Keyence CV-301 Series Instruction Manual

96M0378
Safety Precautions
This instruction manual describes the operation and function of the CV-301. Read this manual carefully to ensure safe use and maximum performance from your CV-
301.
Symbols
The following symbols alert you to important messages. Be sure to read these messages carefully.
Failure to follow instruction may lead to injury. (electric shock, burn, etc.)
Failure to follow instructions may lead to product damage.
Provides additional information on proper operation.
General precautions
• At startup and during operation, be sure to monitor the functions and perfor­mance of the CV-301.
• We recommend that you take substantial safety measures to avoid any damage in the event a problem occurs.
• Do not open or modify the CV-301 or use it in any way other than described in the specifications.
• When the CV-301 is used in combination with other instruments, functions and performance may be degraded, depending on operating conditions and the surrounding environment.
• Do not use the CV-301 for the purpose of protecting the human body.
WARNING
CAUTION
Note:
i
WARNING
CAUTION
Warnings and cautions specific to the CV series
Do not use the CV-301 series at a voltage other than 24 VDC. Improper volt­age may cause fire, electric shock, or equipment failure.
Usage
• Be sure to turn off power to the controller and any connected devices before connecting or disconnecting the cables. Otherwise, the camera may be dam­aged.
• Do not turn off power while setting a parameter. Otherwise, the settings may be partially or completely lost.
• Do not block the ventilation slots on the CV-301 and the peripheral devices. A rise in inner temperature may cause equipment failure.
• Do not disassemble or modify the CV-301. This may cause fire or electric shock.
Use environments and conditions
To use the CV-301 properly and safely, do not install the CV-301 in locations with the following conditions. Use in an improper environment may cause fire, electric shock, or equipment failure.
• Locations with high humidity, large amounts of dust, or poor ventilation
• Locations where the temperature rises excessively due to direct sunlight, etc.
• Locations where the CV-301 is subjected to vibration or impact
• Locations where water, oil, or chemicals may splash the CV-301
• Isolate the cables as far as possible from high-voltage lines and power lines. Otherwise, generated noises may cause equipment malfunction or failure.
• The CV-301 and peripheral devices are precision machines. Avoid any vibration or impact to these devices.
• To install the CV-301 in a location where static electricity is easily built up, be sure to ground the camera unit.
When abnormal conditions are encountered
If the following conditions are encountered, immediately turn off the power. Con­tinuing to use the CV-301 under abnormal conditions may cause fire, electric shock, or equipment failure.
Contact your nearest KEYENCE office for repairs.
• When water or foreign matter enters the controller
• When you drop the CV-301 or the housing is damaged.
• When the controller produces smoke or an abnormal smell
Note 1: Maintenance
Do not wipe the CV-301 with a damp cloth or a cloth moistened with benzine, thinner, or alcohol. If there is a large amount of dust or dirt on the CV-301, remove it using a tightly squeezed cloth moistened with a dilute solution of a neutral deter­gent, and then wipe the unit with a soft, dry cloth.
Note 2: Camera
The CV-301 uses a specially-designed camera. A commercially available camera should not be substituted. (However, any commercially available C-mount lens can be used.)
ii
iii
Warranty
See page 115.
Notice
• No part of this manual may be reprinted or reproduced in any form or by any means without the prior written permission of KEYENCE.
• The content of this manual is subject to change without notice.
• KEYENCE has thoroughly checked and reviewed this manual. Please contact a sales representative if you have any questions or comments regarding this manual or if you find an error.
• KEYENCE assumes no responsibility for any errors or omissions in this manual. No liability is assumed for damages resulting from the use of the information in this manual, item 3 above notwithstanding.
• KEYENCE will replace any incomplete or incorrectly collated manual.
How to use the ferrite core
The ferrite core shown below is packaged with the CV-301 and OP-27221 (RS­232C cable).
1. Open the ferrite core.
2. Insert the cable into the ferrite core and press firmly to close it completely. CV-030 Power supply cable OP-27221
(Not included) (RS-232C cable)
3. Place the ferrite core as close as possible to the CV-301 controller end of the cable.
CV-030 Power supply cable OP-27221
(RS-232C cable)
Note: To conform to CE regulations in Europe, the ferrite core must be attached to the cable.
