Rockwell Automation 5370-CBPK User Manual
ALLEN–BRADLEY
Bulletin 5370
Color CVIM BLISTER-PAKtOption
(Catalog No. 5370-CBPK)
User Manual
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. “Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls” (Publication SGI-1.1)
describes some important differences between solid state equipment and
hard–wired electromechanical devices. Because of this difference, and also
because of the wide variety of uses for solid state equipment, all persons
responsible for applying this equipment must satisfy themselves that each
intended application of this equipment is acceptable.
In no event will the Allen-Bradley Company be responsible or liable for
indirect or consequential damages resulting from the use or application of
this equipment or software.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with
any particular installation, the Allen-Bradley Company cannot assume
responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Allen-Bradley Company with respect to use
of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of the Allen-Bradley Company is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations.
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
!
damage, or economic loss.
Attentions help you:
• identify a hazard
• avoid the hazard
• recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
Table of Contents
Color CVIM BLISTER–PAK Option
User Manual
Introduction
Functional Overview
Chapter 1
Introduction 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents of This Manual 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions Used 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2
Background 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Color CVIM vs. Color CVIM BLISTER-PAK Option 2–3. . . . . . . . . . . . .
System Capabilities 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Modes 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Setup 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blister Setup 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blister Setup Menu 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Setup 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Color 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configure 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tracking 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Archive 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exit 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application Considerations 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Color Teach 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defect Detection 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the BLISTER-PAK
Option
System Setup
Chapter 3
Installation 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reinstallation of USER-PAK and MATH-PAK Options 3–3. . . . . . . . . . . . . . . . . .
Compatibility With Existing Applications 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 4
Accessing System Setup 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camera Configuration 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discrete I/O Configuration 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote I/O Configuration 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
Table of Contents
Color CVIM BLISTER–PAK Option
User Manual
Auto Setup
Chapter 5
Accessing Blister Setup 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Auto Setup 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Teach Count 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Position Tolerance 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Area Tolerance 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Shape Tolerance 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V ariation Scale 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Default Options 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Setup Process 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Learn Colors 5–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select Object Type and Object Colors 5–10. . . . . . . . . . . . . . . . . . . . . . . . .
Move Blisters Into View 5–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position Image Window 5–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Learn Background Color 5–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Learning Pocket Color (Aluminum Blisters Only) 5–13. . . . . . . . . . . . . . . . . .
Move Blisters Into View (Aluminum Blisters Only) 5–14. . . . . . . . . . . . . . . . .
Identify Object Colors 5–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Learn Object Colors 5–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position Teach Window 5–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Verify Blister Window Positions 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Verify Object Counts 5–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Perform Teach–in 5–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Blister Windows
Chapter 6
Adjust One or All 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position Window 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Define Objects 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Object Type 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flipped Objects 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Locate 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Define Background 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Background 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Background Area 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extra Area % (Non–Aluminum Blisters) 6–6. . . . . . . . . . . . . . . . . . . . . . . .
Extra Area % (Aluminum Blisters) 6–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Define Tolerances 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position Tolerance 6–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Area Tolerance 6–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shape Tolerance 6–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Area 6–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advanced Adjustments 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Window Shape 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter (Binary Morphology) 6–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
Table of Contents
Color CVIM BLISTER–PAK Option
User Manual
Runtime Options
Results and Outputs
Reject Tracking
Chapter 7
Runtime Menu Bar 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Menu Bar 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All Tools Display 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stats Page Display Panel 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Page Display Panel 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 8
Results of Object Verification 8–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Inspection Results in Color CVIM MA TH-PAK Formulas 8–1. . . . . . . . . .
Win1.9 8–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Inspection Results in Color CVIM USER-P AK Strings 8–4. . . . . . . . . . .
Active: Pass vs. Active: Fail 8–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Stop 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Stop Error Conditions 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Stop Output Assignments 8–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Results Trigger 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 9
Tracking Menu 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downloading Reject Tracking Parameters 9–2. . . . . . . . . . . . . . . . . . . . . . . . . .
