
8.7.4 Using the Match Tool ...................................................................................................104
8.7.5 Using Remote TEACH with the Match Tool ...................................................................... 106
8.8 Object Tool ..........................................................................................................................106
8.8.1 Object Tool: Input Parameters ......................................................................................106
8.8.2 Object Tool: Test Parameters ........................................................................................112
8.8.3 Object Tool: Results ....................................................................................................112
8.8.4 Using the Object Tool .................................................................................................. 113
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9 Using the Inspection Tools: Analysis Tools ................................................................ 115
9.1 Math Tool ............................................................................................................................115
9.1.1 Math Tool: Input Parameters ........................................................................................115
9.1.2 Math Tool: Test Parameters ..........................................................................................117
9.1.3 Math Tool: Results ...................................................................................................... 117
9.1.4 Using the Math Tool .................................................................................................... 118
9.2 Measure Tool ....................................................................................................................... 119
9.2.1 Measure Tool: Operations ............................................................................................. 119
9.2.2 Measure Tool: Input Parameters ................................................................................... 120
9.2.3 Measure Tool: Test Parameters .....................................................................................122
9.2.4 Measure Tool: Results ................................................................................................. 122
9.2.5 Using the Edge and Measure Tools ................................................................................ 123
9.3 Logic Tool ............................................................................................................................125
9.3.1 Logic Tool: Input Parameters ........................................................................................125
9.3.2 Logic Tool: Test Parameters ......................................................................................... 127
9.3.3 Logic Tool: Results ......................................................................................................127
9.3.4 Using the Logic Tool ....................................................................................................127
10 Emulators ................................................................................................................ 130
10.1 Backup or Restore the Emulator ............................................................................................130
11 Sensor Display ..........................................................................................................131
11.1 Sensor Display Interface ......................................................................................................131
11.2 Locking and Unlocking the Sensor .........................................................................................131
11.3 Sensor Menu ......................................................................................................................132
11.4 Ethernet Menu (ETHER) .......................................................................................................133
11.5 Product Change Menu (PCHANGE) .........................................................................................133
11.6 Input/Output Menu (IO) .......................................................................................................133
VE Series Smart Camera
11.7 Image Menu (IMAGE) ..........................................................................................................133
11.8 Information Menu (INFO) .....................................................................................................
11.9 System Error Menu (SYSERR) ...............................................................................................134
11.10 Display Menu (DISPLAY) .................................................................................................... 134
11.11 Reboot Menu (REBOOT) .....................................................................................................134
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12 Communications Guide ............................................................................................ 135
12.1 Communication Summary ....................................................................................................135
12.1.1 Communication Channels ........................................................................................... 135
12.1.2 Industrial Ethernet .................................................................................................... 135
12.1.3 Image Export ........................................................................................................... 135
12.2 Enabling Communications .................................................................................................... 136
12.2.1 Setting Up Ethernet Communications ...........................................................................136
12.2.2 Windows 7 ............................................................................................................... 136
12.2.3 Communications Channel Ports .................................................................................... 137
13 Industrial Ethernet Overview ...................................................................................138
13.1 Industrial Ethernet Setup .....................................................................................................138
13.1.1 Set the Industrial Ethernet Protocol (EtherNet/IP, PROFINET®, Modbus/TCP, PCCC) ...........138
13.1.2 Set the Trigger Mode .................................................................................................138
13.2 Supported Functions ........................................................................................................... 138
13.2.1 Sensor Input Values .................................................................................................. 139
13.2.2 Sensor Output Values ................................................................................................ 139
13.3 EtherNet/IP ........................................................................................................................139
13.3.1 Inputs to the Sensor (Outputs from the PLC) ................................................................ 142
13.3.2 Outputs from the Sensor (Inputs to the PLC) ................................................................ 143
13.3.3 Input and Output Bits ................................................................................................ 144
13.3.4 Sensor Pass/Fail Bits ..................................................................................................144
13.3.5 Tool-Specific Results: EtherNet/IP ................................................................................ 144
13.3.6 Configuration Assembly Object .....................................................................................146
13.3.7 Data Formats .............................................................................................................146
13.3.8 Minimum Requested Packet Inverval (RPI) Value ...........................................................146
13.3.9 VE Series Smart Camera EDS File Installation in ControlLogix Software ............................. 146
13.3.10 RSLogix5000 Configuration ........................................................................................152
13.4 Modbus/TCP .......................................................................................................................158
13.4.1 Sensor Input Values ................................................................................................... 163
13.4.2 Sensor Output Values ................................................................................................. 164
13.4.3 Input and Output Bits .................................................................................................164
13.4.4 Sensor Pass/Fail Bits ..................................................................................................165
13.4.5 Tool-Specific Results: Modbus/TCP .............................................................................. 165
13.5 PLC5 and SLC 5 (PCCC) .......................................................................................................166
13.5.1 Configuration ............................................................................................................169
13.5.2 Inputs to the Sensor (Outputs from the PLC) ................................................................. 173
13.5.3 Outputs from the Sensor (Inputs to the PLC) ................................................................. 173
13.5.4 Input and Output Bits .................................................................................................174
13.5.5 Sensor Pass/Fail Bits ..................................................................................................174
13.5.6 Tool-Specific Results: PCCC ........................................................................................174
13.6 PROFINET ...........................................................................................................................176
13.6.1 General Station Description (GSD) File ..........................................................................176
13.6.2 VE Series camera PROFINET IO Data Model ................................................................... 176
13.6.3 Configure the VE Series Smart Camera for a PROFINET IO Connection ............................. 176
13.6.4 Description of Modules and Submodules ........................................................................177
13.6.5 Description of Submodules ......................................................................................... 178
13.6.6 Configuration Instructions .......................................................................................... 184
13.7 Troubleshooting ..................................................................................................................194
13.7.1 Industrial Ethernet Error Codes ...................................................................................194
13.7.2 PROFINET ................................................................................................................. 194
14 Troubleshooting .......................................................................................................197
14.1 Vision Manager Error Codes ..................................................................................................197
15 Accessories ...............................................................................................................208
15.1 Cordsets ............................................................................................................................208
15.2 Brackets ............................................................................................................................208
15.3 Lenses .............................................................................................................................. 209
15.3.1 WVGA Lens Working Distance and Field of View ..............................................................209
15.3.2 1.3 MP Lens Working Distance and Field of View ............................................................210
15.3.3 2 MP Lens Working Distance and Field of View ...............................................................210
15.4 C-Mount Lens Filter Models .................................................................................................. 211
15.5 Lens Cover .........................................................................................................................211
15.6 Display Cover .....................................................................................................................212
15.7 Ring Lights .........................................................................................................................212
15.8 Interface Module .................................................................................................................212
15.9 Product CD ........................................................................................................................ 213
VE Series Smart Camera
16 Product Support and Maintenance ........................................................................... 214
16.1 Repairs ..............................................................................................................................
16.2 Maintenance .......................................................................................................................214
16.2.1 Clean the Sensor ........................................................................................................214
16.2.2 Clean the Lens ...........................................................................................................214
16.2.3 Update the Software and Firmware ...............................................................................214
16.3 Contact Us .........................................................................................................................214
16.4 Banner Engineering Corp Limited Warranty ............................................................................ 215
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VE Series Smart Camera
1 Product Description
Self-contained Smart Camera with User-Friendly
Vision Manager
Software
• Banner’s free and easy-to-use Vision Manager Software provides a
number of tools and capabilities that enable
VE Series smart cameras to
solve a wide range of vision applications, such as item detection, part
positioning, feature measurement and flaw analysis
•
Runtime editing capability reduces costly downtime and the software
emulator allows for offline building and troubleshooting of applications
• Factory communications (EtherNet IP, Modbus, and PROFINET) for
integration on the manufacturing floor
• Six optically isolated I/O and an external light connector on the smart
camera
• Two-line, eight-character onboard display provides smart camera
information and focus number and makes it easy to update the smart
camera settings, facilitating fast product changeover
• Robust metal housing with optional lens covers to achieve IP67 rating for
use in harsh environments with heat, vibration, or moisture
• Bright indicator lights for easy viewing of smart camera status
WARNING: Not To Be Used for Personnel Protection
Never use this device as a sensing device for personnel protection. Doing so could lead to
serious injury or death. This device does not include the self-checking redundant circuitry necessary
to allow its use in personnel safety applications. A sensor failure or malfunction can cause either an
energized or de-energized sensor output condition.
CAUTION: Electrostatic Discharge
Avoid the damage that electrostatic discharge (ESD) can cause to the Sensor.
Always use a proven method for preventing electrostatic discharge when installing a lens or attaching a
cable.
CAUTION: Hot Surface
Use caution when handling the camera. The surface of the camera may be hot during operation
and immediately after use.
1.1 Models
1
Model
VE200G1A WVGA, 752 × 480 pixels grayscale
VE201G1A 1.3 MP, 1280 × 1024 pixels grayscale
VE202G1A 2 MP, 1600 × 1200 pixels grayscale
Resolution
1
Model VE202G2A, 2 MP, 1600 × 1200 grayscale with 4-pin D-code M12 Ethernet connection is also available.
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VE Series Smart Camera
2 Overview
VE Series Smart Camera
The
applications. Users can quickly set up the sensor using the Vision Manager software to solve a diverse range of applications
on the factory floor.
2.1 Features
is easy to use and has advanced visual inspection capabilities for automation or control
1. Display
2.
Buttons
Pass/Fail indicator (green/red)
3.
4. Ready/Trigger indicator (green/amber)
5. Power/Error indicator (green/red)
6. Ethernet indicator (amber), not shown
7. Ethernet connection
8. Light connection
9. Power, Discrete I/O connection
Figure 1. Sensor Features
2.1.1 Display
The display is a 2-line, 8-character LCD. The main screen is
the Home Screen, which shows the name of the current
inspection and the slot number (inspection location). Use
Figure 2. Display with Home Screen
the display to view or change several sensor settings.
2.1.2 Indicators
Four LED indicators provide ongoing indication of the sensing status.
Power/Error Indicator
Green = Normal operation
Red = System error
Ready/Trigger Indicator
Green = Ready for trigger
Yellow = Trigger is active
OFF = Not ready for a trigger, triggers will be missed
Pass/Fail Indicator
Green = Previous inspection passed
Red = Previous inspection failed
OFF = No trigger since power up
Ethernet Indicator
Amber solid = Ethernet connection
Amber flashing = Ethernet activity
OFF = no connection
2.1.3 Buttons
Use the sensor buttons Down
access sensor information. See Figure 257 on page
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, Up , Enter , and Escape to configure several sensor settings and to
132
for additional information on using the buttons.
VE Series Smart Camera
2.2 Vision Manager Software
The VE Series Smart Camera is set up using the free Vision Manager Software, available for download at
www.bannerengineering.com.
This easy-to-use image processing software provides a variety of tools and capabilities to solve a wide range of vision
applications such as item detection, part positioning, feature measurement and flaw analysis. Run-time editing allows you
to make changes to an inspection while the sensor is running, reducing costly downtime. Vision Manager
full software emulator, allowing users to develop or troubleshoot inspections offline, without a sensor.
also includes a
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Information
Technology
Equipment
E365235
VE Series Smart Camera
3 Specifications and Requirements
3.1 Specifications
Power
12 V dc to 30 V dc (24 V dc ± 10% if a Banner light source is powered
by the sensor)
Current: 400 mA maximum (exclusive of load and lights)
Use only with a suitable Class 2 power supply, or current limiting power
supply rated 12 V to 30 V dc, 1 A
Supply Protection Circuitry
Protected against reverse polarity and transient overvoltages
Discrete I/O
1 Trigger IN
5 Programmable I/O
Output Configuration
Optically isolated
Output Rating
Output Resistance: < 2 Ω
Strobe Output Resistance: < 13
Programmable Output: 100 mA
External Strobe Output: 100 mA
Off-State Leakage Current: < 100 µA
External Light Maximum Current Draw
600 mA
Exposure Time
0.02 ms to 500 ms
Imager
VE200G1A: 6.9 mm × 5.5 mm, 8.7 mm diagonal (1/1.8-inch CMOS)
VE201G1A: 6.9 mm × 5.5 mm, 8.7 mm diagonal (1/1.8-inch CMOS)
VE202G1A: 7.2 mm × 5.4 mm, 9.0 mm diagonal (1/1.8-inch CMOS)
VE202G2A: 7.2 mm × 5.4 mm, 9.0 mm diagonal (1/1.8-inch CMOS)
Lens
C-mount
Pixel Size
VE200G1A: 5.3 µm
VE201G1A: 5.3 µm
VE202G1A: 4.5 µm
VE202G2A: 4.5 µm
Communication
10/100/1000
2
Mbps Ethernet
Ω
Memory
Device Settings and Inspection Storage Memory: 500 MB
Number of inspection files:
Acquisition
256 grayscale levels
Model Frames Per Second3Image Size
VE200G1A 60 fps, maximum 752 × 480 px
VE201G1A 60 fps, maximum 1280 × 1024 px
VE202G1A 50 fps, maximum 1600 × 1200 px
VE202G2A 50 fps, maximum 1600 × 1200 px
Torque—Tapped Holes for Mounting Screws
8 lbf·in (0.9 N·m) maximum torque
Construction
Housing: Aluminum
Display Label: Polyester
Connections
Ethernet: M12, 8-pin or 4-pin D-code Euro-style female
Light Connector: M8, 3-pin Pico-style female
Power, Discrete I/O:
Environmental Rating
IEC IP67 with an optional lens cover properly installed
Operating Conditions
Operating Temperature: 0 °C to +50 °C (+32 °F to +122 °F)
95% maximum relative humidity (non-condensing)
Stable Ambient Lighting: No large, quick changes in light level; no
direct or reflected sunlight
Storage Temperature: −30 °C to +70 °C (−22 °F to +158 °F)
Vibration and Mechanical Shock
Meets EN 60947-5-2: 30 G Shock per IEC 60068-2-27; 1 mm
amplitude from 10 - 60 Hz per IEC 60068-2-6
Certifications
999
M12, 12-pin Euro-style male
3.2 PC Requirements
Operating System
Microsoft® Windows® operating system version 7, 8, or 10
System Type
32-bit, 64-bit
Hard Drive Space
80 MB (plus up to 280 MB for Microsoft .NET 4.5, if not already
installed)
Memory (RAM)
512 MB minimum, 1 GB+ recommended
Important: Administrative rights are required to install the Vision Manager
2
1000 Mbps communication speed not available on 4-pin Ethernet models
3
This value can vary based on inspection settings.
4
Microsoft and Windows are registered trademarks of Microsoft Corporation in the United States and/or other countries.
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Processor
1 GHz minimum, 2 GHz+ recommended
Screen Resolution
1024 × 768 full color minimum, 1650 × 1050 full color recommended
Third-Party Software
Microsoft .NET 4.5, PDF Viewer (such as Adobe Acrobat)
USB Port
USB 3.0, recommended if a USB to Ethernet adapter used to
communicate with the sensor
software.
VE Series Smart Camera
3.3 Dimensions
All measurements are listed in millimeters [inches], unless noted otherwise.
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VE Series Smart Camera
3.4 Banner Engineering Corp. Software Copyright Notice
This software is protected by copyright, trade secret, and other intellectual property laws. You are only granted the right to use the software and only for the purposes
described by Banner. Banner reserves all other rights in this software. For so long as you have obtained an authorized copy of this software directly from Banner, Banner
grants you a limited, nonexclusive, nontransferable right and license to use this software.
You agree not to use, nor permit any third party to use, this software or content in a manner that violates any applicable law, regulation or terms of use under this
Agreement. You agree that you will not reproduce, modify, copy, deconstruct, sell, trade or resell this software or make it available to any file-sharing or application hosting
service.
Disclaimer of Warranties. Your use of this software is entirely at your own risk, except as described in this agreement. This software is provided "AS-IS." To the maximum
extent permitted by applicable law, Banner, it affiliates, and its channel partners disclaim all warranties, expressed or implied, including any warranty that the software is fit
for a particular purpose, title, merchantability, data loss, non-interference with or non-infringement of any intellectual property rights, or the accuracy, reliability, quality or
content in or linked to the services. Banner and its affiliates and channel partners do not warrant that the services are secure, free from bugs, viruses, interruption, errors,
theft or destruction. If the exclusions for implied warranties do not apply to you, any implied warranties are limited to 60 days from the date of first use of this software.
Limitation of Liability and Indemnity. Banner, its affiliates and channel partners are not liable for indirect, special, incidental, punitive or consequential damages,
damages relating to corruption, security, loss or theft of data, viruses, spyware, loss of business, revenue, profits, or investment, or use of software or hardware that does
not meet Banner minimum systems requirements. The above limitations apply even if Banner and its affiliates and channel partners have been advised of the possibility of
such damages. This Agreement sets forth the entire liability of Banner, its affiliates and your exclusive remedy with respect to the software use. You agree to indemnify and
hold Banner and its affiliates and channel partners harmless from any and all claims, liability and expenses, including reasonable attorney's fees and costs, arising out of your
use of the Services or breach of this Agreement (collectively referred to as "Claims"). Banner reserves the right at its sole discretion and at its own expense, to assume the
exclusive defense and control of any Claims. You agree to reasonably cooperate as requested by Banner in defense of any Claims.