Wind twice.
Wind once.
CV-301
CV-030 camera
CV-301
24 VDC power supply
CV-301
PC
iv
1
2
3
4
5
6
7
8
9
How this manual is organized
Chapter 1 Overview
Describes the check list for the package contents, as well as the features and applications of the CV-301.
Chapter 2 Preparation
Explains how to connect and install the CV-301, how to select lenses, and information about illumination.
Chapter 3 Measurement mode selection by application
Explains the type and operation of the measurement modes and how to select the appropriate mode.
Chapter 4 Setting procedure
Explains how to use the remote control console to set the CV-301. Describes from the basic setting to the advanced setting.
Chapter 5 Operation
Explains how to operate the CV-301.
Chapter 6 RS-232C Interface
Explains how to connect the CV-301 to a personal computer and describes the RS-232C communication to operate the CV-301 using a personal computer.
Chapter 7 I/O terminals
Explains the I/O terminals and connectors, and describes the specifications and timing diagrams.
Chapter 8 Specifications
Describes the specifications and dimensions.
Chapter 9 Appendix
Describes typical troubleshooting procedures and the list of optional parts. An index is also included.
WARRANTIES AND DISCLAIMERS
Contents
Chpater 1 Overview
1.1 Checking the Package Contents ..........................................................8
1.2 Features ..................................................................................................9
1.2.1 Features ....................................................................................................9
1.2.2 Application Examples..............................................................................10
1.2.3 Application in a Complete System ..........................................................12
1.3 Part Names and Functions ..................................................................13
1.4 Operation Flow ..................................................................................... 14
Chapter 2 Preparation
2.1 Connection..............................................................................................10
2.1.1 Connecting Cables..................................................................................10
2.1.2 Mounting Controller.................................................................................11
2.1.3 Mounting Camera ...................................................................................12
2.1.4 Selecting Lens ........................................................................................13
2.1.5 Checking Connection.............................................................................. 15
2.2 Illumination ...........................................................................................16
Chapter 3 Measurement Mode Selection by Application
3.1 Measurement Modes and Typical Applications ................................18
3.1.1 [AREA•CON “Area continuous”] / [AREA•TRG “Area trigger”]................18
3.1.2 [AREA + POS “Area + Position”].............................................................18
3.1.3 [ABS•POS “Absolute position”] ...............................................................20
3.1.4 [REL•POS “Relative position”] ................................................................20
3.2 Selecting Measurement Mode for Application .................................21
Chapter 4 Setting Procedure
4.1 Remote Control Console and Screen Display ...................................24
4.1.1 Remote Control Console.........................................................................24
4.1.2 Screen Page Layout ...............................................................................25
4.2 Preparation and Basic Setting ............................................................ 26
4.2.1 Preparation before Setting ......................................................................26
4.2.2 Basic Setting ........................................................................................... 27
4.2.3 Screen Selection..................................................................................... 30
4.3 [AREA] Mode Setting ...........................................................................32
4.3.1 [AREA•CON] Mode Menu .......................................................................32
4.3.2 Setting Parameters and Procedure.........................................................33
4.4 [POS “Position detection”] Mode Setting ..........................................42
4.4.1 [ABS•POS] Mode Menu ..........................................................................42
4.4.2 Setting Parameters and Procedure.........................................................43
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4.5 High Precision Setting .........................................................................53
4.5.1 Menu Item List ........................................................................................53
4.5.2 Shutter Speed Adjustment ......................................................................60
4.5.3 Advanced “COLOR” Setting....................................................................62
4.5.4 Advanced “Position Adjustment” Setting.................................................65
4.5.5 Illumination Adjustment Function ............................................................70
4.5.6 Erasing Settings......................................................................................71
4.6 Initialization ..........................................................................................72
4.6.1 Initialization Procedure............................................................................72
4.6.2 Initialization by Program No. ...................................................................73
4.7 Input/Output Operation in PROGRAM Mode .....................................74
4.8 Changing Environmental Setting .......................................................75
4.8.1 Change Environmental Setting ...............................................................75
Chapter 5 Operation
5.1 Entering Run Mode .............................................................................. 80
5.2 Settings in Run Mode ..........................................................................81
Chapter 6 RS-232C Interface
6.1 Specifications .......................................................................................84
6.2 Connection ...........................................................................................85
6.3 Command and Data Format ................................................................86
6.3.1 Commands in Program Mode .................................................................86
6.3.2 Commands in Run Mode ........................................................................89
6.3.3 Output Data Format ................................................................................ 90
6.3.4 Command List.........................................................................................91
Chapter 7 I/O Terminal
7.1 I/O Terminal Names and Functions ....................................................94
7.2 Specifications .......................................................................................96
7.3 Timing Diagrams ..................................................................................97
Chapter 8 Specifications
8.1 Specifications .....................................................................................102
8.2 Dimensions .........................................................................................104
Chapter 9 Appendix
9.1 General Troubleshooting ..................................................................108
9.2 Optional Parts List .............................................................................109
WARRANTIES AND DISCLAIMERS 115
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Chapter 1
Overview
Describes the check list for the package contents, as well as the features and applications of the CV-301.