Dictionary IDs for
BLISTER–PAK Menu Items
Index
Appendix A
iii
Chapter 1
Introduction
Figure 1Table 1
Chapter
1
Introduction
This brief chapter provides an overview of the Color CVIM
BLISTER-PAKt option (Cat. No. 5370-CBPK). The topics it covers include
the following descriptions:
• The product.
• The contents of this manual.
• Conventions used.
• Related publications.
Introduction
Contents of This Manual
The Color CVIM BLISTER-PAK option is a software product designed to
simplify the setup and operation of blister packaging inspection or similar
applications. An automated setup procedure makes it easy to configure the
system for simultaneous inspection of multiple blisters.
This manual provides the information necessary to install, set up, and use the
Color CVIM BLISTER-PAK option.
Table 1.A
Summary of Contents
Chapter
1. Introduction Provides an overview of the manual.
2. Functional Overview
3.
4. System Setup
5. Auto Setup
Title Contents
Describes the function of the Color CVIM
BLISTER-PAK option, and explains how it differs
from the standard Color CVIM installation. Provides
a summary of the program’s organization.
Installing the
BLISTER-PAK Option
Describes how to install the Color CVIM
BLISTER-PAK option on your system.
Describes the steps necessary to configure your
system for use with the Color CVIM BLISTER-PAK
option.
Describes the steps necessary to use the Auto
Setup feature to quickly create a unique blister
pattern as a basis for inspection.
6. Adjusting Blister Windows
7. Runtime Options
Describes the Adjust menu, which you can use to
“fine tune” blister window configurations produced
by the auto setup process.
Describes the options available through the Run
menu.
1–1
Chapter 1
Introduction
Chapter ContentsTitle
8. Results and Outputs
Describes the specialized data and output
characteristics of the Color CVIM BLISTER-PAK
option which differ from those found in a standard
Color CVIM installation.
Conventions Used
Related Publications
9. Reject Tracking
Describes the Tracking menu and the requirements
for PLC acquisition of tracking parameters.
Index
The following conventions are used in this manual:
• All menus and screens reproduced in this manual are approximate
renderings of what you will see on your terminal screen. Allen-Bradley
reserves the right to make minor modifications to any menu or screen to
help improve performance.
• Information which you can select or enter into the menus or screens
appear in the text as Sans Serif type.
• A sequence of menu selections is signified by the name of each selection,
in order, separated by an arrow (for example: Setup → Configure →
Machine Stop Conditions).
Other publications to which you may want to refer include:
• Bulletin 5370 Color CVIM Module User’s Reference Manual (Cat. No.
5370-ND009).
• Bulletin 5370 Color CVIM Module Communications Manual (Cat. No.
5370-ND010).
• Color CVIM USER-PAK User Manual (Pub. No. 5370–821).
• Color CVIM MATH-PAK User’s Manual (Cat. No. 5370-ND016).
1–2
Chapter 2
Functional Overview
Figure 2Table 2
Chapter
2
Functional Overview
This chapter contains information that will help you understand the basics of
the Color CVIM BLISTER-PAK option from the Allen-Bradley Company.
Here is a list of the main information topics:
• Background information about the BLISTER-PAK option.
• Comparison of the Color CVIM BLISTER-PAK option to the basic Color
CVIM system.
• List of the BLISTER-PAK option’s capabilities and typical applications
for it.
• Differences among the three basic operating modes: The system setup
mode, the blister setup mode, and the run mode.
• Application considerations, including performance limitations and
suggested methods of detecting specific types of defects.
Background
Blister packaging is presently used almost universally for pharmaceutical
packaging of tablets and capsules in Europe. Its use continues to grow in
North America.
Important: Although the Color CVIM BLISTER–PAK option is designed
primarily for inspecting pharmaceutical tablets and capsules,
blister packaging is suitable also for other products as well.
Throughout this publication, the words “tablet” or “capsule” are
used interchangeably. Instances in which a characteristic unique
to either a capsule or tablet is important are clearly indicated.
A blister package consists of a substrate (usually polyvinyl chloride (PVC) or
aluminum) into which pockets (or alveoli) have been formed, and a foil
backing that forms a seal. Each material begins as a continuous roll, or web.