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VE Series Smart Camera
4 Installation Instructions
4.1 Install the Accessories
1. VE sensor
2. O-ring (used with the lens cover)
3.
C-mount lens (available separately)
4. Filter (optional)
5. Lens cover (optional)
An external light (optional) is not shown.
Figure 3. Install the Accessories
1. If you are using a lens cover: Remove the black thread protector (not shown) from the sensor (1).
2. If you are using a lens cover: Fit a single o-ring (2) into the undercut area behind the sensor threads.
3.
Remove the yellow temporary imager cover (not shown) from the sensor.
CAUTION: Do not remove the imager cover until you are ready to install the lens. Do not touch the imager.
Dirt or dust on the imager can affect sensing reliability.
4. Remove any protective covers from the lens. Handle the lens carefully to avoid smudges and dirt on the optical
elements.
5. Thread the lens (3) onto the sensor.
Make sure that the lens is focused; see Acquire a Good Image on page 16.
6.
7. Use the thumbscrews on the lens to lock the focus and aperture rings and to prevent movement that can occur during
cleaning or accidental contact.
8. If you are using a filter: Thread the filter (4) onto the front of the C-mount lens.
9. If you are using a linear polarization filter: Rotate the outer portion of the filter mount to determine the position where
glare is reduced the most, and use the locking thumbscrew to fasten the filter in position.
10.If you are using a lens cover: Thread the lens cover (5) onto the threaded portion of the sensor.
11.Or, if you are using an external light bracket: Attach an external light bracket to the sensor using the provided
hardware kit.
NOTE: For optimal imaging, provide adequate dissipation of heat. A good heat conductor, such as aluminum, may
be required.
NOTE: A lens cover and a ring light cannot be used together.
4.2 Mount the Sensor
1. If a bracket is needed, mount the sensor onto the bracket.
2. Mount the sensor (or the sensor and the bracket) to the machine or equipment at the desired location. Do not tighten
the mounting screws at this time.
3.
Check the sensor alignment.
4. Tighten the mounting screws to secure the sensor (or the sensor and the bracket) in the aligned position.
4.3 Connect the Cables
1. Power, Discrete I/O connection
Light connection
2.
3.
Ethernet connection
Figure 4. Cable Connections
1. Connect the Ethernet cable to the sensor (3) and to the computer or Ethernet switch.
2.
Connect the power, discrete I/O cable to the sensor (1), and the leads to the appropriate locations. See Table 1 on
page
13 for the power, discrete I/O connections.
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4. Ethernet indicator
VE
Load
+
-
12-30V dc
Output
Power
Supply
Output Common
VE Output
VE
+
-
12-30V dc
Output Common
VE Output
Load
Output
Power
Supply
VE
Input Common
+
-
VE Input
Opto-isolator
12-30V dc
PNP Driver
Input
Power
Supply
VE
Input Common
+
-
VE Input
12-30V dc
Opto-isolator
Input
Power
Supply
NPN Driver
VE Series Smart Camera
3. Connect the external light cable (optional) to the light connection (2) if the light is powered by the sensor.
CAUTION: Use Appropriate Power
If the light is powered by the sensor, the sensor power source must be 24 V dc. This connection is
for Banner lights only.
Table 1: Power and I/O Pinouts
Pin Wire Color Description Direction
1 White Discrete I/O #3 Input/Output
2 Brown 12 V dc to 30 V dc Input
3 Green I/O output common
Important: For PNP (sourcing) outputs connect pin 3
to +V dc, for NPN (sinking) outputs connect pin 3 to 0
V dc. The discrete I/O pins are 1, 5, 8, 10, and 11.
4 Yellow Reserved 5 Gray Discrete I/O #5 Input/Output
6 Pink Trigger input Input
7 Blue Common Input
8 Red Discrete I/O #2 Input/Output
9 Orange I/O input common
-
-
Important: For PNP (sourcing) inputs connect pin 9 to
0 V dc, for NPN (sinking) inputs connect pin 9 to +V
dc. The discrete I/O pins are 1, 5, 6, 8, 10, and 11.
10 Light Blue Discrete I/O #4 Input/Output
11 Black Discrete I/O #1 Input/Output
12 Violet Reserved Shield Bare metal Chassis ground -
4.3.1 Wiring Diagrams
Figure 5. PNP Output
Figure 6. NPN Output
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Figure 7. PNP Input
Figure 8. NPN Input
PNP Inputs & Outputs
+
-
S
S
+
+
-
-
VE
Input Power
Supply
Output Power
Supply
This is a typical example. Applications may vary.
*Programmable I/O shown set as an
output in this example
**Programmable I/O shown set as an
input in this example
1 = White
2 = Brown
3 = Green
4 = Yellow
5 = Gray
6 = Pink
7 = Blue
8 = Red
9 = Orange
10 = Light Blue
11 = Black
12 = Violet
S = Shield
2
7
11
8
1
10
5
6
3
9
4
12
Load
Load
Load
I/O 1 - Output*
I/O 2 - Output*
I/O 3 - Output*
I/O 4 - Input**
I/O 5 - Input**
Trigger - Input
Output Common
Input Common
12-30V dc
12-30V dc
12-30V dc
VE Series Smart Camera
Figure 9. PNP Inputs and Outputs
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NPN Inputs & Outputs
+
-
S
S
+
+
-
-
VE
Input Power
Supply
Output Power
Supply
This is a typical example. Applications may vary.
*Programmable I/O shown set as an
output in this example
**Programmable I/O shown set as an
input in this example
1 = White
2 = Brown
3 = Green
4 = Yellow
5 = Gray
6 = Pink
7 = Blue
8 = Red
9 = Orange
10 = Light Blue
11 = Black
12 = Violet
S = Shield
7
11
8
1
10
5
6
3
9
4
12
2
Load
Load
Load
I/O 1 - Output*
I/O 2 - Output*
I/O 3 - Output*
I/O 4 - Input**
I/O 5 - Input**
Trigger - Input
Output Common
Input Common
12-30V dc
12-30V dc
12-30V dc
VE Series Smart Camera
4.4 Install the Software
1. Download the latest version of the software from www.bannerengineering.com.
2. Navigate to and open the downloaded file.
3. Click Next to begin the installation process.
4. Confirm the software destination and availability for users and click Next.
5. Click Install to install the software.
6. Depending on your system settings, a popup window may appear prompting to allow Vision Manager to make changes
to your computer. Click Yes.
7. Click Close to exit the installer.
Important: Administrative rights are required to install the Vision Manager
Figure 10. NPN Inputs and Outputs
software.
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VE Series Smart Camera
5 Getting Started
Power up the sensor, and verify that the
verify the Ethernet connection.
power/error LED is ON green and that the Ethernet indicator is ON amber to
5.1 Connect to the Sensor
These instructions use Windows® operating system version 7, 8, or 10.
1. Confirm the network connections.
a)
Click the Start button, then on the Start menu, click Control Panel.
b) In Control Panel, click Network and Internet, then click Network and Sharing Center, and then click Change
adapter settings.
c) Right-click on the connection that you want to change, then click Properties.
If you are prompted for an administrator password or confirmation, enter the password or provide confirmation.
d) In the connection properties, click Internet Protocol Version 4 (TCP/IPv4), and then click Properties.
5
Figure 11. Local Area Connection Properties
e) In the Internet Protocol (TCP/IPv4) Properties, select Use the following IP address.
Make sure that the IP address is 192.168.0.2, and the subnet mask is 255.255.255.0.
f)
2. Open Vision Manager from the desktop or the Start menu.
The Sensor Neighborhood tab displays and lists the available sensors.
3.
From Sensor Neighborhood, click
The status changes from Available to Connected and the Sensor screen displays. Click to disconnect
from the sensor.
4. If the desired sensor is not listed, verify that:
•
The network adapter connected to the sensor has the same subnet mask as the sensor (for example,
192.168.0.xxx); view the subnet mask in the Network Adapters list at
Network Adapters
The Ethernet cable is the correct type
•
• The TCP/IPv4 settings are correct
Or, manually enter the sensor's IP address.
NOTE: The sensor's IP address and subnet mask are also available from the sensor display.
to connect to the desired sensor.
Home > Sensor Neighborhood >
5.2 Acquire a Good Image
The sensor needs to capture a good image of each part to ensure that it correctly passes good parts and fails bad parts.
5
Windows is a registered trademark of Microsoft Corporation in the United States and/or other countries.
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VE Series Smart Camera
1. Make sure that the lighting is appropriate for your target. Use supplementary lighting, such as a ring light, if necessary.
2.
Click the
3.
Click the camera tool on Tools and Results.
The Inputs parameters display.
4.
Set the trigger.
a) Expand the Trigger parameters.
b) In the Trigger Mode list, click Internal (continuous images).
5. Run Auto Exposure.
a) Expand the Imager parameters.
b) Expand the Auto Exposure parameters, and click Start to run.
6. Check the lighting on the part.
• Make sure that the lighting is constant and consistent (unchanging over time, no shadows or hot spots).
• Capture the shape and form of the target object with lighting that optimizes its contrast and separates the feature
of interest from the background. Depending on the target, consider other Banner lights.
• Adjust the mounting angle to provide the clearest image of the part features you are inspecting.
7. After checking and adjusting the lighting, run Auto Exposure a second time or adjust the exposure manually by
expanding the Exposure parameters and moving the slider or entering a specific exposure time.
8. Adjust the focus.
a) Place the part so that the area to be focused appears in the center of the Image pane.
b) Expand the Focus Info parameters.
c) Make sure that the Focus Info checkbox is selected.
d) Adjust the focus of the lens while monitoring the focus number.
The focus number is a number between 1 and 255. Use the Image pane to determine when the image is sharp
enough, or use the focus number as a guide. Turn the focus ring on the lens until the focus number is at the highest
possible number between 1 and 255. The focus number is also available on the sensor display.
Sensor screen.
NOTE: There is no optimal value for this number, but it can be used as a guide if you are setting up more
than one sensor that are focused on the same target.
e) Tighten the locking thumbscrews to secure the lens at the desired focus.
5.3 Set Up an Inspection
Vision Manager allows you to set up or make changes to an inspection while the sensor is running. Changes are
automatically saved as they are made.
1.
From the
2. Click
A new inspection is added to the list, the Image pane updates, and the Tools & Results tab shows only the camera
tool.
3. Add tools and adjust them as needed for the inspection.
5.3.1 Add a Tool
1.
Click
The Add Tool window opens.
Sensor screen, click in the upper right corner to view the inspection list.
Add New Inspection.
NOTE: The camera tool for the new inspection inherits the parameters of the camera tool for the previous
inspection, however the two are not linked together.
on the Tools & Results tab.
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2. Click the desired tool.
Tool Name Description
Average Gray
Bead
Blemish
Blob
Edge
Locate
Match
Object
Math
Measure
Logic
Evaluates pixel brightness within an ROI and computes the average grayscale value. See Average Gray
Tool on page 49
Inspects parts for uniformity of adhesive or sealant material, or for uniformity of a gap. See Bead Tool on
page 53
Determines whether flaws are present on a part, or detects whether a feature exists on a part. See
Blemish Tool on page 63
Detects and counts/locates groups of connected light or dark pixels within the ROI and designates them as
blobs (Binary Large Objects). After blobs are found, they can be characterized by size and shape. See Blob
Tool
on page 68.
Detects and counts transitions between bright and dark pixels (edges). Counts the total number of edges,
and determines the position of each edge. See Edge Tool
Finds the first edge on a part and compensates for translation and rotation of downstream tools (if
selected). See Locate Tool on page
Verifies that a pattern, shape, or part in any orientation matches a reference pattern. Can also compensate
for translation and rotation of downstream tools (if selected). See Match Tool on page
Detects the edges of dark and bright segments and locates their midpoints. Counts dark and bright
segments, and measures the width of each dark and bright segment. See Object Tool
Performs mathematical operations using tool data or user-supplied constants. Includes basic arithmetic,
inequality expressions, and statistical information. See Math Tool on page
Measures distance, calculates angles, and creates points and lines for use as inputs to other tools. See
Measure Tool on page 119
Uses Boolean logic to combine or convert tool results, or to drive discrete outputs from tool results. Logic
tool data can be used to evaluate the results of a single tool or multiple tools. See Logic Tool
.
.
.
on page 79.
87.
98.
on page 106.
115.
.
on page 125.
The tool is added to Tools & Results
and the region of interest (ROI) appears on the Image
pane.
3. Configure the tool as needed for your application.
a)
Resize
b) Define or view parameters for the tool on the Input
and rotate the ROI around the feature to be analyzed.
tab, such as ROI shape, threshold, or view the histogram.
c) Define pass or fail criteria on the Test tab, such as the count, size, or match.
5.3.2 Rename a Tool
The default tool name is tool01, tool02, and so on, where the word tool is replaced by the appropriate name (for example,
Locate01, Edge02, etc.).
1. On Tools & Results or on Tools Only, click the tool to select it.
2. Highlight the tool name.
3. Enter the desired tool name.
NOTE: Spaces and special characters are not allowed in the tool name.
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5.3.3 Name an Inspection
The default inspection name is Inspection01, Inspection02, and so on. Rename the inspection to something meaningful to
the application.
1.
Click
2. Double-click the name of the desired inspection.
3.
Enter the new inspection name.
Inspection Management, then click Manage.
Figure 12. Manage
NOTE: Special characters are not allowed in the inspection name.
4. Press Enter or click off of the name to save the new name.
5.3.4 Save an Inspection to a Computer, Network Drive, or Storage Device
Vision Manager automatically saves inspections to the
to your computer or another network location if you want to be able to go back to previous settings.
Use the following procedure to save a copy of an inspection to your computer or a network location.
1.
On the
2. Change the destination folder, if desired.
a)
b)
c)
The path to the location displays above the right column.
3. Select the desired inspection from the inspection list in the left column.
4.
Click
Inspection name.idb displays in the right column and the inspection is transferred (saved) to the selected location.
Inspection Management screen, click Transfer.
Click above the right column.
An explorer window opens.
Navigate to the desired location, network location, or storage device.
Click Select Folder.
The folder is selected and the window closes.
.
VE as they are created and modified. Save a copy of the inspection
Figure 13. Transfer
5.3.5 Modify a Currently Running Inspection
1.
On the Sensor screen, select the desired inspection from the Inspection
The inspection tools and parameters display.
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list.
VE Series Smart Camera
2. Make the desired modifications to the inspection.
Important: Changes are automatically saved as they are made. Save a copy of the inspection if you want to
be able to go back to previous settings. Use the Emulator to set up or make changes to an inspection offline.
5.3.6 Copy a Tool
Duplicate (copy) a tool to include more than one of the same tool in an inspection.
1. Click the desired tool to duplicate.
2.
Click
A duplicate of the tool is created with the same input and test parameters.
3. Set the tool parameters as desired. The two tools are not linked; changes are independent of each other.
.
5.3.7 Delete a Tool
Use the following procedure to delete a tool from an inspection.
Click the tool on Tools & Results or Tools Only to select it.
1.
2.
Click
The tool is deleted.
.
NOTE: There is no undo option. A deleted tool cannot be recovered.
5.3.8 Delete a Tool and All Tools After It
Use the following procedure to delete a selected tool and all of the tools after it.
1. Click the tool on Tools & Results or on Tools Only to select it.
2.
Click
The message "Remove selected tool and all tools after it?" displays.
3. Click Continue.
The tools are deleted.
.
NOTE: There is no undo option. Deleted tools cannot be recovered.
5.3.9 Delete an Inspection
1.
Click Inspection Management, then click Manage.
2.
Select the inspection to be deleted.
NOTE: This inspection cannot be running and it cannot be selected to begin at startup.
3.
Click
The inspection name turns red and "Inspection marked for deletion" displays.
.
Figure 14. Inspection Marked for Deletion
4. Click to another tab to delete the inspection, or click Undo
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to keep the inspection.
VE Series Smart Camera
5.4 Configure the Discrete I/O
From the System Settings
For more details, see Discrete I/O on page
screen, select Discrete I/O
to change the discrete I/O settings.
Figure 15. Discrete I/O
34.
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VE Series Smart Camera
6 Vision Manager Workspace
Vision Manager
• Home Screen on page
firmware, and view sensor and Vision Manager
• Sensor Screen on page 26— The
inspection.
• Inspection Logs Screen on page 30
information. Inspections logs can be viewed when the camera is offline.
• Inspection Management Screen on page 31—The Inspection Management screen includes options to add
inspections to the currently connected sensor, to rename an inspection, and to transfer inspections between a
connected sensor and a network location or storage device.
• System Settings Screen on page
information, discrete I/O, communications settings, system logs, and units.
6.1 Home Screen
has five main working areas, or screens:
22—The
Home screen provides access to connect to a sensor or emulator, update
Sensor screen displays the information needed to create or modify an
— The
34—The
software information.
Inspection Logs screen displays saved images and inspection
System Settings screen provides access to view and adjust sensor
The Home screen provides access to connect to a sensor or emulator, update firmware, and view sensor and Vision
Manager
The following are available from the Home screen:
Only one sensor can be connected to each instance of the software. Open more than one instance of Vision Manager
want to connect to more than one sensor at a time. Only one instance of the software can be connected to the Emulator at
a time.
software information.