1.1 Checking the Package Contents .........................................8
1.2 Features .................................................................................9
1.2.1 Features...................................................................................9
1.2.2 Application Examples ............................................................10
1.2.3 Application in a Complete System .........................................12
1.3 Part Names and Functions ................................................13
1.4 Operation Flow ....................................................................14
Chapter 1 Overview
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1.1 Checking the Package Contents
The CV-301/CV-030 package includes the following parts and equipment. Check that all the parts and equipment are included in the package.
CV-301
Controller (CV-301): 1 Quick Guide: 1
Instruction Manual (this manual): 1
Remote control console: 1 Monitor cable (RCA-RCA): 1
Ferrite cores: 2
CV-030
Camera (CV-030): 1 Mounting bracket: 1 Plastic fitting: 1
We have thoroughly inspected the package contents before shipment. In the event of defective or broken items, please contact your nearest KEYENCE office listed at the end of this manual.
Instruction Manual
Compact Color Vision System
CV-301 Series
B24-025
Quick Guide
Compact Color Vision System
CV-301 Series
B24-024
* M3 x 6 plastic screw (2)
and plastic washer (2) included.
* M3 x 6 screw (2)
and washer (2) included.
Chapter 1 Overview
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3
1.2 Features
This section explains the features and major applications of the CV-301 compact vision system.
1.2.1 Features
New system has achieved high differentiation ability as well as stability. (Patent-pending)
Only the target color can be reliably extracted.
The CV-301s color processing enables reliable differentiation between yellow and white, dark blue and black, or gold plating and silver plating. These colors cannot be differentiated using monochromatic or gray processing.
No detection error due to the shadow on a target surface.
If there is a color difference, the CV-301 can differentiate the target regardless of the variation of illumination distribution, the decrease in light quantity, or the shadow on a target surface caused by differences in individual targets.
Operating principle
The image input circuit converts the cameras analog signal of the color image into digital signals, R, G, and B. The CV series also calculates the difference between these values (R-G, B-G, and R-B), and uses these 6 parameters to extract the color that matches the one on the screen within the preset tolerance. The above operation has made high-speed processing and stable extraction of even dark colors possible.
Extraction with a simple click: Setup time is greatly reduced. (Patent pending)
Just click the color on the screen that you need to extract.
To specify the color to be extracted, place the cursor on the color and click the
mouse button like you would in a Windows application.
The auto-extraction function and zoom function allow simple sensitivity adjust­ment.
Wide applications from presence/absence detection to positioning
Presence/absence detection: Area mode
(position adjustment function provided)
Positioning: Absolute position detection mode
Displacement detection: Relative position detection mode
Refer to page 18 for a description of each mode.
B G R
R–G B–G R–B
Camera
A/D con­version
Difference calculation
Extraction and differen­tiation
Tolerance setting
Image processing
Determina­tion and output
Determination result output Data output
Chapter 1 Overview
1
4
1.2.2 Application Examples
Detecting shelf life printing
M
ilk
M
ilk
M
ilk
Area
Detects the presence/absence of shelf life printing or unclear charac­ters.
Checking for different package types
Area
Differentiates different package types by the color of the package.
Checking for medication information inserts
Medicine
Medicine
Medicine
Area
Detects a missing information insert by the difference between the color of the paper and the cap.