After the web is filled and sealed, it is cut apart into blisters. A typical blister
consists of from 10 to 36 pockets.
The Color CVIM system with the BLISTER-PAK option can be used to
ensure the security of blister packaging operations by applying a number of
tests, such as the following, to each tablet or capsule:
• Verify the presence of the correct color tablet in each pocket.
• Verify the size of each tablet.
• Verify the position of each tablet.
• Detect broken or otherwise defective tablets.
• Detect the presence of extra tablets or foreign material.
2–1
Chapter 2
Functional Overview
Most tablets are a single color (A, Figure 2.1), but some applications require
that two or more different types of tablet (each a different color) appear in
different pockets on the blister. As many as eight different color tablets
sometimes occupy a single blister.
Other applications involve multi-colored tablets, which may be inverted or
“flipped,” and thereby appear from above to be either of two colors (example
B in Figure 2.1). Two-color capsules (example C in Figure 2.1) may or may
not be placed in a known orientation.
Figure 2.1
Variations in Tablet and Capsule Configuration
AB C
PVC blister materials vary, too. Often they are clear, but in many cases they
are white or colored. Clear PVC is the easiest to manage in a vision
inspection setting because background color can be controlled by changing
the type of material below the web. White PVC cannot be used with white
tablets, so it is often replaced with a colored PVC web.
Aluminum blisters present special challenges because aluminum’s reflective
properties and the gradual slope of the pocket walls make it hard to light.
Side lighting gives a black background, but the sloping walls of the pockets
appear gray, and can even change color as they reflect the color of their
contents. The BLISTER–PAK option, however, provides a feature that can
accommodate the apparent difference between the general background color
and the pocket color in aluminum blisters (or non–aluminum blisters that
present a similar problem).
2–2
Chapter 2
Functional Overview
Standard Color CVIM vs. Color CVIM BLISTER-PAK Option
System Capabilities
The Color CVIM BLISTER-PAK option is a special version of the Color
CVIM firmware designed to meet the demands of blister packaging
inspection. It provides a flexible tool that is extremely robust, yet easy to set
up and use.
The BLISTER-PAK option is a distinct software product that installs over
and actually replaces the standard firmware in the Color CVIM module. It
provides a set of features especially optimized to perform high quality blister
inspection. In addition, it provides:
• Automated application setup.
• Compatibility with Allen-Bradley’s Color MATH-PAKt option,
including special object verification results that can be used directly by
MATH-PAK.
• Compatibility with Allen-Bradley’s Color USER-PAKt option, including
the ability to simplify the user interface by hiding unneeded menu items
from view, and customizing displays and serial port outputs.
The Color CVIM BLISTER-PAK option provides the following capabilities:
• Up to 48 blisters per image.
• Up to 80 tablets or 40 capsules per blister.
• Up to 600 total tablets or 300 total capsules per image.
• Automatic color balance adjustment.
• Automatic compensation for lighting variation.
• Automatic background color definition.
• Automatic tablet or capsule color definition.
• Automatic blister region positioning.
• Automatic tolerance setting.
• Automatic compensation for inconsistent blister positioning.
• Ability to inspect single color tablets, 2-color tablets (flipped), and
2-color capsules.
• Detection of:
– Foreign material.
– Empty blisters or missing tablets or capsules.
– Extra tablets or capsules.
– Wrong color tablets or capsules.
– Oversize tablets or capsules.
– Positioning errors.
– Undersize tablets or capsules.
– Incorrect shapes.
– Capsule orientation errors.
2–3
Chapter 2
Functional Overview
• Configurable machine stop output.
• Output signals for accept, reject, or empty blister.
• Unlimited number of stored configurations (using removable memory
cards).
• User input via light pen, mouse, or trackball.
• Runtime display that is fully customizable without programming (using
the Color CVIM USER-PAK option).
• Up to three levels of password security (using the Color CVIM
USER-PAK option).
• Runtime display showing the status of every blister and location of
defects.
• 512 x 480 maximum image resolution.
• 256 x 256 x 256 color resolution.
• Compatibility with color and monochrome cameras.
• Communications via two user configurable RS-232 ports and
Allen-Bradley proprietary Remote I/O.