• Sensor Neighborhood
• Sensor Maintenance
• Emulators
• About
Figure 16. Home Screen
if you
6.1.1 Sensor Neighborhood
Use Sensor Neighborhood on the
default when the software is launched.
Active Sensors Tab
Use the Active Sensors tab in Sensor Neighborhood to connect to an active sensor.
Navigate: Home > Sensor Neighborhood >
This tab includes sensor information such as sensor status, sensor name, IP address, MAC address, and model number.
Sensors can also be added to Favorites.
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Home screen to connect to active sensors. Sensor Neighborhood opens by
Active Sensors.
VE Series Smart Camera
Figure 17. Active Sensors Tab
To connect to a sensor, click
next to the desired sensor. To disconnect from a sensor, click .
To view or change sensor Status, MAC Address, Sensor Name, IP Address, Subnet Mask, and Gateway, click .
To add the sensor to a Favorites Group, click . The icon changes to .
To manually connect to a sensor with a known IP address, enter the IP address in the Enter IP Address field and click
.
Favorites Tab
Save sensors to the Favorites tab for easy access to them. Sensors are saved to groups.
Navigate:
Home > Sensor Neighborhood >
Favorites.
Figure 18. Favorites Tab
Click Add New Group to create a new Favorites Group. To add a sensor to the group, on the Active Sensors tab, click
or from the Favorites tab, enter the sensor IP address and click to verify the connection to the sensor and
automatically save it to the selected group.
To manually add a sensor with a known IP address to the Favorites tab, enter the IP address in the Enter IP Address
field and select the desired group.
To remove a sensor from a group, click the across from the sensor name. To move the sensor to another group, click
the
and select the desired group.
To remove a group and all the sensors within the group, click the across from the group name.
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VE Series Smart Camera
Network Adapters Tab
Use the Network Adapters tab on Sensor Neighborhood
sensors.
to view the network adapters that the system searches to find
Navigate:
Network adapter information including Link Status (connected/not connected), Adapter name, IP Address, and Subnet
Mask is also available.
Home > Sensor Neighborhood >
Network Adapters.
Figure 19. Network Adapters Tab
6.1.2 Sensor Maintenance
Use Sensor Maintenance on the
sensor.
Home screen to update the firmware on a sensor and to backup or restore the
Figure 20. Sensor Maintenance Tab
Sensor Maintenance includes sensor information such as sensor Status, Sensor Name, IP address, MAC address, Model
number, Firmware Version, and which sensors are tagged as favorites.
Actions include update firmware
, view or change some sensor settings , and backup or restore sensor data .
Update the Firmware
1.
From the Home screen, click Sensor Maintenance.
2. Make sure that the desired sensor is not connected to the
3.
Click
This process can take several minutes. Do not close the program or remove power from the sensor during the update
process.
When the process is complete, the sensor restarts and the status returns to Available.
firmware version in the Firmware Version column.
next to the sensor and follow the prompts.
NOTE: During the firmware update process, there are options to restore the sensor to the factory default
settings and to create a backup before updating the firmware.
Important: All stored inspections are deleted when factory default settings are restored. Ethernet settings and
favorites lists are retained.
Vision Manager software and that the status is Available.
Vision Manager
displays the new
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VE Series Smart Camera
Backup or Restore the Sensor
System settings and inspections can be backed up and restored. Firmware is not included in the backup or restore.
The backup file is saved to the location of your choice.
1.
From the
2. Make sure that no sensors or emulators are connected to the
status is Available.
3.
Click
4. Follow the prompts to save a backup file.
A message displays saying that the backup was successful.
5.
To restore the sensor data, click , then click Restore.
6. Follow the prompts to restore the sensor data. An Emulator backup file can be used to restore the sensor.
A message displays saying that the restore was successful.
Home screen, click Sensor Maintenance.
Vision Manager software and that the desired sensor's
, then click Backup.
NOTE: This process can take several minutes.
6.1.3 Emulators
Use Emulators
Click to connect to the desired emulator. This tab also displays the Image location on the computer, as well as the
emulator version information.
Click under Image Location to change the directory for the reference images. The default directory for images is C: >
Users >
bitmap (BMP) images and inspection logs are supported. Bitmap images should be the same resolution as the VE camera.
If inspection logs are placed in the Images directory, the emulator automatically extracts the image out of the inspection
log and uses it to run the currently loaded inspection.
The Emulators tab includes all available features and all tools function the same as they do when running on a sensor. On
the emulator, execution time is not calculated.
on the Home
Public > Documents > Banner Vision Manager > VE Series > VE xMP > Images. Both 8-bit monochrome
screen to connect to the emulator.
Figure 21. Emulators
Backup or Restore the Emulator
Emulator settings and inspections can be backed up and restored.
The backup file is saved to the location of your choice.
1.
From the
2. Make sure that no sensors or emulators are connected to the
3.
Click
4. Follow the prompts to save a backup file.
A message displays saying that the backup was successful.
5.
To restore the sensor data, click
6. Follow the prompts to restore the sensor data. A sensor backup file can be used to restore the emulator.
Home screen, click Emulators.
Vision Manager software.
, then click Backup.
, then click Restore.
NOTE: This process can take several minutes.
A message displays saying that the restore was successful.
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VE Series Smart Camera
6.1.4 About
Use About to view Vision Manager
software information, including the version number.
6.2
Sensor Screen
The Sensor screen displays the information needed to create or modify an inspection.
1. Screens—Home, Sensor, Inspection Logs, Inspection Management, System Settings
2. Manual Trigger button—Click to manually trigger the sensor
3. Inspection
4. Summary pane—Includes the Inspection Summary and the I/O Summary
5. Parameters
selected in the Tools and Results pane
6. Tools and Results pane—Includes Tools and Results, Tools Only, and All Results, which display the camera tool, the tools that are
included in the current inspection, and the results of the inspection
7. Image Pane Parameters panel—Includes ROI view buttons, zoom, x and y coordinates, grayscale value, and full image display button, as
well as sensor messages
8. Image pane—Displays the current image captured by the sensor; this includes the region of interest (ROI) for the tool for the selected
inspection
list—Select the desired inspection to start, and to view or modify the inspection
pane—Includes user-adjustable Inputs parameters or Test parameters for the tools in an inspection, depending on what is
Figure 22. Sensor Screen
6.2.1 Image Pane Parameters
Use the Image Pane Parameters to change how the Image pane displays and to view status messages.
Figure 23. Image Pane Parameters
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VE Series Smart Camera
ROI View Buttons
Click
to view all tool ROIs and annotations.
Click to view the ROI and annotations for the selected tool only.
Click to hide all ROIs annotations and view the image only.
NOTE: The Image Overlays parameter for each tool also control which ROI is shown and this
parameter overrides the ROI view buttons.
Zoom
Slide to zoom the Image pane in and out.
Status Messages
View status messages such as "Applying Changes" and "Waiting for Trigger". Some messages, such as "Applying
Changes," display only momentarily while a parameter change is serviced by the sensor. Other messages such as
"Waiting for Trigger" require an action to be completed.
X and Y Coordinates and Grayscale Value
Displays the current x and y coordinates and grayscale value for the location the pointer is at in the Image pane.
Full Image Display Mode Button
Click to expand the image to fill the screen. The image pane and impage pane parameters are the only items
shown. Click to return to the standard view.
6.2.2 Summary Pane
The Summary pane includes both the Inspection Summary
When expanded, the Inspection Summary displays inspection pass, fail, and missed trigger statistics since the last time
the inspection summary results were reset. A green checkmark indicates that an inspection passed, and a red X indicates
that an inspection failed. A dash indicates that there is no information to display.
and the I/O Summary.
Figure 24. Inspection Summary
The History Trend below the pass/fail statistics provides another visual indication of whether or not an inspection passed,
as well as an indication of when changes are made.
• Green indicates that an inspection passed
Red indicates that an inspection failed
•
• Blue indicates that a change was made to the inspection
• Pink indicates that a product change was made—either a new inspection was added or the inspection was changed
to a different one
The History Trend holds up to 400 entries and updates after an inspection is completed. The entries are recorded first in,
first out, with the newest entry displayed on the left of the History Trend. Point to an entry on the History Trend for
information about the entry. For example, pointing to a green entry displays the frame number.
Click Reset to clear the Inspection Summary statistics. The History Trend does not reset.
When collapsed, the Inspection Summary displays only pass and fail information. A green number on the left represents
the number of inspections that passed. A red number on the right represents the number of inspections that failed since
the last reset.
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VE Series Smart Camera
When expanded, the I/O Summary displays input and output status information and system errors, if present. When
collapsed, no I/O Summary information is visible.
Figure 25. I/O Summary
Inputs and outputs display on the I/O Summary after they are configured from the
Configure the Discrete I/O on page 21). Green indicates that the I/O is active. Light gray indicates that the I/O is inactive.
The System Error indicator flashes red when an error is present. View and clear the error from the System Settings
screen (see Logs on page 39
).
Figure 26. IO Summary with Error
System Settings screen (see
6.2.3 Tools & Results
Tools & Results shows the camera tool and the inspection tools that are included in the current inspection, as well as the
results for the currently selected tool.
Figure 27. Tools & Results
Use Tool & Results to add and configure tools in an inspection and to view results. Click a camera tool or inspection tool
on Tools & Results to access the Parameters
See Using the Camera Tool on page 45, Using the Inspection Tools: Vision Tools on page 49, and Using the Inspection
Tools: Analysis Tools on page 115 for additional tools information.
pane for that camera or tool.
6.2.4 Tools Only
Tools Only shows the camera tool and the inspection tools that are included in the current inspection.
Figure 28. Tools Only
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VE Series Smart Camera
Use Tools Only to add and configure tools in an inspection. Click a camera tool or inspection tool on Tools Only to access
the Parameters
See Using the Camera Tool on page 45, Using the Inspection Tools: Vision Tools on page 49, and Using the Inspection
Tools: Analysis Tools on page 115 for additional tools information.
pane for that camera or tool.
6.2.5 All Results
All Results lists the results for the current inspection, camera tool, and inspection tools.
Figure 29. All Results
At a glance, view the Result (pass/fail/status), execution Time (in milliseconds), Pass Count, and Fail Count for each item.
Expand each item for additional details.
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6.3 Inspection Logs Screen
The Inspection Logs screen displays saved images and inspection information. Inspections logs can be viewed when
the camera is offline.
1. Log Sources pane—Choose the source for the inspections logs to view, and set the criteria for collecting logs
2. Loaded Logs pane—View and filter the inspection logs
3. Image pane—Displays the saved inspection image captured by the sensor. This includes the tools that were used in that inspection
4. Summary pane—Displays saved information from a specific inspection and frame number
5. Parameters pane—Displays the logged Input or Test parameters, depending on what is selected in the Tools & Results pane
6. Tools and Results
the tools that are included in the logged frame, and the results of the inspection
7. Image Pane Parameters panel—Includes ROI view buttons, zoom, x and y coordinates, and grayscale value, as well as sensor messages
pane—Includes the Tools & Results
Figure 30. Inspection Logs Screen
tab, the Tools Only tab, and the All Results tab, which display the camera tool,
6.3.1 Log Sources
View logs from either the sensor or a network folder or storage device.
Click
Thumbnail views of the images display in the Loaded Logs pane. While inspection logs are loading, the Percent Bar
displays and shows the percentage of inspection logs that have loaded; it is removed when all inspection logs have finished
loading.
Expand Sensor to set the criteria for what is collected in the inspection logs. Set the Log Criteria:
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to move the inspection logs from the sensor to the computer. Click to navigate to saved inspection logs.
• All
•
Pass Only
• Fail Only
• By Slot Number
• Remote Teach All
VE Series Smart Camera
• Remote Teach Pass
• Remote Teach Fail
Set the Strategy
• First N Logs
• Last N Logs
Set the Capture Limit (limits the number of inspection logs the sensor holds in internal memory):
• Low Count
• Medium Count
• High Count
:
Filter logs to be viewed by pass
inspection previews. Click
, fail , remote teach , or inspection number using the buttons to the left of the
to clear all filters.
6.3.2 Loaded Logs
After log information is loaded from the Log Sources pane, click on a thumbnail to view the full frame in the Image pane.
The Inspection Summary shows whether or not the inspection passed, which inspection was being used, and which
frame number you are viewing. Click the camera tool or an inspection tool in the Tools and Results pane to view
additional logged information in the Parameters pane, such as camera exposure, the reference pattern, or the filters used
during the inspection, as well as to view specific results for the frame.
NOTE: Some parameters are disabled in the Inspection Logs. For example, if histogram information was not
collected during the inspection, it cannot be viewed from the log.
6.4
The Inspection Management screen includes options to add inspections to the currently connected sensor, to
rename an inspection, and to transfer inspections between a connected sensor and a network location or storage device.
The following are available from the Inspection Management
• Manage
• Transfer
The inspection CRC is listed for each inspection on both the Manage and Transfer screens. When an inspection is created, it
is assigned a Cyclic Redundancy Check code, or CRC. The CRC is generated by considering each setting within the
inspection (this includes the input parameters of all tools). When a change is made to the input parameters of any tool
within the inspection, a new CRC is generated. Because of this, CRC becomes a very simple yet powerful way to determine
if a change was made to the inspection since the last time it was modified.
Inspection Management Screen
screen:
NOTE: Changing an inspection's name and slot number does not modify its CRC.
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VE Series Smart Camera
6.4.1 Manage
Use Manage to add new inspections, delete existing inspections, rename inspections, set an inspection to run at startup,
or copy an inspection.
Figure 31. Manage
Also displayed are the sensor name, inspection name, and whether the inspection is running.
Copy an Inspection
Duplicate (copy) an inspection to use as a starting point for a new inspection.
1.
On the Inspection Management screen, click Manage
2.
Locate the inspection to copy and click
A duplicate of the inspection is created with the same tools and parameters and is added to the inspection list as
Inspection (#).
3. Adjust the inspection as desired. The two inspections are not linked; changes are independent of each other.
.
.
Delete an Inspection
1.
Click
2. Select the inspection to be deleted.
3.
Click .
The inspection name turns red and "Inspection marked for deletion" displays.
4. Click to another tab to delete the inspection, or click Undo
Inspection Management, then click Manage.
NOTE: This inspection cannot be running and it cannot be selected to begin at startup.
Figure 32. Inspection Marked for Deletion
to keep the inspection.
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VE Series Smart Camera
Set an Inspection to Begin at Startup
NOTE: Only one inspection can begin at startup.
1.
On the Inspection Management screen, click Manage
2.
Locate the desired inspection and click
The turns green and the inspection will begin at the next startup.
.
.
6.4.2 Transfer
Use Transfer to transfer inspections between a connected sensor and a computer, network drive, or storage device.
Figure 33. Transfer
Click
to navigate to and select a different folder. Click to open the folder to view the files.
Save an Inspection to a Computer, Network Drive, or Storage Device
Vision Manager
to your computer or another network location if you want to be able to go back to previous settings.
Use the following procedure to save a copy of an inspection to your computer or a network location.
1.
On the
2. Change the destination folder, if desired.
a)
Click above the right column.
An explorer window opens.
b) Navigate to the desired location, network location, or storage device.
c)
Click Select Folder.
The folder is selected and the window closes.
The path to the location displays above the right column.
3. Select the desired inspection from the inspection list in the left column.
4.
Click
Inspection name.idb displays in the right column and the inspection is transferred (saved) to the selected location.
automatically saves inspections to the
Inspection Management screen, click Transfer.
.
VE as they are created and modified. Save a copy of the inspection
Figure 34. Transfer
Save Inspections to a VE Sensor
Inspections stored on a computer or network drive or created in the emulator can be saved to the connected VE sensor.
1.
On the
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Inspection Management screen, click Transfer.
VE Series Smart Camera
2. Select the desired location.
a)
Click
Navigate to the desired folder.
b)
The path to the location displays above the right column.
3.
In the list on the left, select (Next Empty Slot) to add the inspection to the list or select an existing inspection to
replace.
4. Select the desired inspection from the list on the right.
5.
Click
Inspection name displays in the left column and the inspection is transferred to the sensor.
above the right column.
.
6.5 System Settings Screen
The System Settings screen provides access to view and adjust sensor information, discrete I/O, communications
settings, system logs, and units.
The following are available from the System Settings screen:
• Sensor Info
• Discrete I/O
• Communications
• Logs
• Units
• System Reset
6.5.1 Sensor Info
Use Sensor Info to view or change sensor information, including sensor name, IP address, subnet mask, and gateway.
Figure 35. Sensor Info
Click to access the sensor properties editing window. Click to refresh the information.
• Sensor Name—View or change the sensor name
Model—View the model number of the sensor
•
• Serial Number—View the serial number of the sensor
• Firmware Version—View the current firmware version of the sensor
• Up Time—View the amount of time the sensor has been running since it was last powered on
• Hour Count—View the number of hours the sensor has been powered on over its lifetime
• Boot Count—View the number of times the sensor has been powered on over its lifetime
6.5.2 Discrete I/O
Use Discrete I/O to view the I/O and pin numbers; view the status; and set the function, active level, output delay, latch
type, and output duration for each pin.
From the
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System Settings screen, select Discrete I/O
to change the discrete I/O settings.