Area
Detects a bad mark on a defective product without being affected by the background characters.
Detecting bad mark on IC
Detecting stain on sheet material
Area
Detects stain on sheet material by the difference in color.
Checking for lack of plating
Area
Differentiates between gold and silver to detect the lack of plating.
Chapter 1 Overview
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5
Detecting target for robot handling
Absolute position
Controls robot handling using the position detection data.
Detecting marks on packaging material
Absolute position
Detects marks on packaging material without being affected by the back­ground print pattern.
Detecting misaligned labels
Relative position
Detects a displaced label on a bottle in the up/down/right/left direction.
Checking liquid level
Relative position
Determines the liquid level by the relationship between the position of a bottle cap and a liquid surface.
Tea
Tea
Tea
Reference pages for each mode
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Chapter 1 Overview
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1.2.3 Application in a Complete System
Indicator, buzzer
Issues an alarm depending on the comparator output.
Control output
Photoelectric sensor, proximity sensor
Detects a target and sends a signal to the trigger input terminal.
Trigger input
Controller CV-301
24 VDC power supply
[600 mA min.]
Programmable logic controller
Captures the control output, changes the program Nos., and reads the coordinate data.
Camera CV-030 (The lens is optional.)
TFT Color Monitor CV-M30 (Optional)
Monitor cable
(cable length: 2 m) (accessory)
Remote control console
(accessory)
Personal computer
Controls the CV-301 and collects data through the RS-232C interface.
Chapter 1 Overview
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1.3 Part Names and Functions
The following illustration shows the part names and functions of the CV-301 .
Controller
Power input terminal (24 VDC, 0 V)
The input terminal of the 24 VDC (600 mA) power supply
Power indicator
Illuminates when power is supplied.
Input/output terminal
Used to input/output signals.
Video output terminal (RCA connector)
Connected to a monitor.
Modular connector
Connected to the remote control console or the RS-232C communication cable.
Camera connector
Connected to the camera cable.
I/O connector
Used to input/output data.
Power supply unit (Option)
Camera (CV-030)
Color, 240,000 pixel CCD camera
Remote control console
Selects a target or sets a menu item.
TFT Color Monitor CV-M30 (Option)
Displays images captured with the camera or shows setting menus.
Lens (Option)
Brightness and focus are adjusted using a diaphragm ring and a focus ring.
Chapter 1 Overview
1
8
1.4 Operation Flow
This section describes the general operation flow for detection using the CV-301.
Chapter 2 Connecting devices
Page 10
Connect the remote control console, camera, and monitor to the controller.
Mounting camera
Page 12
Mount the camera and attach the lens.
Chapter 3 Selecting measurement mode
Page 18
Select the measurement mode best suited to your application.
Chapter 4 Basic setting
Page 27
Operate the remote control console for the detection setting.
High precision setting
Page 53
Use various functions such as shutter speed selection or position adjustment.
Chapter 5 Operating CV-301
Page 79
Detect a target with the preset parameters.
Chapter 6 Using RS-232C
Page 83
Save and load the preset parameters and output the mea­sured value to a PC.
Chapter 7 Outputting data
Page 93
Use the I/O terminals or I/O connectors to provide comparator output and numerical value output.
Chapter 2
Preparation
Explains how to connect and install the CV-301, how to select lenses, and provides information about illumination.
2.1 Connection ..........................................................................10
2.1.1 Connecting Cables ................................................................10
2.1.2 Mounting Controller ...............................................................11
2.1.3 Mounting Camera ..................................................................12
2.1.4 Selecting Lens .......................................................................13
2.1.5 Checking Connection.............................................................15
2.2 Illumination ..........................................................................16
Chapter 2 Preparation
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10
2.1 Connection
This section describes how to connect cables, mount the controller and camera, and select a lens.
2.1.1 Connecting Cables
Be sure to turn off the controller before connecting cables. If you connect the cables while the controller is turned on, the camera or peripheral equipment may be damaged.
1. Insert the connector for the camera cable.
2. Insert the modular connector for the remote control console cable.
3. Insert the RCA connector for the monitor cable.
4. Connect the cable for the power supply unit. Connect the controller’s input/output terminals number 1 and 2 with the 24
VDC power supply unit. Do not turn on power until the mounting procedure is completed.