• Discrete input from Part Trigger and Results Trigger.
• 14 user-configurable discrete outputs and 128 additional discrete outputs
via Remote I/O.
• Reject Tracking menu for input of parameters to an Allen–Bradley PLC
or SLC.
• Statistics display showing the accept and reject counts for each blister and
the type of defect.
• Fault display showing locations of recent defects.
Operating Modes
2–4
The Color CVIM BLISTER-PAK option provides three distinct operating
modes. Each mode is described below, along with information on when and
how you will use it.
System Setup
The system setup mode allows you to define various parameters that control
the overall Color CVIM BLISTER-PAK system behavior. You will use the
system setup mode when first installing your color CVIM module, or when
making major changes to it. For example, you may use it when adding new
cameras or other hardware. With the exception of the object verification
window operation (explained in Chapter 6), this mode operates exactly the
same as the configuration mode in the standard Color CVIM firmware. Refer
to the Bulletin 5370 Color CVIM Module User’s Reference Manual (Cat. No.
5370-ND009) for information on setup.
Chapter 2
Functional Overview
When the system setup mode is selected, the Exit menu provides access to
the blister setup mode, the runtime configuration functions, and the runmode
function.
Blister Setup
The blister setup mode provides a simple user interface designed specifically
for setting up blister inspection applications. It provides automatic setup and
easy adjustment of blister inspection configurations.
When the blister setup mode is selected, the Exit menu provides access to the
system setup mode and the runmode function.
Run
The runmode function allows you to use the configured Color CVIM system
for inspections. While in the run mode, the Color CVIM module acquires and
analyzes an image upon receipt of each trigger signal. Upon powerup, the
system enters the run mode automatically.
Blister Setup Menu
When the system is in the run mode, the Setup menu item (in the runmode
menu bar) provides return access to either the Blister Setup menu or the
System Setup menu, whichever was used last.
The main difference between the standard Color CVIM firmware and the
Color CVIM BLISTER-PAK option is the ease with which the latter version
manages the special challenges of blister pack inspections. The Blister
Setup menu bar, which is unique to the Color CVIM BLISTER-PAK
software, makes this convenience possible.
When you pick the Blister Setup menu item in the Exit menu, the Blister
Setup menu bar appears.
In the remaining paragraphs you will find a brief description of each menu
item that appears in the Blister Setup menu bar.
Auto Setup
Select the Auto Setup menu item to begin stepping through the automated
sequence required to create a blister inspection configuration. A help window
opens when you begin the auto setup process, and it remains open throughout
to provide helpful tips and explanations. As you complete each step of the
auto setup procedure, you will be given the choice of continuing on to the
next step or quitting the procedure and returning to the main Blister Setup
menu.
2–5
Chapter 2
Functional Overview
Color
The Color menu item provides access to the same Color menu that appears
when you select the Color menu item in the System Setup menu bar. Using
the choices presented here, you can select and define colors to use for blister
packaging operation inspection and analysis. For information on the items
that appear on this menu refer to Chapter 3 of the Bulletin 5370 Color CVIM
Module User’s Reference Manual (Pub. No. 5370-ND009).
Adjust
The Adjust menu item provides access to adjustments that you can use to
“fine tune” the settings established during the auto setup process. You can
use it to adjust a single window or all windows simultaneously. Parameters
you can change include tolerances, window positions, colors, window shape,
and filtering through up to six stages of binary morphology.
Configure
The Configure menu item provides access to the settings necessary to
control the auto setup process and machine stop conditions.
Tracking
The Tracking menu item provides access to settings that you can use to
configure your process control equipment, through the Color CVIM
module’s Remote I/O port, for reject tracking.
Archive
The Archive menu item in the Blister Setup menu bar provides access to the
same Archive menu that appears when you select the Archive menu item in
the System Setup menu bar. The items on this menu enable you to transfer
configurations and screen images among the Color CVIM module’s random
access memory (RAM) and its internal non-volatile memory (EEPROM), or
an external battery-backed memory card inserted through the module’s front
cover. For additional information on archival functions, please refer to
Bulletin 5370 Color CVIM Module User’s Reference Manual (Cat. No.