VE Series Smart Camera
Figure 36. Discrete I/O
I/O
The VE has five configurable I/O. These are pins 1, 5, 8, 10, and 11.
Pin #
The pin number on the cable connection. See Table 1 on page
13.
Wire Color
The corresponding wire color for each pin. See Table 1 on page 13.
Status
Indicates whether or not the I/O is active.
Green = active
Gray = inactive
Function
The following input and output options are available:
• Disabled—The pin is not configured
• General Ouput—Used in conjunction with the Logic Tool to configure individual discrete outputs based on
specific tool results.
• Pass—Active when the inspection passes.
• Fail—Active when the inspection fails
• Ready—Active when the sensor is ready to accept another trigger
• System Error—Active when a system error occurs
• Online—Active when the Camera is connected
• Missed Trigger—Active when a trigger is missed
• Product Change—The input is used in conjunction with one of the four I/O points programmed as Product
Select lines. The inspection loaded will be executed following a valid trigger. See Function: Product Change
on page 36 for additional details on Product Change
• Product Select Bit 0/1/2/3—Available when Product Change is selected on another I/O; used in conjunction
with Product Change to select inspection locations at which to begin execution. See Function: Product
Change on page 36
• Remote Teach—Sets the pin to accept input pulses for remote teaching the sensor
Invert
Select to switch when the I/O is active or inactive.
Output Delay (ms)
The time from when a trigger starts an inspection until the sensor output turns on. It is available for the General
Output, Pass, Fail, and Missed Trigger functions of the selected pin.
NOTE: If the inspection execution time is longer than the output delay, the output becomes active
immediately after the processing is finished.
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VE Series Smart Camera
Latch Type
Select the behavior of the I/O pin when in active state; available when the I/O is configured as an output.
• Latched—Maintains state until the condition of the associated function changes; available for the following
functions: General Output, Pass, Fail, Ready, System Error, Online, and Missed Trigger
•
Pulsed—Maintains active state for a selected period of time, then returns to the inactive state; available for
the following functions: General Output, Pass, Fail, System Error, and Missed Trigger
• Trigger Gated—Output signal is only active upon trigger signal being active
Output Duration (ms)
The length of time the output is active.
This option is available for the Latch Type = Pulsed.
Function: Product Change
The sensor can be commanded to load inspections from slots 1 to 15 using the combination of Product Change and Product
Select functions of the discrete I/O pins.
Set the state of the Product Select pins as described in Product Select Inputs on page 36. Then set the state of the
Product Change pin to Active when the sensor is in the Ready state. The sensor immediately loads the selected inspection
and is ready to execute when it receives a trigger. For Product Change to be successful, select at least one of the I/O pins
to function as Product Select.
Product Select Inputs
The VE has four dedicated Product Select lines that can be thought of as making a Binary Code Decimal (BCD) table.
Access inspections 0 through 15 using the following pin combinations:
Inspection Number Product Select #3 Product Select #2 Product Select #1 Product Select #0
0 OFF OFF OFF OFF
1 OFF OFF OFF ON
2 OFF OFF ON OFF
3 OFF OFF ON ON
4 OFF ON OFF OFF
5 OFF ON OFF ON
6 OFF ON ON OFF
7 OFF ON ON ON
8 ON OFF OFF OFF
9 ON OFF OFF ON
10 ON OFF ON OFF
11 ON OFF ON ON
12 ON ON OFF OFF
13 ON ON OFF ON
14 ON ON ON OFF
15 ON ON ON ON
6.5.3 Communications
Use Communications to view or change communication information, to set the industrial protocol, and to set image
export settings.
Ethernet Settings Tab
Use the Ethernet Settings
Navigate:
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System Settings > Communications > Ethernet Settings.
tab to view or change some Ethernet settings.
VE Series Smart Camera
Figure 37. Ethernet Settings Tab
On the Ethernet Settings tab , click to access the sensor properties editing window and view or change the following:
•
IP Address—View or change the IP address of the sensor
Subnet Mask—View or change the subnet address of the sensor
•
• Gateway—View or change the gateway address of the sensor
• MAC Address—View the MAC address of the sensor
To change the Max Speed, the maximum negotiation speed with the network, select the desired speed from the list:
• 1000 Full Duplex
• 100 Full Duplex (default)
• 100 Half Duplex
Industrial Protocols Tab
Use the Industrial Protocols tab to set the protocol the sensor uses to communicate and to select output data (map) to
send to a PLC.
Navigate:
System Settings > Communications > Industrial Protocols.
Figure 38. Industrial Protocols Tab
On the Industrial Protocols tab, select the desired protocol to enable it.
• Disabled (default)
•
EtherNet/IP
• PROFINET
• Modbus/TCP
• PCCC
A 32 Bit Format setting displays if Ethernet/IP, Modbus/TCP, or PCCC is chosen. Select LSW-MSW or MSW-LSW from
the list.
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VE Series Smart Camera
Figure 39. Industrial Protocols Tab—EitherNet/IP Selected
A customizable map to output camera or inspection tool-specific results also displays. The map includes the following:
Register/Byte/Word (depending on the protocol selected)
•
Inspection Slot #
•
• Tool Type
• Tool Name
• Result
• Type
• Actions
NOTE:
• Inspection Slot # changes automatically depending on which inspection includes the tool.
Type changes automatically depending on how much space is available.
•
• Data in registers 1–16 are fixed and contained in the PLC input assemblies (EtherNet/IP, Modbus/TCP, and
PCCC).
Click Apply Changes to send the current map to the camera.
Click
to print and save a PDF of the current map. The PDF includes all data, whether system-defined or user-defined.
Click above the map to return the map to the default settings. All user-defined output data is deleted. Click in the
Actions column to delete an individual result.
For additional information see:
• Set the Industrial Ethernet Protocol (EtherNet/IP, PROFINET®, Modbus/TCP, PCCC) on page 138
• Tool-Specific Results: EtherNet/IP on page 144
• Tool-Specific Results: Modbus/TCP on page 165
• Tool-Specific Results: PCCC on page 174
• Tool-Specific Results: PROFINET on page 183
Image Export Tab
Use the Image Export tab to set the parameters used to export images.
Navigate:
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System Settings > Communications > Image Export.
VE Series Smart Camera
Figure 40. Image Export Tab
On the Image Export tab, set the image export parameters:
Export
Set which images to export:
Disabled
•
• All (default)
• Pass only
• Fail only
Port Number
Set the port number to use for the export. The default is 32200.
Hold READY
Select to prevent new triggers from being accepted until the current image has been exported.
Clear the checkbox to accept new triggers while the current image is exported.
Important: When the checkbox is cleared, not all images will be exported. When the checkbox is
selected, the ready signal is held active until the image has been exported across Ethernet;
inspection times will increase based on network throughput.
For additional information, see Image Export on page 135
.
6.5.4 Logs
The Logs default view is the System tab. Use the System Tab to view, export, or clear system logs and communication
logs. Select or clear the Display checkboxes to customize which events are shown.
Navigate: System Settings > Logs > System.
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VE Series Smart Camera
Figure 41. System Tab
To clear a system error flag (or state), click Clear System Error.
NOTE: The system error log entry will not be cleared from the log.
To export system logs, click Export Log and follow the prompts. Logs are exported as a .slog file.
To clear the log, click Clear Log.
View a system log exported from another sensor using the View Exported Logs
tab.
Navigate: System Settings > Logs > View Exported Log. Click Load Log and navigate to the desired log file to view it.
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VE Series Smart Camera
Figure 42. View Exported Log Tab
6.5.5 Units
Use Units to select a unit to display and to publish results that represent distance, size, and location calculations.
Figure 43. Units
By default, distance, size, and location calculations are shown in pixels. To change the displayed units, from the Mode list,
select Scaling and then select the desired measurement unit and parameters. The following Measurement Units are
available:
• Microns (µm)
Millimeters (mm)
•
• Centimeters (cm)
• Meters (m)
• Mils (mil)
• Inches (in)
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VE Series Smart Camera
• Feet (ft)
• Yard (yd)
Click
Apply Changes to save the changes. Applying a scaling factor changes the measurements listed in the Tools and
Results to the selected unit and applies the scale to all inspections.
Scale Units Using a Known Measurement
Use a known measurement, such as ruler, to configure the scaling factor for converting pixels to the desired unit.
The conversion factor for using scaled units can be determined using any object of a known size. For illustration purposes,
this example uses a ruler as the object. This procedure is an example only.
NOTE:
• Make sure the camera focus is as sharp as possible.
Span more pixels for increased accuracy.
•
• Use objects closer to the center of the FOV to limit the distortion that naturally occurs closer to the edges
of the FOV.
1. Place the ruler in the FOV.
2.
Add a Measure tool.
3. Point to the 0 line on the ruler and write down the x and y coordinates shown in the Image Parameters pane.
Figure 44. X and Y Coordinates
4. Expand Measure from...
and select Constant.
5. In the Point (X, Y) field, enter the x and y coordinates from step 3.
6. Point to the 10 mm (1 cm) line on the ruler and write down the x coordinate shown in the Image Parameters pane.
7. Expand Measure to... and select Constant.
8. In the Point (X, Y) field, enter the x you wrote down in step 6 and y coordinate from step 3. (The y coordinates must
be the same.)
The Measure tool measures between the two points.
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VE Series Smart Camera
9. Write down the Distance (px) show in Tools & Results.
In this example, the distance is 101.00 px.
Figure 45. Distance Measurement Between the Two Points
10.On the System Settings
screen, click Units.
11.From the Mode list, select Scaling.
The scaling parameters display.
12.Select the desired Measurement Unit. For this example, the unit is Millimeters.
13.In the Measurement in Pixels field, enter the distance from step 9.
14.In the Measurement in Millimeters field, enter 10 because the known distance was 10 mm.
Figure 46. Units Configured
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VE Series Smart Camera
15.Click Apply Changes.
Applying a scaling factor affects all existing inspections. The currently running inspection is immediately modified on
the next trigger and other inspections are modified when they are loaded.
Figure 47. Tools and Results Showing the New Units
6.5.6 System Reset
Use System Reset to reboot the sensor or to restore the sensor to the factory default settings.
Click Reboot Sensor to stop, shutdown, and restart the sensor. The start up inspection is loaded after the sensor reboot.
Click
Reset to Factory Defaults to restore the sensor to the factory default settings.
Important: All stored inspections are deleted when factory default settings are restored. Ethernet settings and
favorites lists are retained.
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VE Series Smart Camera
7 Using the Camera Tool
The camera tool controls the sensor's camera function during an inspection. Configure the camera tool using the
parameters in the Parameters pane:
• Imager
•
Focus Info
• Trigger
• External Strobe
• Image Histogram
Figure 48. Camera Tool Input Parameters
When the camera tool is selected, it is highlighted orange in Tools & Results and in Tools Only, the Inputs tab displays
on the Parameters pane, and the camera tool results are highlighted in All Results.
7.1 Imager
Use the Imager parameters to adjust the exposure and gain.
Figure 49. Imager
Exposure
Exposure time is the amount of time the camera allows light to energize the imager chip. Increasing the exposure
time allows more light to energize the imager chip, which brightens the picture. Use the slider or enter the desired
exposure time in milliseconds.
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VE Series Smart Camera
Gain
Gain is an electronic boost to the image signal. Increasing gain increases image brightness without increasing
exposure time. Use the slider or enter the desired gain number.
NOTE: Gain brightens both the light pixels and the dark pixels. High gain values will make the
image appear grainy.
Auto Exposure
During Auto Exposure, the exposure time and gain are optimized for the current inspection. Click Start
Auto Exposure.
NOTE: Several triggers may be required to calculate the optimized values for exposure and gain.
to begin
7.2 Trigger
Use the Trigger parameters to set the method and rate at which the sensor captures images. Trigger parameters are
stored in the inspection file and can be different for each inspection.
Figure 50. Trigger
Internal (default)
The sensor triggers itself at a user-defined rate. Use the slider or enter the desired rate, from 10 ms to 10,000
ms. The default rate is 100 ms.
External
The sensor is triggered either manually using the trigger button in the Vision Manager software or it is
triggered by an external source (via the trigger pin), such as a photoelectric sensor. The external trigger option
has the following parameters:
• Trigger Polarity—Sets when the image is captured compared to the trigger signal. 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. The default is Leading Edge.
• Trigger Delay
sensor captures the image. Use the slider or enter the desired time in milliseconds, from 0 ms to 10,000
ms. The default is 0 ms.
• Minimum Trigger Width—Eliminates unwanted triggers by accepting triggers only if they last for a
specified duration. Use the slider or enter the desired minimum trigger width in milliseconds, from 1 ms to
5,000 ms. The default is 1 ms.
• Trigger Divide—Sets the logic for how valid trigger inputs are related to actual images taken. If the
Trigger Divide is set to 1, an image is captured in response to every valid trigger. If it is set to 2, an image
is captured in response to every second valid trigger, and so on. Use the slider or enter the desired trigger
divide, from 1 to 1,000. The default is 1.
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—Sets the fixed time from the instant the sensor receives a valid trigger to the instant the
VE Series Smart Camera
Free Run
The sensor immediately issues a new trigger at the end of an inspection.
Industrial Ethernet
The Industrial Ethernet communications channel controls the trigger. A PLC or HMI triggers the camera tool over
an Industrial Ethernet protocol such as EtherNet/IP or PROFINET.
7.3 Focus Information
Select the Focus Info checkbox and expand the parameter to view the current focus number for the installed lens.
Figure 51. Focus Info
The focus number is a number between 1 and 255. Use the Image pane to determine when the image is sharp enough, or
use the focus number as a guide. Turn the focus ring on the lens until the focus number is at the highest possible number
between 1 and 255. The focus number is also available on the sensor display.
NOTE: There is no optimal value for this number, but it can be used as a guide if you are setting up more than one
sensor that are focused on the same target.
7.4 External Strobe
Use External Strobe to control an external light connected to the sensor.
Figure 52. External Strobe
Strobe Type
The strobe type of the VE Series camera
behavior of the light will be inverted.
• Active Low—A 0 V dc external strobe signal is provided by the VE Series camera when the external light
should be ON. A +5 V dc external strobe signal is provided by the VE Series camera when the external
light should be OFF. This is the default strobe type setting for the VE Series camera and many of the
external vision lights Banner offers.
• Active High—A +5 V dc external strobe signal is provided by the VE Series camera when the external light
should be ON. A 0 V dc external strobe signal is provided by the VE Series camera when the external light
should be OFF.
Mode
• Always Off—The external light is always OFF
• Always On—The external light is always ON
• Exposure Based—The external light is ON for the duration of the camera exposure time
• Time Based—The external light is ON for the duration of a user-defined time period
should match the style of external light used, otherwise the ON/OFF
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Exposure Delay
The external light turns ON after a user-defined time delay, in milliseconds, after a valid trigger. Available only
when the Mode is Exposure Based or Time Based.
Duration
The external light is ON for a user-defined amount of time, in milliseconds. Available only when the Mode is Time
Based.
7.5 Camera Tool: Results
Click the camera tool on Tools & Results or expand the camera tool on All Results
Figure 53. Camera Tool Results
Focus Number
The focus number for the frame being viewed, if the Focus Number parameter is enabled in the Camera tool. See
Focus Information on page 47 for more information on the Focus Number.
Execution Time
The execution time for the camera tool. This is the total time required to capture an image.
Expand Execution Time to see the historical minimum and maximum execution times up to this point for the
selected tool.
Status
Status and error messages display as appropriate.
to view camera information.
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VE Series Smart Camera
8 Using the Inspection Tools: Vision Tools
Vision sensor tools include Average Gray, Bead, Blemish, Blob, Edge, Locate, Match, and Object.
Click a tool on Tools & Results or on Tools Only
contains both an Inputs tab and a Test tab. Define parameters for the tool itself on the Inputs tab. Define pass or fail
criteria for the tool on the Test tab. When a tool is selected, the tool is highlighted orange in Tools & Results and in
Tools Only, the tool ROI is selected in the Image pane, and the tool results are highlighted in All Results.
For many of the parameters, move the slider to set the desired number, or move both sliders to set minimum and
maximum limits, where applicable. Numbers and limits can also be entered manually.
In parameters with colors in the sliders, vertical green bars represent current image information. Light gray backgrounds
indicate the range over which a value has varied over time.
to access the Parameters
pane for that tool. The Parameters pane
8.1
Use the Average Gray tool to determine the brightness levels of pixels found within the ROI.
Each pixel has a grayscale intensity value from 0 to 255, where 0 is black and 255 is white. The tool records the grayscale
value of each pixel in an ROI and averages them. With this information, the tool can detect changes in intensity that can
indicate several conditions, such as missing objects, holes, texture changes, and possible color changes.
Example applications:
•
•
• Check for presence/absence of a label or other objects
Average Gray Tool
Spot-check for holes
Check for a change in surface texture
8.1.1 Average Gray Tool: Input Parameters
Use the Input parameters to configure how the tool analyzes an image.
Figure 54. Average Gray Tool—Input Parameters
ROI
The Region of Interest (ROI) is the user-defined group of pixels in the image that the sensor analyzes.
Figure 55. ROI Shape Selection
Resize and rotate the ROI around the feature to be analyzed. Change the shape of the ROI to a square, ellipse, or
circle as needed by expanding ROI on the Parameters pane and selecting the desired shape. An ROI can be as large as
the entire Field of View (FOV). The ROI automatically displays on the Image
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pane when a tool is added.
