Using Cameras with a
PLC
Troubleshooting Case Study
Programmable Controller
KV-8000
Series
Troubleshooting with equipment
PLCs
Using the Machine Operation Recorder function while
controlling equipment
Equipment problems are recorded (with the Machine Operation Recorder function) at the same time as
equipment is controlled.
The camera video before and after a problem occurs, all the devices of the PLC for each scan, and the
operation history of the operator are all recorded.
Camera
Device roles
Camera
Video capturing
KV-8000
Equipment
Series
KV-8000
Series
control
Machine
Operation
Recorder
Camera
input
Series
VT5
VT5
Series
Equipment operations
and parameter
settings
Real-time
monitoring of the
camera video
Equipment
PLC
2
Details that can be recorded with the Machine Operation Recorder
function
Ladder operations, camera video, and the operation history can all be linked and played back.
Equipment
PLC ladder/
signals
The behaviour of all devices can
be checked each scan.
Camera
video
Mechanical, target, and human
movements are recorded with two types
of cameras.
HMI
operation
history
The operation history from the HMI and
the inputs from the host PC are recorded.
Troubleshooting with PLCs added
to existing installations
Using the Machine Operation Recorder function with it added to
existing equipment
Equipment problems are recorded (with the Machine Operation Recorder function) by acquiring signals from
an existing equipment PLC in a program-less manner.
The camera video before and after a problem occurs and specific devices at each communication cycle are
recorded.
Camera
Device roles
Camera
Video capturing
Existing equipment
Existing
equipment PLC
Equipment control
PLC KV-8000
PLC link
KV-8000
Series
PLC link with an
existing
equipment PLC
Machine
Operation
Recorder
* The KV-XLE02 or KV-XL202/
XL402 is required.
Series
Camera
input
*
PLC added to an
existing installation
Signals from
an existing
equipment
PLC
Linked devices can be checked at each
communication cycle.
Details that can be recorded with the
Machine Operation Recorder function
Changes to specific devices and the camera video
can be linked and played back.
Camera
video
Mechanical, target, and human movements
are recorded with two types of cameras.
Linked playback even when
added to an existing
installation
Linked playback of waveforms and video
3
Case
1
Robot path
Conventional
KV-8000
Robots
It is difficult to isolate the causes of problems in processes that use robots.
Solved with the Machine
Operation Recorder function
The behaviour of the robot is recorded, enabling quick identification of the
cause.
Image capturing target
Robot behaviour (path)
Installation results
• Because video of the problem
occurring is recorded, the issue can
be identified immediately even in
situations where operators are not
close to the machine, such as with
unmanned lines.
• The cause—be it the robot, the
operator, or something else—can be
isolated in the initial response to the
problem.
Troubleshooting details
Just the data before and after the
occurrence of a problem is recorded.
The KV-8000 can automatically record just the data before
and after the occurrence of a problem. This makes it
possible to immediately understand the situation by
eliminating the hassle of searching for the scenes to view.
Problem
Automatic recording just before and after the problem
Eliminating the hassle of searching for the scenes to view makes it
possible to understand the situation in the minimal amount of time.
Used camera
Wide field and high-resolution camera
KV-CA1W
EquipmentEquipment Added to existing installation
Judgement is fast during the initial
response to isolate the cause.
The operation history of the operator is retained and is
synchronised with the robot behaviour. This makes it
possible to accurately and quickly isolate the cause
during the initial response to the problem.
Use the camera to
1
check the operation
of the robot.
Isolate the mechanical cause. Isolate the human cause.
Use events to check
2
the operation
history.
4
Case
2
Robotic hand
Conventional
KV-8000
Robotic hand
Transferring defects/quality defects occur with unknown causes in a process
that uses a robot.
Solved with the Machine
Operation Recorder function
The status of both the robotic hand and the ladder execution are known,
so the cause investigation is quick.
Image capturing target
• The robotic hand as it grips the target
• The welding status
• The target assembly status
Installation results
•
The program execution status and the
operation of the robotic hand at the time of
the problem can be linked and played back,
which makes it easy to investigate the cause.