5370-ND009).
2–6
Exit
The Exit menu item provides access to the System Setup menu bar and the
run mode. When you select this menu item, you also have the option of
saving the current configuration.
Chapter 2
Functional Overview
Application Considerations
This section describes various aspects of the BLISTER–PAK option’s setup
and inspection processing that must be considered when planning an
application. These include some limitations of the inspection processing, and
techniques for most effectively using the BLISTER–PAK option to detect
specific types of defects.
Color Teach
Uniform Background Color –– The taught background color is used for
determining the object positions when teaching the foreground colors, and
for detection of foreign material if background inspection is enabled. A
relatively uniform background is required in order to be able to train the
background color effectively, and in most applications this can be achieved
through careful lighting and imaging design. Ideally, the background region
surrounding the tablets or capsules should be the same color throughout the
image, without any glare or other anomalies that might be confused with
foreign material. The background should also be of a color that contrasts
with the color(s) of the tablets / capsules to be inspected.
If it is not possible to teach a background color that effectively defines the
background region, the application can usually still be done. In such a case, it
will be necessary to train the foreground color(s) manually, as the automatic
color teach will not work. In this case it will also be necessary to disable
background inspection. All other inspection operations can be performed if
the foreground colors can be taught adequately.
3–Color Capsules –– Some capsules are produced with two
different–colored halves, and a central band of a third color. The
BLISTER–PAK option can be used to inspect these capsules as 2–color
capsules, but it will not verify the presence of the central color band. If the
band is exceptionally wide, it may be necessary to teach the two foreground
colors manually because the automatic color–teach may not work properly.
Defect Detection
The BLISTER–PAK option tests for all defects within a single blister in a
specific priority order, as follows (the defect types appear in this order on the
Machine Stop menu):
• Foreign –– This error is possible only when background inspection is
enabled, and is reported if an extra “hole” exists in the background color,
or if the area of the region around a particular pocket exceeds the area of
the object(s) it contains plus the Extra Area tolerance.
• Empty –– This error is reported if a blister contains no objects of the
taught color(s). It is not considered more significant than the errors to
follow, but is detected first because no other errors are possible if the
blister contains no objects.
• Extra –– This error is reported if a blister contains more objects than
were trained. This might include an object of a known color.
2–7
Chapter 2
Functional Overview
• Color –– This error is reported if a blister contains an object whose color
is one of the trained colors but is not the correct color for its position.
• Oversize –– This error is reported if a blister contains an object whose
area is too large. This might include two tablets that are touching each
other.
• Position –– This error is reported if a blister contains an object whose
position is too far from the taught position.
• Undersize –– This error is reported if a blister contains an object whose
area is too small but whose shape is within the set shape tolerances. This
is very similar to the Broken error, and sometimes the system cannot
distinguish between the two because the shape measurement tends to vary
a great deal for small objects.
• Broken –– This error is reported if a blister contains an object whose area
is too small and whose shape is outside the set shape tolerances.
• Shape –– This error is reported if a blister contains an object whose area
is within the set area tolerances but whose shape is outside the set shape
tolerance.
• Missing –– This error is reported if one or more of the objects expected in
the blister is missing.
Detection vs. Classification –– Defect detection refers to the ability to
determine that some type of defect is present, whereas defect classification
refers to the ability to determine exactly what kind of defect exists. The
BLISTER–PAK option will reject any blister in which it detects a defect, but
there are cases where a given defect in a blister may not be classified reliably
because the defect itself is ambiguous, or because of limitations in the image
processing methods used.
For example, consider the case of a tablet that is broken. If the tolerances
have been set properly, the blister containing the broken tablet will be
rejected because the area of the tablet is too small, but the defect may not be
classified as expected. The expected classification of this defect would be
“Broken”, but if the shape tolerances were set widely enough, it may be
classified as “Undersize” because the shape is sufficiently close to the
original shape of the tablet. Also, when a tablet is broken, it’s center may be
shifted far enough within its pocket to be classified as a “Position” error. This
is the correct classification, but not necessarily what an operator might
expect.