VE Series Smart Camera
Masks
Add and define a mask to exclude a group of pixels from the tool analysis.
Figure 56. Masks Parameters
A mask created for a tool will not apply to any other tool in the inspection. Up to 10 masks can be added to a tool.
1. Expand Masks
2.
Click
3.
Select the mask shape. The mask ROI can be rectangular, elliptical, or circular.
4.
Resize
5.
To delete a mask, click
on the Inputs tab.
. The mask ROI automatically displays on the Image pane.
and rotate the mask ROI around the pixels to be excluded.
.
Pixel Intensity Range
Set the intensity range of pixels to analyze. Pixels with brightness values outside of this range are ignored.
Figure 57. Pixel Intensity Range Parameters
The default settings of 0 to 255 allow all pixels to be included in the average calculation.
NOTE: An average grayscale result of – indicates that all pixels in the ROI have been excluded by the pixel
intensity range parameter.
Image Overlays
Choose whether to display or hide the ROI or masks.
Figure 58. Image Overlays—Default
These options override the ROI view buttons
specific tool is selected, the ROI information is shown.
Hide ROI
Hides the ROI when the tool is not
Hide Masks
Hides the Mask ROI when the tool is not selected.
selected.
on the Image Pane Parameters when no tool is selected. When a
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Tool Histogram
The Tool Histogram graphically displays pixel intensity information within the current ROI.
Figure 59. Example Histogram
Select the Tool Histogram checkbox to enable the histogram. The default is enabled. Expand the Tool Histogram
parameter to view the histogram.
The histogram is a display of the grayscale values on the x axis and the number of pixels on the y axis. The histogram
displays the amount of pixels for each grayscale value. The graph displays information for all grayscale values (0 to 255).
Move the pointer anywhere over the histogram to view specific information. The information updates as the position of the
pointer changes.
Inspection Pass/Fail
Select the Contribute to Inspection Pass/Fail check box (default) if the tool will influence the Pass/Fail status of the
inspection.
Figure 60. Inspection Pass/Fail
The Pass/Fail contribution influences the following:
• Discrete output Pass
•
Discrete output Fail
• Pass/Fail results counter
• Pass (Green) and Fail (red) LEDs on the Sensor
Select this checkbox if the overall Pass/Fail status of the inspection is dependent on the current tool.
8.1.2 Average Gray Tool: Test Parameters
Use the Test parameters to configure the pass/fail conditions for the tool.
Select the parameter checkbox to enable it. Where applicable, the vertical green bar shows the current parameter
information and the light gray backgrounds show the range over which a value has varied over time.
Where applicable, use the sliders or enter the minimum and maximum for the selected test parameters.
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VE Series Smart Camera
Average Grayscale
The grayscale value range.
Standard Deviation
The standard deviation range.
Figure 61. Average Gray Tool—Test Parameters
8.1.3 Average Gray Tool: Results
Tools & Results and All Results list information from the current and previous inspections.
A red box around a tool indicates that the tool failed. Status provides information about the specific failure.
All Results displays the Result, Time, Pass Count, and Fail Count information at a glance. Expand the inspection tool to
see specific results for that tool.
Average Grayscale
The average grayscale value of the pixels in the ROI.
Standard Deviation
The standard deviation of the average grayscale value for the pixels in the ROI.
Execution Time
The execution time, in milliseconds, for the currently selected tool in the current inspection.
Expand Execution Time to see the historical minimum and maximum execution times up to this point for the
selected tool.
Use the reset button in the Inspection Summary to reset these historical values.
Status
Status and error messages display as appropriate.
8.1.4 Using the Average Gray Tool
Follow these steps for a typical presence/absence Average Gray inspection.
NOTE: This procedure is an example only.
1. Add an Average Gray tool to the inspection.
2. Adjust the ROI to frame the desired feature.
Set the Test parameters to set the pass/fail criteria.
3.
a) On the Test tab, select the Average Grayscale checkbox.
This option sets the grayscale range that must be present in the ROI so that a part passes.
b) Move the sliders or enter the minimum and maximum grayscale. Inspections outside of this range will fail. For this
example, the minimum is 56.12 and the maximum is 74.83.
The green bar indicates the current grayscale and the light gray background indicates the grayscale over time since
the last reset.
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4. Test a complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad parts.
Figure 62. Average Gray—Pass Figure 63. Average Gray—Fail
8.2 Bead Tool
Use the Bead tool to inspect parts for uniformity of adhesive or sealant material, or for uniformity of a gap. In an industrial
setting, this "bead" of material is commonly applied in a strip along a known path. The Bead tool looks at this pre-defined
path and verifies whether the adhesive or sealant has been correctly applied.
For the purposes of this tool, a bead is any long, narrow strip of approximately consistent width and approximately
consistent color. The bead must have sufficient contrast with the background so that a simple grayscale threshold scheme
can separate the two. Background clutter and optical noise, such as shiny spots or holes in the bead, are permitted, but
their presence may degrade the robustness of a bead inspection.
The Bead tool assumes that the bead material has been applied by a mechanized system and is consistent in location and
direction. The tool does not attempt to detect, follow, or account for variations in bead location.
Example applications:
• Detect uniformity of a bead of adhesive
Detect uniformity of a gap between two adjacent materials
•
8.2.1 Bead Tool: Input Parameters
Use the Input parameters to configure how the tool analyzes an image.
Figure 64. Bead Tool—Input Parameters
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ROI
The Region of Interest (ROI) is the user-defined group of pixels in the image that the sensor analyzes.
Figure 65. Bead Tool ROI
The ROI is configurable to follow the desired path of the adhesive or sealant being analyzed. Adjust the width of the ROI
and set the sample rate. From the list select the frequency of bead width measurements: Every Pixel, Every 2nd Pixel, or
Every 4th Pixel. See Bead Tool: Adjust the ROI on page 59
.
Masks
Add and define a mask to exclude a group of pixels from the tool analysis.
Figure 66. Masks Parameters
A mask created for a tool will not apply to any other tool in the inspection. Up to 10 masks can be added to a tool.
1. Expand Masks
2.
Click
Select the mask shape. The mask ROI can be rectangular, elliptical, or circular.
3.
4.
Resize
5.
To delete a mask, click .
on the Inputs tab.
. The mask ROI automatically displays on the Image pane.
and rotate the mask ROI around the pixels to be excluded.
Threshold
The threshold parameter separates the bead from the background, in terms of contrast.
Threshold Type: Adaptive
Select Adaptive when there are lighting changes that cause the acquired image to change.
Figure 67. Threshold Type—Adaptive
An adaptive threshold is a technique that adjusts the threshold for the tool based upon lighting changes and image content
within the ROI. It performs best if used with bi-modal images, which have a clear contrast in the ROI. Adaptive threshold
chooses the current threshold value by converging to a value based on the average value of the pixels above and below
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the previous threshold value; it will not move the value of the threshold above or below the minimum and maximum
limits.
Adaptive Threshold: Bead/Blob Type
Defines whether the bead/blob is dark against a relatively brighter background or bright against a darker background.
This parameter defines the appearance of the feature of interest. For example, if you have a dark adhesive or part on a
bright background, choose Dark.
Choosing Dark with an adaptive threshold type causes the tool to limit the threshold to the range specified by the
threshold level minimum and maximum limits. The tool identifies all grouped pixels below the threshold chosen as dark
beads/blobs.
Choosing
threshold level minimum and maximum limits. The tool identifies all grouped pixels above the specified minimum limit and
less than or equal to the maximum limit as bright beads/blobs.
Bright with an adaptive threshold type causes the tool to limit the threshold to the range specified by the
Adaptive Threshold: Threshold
Use the sliders or enter the desired minimum and maximum possible grayscale threshold.
The green line is the current threshold value, chosen by the tool, and the sliders represent boundaries beyond which you
do not want the tool to move the threshold settings.
Reject Level
When the Bead/Blob Type is set to Bright, use the Reject Level to narrow the range of pixel intensities to be considered
in an inspection.
Leaving the defaults at 0 for low and 255 for high means that the tool takes into consideration all grayscale levels in the
ROI from 0 (black) to 255 (white).
Reject Level Example
Consider setting up an inspection for a relatively bright object that ranges from 180 to 200 in pixel intensity and takes up
15 percent of the FOV. The remaining 85 percent of the FOV ranges from 230 to 255 in pixel intensity. Setting a Reject
Level of 220 allows the tool to pay attention to only the bright object being inspected. Masking the bright parts of the FOV
is not necessary because only pixels whose intensity is less than the Reject Level will contribute to bright beads/blobs.
Threshold Type: Fixed
Select Fixed when the lighting and image content remain relatively constant for all inspections.
Figure 68. Threshold Type—Fixed
Fixed Threshold: Bead/Blob Type
Defines whether the bead/blob is dark against a relatively brighter background or bright against a darker background.
This parameter defines the appearance of the feature of interest. For example, if you have a dark adhesive or part on a
bright background, choose Dark.
Choosing Dark with a fixed threshold type causes the tool to fix the threshold at the level specified by the Threshold level
parameter. The tool identifies all grouped pixels below the specified threshold as dark beads/blobs.
Choosing
Threshold level parameter. The tool identifies all grouped pixels above the specified Bright threshold and less than or equal
to the Reject level as bright beads/blobs.
Bright with a fixed threshold type causes the tool to fix the threshold at the Bright level specified by the
Fixed Threshold: Threshold
Use the slider to define the dark/bright cutoff point.
Any pixels brighter than this point define the bright bead while those darker than this point define the dark bead.
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Reject Level
When the Bead/Blob Type is set to Bright, use the Reject Level to narrow the range of pixel intensities to be considered
in an inspection.
Leaving the defaults at 0 for low and 255 for high means that the tool takes into consideration all grayscale levels in the
ROI from 0 (black) to 255 (white).
Reject Level Example
Consider setting up an inspection for a relatively bright object that ranges from 180 to 200 in pixel intensity and takes up
15 percent of the FOV. The remaining 85 percent of the FOV ranges from 230 to 255 in pixel intensity. Setting a Reject
Level of 220 allows the tool to pay attention to only the bright object being inspected. Masking the bright parts of the FOV
is not necessary because only pixels whose intensity is less than the Reject Level will contribute to bright beads/blobs.
Good Bead Width
Move the sliders or enter the desired minimum and maximum bead width.
The red section is bead that is too narrow or is a gap. The green section is good bead width. The blue section is bead that
is too wide.
Figure 69. Good Bead Width
Filters
Select the checkbox to ignore boundary pixels.
Figure 70. Bead Tool Filters
Boundary pixels are bead pixels that touch the ROI. If boundary pixels are ignored, one or more segments may also be
ignored.
Image Overlays
Chose whether to display or hide the annotations, ROI, or masks when this tool is not selected. Masks are hidden by
default.
Figure 71. Image Overlays—Default
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These options override the ROI view buttons on the Image Pane Parameters when no tool is selected. When a
specific tool is selected, the ROI information is shown.
Hide Annotations
Hides the annotations on the live image for the tool, even when the tool is selected.
Figure 72. Show Bead Tool Annotations Figure 73. Hide Bead Tool Annotations
Hide ROI
Hides the ROI when the tool is not selected.
Hide Masks
Hides the Mask ROI when the tool is not selected.
Tool Histogram
The Tool Histogram graphically displays pixel intensity information within the current ROI.
Figure 74. Example Histogram
Select the Tool Histogram checkbox to enable the histogram. The default is enabled. Expand the Tool Histogram
parameter to view the histogram.
The histogram is a display of the grayscale values on the x axis and the number of pixels on the y axis. The histogram
displays the amount of pixels for each grayscale value. The graph displays information for all grayscale values (0 to 255).
Move the pointer anywhere over the histogram to view specific information. The information updates as the position of the
pointer changes.
Inspection Pass/Fail
Select the Contribute to Inspection Pass/Fail check box (default) if the tool will influence the Pass/Fail status of the
inspection.
Figure 75. Inspection Pass/Fail
The Pass/Fail contribution influences the following:
• Discrete output Pass
Discrete output Fail
•
• Pass/Fail results counter
• Pass (Green) and Fail (red) LEDs on the Sensor
Select this checkbox if the overall Pass/Fail status of the inspection is dependent on the current tool.
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8.2.2 Bead Tool: Test Parameters
Use the Test parameters to configure the pass/fail conditions for the tool.
Select the parameter checkbox to enable it. Where applicable, the vertical green bar shows the current parameter
information and the light gray backgrounds show the range over which a value has varied over time.
Where applicable, use the sliders or enter the minimum and maximum for the selected test parameters.
Count—Good
The number of good beads.
Count—Narrow/Gap
The number of narrow beads.
Count—Wide
The number of wide beads.
Largest Width
The maximum width found.
Smallest Width
The minimum width found.
Average Width
The average width found.
Total Length—Good
The total length of good beads.
Total Length—Narrow/Gap
The total length of narrow beads.
Total Length—Wide
The total length of wide beads.
Longest Length—Good
The longest good bead length.
Longest Length—Narrow/Gap
The longest narrow bead length.
Figure 76. Test Parameters
Longest Length—Wide
The longest length of wide beads.
8.2.3 Bead Tool: Results
Tools & Results
A red box around a tool indicates that the tool failed. Status provides information about the specific failure.
All Results displays the Result, Time, Pass Count, and Fail Count information at a glance. Expand the inspection tool to
see specific results for that tool.
Count - Good
The number of beads that fall within the user-defined good bead width.
Expand Count - Good to see the length of each bead, the total length of all beads, and the longest length.
Count - Narrow/Gap
The number of narrow beads or gaps that qualify as having a narrow bead width.
Expand Count - Narrow/Gap to see the length of each bead, the total length of all beads, and the longest
length.
Count - Wide
The number of wide beads that qualify as having a wide bead width.
Expand Count - Wide to see the length of each bead, the total length of all beads, and the longest length.
Average Width
The average width of all beads.
Expand Average Width to see the largest width and the smallest width.
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list information from the current and previous inspections.
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Adaptive Threshold
The grayscale value used to detect the bead when the Threshold Type is Adaptive. If the tool cannot calculate this
value, or if the Threshold Type is Fixed, this value displays as --.
Execution Time
The execution time, in milliseconds, for the currently selected tool in the current inspection.
Expand Execution Time to see the historical minimum and maximum execution times up to this point for the
selected tool.
Use the reset button in the Inspection Summary to reset these historical values.
Status
Status and error messages display as appropriate.
8.2.4 Bead Tool: Adjust the ROI
Follow these steps to adjust the Bead tool ROI.
NOTE: This procedure is an example only. Use the appropriate steps to adjust the Bead tool ROI for your
application.
1. Add a Bead tool to the inspection.
2. Move the ROI over the bead to be inspected.
3.
Move an
4.
Click the
anchor point to a new position by clicking on the anchor point when the Hand icon displays.
plus sign on either end of the bead ROI to add more anchor points.
Figure 77. Add a Bead Tool
Figure 78. Click to Move Anchor Point
Figure 79. Add Anchor Point
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5. Click on a line to add an inline anchor point.
a) Point to the ROI line; the pointer changes to a +.
Figure 80. Add Inline Anchor Point
b)
Click to select the location for the new anchor point; is added on the line.
Figure 81. Inline Anchor Point Location Selected
c)
Click the point again to set the location on the line. The
Figure 82. Inline Anchor Point Set
6.
Click on an anchor point and the Trash icon displays above it; click the Trash to delete the point.
changes to .
7. Use the ROI sliders in the Input
Figure 83. Click to Delete Anchor Point
tab to change the ROI width.
Figure 84. Bead Tool ROI Width
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8. Use the Good Bead Width parameter under Characteristics to define the good bead width.
Green indicates that the bead width is acceptable. Red indicates that the bead width is too narrow or that a gap exists.
Blue indicates that the bead width is too wide.
Figure 85. Good, Narrow, and Wide Adhesive Widths
8.2.5 Using the Bead Tool
Follow these steps to configure a Bead tool for a dark adhesive on a bright background.
NOTE: This procedure is an example only.
In this example, scaling is on (System Settings >
Units > Scaling) with the Measurement Unit set at Millimeters, the
Measurement in Pixels set at 810, and the Measurement in Millimeters set at 70.
1. Add a Bead tool to the inspection.
2. Adjust the ROI path and width to match the adhesive bead.
See Bead Tool: Adjust the ROI on page 59.
Figure 86. Bead ROI
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3. Set the threshold.
a) Expand the Threshold
parameters.
b) From the Threshold Type list, select Fixed.
Select Fixed when the lighting and image content remain relatively constant for all inspections.
c) From the Bead Type list, select Dark because in this case the adhesive is dark against a bright background.
d) Expand the Threshold parameters.
e) Move the slider until the adhesive bead shows as green in the ROI and the background is ignored. In this example,
that number is 137.
Figure 87. Threshold
4. Set the bead width.
Expand the Good Bead Width parameter.
a)
b) Move the sliders to define the minimum and maximum acceptable bead width. In this example, the minimum bead
width is 1.72 mm and the maximum bead width is 4.83 mm.
Figure 88. Good Bead Width
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5. Set the test parameters to set the pass/fail criteria.
a) On the Test tab, select the Count - Good checkbox to enable the test parameter.