CAUTION
Power supply unit
Input/output terminal
Controller
Remote control console
Camera
Monitor
Modular connector
RCA connector
Camera cable connector
1
2
3
4
5 6
7
8
9
10
11
12
13 14 15 16
1: 24 VDC
2: 0 V
Chapter 2 Preparation
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11
Allow sufficient space for ventilation (approx. 30 mm) around the controller.
• Do not place the controller upside down.
• Do not block the ventilation slots, as this may cause the controller to stop operating.
2.1.2 Mounting Controller
DIN rail mounting
The controller is designed to be mounted to the DIN rail. To mount or dismount the controller, move the claw at the bottom of the controller in the direction of the arrow.
Screw mounting
Pull out the four mounting brackets and mount the controller using screws.
Mounting position
Mount the controller with the front facing the operator or facing up.
Retractable mounting claw
Retractable
mounting
bracket
Horizontally with front facing operator:
Correct
With front facing up:
Correct
Vertically with front facing operator:
Correct
With front facing down:
Incorrect
CAUTION
Chapter 2 Preparation
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12
2.1.3 Mounting Camera
1. Mount a lens to the camera. Select a lens based on the target size and the distance between the lens and
the target.
Refer to the next page.
2. Secure the camera. The following two methods can be used to secure the camera.
Using the included plastic fitting
The plastic fitting has the following screw holes. Use the appropriate ones to secure the camera.
1) Screw hole for tripod (1/4-20 UNC): 1
2) M3 screw holes: 2
3) M4 screw holes: 2
Using the included mounting bracket
The mounting bracket has the following screw hole and slots. Use the appropri­ate ones to secure the camera.
1) Screw hole for tripod (1/4-20 UNC): 1
2) 4 mm diameter slots: 2
Be sure to insulate the camera when mounting it. Otherwise, the internal circuit of the camera may become damaged.
Lens
CAUTION
1) Screw hole for tripod
M3 screw holes
Plastic fitting
Included screws (M3 x 6) and washers
2) M3 screw holes
3)M4 screw holes
M3 screw holes
1) Screw hole for tripod
2) 4 mm diameter slots
Mounting bracket
Included screws (M3 x 6) and washers
Chapter 2 Preparation
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13
2.1.4 Selecting Lens
Select the lens based on the target size (Y) and the distance between the lens and the target (working distance). Refer to the following chart to select the best lens for your application.
* Type of lens
The value in the chart () indicates the thickness of the close-up adapter (option). Insert the close-up adapter between the lens and the camera.
WD: Working distance (mm)
PROG
No 0 MODE
AREA•CON SHUTTER REGISTER
WINDOW 1
MEASURE
000000
TOL H=000000 L=000000 ILLU OFF T=000017 RAW SCRN
- - - - - -
Y
50
40
30
20
15
10
1.5
0.5
0.5
1.5
15
10
5
1
1
1.5
5
1000
10000
100
10
10
100
1000
CV-L50*
CV-L16*CV-L6*
CV-L3*
0.5
Y: Field (mm)
Y
WD
Close-up adapter
Chapter 2 Preparation
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14
How to read the chart
Using a 16 mm lens with a working distance of 500 mm, a field of approximately 70 mm is obtained. Combining a 50 mm lens and a 5 mm close-up adapter provides a field of about 20 mm.
Note 1: The figures in the chart on the previous page are referencce values only. You may need to make some adjustments when setting the actual product.
Note 2: Some types of monitors may not show the frame of the screen. Although this does not affect the measurement result, if you need to see the screen up to the corners, use an under-scanning type monitor.
No 0 MOD
AR
E
SHU
T
REG
I
WIN
D
ME
A
000
0
TO
L
H=0
0
L=0
0
ILLU OFF T=00
0
PROG
No 0 MODE
AREA•CON SHUTTER REGISTER
WINDOW 1
MEASURE
000000
TOL H=000000 L=000000 ILLU OFF T=000017 RAW SCRN
- - - - - -
Over-scanning type monitor Under-scanning type monitor
Chapter 2 Preparation
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15
2.1.5 Checking Connection
1. Turn on the power. Turn on the connected 24 VDC power supply.
2. Check the monitor. A raw (unprocessed) screen is displayed.
* A raw screen is a screen which is seen through the camera.