•
The original video is retained, so the
operation can be checked without needing
teaching pendant operations and other such
work that requires specialised knowledge.
Used camera
Wide field and high-resolution camera
KV-CA1W
Troubleshooting details
Equipment Added to existing installation
Quickly investigate the cause with
linked playback.
The robot operations and the ladder execution status can be
checked in the same chronological order. The status before and
after the problem occurs can be checked with video and
waveforms, which leads to quick identification of the cause.
Ladder execution status
Problem
occurrence
(Cycle changes before and
after the problem)
These can be linked and
played back in the same
chronological order.
Robot operations
(Robot operations before and
after the problem)
5
Case
Mechanical mechanisms
3
Conventional
• After a problem has occurred, it is not possible to judge whether the issue was a
mechanical mechanism.
• The system needs to be restored quickly, but it is not possible to tell whether the
mechanical status is such that it is OK to restart the system.
Solved with the Machine Operation Recorder function
KV-8000
It is possible to determine whether the cause of the problem was the mechanical
mechanisms without having to wait for the problem to occur again.
Image capturing target
• Mechanical parts of the target
processing section
• Suctioned transfer
Mechanical mechanisms
• Sensor installation status
Installation results
• The mechanical mechanisms can be
recorded, which enables prompt
analysis without the need to wait
on-site for the problem to occur again.
•
The status of the mechanical mechanisms
when a problem occurs can be recorded
automatically, so there is no need to stop
equipment in order to investigate the cause.
Used camera
Compact standard camera
KV-CA1H
Troubleshooting details
Equipment Added to existing installation Equipment Added to existing installation
Automatic recording enables prompt
analysis.
The problem can be recorded automatically, so analysis
can be started without having to wait for the problem to
reoccur. This eliminates the time and effort spent in
waiting for a reoccurrence and leads to prompt solutions.
Conventional
method
KV-8000
6
Problem
occurrence
Recording
Problem
occurrence
Waiting for
problem
reoccurrence
Analysis
Problem
occurrence
Analysis can be
started without having
to wait for the problem
to reoccur.
Analysis
The cause can even be investigated
during operation.
The mechanical status when a problem occurs is recorded,
so it is possible to judge whether the system can be
restarted. The cause can be investigated without having to
stop the equipment, which maintains the operation rate.
There are no
mechanical problems,
so operation can be
restarted while the
cause is investigated in
the office.
The mechanical status
is recorded before and
after the problem.
Case
4
Overall equipment
Conventional
KV-8000
• It is not possible to predict where problems will occur.
• Operators cannot notice changes in the locations that are normally difficult to see.
A wide field and high-resolution camera makes it possible to check the overall
equipment as well as the locations that are difficult to see.
Preprocessing mechanical mechanisms
Solved with the Machine
Operation Recorder function
Image capturing target
From the unloader to the preprocessing
Installation results
• Operators can notice changes in the
locations where it is difficult for people
to enter or where it is difficult to
perform visual checks.
• If it is not possible to predict the
locations where problems will occur,
overall equipment changes can be
captured with a wide field camera.
Conveyor direction
Used camera
Wide field and high-resolution camera
KV-CA1W
Troubleshooting details
Equipment EquipmentAdded to existing installation Added to existing installation
Record the locations that are difficult to see.
A wide field and high-resolution camera makes it
possible to record (with high resolution) the overall
device as well as the locations that are normally difficult
to see. This is useful in detecting problems that cannot
be anticipated in advance.
Even when zoomed
in, the target and the
Target
mechanical
mechanisms can be
checked sufficiently.
Real-time monitoring is possible.
By installing cameras, the locations that are difficult for
operators to see can be checked in real time with video
on the HMI. A sample screen is also available and can
be put to use immediately.
On the HMI screen,
settings such as
the image quality
and exposure can
be fine-tuned.
KV-CA1W
VT5 Series
7
Case
5
Operator line of flow
Conventional
KV-8000
It is not possible to check whether the operator line of flow is optimal when a
problem occurs.
Solved with the Machine
Operation Recorder function
The operator line of flow when a problem occurs is known.