This option sets the number of good beads that must be present with the tool parameters so that a part passes.
b)
Expand Count - Good and move the sliders or enter the minimum and maximum as 1 and 1.
This means that the inspection must find one and only one bead within the ROI that meets the Good Bead Width
definition.
c) Select the Count - Narrow/Gap checkbox to enable the test parameter.
This option sets the allowable number of gaps in the bead.
d) Move the sliders or enter the minimum and maximum as 0 and 0.
This means that no gaps are allowed. If gaps are found, the inspection fails.
Figure 89. Test Criteria
6. Test a complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad parts.
Figure 90. Bad Part—Narrow Bead Width
Figure 91. Bad Part—Gap
8.3 Blemish Tool
Use the Blemish tool to determine whether flaws are present on a part (for example, scratches on a disc), or to make sure
that a feature exists on a part.
Although finding features is more commonly an application for a Blob tool, the Blemish tool may be a better option to find
a feature when dealing with variable materials or inconsistent lighting.
Example applications:
• Check for scratches on a part, and reject parts where the scratches are too numerous or larger than acceptable
•
Check for the presence of a label or marking on a part that may vary in brightness level
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8.3.1 Blemish Tool: Input Parameters
Use the Input parameters to configure how the tool analyzes an image.
Figure 92. Blemish Tool—Input Parameters
ROI
The Region of Interest (ROI) is the user-defined group of pixels in the image that the sensor analyzes.
Figure 93. ROI Shape Selection
Resize
circle as needed by expanding ROI on the Parameters pane and selecting the desired shape. An ROI can be as large as
the entire Field of View (FOV). The ROI automatically displays on the Image
and rotate the ROI around the feature to be analyzed. Change the shape of the ROI to a square, ellipse, or
pane when a tool is added.
Masks
Add and define a mask to exclude a group of pixels from the tool analysis.
Figure 94. Masks Parameters
A mask created for a tool will not apply to any other tool in the inspection. Up to 10 masks can be added to a tool.
1. Expand Masks
2.
Click
Select the mask shape. The mask ROI can be rectangular, elliptical, or circular.
3.
4.
Resize
5.
To delete a mask, click
on the Inputs tab.
. The mask ROI automatically displays on the Image pane.
and rotate the mask ROI around the pixels to be excluded.
.
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Sensitivity
Set the Sensitivity to define how sensitive the sensor is to finding blemish or other edges within the ROI. The sensitivity
value helps account for light variations that can affect how well the sensor detects edges on inspected parts.
Figure 95. Sensitivity
The Sensitivity scale is from 0 to 100 where 0 means least sensitive and 100 means most sensitive. If set near 0, the
sensor finds very sharp edges with strong contrast. If set near 100, the sensor finds very dim or blurry edges, and may be
unstable. The default is 80.
Edge Length Range
Shows the different contiguous edge segments found.
Figure 96. Edge Length Range
Use the sliders to specify the edge length range in pixels. Edges found within this range will be considered when
calculating the Pass Count. Green represents lengths within the specified range and yellow represents lengths outside of
the specified range.
Image Overlays
Chose whether to display or hide the annotations, ROI, or masks when this tool is not selected. Masks are hidden by
default.
Figure 97. Image Overlays—Default
These options override the ROI view buttons
specific tool is selected, the ROI information is shown.
Hide Annotations
Hides the annotations on the live image for the tool, even when the tool is selected.
on the Image Pane Parameters when no tool is selected. When a
Figure 98. Show Blemish Tool Annotations
Hide ROI
Hides the ROI when the tool is not
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Figure 99. Hide Blemish Tool Annotations
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Hide Masks
Hides the Mask ROI when the tool is not selected.
Tool Histogram
The Tool Histogram graphically displays pixel intensity information within the current ROI.
Figure 100. Example Histogram
Select the Tool Histogram checkbox to enable the histogram. The default is enabled. Expand the Tool Histogram
parameter to view the histogram.
The histogram is a display of the grayscale values on the x axis and the number of pixels on the y axis. The histogram
displays the amount of pixels for each grayscale value. The graph displays information for all grayscale values (0 to 255).
Move the pointer anywhere over the histogram to view specific information. The information updates as the position of the
pointer changes.
Inspection Pass/Fail
Select the Contribute to Inspection Pass/Fail
inspection.
check box (default) if the tool will influence the Pass/Fail status of the
Figure 101. Inspection Pass/Fail
The Pass/Fail contribution influences the following:
• Discrete output Pass
•
Discrete output Fail
• Pass/Fail results counter
• Pass (Green) and Fail (red) LEDs on the Sensor
Select this checkbox if the overall Pass/Fail status of the inspection is dependent on the current tool.
8.3.2 Blemish Tool: Test Parameters
Use the Test parameters to configure the pass/fail conditions for the tool.
Select the parameter checkbox to enable it. Where applicable, the vertical green bar shows the current parameter
information and the light gray backgrounds show the range over which a value has varied over time.
Where applicable, use the sliders or enter the minimum and maximum for the selected test parameters.
Count
The total number of edge pixels.
Figure 102. Blemish Tool—Test Parameters
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8.3.3 Blemish Tool: Results
Tools & Results and All Results
A red box around a tool indicates that the tool failed. Status provides information about the specific failure.
All Results displays the Result, Time, Pass Count, and Fail Count information at a glance. Expand the inspection tool to
see specific results for that tool.
Count
The total number of edge pixels counted.
Length Range
The minimum and maximum edge lengths found.
Expand Length Range to see the minimum and maximum edge pixels counted, and the total edge pixels for each
blemish.
Execution Time
The execution time, in milliseconds, for the currently selected tool in the current inspection.
Expand Execution Time to see the historical minimum and maximum execution times up to this point for the
selected tool.
Use the reset button in the Inspection Summary to reset these historical values.
Status
Status and error messages display as appropriate.
list information from the current and previous inspections.
8.3.4 Using the Blemish Tool
Follow these steps for an example Blemish inspection to check for a date/lot code on a product.
NOTE: This procedure is an example only.
1. Add a Blemish tool to the inspection.
2. Adjust the ROI to frame the date/lot code.
3.
Set the sensitivity.
a) Expand the Sensitivity parameters.
b) Move the slider or enter 75 for this example.
A low sensitivity setting finds only high contrast edges, while a high sensitivity setting finds lower contrast edges as
well. Note that the color does not matter; the tool will still find the edges of the date/lot code.
Figure 103. Light Date/Lot Code on a Dark Background
4. Leave the default minimum and maximum edge length range (100 px and 165000 px).
This defines how long the edge has to be before it is counted and how small it can be before it is ignored. Green means
that the edge is within the criteria to be counted and yellow means it is outside of the criteria and is being ignored.
Set the Test parameters to set the pass/fail criteria.
5.
a)
On the Test tab, select the Count checkbox.
This options sets the number of edges that must be present within the ROI that match the inspection parameters so
that the tool passes.
b) Move the sliders or enter the minimum count at 242 and the maximum count at 233230.
For example, a minimum and maximum count of 0 and 0 means that the part must have zero edges within the ROI
that match the inspection parameters. In this case, the part must be blemish-free.
Figure 104. Dark Date/Lot Code on a Light Background
NOTE: The green bar indicates the current count and the light gray background indicate the count over
time since the last reset.
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6. Test a complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad parts.
Figure 105. Bad Part—Missing Date/Lot Code
8.4 Blob Tool
Use the Blob tool to detect and count groups of like-colored pixels within the ROI.
A user-selected range of brightness levels defines the pixels of interest. Then, the Blob tool merges pixels of interest that
touch each other into groups, called blobs. The Blob tool then counts the number of blobs in the ROI, calculates their size
in pixel area, and defines each blob’s center of mass location.
Example applications:
• Count pills
•
Measure hole size
• Verify the number of characters in a date/lot code
• Detect LCD segments
• Detect missing products during packaging
8.4.1 Blob Tool: Input Parameters
Use the Input parameters to configure how the tool analyzes an image.
Figure 106. Blob Tool—Input Parameters
ROI
The Region of Interest (ROI) is the user-defined group of pixels in the image that the sensor analyzes.
Figure 107. ROI Shape Selection
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Resize and rotate the ROI around the feature to be analyzed. Change the shape of the ROI to a square, ellipse, or
circle as needed by expanding ROI on the Parameters pane and selecting the desired shape. An ROI can be as large as
the entire Field of View (FOV).
The ROI automatically displays on the Image
pane when a tool is added.
Masks
Add and define a mask to exclude a group of pixels from the tool analysis.
Figure 108. Masks Parameters
A mask created for a tool will not apply to any other tool in the inspection. Up to 10 masks can be added to a tool.
1.
Expand Masks
2.
Click
Select the mask shape. The mask ROI can be rectangular, elliptical, or circular.
3.
4.
Resize
5.
To delete a mask, click .
on the Inputs tab.
. The mask ROI automatically displays on the Image pane.
and rotate the mask ROI around the pixels to be excluded.
Threshold
The threshold parameter is used to mark a transition point.
Threshold Type: Adaptive
Select Adaptive when there are lighting changes that cause the acquired image to change.
Figure 109. Threshold Type—Adaptive
An adaptive threshold is a technique that adjusts the threshold for the tool based upon lighting changes and image content
within the ROI. It performs best if used with bi-modal images, which have a clear contrast in the ROI. Adaptive threshold
chooses the current threshold value by converging to a value based on the average value of the pixels above and below
the previous threshold value; it will not move the value of the threshold above or below the minimum and maximum
limits.
Adaptive Threshold: Bead/Blob Type
Defines whether the bead/blob is dark against a relatively brighter background or bright against a darker background.
This parameter defines the appearance of the feature of interest. For example, if you have a dark adhesive or part on a
bright background, choose Dark.
Choosing Dark with an adaptive threshold type causes the tool to limit the threshold to the range specified by the
threshold level minimum and maximum limits. The tool identifies all grouped pixels below the threshold chosen as dark
beads/blobs.
Choosing Bright with an adaptive threshold type causes the tool to limit the threshold to the range specified by the
threshold level minimum and maximum limits. The tool identifies all grouped pixels above the specified minimum limit and
less than or equal to the maximum limit as bright beads/blobs.
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Adaptive Threshold: Threshold
Use the sliders or enter the desired minimum and maximum possible grayscale threshold.
The green line is the current threshold value, chosen by the tool, and the sliders represent boundaries beyond which you
do not want the tool to move the threshold settings.
Reject Level
When the Bead/Blob Type is set to Bright, use the Reject Level to narrow the range of pixel intensities to be considered
in an inspection.
Leaving the defaults at 0 for low and 255 for high means that the tool takes into consideration all grayscale levels in the
ROI from 0 (black) to 255 (white).
Reject Level Example
Consider setting up an inspection for a relatively bright object that ranges from 180 to 200 in pixel intensity and takes up
15 percent of the FOV. The remaining 85 percent of the FOV ranges from 230 to 255 in pixel intensity. Setting a Reject
Level of 220 allows the tool to pay attention to only the bright object being inspected. Masking the bright parts of the FOV
is not necessary because only pixels whose intensity is less than the Reject Level will contribute to bright beads/blobs.
Threshold Type: Fixed
Select Fixed when the lighting and image content remain relatively constant for all inspections.
Figure 110. Threshold Type—Fixed
Fixed Threshold: Threshold
Use the sliders to define the range of brightness values of interest.
Area Range
Set the size range of blobs that the tool will count.
Figure 111. Area Range
Green represents blobs that are within the set range, and yellow represents blobs that are outside of the set range.
Blob Statistics
Select to calculate and display advanced results on Tools & Results and All Results.
Figure 112. Blob Statistics
When enabled, Perimeter, Compactness, Major Axis Length, Minor Axis Length, Major Axis Angle, Eccentricity, Minimum
Radius, Maximum Radius, Minimum Radius Position, and Maximum Radius Position will be calculated in addition to Area
and Centroid.
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Filters
Set filters for tool analysis.
Figure 113. Blob Tool Filters
Discard Blobs that Touch ROI
Select to exclude blobs that touch the perimeter of the ROI.
Fill Holes within Blob
Select to ignore (by filling) small features such as scratches and glare that might otherwise appear as small
imperfections or non-blobs within a larger blob. After selecting this option, use the slider or enter the size of the
largest hole to fill.
Image Overlays
Chose whether to display or hide the annotations, ROI, or masks when this tool is not selected. Masks are hidden by
default.
Figure 114. Image Overlays—Default
These options override the ROI view buttons
on the Image Pane Parameters when no tool is selected. When a
specific tool is selected, the ROI information is shown.
Hide Annotations
Hides the annotations on the live image for the tool, even when the tool is selected.
Figure 115. Show Blob Tool Annotations
Figure 116. Hide Blob Tool Annotations
Hide ROI
Hides the ROI when the tool is not selected.
Hide Masks
Hides the Mask ROI when the tool is not selected.
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Tool Histogram
The Tool Histogram graphically displays pixel intensity information within the current ROI.
Figure 117. Example Histogram
Select the Tool Histogram checkbox to enable the histogram. The default is enabled. Expand the Tool Histogram
parameter to view the histogram.
The histogram is a display of the grayscale values on the x axis and the number of pixels on the y axis. The histogram
displays the amount of pixels for each grayscale value. The graph displays information for all grayscale values (0 to 255).
Move the pointer anywhere over the histogram to view specific information. The information updates as the position of the
pointer changes.
Inspection Pass/Fail
Select the Contribute to Inspection Pass/Fail
inspection.
check box (default) if the tool will influence the Pass/Fail status of the
Figure 118. Inspection Pass/Fail
The Pass/Fail contribution influences the following:
• Discrete output Pass
•
Discrete output Fail
• Pass/Fail results counter
• Pass (Green) and Fail (red) LEDs on the Sensor
Select this checkbox if the overall Pass/Fail status of the inspection is dependent on the current tool.
8.4.2 Blob Tool: Test Parameters
Use the Test parameters to configure the pass/fail conditions for the tool.
Select the parameter checkbox to enable it. Where applicable, the vertical green bar shows the current parameter
information and the light gray backgrounds show the range over which a value has varied over time.
Where applicable, use the sliders or enter the minimum and maximum for the selected test parameters.
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Count
The number of blobs found.
Total Area
The total area of all of the blobs found.
Individual Blobs
Figure 119. Blob Tool—Test Parameters
From the Specific Blob
Blobs, First Blob, or Specific Blob, to view area
and centroid information about the blobs.
When Specific Blob is selected, choose the specific
blob using the Blob Index.
To verify if blobs within the ROI are of a specific
area, select the Area checkbox and use the sliders
or enter the minimum and maximum blob size.
When Calculate Blob Statistics is enabled,
additional parameters for the selected blob become
available. These include Perimeter, Compactness,
Major Axis Length, Minor Axis Length, Eccentricity,
Minimum Radius, Maximum Radius, and Major Axis
Angle.
dropdown list, select
All
8.4.3 Blob Tool: Results
Tools & Results and All Results
A red box around a tool indicates that the tool failed. Status
All Results displays the Result, Time, Pass Count, and Fail Count information at a glance. Expand the inspection tool to
see specific results for that tool.
Count
The number of blobs found.
Total Area
The total area of all of the blobs found.
Area Range
The minimum and maximum areas of the blobs found.
Expand Area Range to see the area and centroid (center point) for each blob.
Statistics
Advanced statistical information about each blob.
When enabled, Perimeter, Compactness, Major Axis Length, Minor Axis Length, Major Axis Angle, Eccentricity,
Minimum Radius, Maximum Radius, Minimum Radius Position, and Maximum Radius Position will be calculated in
addition to Area and Centroid.
Available when Caculate Blob Statistics is checked. See the following sections for more details.
Adaptive Threshold
The grayscale value for the software-selected threshold value used to generate the blobs.
This result is blank if the threshold type is set to Fixed.
Execution Time
The execution time, in milliseconds, for the currently selected tool in the current inspection.
Expand Execution Time to see the historical minimum and maximum execution times up to this point for the
selected tool.
Use the reset button in the Inspection Summary to reset these historical values.
Status
Status and error messages display as appropriate.
list information from the current and previous inspections.
provides information about the specific failure.
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Area
The area (A) is a count of the total number of pixels that belong to the blob.
Centroid
The centroid (xc, yc) is the point at the center of mass of the blob.
For simple blobs such as solid circles, ellipses, or rectangles, this is the center of the shape. For more complicated shapes
it is helpful to imagine a piece of cardboard cut in the shape of the blob. The centroid is the point where you could balance
the cardboard on the tip of a pencil. For complicated shapes—especially shapes with unfilled holes—the centroid might lie
outside of the shape.
The x coordinate of the centroid is calculated by adding the x coordinates of each pixel in the blob and dividing by the
area. The y coordinate is similar:
Perimeter
The perimeter (P) gives an approximate measurement of the length of the circumference of the blob.
Because blobs are built from individual pixels, it is most practical to estimate the perimeter by counting the contributions
of individual pixels on the blob's boundary. The following describes the exact values that are added to the perimeter for
each possible pixel configuration. In each example, the description refers to the center pixel in the corresponding pictures.