3. Adjust the diaphragm and focus of the lens.
1) Turn the diaphragm ring and focus ring to adjust the diaphragm and focus
while watching the monitor.
2) After adjustment is complete, secure the lock-screws to lock the rings.
• Diaphragm adjustment
Adjust the diaphragm so that the screen displays a clear contrast and the target can be easily distinguished from the background.
• Focus adjustment
Adjust the focus until the target contour becomes clear. If the diaphragm is adjusted so that the image is too bright or too dark, proper focus adjustment will not be obtained. Adjust the diaphragm at the same time as the focus.
Notes: Check the following items if nothing appears on the monitor.
• Did you use the 24 VDC (600 mA) power supply? Are the “+24 V” and “0 V” power supply terminals properly connected?
• Are the cables for the camera, remote control console, and monitor properly connected?
• Did you remove the cap from the lens?
• Is the lens diaphragm opened enough?
PROG
No 0
MODE
AREA•CON SHUTTER REGISTER
WINDOW 1
MEASURE
000000
TOL H=000000 L=000000 ILLU
OFF T=000017 RAW SCRN
- - - - - - - -
Diaphragm ring lock-screw
Focus ring lock-screw
Chapter 2 Preparation
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16
• Is the monitor turned on?
• Is the video input terminal for the monitor properly connected?
2.2 Illumination
Use illumination for more stable detection. If you install the CV-301 in locations with the following conditions, the detection
may not be accurate. Change the location or use the speciallydesigned illumination equipment.
• Locations directly exposed to sunlight
• Locations where the ambient light varies greatly depending on the time of day
• Locations where the illumination level is changed by the movement of a ma­chine or people.
Illumination equipment
Ring lamp
Mount the ring lamp around the lens to evenly illuminate the target. The ring lamp is available as an option (CV-R11).
Other than the ring lamp, the fiber light and other illumination equipment are also available. Order the model that best suits your application.
Note: The illumination lamp has a recommended service life. When the light intensity changes, detection errors may result. Replace the lamp before this prob­lem occurs.
Ring lamp
Target
Chapter 3
Measurement Mode Selection by Application
Explains the type and operation of the measurement modes and how to select the appropriate mode.
3.1 Measurement Modes and Typical Applications ...............18
3.1.1 [AREA•CON “Area continuous”] /
[AREA•TRG “Area trigger”] ....................................................18
3.1.2 [AREA + POS “Area + Position”] ...........................................18
3.1.3 [ABS•POS “Absolute position”]..............................................20
3.1.4 [REL•POS “Relative position”] ............................................... 20
3.2 Selecting Measurement Mode for Application .................21
Chapter 3 Measurement mode selection by application
3
18
3.1 Measurement Modes and Typical Applications
The CV-301 has 4 measurement modes: [AREA•CON (TRG) “Area continuous (trigger)”], [AREA + POS “Area + Position”], [ABS•POS “Absolute position”], and [REL•POS “Relative position”]. This manual describes how to set the [AREA] mode.
3.1.1 [AREA•CON “Area continuous”] / [AREA•TRG “Area trigger”]
Typical applications: Detection of presence/absence of a target, detection of a
missing target, detection of color and shape of a target, and measurement of area
• Measures the area of a target.
• Measures the area of the extracted color in the window or the area of the background.
• Up to eight windows can be drawn at a single setting. The measured data for each window will be output.
• To detect a target continuously, use the [AREA•CON “Area continuous”] mode.
• To detect a target using an external trigger with intervals, use the [AREA•TRG “Area trigger”] mode.
3.1.2 [AREA + POS “Area + Position”]
Typical applications: Detection of presence/absence of a target, detection of a
missing target, detection of color and shape of a target, measurement of area, and positioning
• Corrects the position of the window using [POS “Position adjustment”] in the [AREA•TRG] mode.
• The camera can be set to trigger mode only.
• There are two methods of [POS “Position adjustment”]: Pattern search and line sensor.
[POS “Position adjustment”]
To correct the window position, select one of the following two methods according to your application.
RUN
No 0 MODE
AREACON
WINDOW 1
MEASURE 005512
TOL H=100000 L= 003000
T=000017 PROCES2
-------
Window
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