2–8
Chapter 3
Installing the BLISTER–PAK Option
Figure 3Table 3
Chapter
3
Installing the BLISTER-PAK Option
This chapter contains information that will help assure a smooth and
successful installation of the BLISTER-PAK option on your Color CVIM
module. It includes the following information:
• Installing the Color CVIM BLISTER-PAK option.
• Using the Color CVIM BLISTER-PAK option with the MATH-PAK and
USER-PAK options.
Installation
The Color CVIM BLISTER-PAK option is provided on a single memory
card. You need install the BLISTER-PAK option only once. The
BLISTER-PAK option remains installed for all subsequent powerup cycles.
Important: Installation of the Color CVIM BLISTER-PAK option results in
modification of the standard Color CVIM firmware, and is not
reversible.
ATTENTION: Inspection configurations created under the
standard Color CVIM firmware cannot be used with the
BLISTER–PAK software, and vice versa. Any configurations
!
Use the following steps to install the BLISTER-PAK option on your Color
CVIM module:
1. Remove power from the Color CVIM module.
2. Insert the BLISTER-PAK option card in the Archive Memory slot on the
front of the Color CVIM module. Insert the end with the metal strip
facing right as shown in Figure 3.1 on page 3–2.
created and stored using standard Color CVIM firmware
will be rejected by the BLISTER–PAK software.
3–1
Chapter 3
Installing the BLISTER–PAK Option
Figure 3.1
Using the Installation RAM card
CVIM Module
BLISTER-PAK
Installation Card
Card Label Metal Strip
3. Apply power to the Color CVIM module to start the loading sequence.
ATTENTION: Do Not remove power to the Color CVIM
module during loading of the BLISTER-PAK option. Doing so
!
may damage the Color CVIM module.
During the loading process, the Pass/Fail LED alternates between orange
and green.
When the loading process is complete, the CVIM module begins its
normal powerup sequence.
4. Verify that the BLISTER-PAK option is installed by checking the title
banner on the monitor after powerup. If the BLISTER-PAK option is
correctly installed, a message (similar to the one illustrated in Figure 3.2
on page 3–3) will appear on the banner indicating the presence of the
BLISTER-PAK option.
3–2
Chapter 3
Installing the BLISTER–PAK Option
Figure 3.2
Title Banner With BLISTER-PAK Option Installed
Reinstallation of USER-PAK and MATH-PAK Options
Compatibility With Existing Applications
Installing the Color CVIM BLISTER-PAK option nullifies any pre-existing
installation of the USER-PAK and/or MATH-PAK options on your Color
CVIM module. If you install the BLISTER-PAK option over an existing
USER-PAK or MATH-PAK installation, you must reinstall those options.
Installation of the Color CVIM BLISTER-PAK option results in
modifications to the standard Color CVIM firmware. Those modifications
deliver a range of powerful new functionality, but also result in elimination
of some features of the Color CVIM that are unlikely to be used in an
environment where blister packaging inspection is required.
Here are the main differences between the standard Color CVIM firmware
features and the features available with the Color CVIM BLISTER-PAK
option:
• Calibration –– The BLISTER–PAK option does not contain the
calibration feature.
• Communications –– The BLISTER–PAK option does not support
Pyramid Integrator backplane communications.
3–3
Chapter 4
System Configuration
Figure 4Table 4
Chapter
4
System Setup
Use this chapter as a guide as you first set up your basic system to meet the
needs of your own unique inspection environment. It includes information on
topics such as camera installation, discrete I/O, and communications issues.
The initial configuration of your blister inspection system resembles that
used for a standard Color CVIM module. We have elected not to duplicate
the mass of that information here. As a result, you will be asked throughout
this chapter to refer to specific sections of the documentation that came with
your Color CVIM Module. Titles referenced include:
• Bulletin 5370 Color CVIM Module User’s Reference Manual (Cat. No.
5370-ND009).
• Bulletin 5370 Color CVIM Module Communications Manual (Cat. No.
5370-ND010).
Accessing System Setup
Camera Configuration
When you select the Setup menu item from the run mode, the module will
enter either the system setup mode (see Figure 4.1) or the blister setup mode.
To access the system setup mode while in the blister setup mode, click on the
Exit menu item.