A pixel with no neighbors that belong to the same blob contributes 3.14
linear pixels to the perimeter of the blob. This can happen only in a blob
that has an area of one. Since such small blobs are usually ignored, this
circumstance is rare.
A pixel with one neighbor that belongs to the same blob contributes
2.571 linear pixels to the perimeter of the blob.
A pixel with two neighbors that belong to the same blob, forming a
straight line, contributes exactly 2 linear pixels to the perimeter of the
blob.
A pixel with two neighbors that belong to the same blob, forming a
corner, contributes 1.414 linear pixels to the perimeter of the blob.
A pixel with three neighbors that belong to the same blob contributes
exactly 1 linear pixel to the perimeter of the blob.
A pixel with four neighbors that belong to the same blob contributes
nothing to the perimeter of the blob.
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This method of counting slightly overestimates the "true" perimeter. For example, a circle with a radius of 100 pixels has a
computed perimeter of approximately 660 pixels, compared with the expected value of 628 pixels.
If the sensor is configured to convert pixel distances to other units, (for example, millimeters), the perimeter is given in
those units. If the blob contains holes that have not been filled, the length of the perimeter includes the points on the
perimeters of these holes.
Compactness
Compactness is a measurement of the space a blob occupies.
The compactness is high for blobs that are nearly circular and low for blobs that are elongated or complicated.
compactness =
Where A is the area and P is the perimeter of the Blob in question. An idealized circle would have a compactness of 100,
but because the perimeter is approximated (see above), the highest realistic value for most blobs is roughly 90. Very small
blobs with just a handful of pixels may reach or even exceed the theoretical maximum of 100, again because of the
approximations in the perimeter calculation.
Major Axis Length, Minor Axis Length, and Major Axis Angle
Major Axis Length, Minor Axis Length, and Major Axis Angle are determined using a best fit ellipse.
To understand Major Axis Length, Minor Axis Length, and Major Axis Angle, it is important to note that these are not
measurements of the blob itself because the blob may be an irregular shape. Rather, these measurements are determined
by a well-defined shape, a "best fit ellipse".
Figure 120. Best Fit Ellipse
These three results combine to give information about the elongation and orientation of a blob . The equations used to
compute these statistics are complicated, but the results usually have an intuitively useful meaning, described below. The
first step in computing these results is to compute the M
2,0
, M
and M
0,2
statistical moments:
1,1
where A is the area, (xc, yc) are the coordinates of the centroid, and (xi, yi) are the coordinates of pixel i. These values
represent the variance with respect to x, the variance with respect to y, and the covariance, respectively. The final results
can be calculated as follows:
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The following table gives a more practical perspective on how to interpret these results. If the sensor is configured to
convert pixels to other units, the major and minor axis lengths are given in those units. The major axis angle is always
given in degrees.
Blob Shape Meaning of Major Axis
Length
Circular, no holes Diameter of the circle Equal to the major axis
Elliptical, no holes Length of the ellipse Width of the ellipse Orientation of the ellipse
Square, no holes Diameter of a circle that best
approximates the square
Rectangular, no holes Length of an ellipse that best
approximates the rectangle
Complicated shape, no holes Length of an ellipse that best
approximates the shape
Any shape with holes Results vary depending on
exact shape—experiment on
your particular shape
Meaning of Minor Axis
Length
length
Equal to the major axis
length
Width of an ellipse that best
approximates the rectangle
Width of an ellipse that best
approximates the shape
Results vary depending on
exact shape—experiment on
your particular shape
Meaning of Major Axis
angle
Unstable
Unstable
Orientation of the rectangle
Orientation of the shape—
unstable if length and with
are nearly equal
Results vary depending on
exact shape—experiment on
your particular shape
Eccentricity
The eccentricity of a blob is the length of the major axis divided by the length of the minor axis.
For circular regions and other regions with radial symmetry (such as a square), the value will be very close to 1. For
elongated regions, the value will increase.
Max Radius and Max Radius Position
The Maximum Radius of a blob is the distance from the centroid of the blob to the farthest pixel on that blob's perimeter.
The Maximum Radius Position gives the pixel coordinates of that farthest perimeter point.
If the sensor is configured to convert pixels to other units, the maximum radius will be given in those units.
Min Radius and Min Radius Position
The Minimum Radius of a blob is the distance from the centroid of the blob to the closest pixel on that blob's perimeter.
The Minimum Radius Position gives the pixel coordinates of that closest perimeter point.
If the blob contains unfilled holes, the minimum radius position may be on the perimeter of a hole. If the sensor is
configured to convert pixels to other units, the minimum radius will be given in those units.
8.4.4 Using the Blob Tool
Follow these steps for an example blob inspection in a pill counting application.
NOTE: This procedure is an example only.
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1. Add a Blob tool to the inspection.
2. Adjust the ROI to frame the first set of pills in the blister pack.
Figure 121. Adjust ROI
3. Set the threshold.
a) Expand the Threshold parameters.
b) From the Threshold Type list, select Fixed.
Select Fixed when the lighting and image content remain relatively constant for all inspections.
c) Expand the second Threshold parameters.
d) Move the sliders to define the minimum and maximum threshold.
This sets a minimum and maximum brightness within the ROI to include or exclude.
Figure 122. Threshold
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4. Set the area range.
This defines the size range of pixel groups to include or exclude.
a) Expand the Area Range
parameters.
b) Move the sliders to define the minimum and maximum size of pixel groups.
Yellow indicates that a group of pixels is outside of the set range.
Figure 123. Area Range
5. Set the Test parameters to set the pass/fail criteria.
On the Test tab, select the Count checkbox to enable the test parameter.
a)
This options sets the number of blobs that must be present within the ROI that match the inspection parameters so
that the tool passes.
b) Expand Count and move the sliders or enter the minimum and maximum count as 10 and 10.
NOTE: The green bar indicates the current count and the light gray background indicates the count over
time.
6. Copy the Blob tool.
a)
With the Blob tool selected, click .
The tool and all of the settings are duplicated (copied) and all of the tools are deselected.
b)
Select one of the Blob tools and click
a second time.
There are now three Blob tools with the same settings.
7. Click Blob02 (the second Blob tool) and move the ROI over the second blister pack.
Click Blob03 (the third Blob tool) and move the ROI over the third blister pack.
8.
9.
Click
to show all three ROI at the same time.
10.Test a complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad parts.
Figure 124. Bad Part—Missing Pill
Figure 125. Bad Part—Broken Pill
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8.5 Edge Tool
Use the Edge tool to detect and count transitions between bright and dark pixels (edges).
The Edge tool counts the total number of edges, and determines the position of each edge. Edge position information can
be used for distance or angle measurements when used with a Measure tool.
Example applications:
•
Measure the height and width of a part
Count the pins on a integrated circuit
•
• Measure the height of a needle
• Measure the deflection of an automotive gauge
• Detect the edge of a web
• Verify that a bottle cap is on completely
8.5.1 Edge Tool: Input Parameters
Use the Input parameters to configure how the tool analyzes an image.
Figure 126. Edge Tool—Input Parameters
ROI
The Region of Interest (ROI) is the user-defined group of pixels in the image that the sensor analyzes.
Figure 127. ROI Parameters
The ROI is a line of pixels that can be shortened, lengthened, or widened as needed for the inspection. Tool analysis
follows the direction of the arrow. Set the width and the sample rate for the region of interest. The ROI automatically
displays on the Image
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ROI Width
The ROI width increases in increments of 4 pixels (for example, 1, 5, 9, 13, ...) up to the total FOV size.
Note that:
• Narrow ROIs execute faster but could miss the edge
•
Wide ROIs are more consistent but don't execute as fast
• A wide ROI provides an average value/location, which results in improved repeatability
• The ROI must be 13 pixels or wider to calculate the rotation of a part (Locate tool only)
Sample Rate
The sample rate sets the number of samples per pixels (one sample per pixel, two samples per pixel, etc.). The
sample rate determines the sub-pixel resolution, which increases the resolution of the tool, and increases the
inspection time.
Figure 128. 1 px Wide ROI Figure 129. 13 px Wide ROI
Threshold
The Threshold parameter marks the grayscale transition point.
The tool marks the edge where the pixel intensity crosses the threshold level. From the Threshold Type list, select one of
the following:
•
Absolute
•
Relative (default)
• Edge Strength
Threshold Type: Absolute
Finds an edge at a specific grayscale level.
Figure 130. Absolute Threshold Parameters
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.
Absolute Threshold: Value
Enter a specific grayscale value from 0 to 255.
Edge Polarity
Edge Polarity defines the type of edges the tool will find.
•
Dark to Bright—Finds edges where pixel intensities start below the threshold value and cross above the threshold
value
Bright to Dark—Finds edges where pixel intensities start above the threshold value and cross below the threshold
•
value
• Bright or Dark—Finds any edge
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Absolute Threshold: Edge Profile Graph
Figure 131. Absolute Threshold—Edge Profile Graph
For absolute threshold, the x axis is the length of the ROI. The y axis is the actual grayscale value from 0 to 255. The light
blue line shows the absolute pixel intensity. The horizontal gray threshold line moves up or down with the threshold value.
Point to a location on the graph—the corresponding location is the yellow line on the tool ROI displayed on the image.
Threshold Type: Relative
Finds an edge at a relative pixel intensity. This is the default threshold setting.
Figure 132. Relative Threshold Parameters
The brightest grayscale level found along the ROI 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.
Relative Threshold: Percent
Choose the percentage value at which the edge should be marked.
Edge Polarity
Edge Polarity defines the type of edges the tool will find.
• Dark to Bright—Finds edges where pixel intensities start below the threshold value and cross above the threshold
value
•
Bright to Dark—Finds edges where pixel intensities start above the threshold value and cross below the threshold
value
• Bright or Dark—Finds any edge
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Relative Threshold: Edge Profile Graph
Figure 133. Relative Threshold—Edge Profile Graph
For relative threshold, the x axis is the length of the ROI. The y axis is the pixel intensity along the ROI, with 0% as the
darkest pixel in the ROI and 100% as the lightest pixel in the ROI. The light blue line shows the percentage pixel intensity
relative to the horizontal gray threshold line. The threshold line moves up or down with the percent value.
NOTE: Because the pixel intensity is relative to what is seen in the ROI, this does not necessarily mean that 0% =
pure black or that 100% = pure white.
Point to a location on the graph—the corresponding location is the yellow line on the tool ROI displayed on the image.
Threshold Type: Edge Strength
Measures the rate of change of grayscale values and needs sharply-defined transitions to find edges.
Figure 134. Edge Strength Threshold Parameters
Edge strength ignores gradual changes in light levels across the tool better than other threshold types and it filters out
weak or gradual edges.
Edge Strength Threshold: Edge Strength
Enter an edge strength value from 1 to 255.
Edges are selected by the edge strength method, which measures the rate of change from bright to dark or dark to bright.
Enter an edge strength threshold in the range from 1 to 255. The default value is 20. As this value is reduced, the tool
finds weak, blurry, or more gradual edges.
Edge Polarity
Edge Polarity defines the type of edges the tool will find.
•
Dark to Bright—Finds edges where pixel intensities start below the threshold value and cross above the threshold
value
•
Bright to Dark—Finds edges where pixel intensities start above the threshold value and cross below the threshold
value
• Bright or Dark—Finds any edge
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Edge Strength Threshold: Edge Profile Graph
Figure 135. Edge Strength Threshold—Edge Profile Graph
For edge strength threshold, the x axis is the length of the ROI. The y axis has two measurements. The first is the light
blue axis. It represents Edge Strength, a measure of the rate of change of pixel grayscale values. The second is the dark
gray axis. It represents Edge Profile, which gives the absolute grayscale level across the tool ROI. The blue line is the rate
of change of the grayscale value along the ROI. The two horizontal gray lines are the edge strength threshold plus and
minus.
Point to a location on the graph—the corresponding location is the yellow line on the tool ROI displayed on the image.
Filters
Set filters for tool analysis.
Figure 136. Edge Tool Filters
Smoothing
Runs a rolling average along the ROI length. It filters out sharp changes in the edge profile.
NOTE: A high filter number may miss the edge of a narrow line.
Minimum Edge Width
Filters out small spike-of-intensity changes, and narrow dark or bright bands. It determines the distance before
and after an edge that must be free from additional transitions or the end of the ROI before the edge is recognized
as valid.
NOTE: A high filter number may miss the edge of a narrow line.
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Edge Profile
The Edge Profile graph changes depending on which threshold type is selected. Refer to the Threshold section and the
specific threshold types for details on the Edge Profile graph.
Image Overlays
Chose whether to display or hide the annotations or the ROI when this tool is not
Figure 137. Image Overlays—Default
These options override the ROI view buttons on the Image Pane Parameters when no tool is selected. When a
specific tool is selected, the ROI information is shown.
Hide Annotations
Hides the annotations on the live image for the tool, even when the tool is selected.
selected.
Figure 138. Show Edge Tool Annotations
Hide ROI
Hides the ROI when the tool is not selected.
Figure 139. Hide Edge Tool Annotations
Tool Histogram
The Tool Histogram graphically displays pixel intensity information within the current ROI.
Figure 140. Example Histogram
Select the Tool Histogram checkbox to enable the histogram. The default is enabled. Expand the Tool Histogram
parameter to view the histogram.
The histogram is a display of the grayscale values on the x axis and the number of pixels on the y axis. The histogram
displays the amount of pixels for each grayscale value. The graph displays information for all grayscale values (0 to 255).
Move the pointer anywhere over the histogram to view specific information. The information updates as the position of the
pointer changes.
Inspection Pass/Fail
Select the Contribute to Inspection Pass/Fail
inspection.
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check box (default) if the tool will influence the Pass/Fail status of the
Figure 141. Inspection Pass/Fail
VE Series Smart Camera
The Pass/Fail contribution influences the following:
• Discrete output Pass
•
Discrete output Fail
• Pass/Fail results counter
• Pass (Green) and Fail (red) LEDs on the Sensor
Select this checkbox if the overall Pass/Fail status of the inspection is dependent on the current tool.
8.5.2 Edge Tool: Test Parameters
Use the Test parameters to configure the pass/fail conditions for the tool.
Select the parameter checkbox to enable it. Where applicable, the vertical green bar shows the current parameter
information and the light gray backgrounds show the range over which a value has varied over time.
Where applicable, use the sliders or enter the minimum and maximum for the selected test parameters.
Total Count
The total number of edges.
Dark to Bright Count
The total number of edges that start below the
threshold value and cross above the threshold value.
Bright to Dark Count
The total number of edges that start above the
threshold value and cross below the threshold value.
Maximum Edge Strength
The greatest rate of change value observed by the
tool.
Figure 142. Edge Tool—Test Parameters
Available when the Threshold Type is set to Edge
Strength.
8.5.3 Edge Tool: Results
Tools & Results and All Results list information from the current and previous inspections.
A red box around a tool indicates that the tool failed. Status
All Results displays the Result, Time, Pass Count, and Fail Count information at a glance. Expand the inspection tool to
see specific results for that tool.
Total Count
The total number of edges.
Expand Total Count to see the location of each edge.
Dark to Bright Count
The total number of edges that start below the threshold value and cross above the threshold value.
Expand Dark to Bright Count to see the location of each edge.
Bright to Dark Count
The total number of edges that start above the threshold value and cross below the threshold value.
Expand Bright to Dark Count to see the location of each edge.
Maximum Edge Strength
The greatest rate of change value observed by the tool.
Available when the Threshold Type is set to Edge Strength.
Execution Time
The execution time, in milliseconds, for the currently selected tool in the current inspection.
Expand Execution Time to see the historical minimum and maximum execution times up to this point for the
selected tool.
Use the reset button in the Inspection Summary to reset these historical values.
Status
Status and error messages display as appropriate.
provides information about the specific failure.
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8.5.4 Using the Edge and Measure Tools
Follow these steps for an example Edge inspection to check the position of a plunger in a syringe.
This procedure uses two Edge tools and a Measure tool to determine the position of the plunger in the barrel.
NOTE: This procedure is an example only.
1. Add an Edge tool to the inspection.
2. Adjust the ROI position, length, and width.
a)
Position the ROI vertically over the top of the plunger.
b) Expand ROI, then expand ROI Width.
c) Set the ROI width to 161 px.
Figure 143. ROI Over the Top of the Plunger
3. Set the threshold.
Expand the Threshold parameters.
a)
b) Set the Threshold Type to Edge Strength.
c) Leave Edge Strength at the default (20).
d) Select Bright to Dark from the Edge Polarity list.
The tool finds the top of the plunger.
4. Add a second Edge tool.
5. Adjust the ROI position, length, and width.
a) Position the ROI vertically over the top of the barrel.
b) Expand ROI, then expand ROI Width.
c) Set the ROI width to 97 px.
Figure 144. ROI Over the Top of the Barrel
6. Set the threshold.
a)
Expand the Threshold parameters.
b) Set the Threshold Type to Edge Strength.
c) Expand Edge Strength and set it to 21.
d) Select Dark to Bright from the Edge Polarity list.
The tool finds the lower edge of the barrel.
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7. Add a Measure tool.
a) Expand Measure From...
and select Edge02 from the Tool list.
b) Expand Measure To... and select Edge01 from the Tool list.
Figure 145. Measure Tool
8. Set the Test parameters to set the pass/fail criteria.
a)
On the Test tab, select the Distance Y checkbox to enable the test parameter.
b) Move the sliders slightly above and below the green line to allow for very slight variations in the distance.