Image capturing target
Operator line of flow
Installation results
• The operator line of flow when a
problem, for which recovery takes a
long time, occurs is known. This
makes it possible to implement
countermeasures such as changing
the equipment layout.
• The record data can be converted into
a video file, which makes it easy to
Operator line
of flow
share this data with and deploy this
data to other workers.
Used camera
Wide field and high-resolution camera
KV-CA1W
Troubleshooting details
Equipment
To increase the operation rate, it is important to reduce the time and effort spent handling problems for which recovery takes a
long time. By subcategorising alarms and recording the operator line of flow when the corresponding alarm occurs, it is possible
to consider countermeasures. Furthermore, recorded videos can be output as .AVI files, so videos containing lines of flow after
countermeasures have been implemented can be shared with other operators to prompt them to improve their own lines of flow.
Use a Pareto alarm chart to
1
subcategorise the problems
that take time to recover from.
Increase the operation rate by improving the line of flow.
Record the operator line of flow
2
when the corresponding
problem occurs, analysing the
cause of the long recovery time.
Generate an .AVI file of the line
3
of flow after implementing
countermeasures and share
this file with other operators as
an improvement procedure.
avi
Sharing
8
Case
6
Operator countermeasure
Conventional
KV-8000
Operator
countermeasure
It is difficult to accurately grasp the countermeasure details when a problem
occurs.
Solved with the Machine
Operation Recorder function
The countermeasure details are maintained as a video, so the situation can
be understood accurately.
Image capturing target
Operator countermeasure details
Installation results
• Operators can accurately grasp the
countermeasure without having to ask
questions.
• The appropriateness of the operations
directly before the problem and of the
countermeasure details after the
problem can be checked.
Used camera
Compact standard camera
KV-CA1H
Troubleshooting details
Equipment Added to existing installation
Operators can accurately grasp the operation
details without having to ask questions.
The countermeasure details when a problem occurs can
be recorded as a video, which makes it possible to
accurately grasp the situation. Furthermore, the HMI
operation history can be recorded in the same
chronological order, which is useful in troubleshooting.
Operation history
Countermeasure video
Linked
Equipment Added to existing installation
The operation details before and after
the problem are understood.
Information can be recorded both before and after a
problem occurs: were operations related to the trouble
occurrence performed in advance, were the
countermeasures after the problem occurred
appropriate?
Recording time
Operations directly before
the problem
File saving trigger
Countermeasure after
the problem
9
Camera sample images
Wide field and high-resolution camera KV-CA1W
Robot close-up
Equipment outer appearance
Equipment top view
Equipment rear view
Through an acrylic sheet
10
Equipment bottom view
Compact standard camera KV-CA1H
Target close-up
Equipment outer appearance
Hand close-up
Equipment rear view
Mechanism bird’s-eye view
Horizontal view
11
Lineup
CPU
Camera input Camera
CPU unit
KV-8000
■ LD instruction execution speed: 0.96μs
■ Program capacity: 1500ksteps maximum
■ Machine Operation Recorder function
■ EtherNet/IP™ port
Camera input unit
KV-CA02
■ Maximum number of connected units per
system: 4
■ Number of camera input ports: 2
■ Camera hot swapping supported
Compact standard camera
KV-CA1H
■ Resolution: 640 (H)×480 (V)
■ Frame rate: 10/30/120fps
■ Viewing angle: • Horizontal viewing angle:
Approximately 60°
• Vertical viewing angle:
Approximately 47°
SD card
Shared camera options
Industrial SD card
KV-M16G/M4G
■ SLC standard
■ Recording capacity: 16GB/4GB
Camera cable
KV-C5/C10/C20
■ Cable length: 5m/10m/20m
Mounting adapter
OP-88386
■ For mounting on a stand
(The stand must be prepared
separately.)
Wide field and high-resolution camera
KV-CA1W
■ Resolution: 1280 (H)×960 (V)
■ Frame rate: 10/30fps
■ Viewing angle: • Horizontal viewing angle:
• Vertical viewing angle:
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Adjustable bracket
OP-88387
■ For mounting on a pole
(Separately prepare a support pole
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