Camera configuration involves mainly these activities: focusing the camera,
identifying the camera type, selecting the camera resolution, and optimizing
the Color CVIM system for use with the intended lighting system. Most
camera configuration activities are performed from the Camera menu,
which is accessed from the Env/Cam menu, as shown in Figure 4.1.
Figure 4.1
Selecting Camera Menu
For complete details about camera configuration, refer to Chapter 4 in the
Color CVIM Module User’s Reference Manual, Cat. No. 5370–ND009.
4–1
Chapter 4
System Configuration
Discrete I/O Configuration
Discrete I/O configuration involves mainly the assignment of various input
and output signals to discrete I/O lines. Most discrete I/O configuration
activities are performed from the I/O menu, which is accessed from the
Env/Cam menu, as shown in Figure 4.2.
Figure 4.2
Selecting I/O Menu
For complete details about discrete I/O configuration, refer to Chapter 11 in
the Color CVIM Module User’s Reference Manual, Cat. No. 5370–ND009.
Remote I/O Configuration
NOTE: The Color CVIM BLISTER-PAK option provides three new
discrete I/O features; namely, the active–pass/active–fail option, the machine
stop output signal option, and the results trigger option. These options are
discussed in detail in Chapter 8, Results and Outputs, under the
corresponding headings.
In order to use the Remote I/O port of the Color CVIM, the port must be
configured as described in Chapter 4 of the Color CVIM Communications
Manual, Cat. No. 5370–ND010.
4–2
Chapter 5
Auto Setup
Figure 5Table 5
Chapter
5
Auto Setup
The Color CVIM BLISTER-PAKt option provides a number of
enhancements to the Color CVIM module that help make it easy to set up
and use blister packaging inspection applications. The auto setup feature is a
key element in that flexibility and improved usability.
Auto setup simplifies the job of defining the large number of inspection tools
commonly required for blister packaging inspection applications. Auto setup
allows almost anyone to learn quickly how to configure and use the Color
CVIM for blister inspection.
Use this chapter as a guide as you create an inspection configuration that
meets particular needs presented by a particular blister. It includes
information on using the auto setup feature.
Accessing Blister Setup
Configuring Auto Setup
When you select the Setup menu item from the run mode, the module will
enter either the system setup mode or the blister setup mode. To access the
blister setup mode while in the system setup mode, click on the Exit menu
item.
Before beginning the auto setup process for the first time, you should set the
following parameters in the Configure menu as required for your blister
inspection application:
• Teach count.
• Minimum position tolerance.
• Minimum area tolerance.
• Minimum shape tolerance.
• Variation scale.
The Color CVIM BLISTER-PAK software provides default settings for each
of these parameters, but you can modify them as required. You can change
the default configuration values to meet your specific needs at any time
before auto setup. To do so, select the Configure menu item in the Blister
Setup menu bar, then select the specific parameter item from the Configure
menu. Use the onscreen calculator (Figure 5.1 on page 5–2) to enter a new
value.
5–1
Chapter 5
Auto Setup
Figure 5.1
Example: Onscreen Calculator Keypad
Teach Count
The last step of the auto setup process involves “teaching” the system by
examining a specified number “good” sample blisters. This enables the
system to determine the expected values of each object, and the expected
variation of these values, during production inspection operations.
The teach count parameter determines the number of sample blisters the
system should examine during the auto setup process before calculating
range values for the position, area, and shape tolerance parameters. Because
the teach count setting determines the sample size, it has a direct effect on the
statistical validity of these calculated range values.
A low teach count requires less time when performing the “teach–in” step
than a high teach count. However, with a low teach count you may not
observe the complete range of variation that is likely during actual
production. The result of a small sample size could be excessively tight
tolerances, resulting in false rejects. On the other hand, a high teach count is
likely to more accurately represent the range of variations that can be
expected during actual production.
Note that the variation scale setting discussed on page 5–6 can be used to
expand the taught tolerance values slightly. This capability can help
compensate for the narrowed range of variation that the system may
encounter with a low teach count.
When you select the Teach Count menu item, an onscreen calculator
appears, on which you can enter a teach count value between 0 and 1000.