NOTE: The green bar indicates the current distance and the light gray background indicates the distance
over time.
9.
Click to show all ROIs at the same time.
Figure 146. All Tools Shown
10.Test a complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad parts.
Figure 147. Good Part Figure 148. Bad Part—Plunger Too High
8.6 Locate Tool
Use the Locate tool to find the edge of a part and to compensate for translation and rotation (if selected).
This tool finds and marks the position of the first edge along the ROI line and aligns and positions related tools consistently
over a feature of interest. When Rotation is enabled, the Locate tool calculates the angle at which the tool intersects the
feature's edge and rotates the Regions of Interest (ROIs) of downstream tools accordingly.
When a Locate tool is added to an inspection, the inspection fails and there is a red box around Use as Reference. This is
because a reference point has not yet been set. Configure the Locate tool as desired, and then set the reference point.
Example application: Adjust inspection tools for a part that moves and/or rotates in the FOV.
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8.6.1 Locate Tool: Input Parameters
Use the Input parameters to configure how the tool analyzes an image.
Figure 149. Locate Tool—Input Parameters
Note that the Use as Reference parameter appears as an error until the reference point is set.
ROI
The Region of Interest (ROI) is the user-defined group of pixels in the image that the sensor analyzes.
Figure 150. ROI Parameters
The ROI is a line of pixels that can be shortened, lengthened, or widened as needed for the inspection. Tool analysis
follows the direction of the arrow. Set the width and the sample rate for the region of interest. The ROI automatically
displays on the Image
ROI Width
The ROI width increases in increments of 4 pixels (for example, 1, 5, 9, 13, ...) up to the total FOV size.
Note that:
• Narrow ROIs execute faster but could miss the edge
• Wide ROIs are more consistent but don't execute as fast
• A wide ROI provides an average value/location, which results in improved repeatability
• The ROI must be 13 pixels or wider to calculate the rotation of a part (Locate tool only)
Sample Rate
The sample rate sets the number of samples per pixels (one sample per pixel, two samples per pixel, etc.). The
sample rate determines the sub-pixel resolution, which increases the resolution of the tool, and increases the
inspection time.
pane when a tool is added.
Figure 151. 1 px Wide ROI Figure 152. 13 px Wide ROI
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Threshold
The Threshold parameter marks the grayscale transition point.
The tool marks the edge where the pixel intensity crosses the threshold level. From the Threshold Type list, select one of
the following:
•
Absolute
•
Relative (default)
• Edge Strength
Threshold Type: Relative
Finds an edge at a relative pixel intensity. This is the default threshold setting.
Figure 153. Relative Threshold Parameters
The brightest grayscale level found along the ROI 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.
Relative Threshold: Percent
Choose the percentage value at which the edge should be marked.
Edge Polarity
Edge Polarity defines the type of edges the tool will find.
Dark to Bright—Finds edges where pixel intensities start below the threshold value and cross above the threshold
•
value
•
Bright to Dark—Finds edges where pixel intensities start above the threshold value and cross below the threshold
value
• Bright or Dark—Finds any edge
Relative Threshold: Edge Profile Graph
Figure 154. Relative Threshold—Edge Profile Graph
For relative threshold, the x axis is the length of the ROI. The y axis is the pixel intensity along the ROI, with 0% as the
darkest pixel in the ROI and 100% as the lightest pixel in the ROI. The light blue line shows the percentage pixel intensity
relative to the horizontal gray threshold line. The threshold line moves up or down with the percent value.
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NOTE: Because the pixel intensity is relative to what is seen in the ROI, this does not necessarily mean that 0% =
pure black or that 100% = pure white.
Point to a location on the graph—the corresponding location is the yellow line on the tool ROI displayed on the image.
Threshold Type: Absolute
Finds an edge at a specific grayscale level.
Figure 155. Absolute Threshold Parameters
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.
Absolute Threshold: Value
Enter a specific grayscale value from 0 to 255.
Edge Polarity
Edge Polarity defines the type of edges the tool will find.
•
Dark to Bright—Finds edges where pixel intensities start below the threshold value and cross above the threshold
value
Bright to Dark—Finds edges where pixel intensities start above the threshold value and cross below the threshold
•
value
• Bright or Dark—Finds any edge
Absolute Threshold: Edge Profile Graph
Figure 156. Absolute Threshold—Edge Profile Graph
For absolute threshold, the x axis is the length of the ROI. The y axis is the actual grayscale value from 0 to 255. The light
blue line shows the absolute pixel intensity. The horizontal gray threshold line moves up or down with the threshold value.
Point to a location on the graph—the corresponding location is the yellow line on the tool ROI displayed on the image.
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Threshold Type: Edge Strength
Measures the rate of change of grayscale values and needs sharply-defined transitions to find edges.
Figure 157. Edge Strength Threshold Parameters
Edge strength ignores gradual changes in light levels across the tool better than other threshold types and it filters out
weak or gradual edges.
Edge Strength Threshold: Edge Strength
Enter an edge strength value from 1 to 255.
Edges are selected by the edge strength method, which measures the rate of change from bright to dark or dark to bright.
Enter an edge strength threshold in the range from 1 to 255. The default value is 20. As this value is reduced, the tool
finds weak, blurry, or more gradual edges.
Edge Polarity
Edge Polarity defines the type of edges the tool will find.
•
Dark to Bright—Finds edges where pixel intensities start below the threshold value and cross above the threshold
value
Bright to Dark—Finds edges where pixel intensities start above the threshold value and cross below the threshold
•
value
• Bright or Dark—Finds any edge
Edge Strength Threshold: Edge Profile Graph
Figure 158. Edge Strength Threshold—Edge Profile Graph
For edge strength threshold, the x axis is the length of the ROI. The y axis has two measurements. The first is the light
blue axis. It represents Edge Strength, a measure of the rate of change of pixel grayscale values. The second is the dark
gray axis. It represents Edge Profile, which gives the absolute grayscale level across the tool ROI. The blue line is the rate
of change of the grayscale value along the ROI. The two horizontal gray lines are the edge strength threshold plus and
minus.
Point to a location on the graph—the corresponding location is the yellow line on the tool ROI displayed on the image.
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Filters
Set filters for tool analysis.
Figure 159. Locate Tool Filters
Smoothing
Runs a rolling average along the ROI length. It filters out sharp changes in the edge profile.
NOTE: A high filter number may miss the edge of a narrow line.
Minimum Edge Width
Filters out small spike-of-intensity changes, and narrow dark or bright bands. It determines the distance before
and after an edge that must be free from additional transitions or the end of the ROI before the edge is recognized
as valid.
NOTE: A high filter number may miss the edge of a narrow line.
Enable Rotation
Runs a rotation compensation calculation when enabled. ROIs that follow rotate according to the difference
between the reference image and the current inspection image.
Edge Profile
The Edge Profile graph changes depending on which threshold type is selected. Refer to the Threshold section and the
specific threshold types for details on the Edge Profile graph.
Use as Reference
Choose whether to use this tool as a reference for other tools.
Figure 160. Use As Reference—No Reference Point Set
Adjust Downstream Tool ROIs
Select Adjust Downstream Tool ROIs to have tools added after this tool use the this tool to set the location of
the additional ROIs.
Click Set Reference Point button so that the tool affects the related tools, otherwise the tool and all related tools
will fail. If changes are made to the tool parameters that affect the reference point, the reference point must be
set again.
Force to Absolute
Select Force to Absolute to change this tool from relative positioning to absolute positioning.
When disabled, the tool ROI positions itself independent to any other locational tool preceding it in the inspection.
Figure 161. Use As Reference—Reference Point Set
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Image Overlays
Chose whether to display or hide the annotations or the ROI when this tool is not selected.
Figure 162. Image Overlays—Default
These options override the ROI view buttons on the Image Pane Parameters when no tool is selected. When a
specific tool is selected, the ROI information is shown.
Hide Annotations
Hides the annotations on the live image for the tool, even when the tool is selected.
Figure 163. Show Locate Tool Annotations
Hide ROI
Hides the ROI when the tool is not selected.
Figure 164. Hide Locate Tool Annotations
Tool Histogram
The Tool Histogram graphically displays pixel intensity information within the current ROI.
Figure 165. Example Histogram
Select the Tool Histogram checkbox to enable the histogram. The default is enabled. Expand the Tool Histogram
parameter to view the histogram.
The histogram is a display of the grayscale values on the x axis and the number of pixels on the y axis. The histogram
displays the amount of pixels for each grayscale value. The graph displays information for all grayscale values (0 to 255).
Move the pointer anywhere over the histogram to view specific information. The information updates as the position of the
pointer changes.
Inspection Pass/Fail
Select the Contribute to Inspection Pass/Fail
inspection.
The Pass/Fail contribution influences the following:
• Discrete output Pass
Discrete output Fail
•
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check box (default) if the tool will influence the Pass/Fail status of the
Figure 166. Inspection Pass/Fail
VE Series Smart Camera
• Pass/Fail results counter
• Pass (Green) and Fail (red) LEDs on the Sensor
Select this checkbox if the overall Pass/Fail status of the inspection is dependent on the current tool.
8.6.2 Locate Tool: Test Parameters
Use the Test
Select the parameter checkbox to enable it. Where applicable, the vertical green bar shows the current parameter
information and the light gray backgrounds show the range over which a value has varied over time.
Where applicable, use the sliders or enter the minimum and maximum for the selected test parameters.
parameters to configure the pass/fail conditions for the tool.
Edge Point X
The x coordinate of the Edge Point; the first suitable
edge that the Locate tool found.
Edge Point Y
The y coordinate of the Edge Point; the first suitable
edge that the Locate tool found.
Edge Angle
The angle with respect to horizontal at which the
Locate tool intersects the part.
Offset Point X
The x-dimension offset between the current Edge
Point and the reference point.
Available when Adjust Downstream Tool ROIs is
enabled.
Offset Point Y
The y-dimension offset between the current Edge
Figure 167. Locate Tool—Test Parameters
Point and the reference point.
Available when Adjust Downstream Tool ROIs
enabled.
Offset Angle
The angular difference between the current Edge
Angle and the angle from the reference point.
Available when Adjust Downstream Tool ROIs is
enabled.
Maximum Edge Strength
A measure of how much bright/dark contrast is
found in the current Edge Point. A high number
indicates an edge for which the grayscale value
changed rapidly.
Available when the Threshold is set to Edge
Strength.
is
8.6.3 Locate Tool: Results
Tools & Results and All Results list information from the current and previous inspections.
A red box around a tool indicates that the tool failed. Status
All Results displays the Result, Time, Pass Count, and Fail Count information at a glance. Expand the inspection tool to
see specific results for that tool.
Edge Point
The x and y coordinates of the Edge Point; the first sutable edge the Locate tool found.
Edge Angle
The angle with respect to horizontal at which the Locate tool intersects the part.
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Offset
The offset between the Edge Point and the reference point.
Expand Offset to see the coordinates of the Reference Point, the Reference Angle, the Offset Point, and the Offset
Angle.
Maximum Edge Strength
The greatest rate of change value observed by the tool.
Available when the Threshold Type is set to Edge Strength.
Execution Time
The execution time, in milliseconds, for the currently selected tool in the current inspection.
Expand Execution Time to see the historical minimum and maximum execution times up to this point for the
selected tool.
Use the reset button in the Inspection Summary to reset these historical values.
Status
Status and error messages display as appropriate.
8.6.4 Using the Locate Tool
Follow these steps for an example Locate inspection to adjust for a target that moves in the field of view, allowing for the
precise placement of the vision tools that follow the Locate tool.
This procedure uses a Locate tool to determine the position of the vial. Using the vial position information, three Edge tools
and two Measure tools determine the position of the stopper. The Locate tool is used to ensure that the Edge02 and
Edge03 tools are placed correctly alongside (but not on top of) the vial, even if the vial targets move from side to side in
the field of view from inspection to inspection. See Using the Edge and Measure Tools on page
up an Edge tool and a Measure tool.
86 for details on how to set
NOTE: This procedure is an example only.
1. Add a Locate tool to the inspection.
2. Adjust the ROI position, length, and width.
a) Position the ROI horizontally across the side of the vial.
b) Leave the ROI Width at the default (13 px).
Figure 168. Locate ROI
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3. Find the edge that you want the tool to locate.
a) Expand the Edge Profile
parameters. Use the graph as a guide for the remaining steps.
To make sure that you find the edge you want, observe how the Edge Profile graph changes as the Inputs change.
Point to a location on the graph—the corresponding location is the yellow line on the tool ROI displayed on the
image. The horizontal gray line is the Threshold percent.
b) Expand the Threshold parameters.
c) Select Edge Strength from the Threshold Type list.
d) Select Bright to Dark from the Edge Polarity list.
e) Adjust the Edge Strength until only the desired edge is found. In this example it is 20.
4. Expand Filters and set Smoothing to Smooth3 to filter out sharp changes in the edge profile.
5. Set the reference point.
a) Expand the Use as Reference parameters.
b) Leave Adjust Downstream Tool ROIs checked so that it is enabled (default).
c) Click Set Reference Point.
A blue circle displays on the Image pane at the location of the reference point and all following tools use this point as a
reference.
Figure 169. Reference Point
6. If the blue circle does not represent the desired reference point, repeat steps 3 to 5 and adjust the parameters until
the desired reference point is found.
Add an Edge tool to detect the top of the stopper.
7.
Figure 170. Edge Tool at the Top of the Stopper
Add an Edge tool to detect the bottom of the lip on the left side of the vial.
8.
Figure 171. Edge Tool at the Left Side of the vial
9. Add an Edge tool to detect the bottom of the lip on the right side of the vial.
Figure 172. Edge Tool at the Right Side of the vial
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10.Add a Measure tool to measure from Edge02 (the left side of the vial) to Edge03 (the right side of the vial).
Figure 173. Measure Tool from Edge02 to Edge03
11.Add a Measure tool to measure from Edge01 to Measure01 to determine the position of the stopper in the vial.
Figure 174. Measure Tool from Edge01 to Measure1
12.Adjust the Measure02 Test
parameters to set the pass/fail criteria.
a) On the Test tab, select the Distance Y checkbox to enable the test parameter.
b) Move the sliders slightly above and below the green line to allow for very slight variations in the distance.
NOTE: The green bar indicates the current distance and the light gray background indicates the distance
over time.
13.
Click to show all ROIs at the same time.
Figure 175. All Tools Shown
14.Test a complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad parts.
Figure 176. Bad Part—Stopper Too High
Figure 177. Bad Part—Missing Stopper
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8.7 Match Tool
Use the Match tool to verify that a pattern, shape, or part in any orientation matches a reference pattern. The Match tool
can also compensate for translation and rotation of downstream tools (if selected).
The reference pattern is taught during setup. A reference pattern might include alphanumeric characters, logos, or any
other shapes. During an inspection, the sensor checks that each part or package being inspected matches the reference
pattern. The number of expected patterns can also be determined.
When a Match tool is added to an inspection, the inspection fails and there is a red box around Pattern. This is because a
reference pattern has not yet been taught. Configure the Teach ROI as desired, and then teach the reference pattern.
Example applications:
•
Date/Lot code inspections
Label inspections
•
• Part etching inspections
• Part orientation inspections
• Part shape inspections
8.7.1 Match Tool: Input Parameters
Use the Input parameters to configure how the tool analyzes an image.
Figure 178. Match Tool—Input Parameters
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Search ROI
The Search Region of Interest (ROI) is the user-defined group of pixels in the image that the sensor analyzes.
Figure 179. Search ROI
The Search ROI is indicated by a red or green box that is always rectangular. By default the Search ROI is 20% to 30%
larger than the Teach ROI, which is blue. The sensor searchs for the match only within the Search ROI.
Resize the Search ROI as needed for the inspection.
Teach ROI
The Teach Region of Interest (ROI) is the user-defined group of pixels in the image that the sensor uses to teach a
reference pattern.
Figure 180. Teach ROI
Resize and rotate the ROI around the feature to be used as the reference pattern. Change the shape of the ROI to a
square, ellipse, or circle as needed by expanding Teach ROI on the Parameters
The Teach ROI automatically displays on the Image pane when a Match tool is added.
pane and selecting the desired shape.
Pattern
Displays the reference pattern that the sensor is looking for. A teach is required for the Match tool. Click Teach to set the
match tool criteria and display the reference pattern.
Figure 181. Teach Required Figure 182. Pattern Taught
A red error displays until the teach is performed and the reference pattern is taught. When new patterns are added, you
will need to teach the reference pattern again.
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Percent Match
Set the percent match to indicate the quality of the match (10% is a slight match; 100% is a perfect match). The default
is 60%.
Figure 183. Percent Match
Rotation Range
Select the range within which the pattern may be rotated and still count as a match to the reference image. The default is
45 degrees.
Figure 184. Rotation Range
The larger the Rotation Range, the longer the execution time of the tool. In general, this means that the execution time of
the inspection increases.
Precision
Select either Fine Search or
accurate results.
Coarse Search. Course Search is the default. Fine Search is slower but provides more
Figure 185. Precision
Timeout
Set the amount of time the tool looks for the pattern before it stops.
Figure 186. Timeout
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