The teach count value in the default configuration is 0. (When the teach
count is 0, the inspection tolerances will simply be set to the minimum
tolerance values as defined in the following sections.)
5–2
Chapter 5
Auto Setup
Minimum Position T olerance
The minimum position tolerance parameter sets the minimum value to which
the position tolerance will be set during the “teach–in” process, even if the
observed position variation is less. The default value is 10%.
During inspection, the system attempts to match the camera image of objects
with the stored image of those objects. In an ideal world, every object in
every pocket of every blister would appear in exactly the same position.
However, in the real world of production inspection, at least some variation
in position is almost certain to occur. This variation is known as positional
offset.
During the auto setup process, the Color CVIM BLISTER-PAK option
accommodates positional offset by evaluating variations in the positions of
the sample objects and, on the basis of that evaluation, automatically
calculating X and Y position tolerance values for each blister. These are
expressed as percentages.
It is possible, however, that very little positional offset may occur during the
carefully controlled conditions of an application “teach-in.” This could result
in calculated tolerance values that are be much lower than the actual
positional offsets expected during production inspection operations.
If you expect that the values calculated by the auto setup process are likely to
be too low, you can use the Min. Pos. Tolerance menu item (before starting
the auto setup process) to enter higher minimum values that will override
any calculated values that are lower. These higher minimum values can be
based on the known mechanical characteristics of your own installation, on
experience, or on other criteria.
When you select the Min. Pos. Tolerance menu item, an onscreen
calculator appears, on which you can enter a minimum position tolerance
value between 0% and 100%. The value that you enter determines the
minimum acceptable positional offset range for each axis.
For example, if you enter a value of 12, it establishes a minimum acceptable
offset range of 12% for both the X–axis and the Y–axis. If the auto setup
process then calculates a position tolerance of 7% for the X–axis and 14%
for the Y–axis, the position tolerance for the X–axis would be forced to 12
%
(the minimum value), while the position tolerance for the Y–axis would
change to 14%, since it is higher than the minimum position tolerance.
NOTE: Changing the minimum position tolerance after completing the auto
setup process will have no effect on the current position tolerance values.
You can, however, alter the current position tolerance as explained on page
6–9 under the Position Tolerance heading.
5–3
Chapter 5
Auto Setup
Minimum Area Tolerance
The minimum area tolerance parameter sets the minimum value to which the
area tolerance will be set during the “teach–in” process, even if the observed
area variation is less. The default value is 10%.
During inspection, the system attempts to match the camera image of objects
with the stored image of those objects. In an ideal world, every object in
every pocket of every blister would appear to have exactly the same area.
However, in the real world of production inspection, at least some variation
in area is almost certain to occur.
For purposes of the Color CVIM BLISTER-PAK option, the area of a
previously learned color (along with its shape and relative position)
determines the definition of an object or blister. Area is determined by
counting the number of contiguous pixels covered by a color.
During the auto setup process, the Color CVIM BLISTER-PAK option
accommodates area fluctuations by evaluating the variations in the area of
the sample objects and, on the basis of that evaluation, automatically
calculating area tolerance values for each blister. These are expressed as
percentages.
It is possible, however, that a very small range of area values may be
encountered during the carefully controlled conditions of an application
“teach-in.” This could result in calculated tolerance values that are much
lower than the actual area variations expected during production inspection
operations.
If you expect that the values calculated by the auto setup process are likely to
be too low, you can use the Min. Area Tolerance menu item (before the auto
setup process) to enter higher minimum values that will override any
calculated values that are lower. These higher minimum values can be based
on the known mechanical characteristics of your own installation, on
experience, or on other criteria.
When you select the Min. Area Tolerance menu item, an onscreen
calculator appears, on which you can enter minimum area tolerance values
between 0% and 100%. The value that you enter determines the minimum
acceptable range of area variation.
For example, if you enter a value of 15, it establishes a minimum acceptable
area range of 15%. If the auto setup process then calculates an area
tolerance of +12% and –17%, the plus (+) value would be forced to 15% (the
minimum value), while the minus (–) value would remain at 17%, since it is
higher than the minimum area tolerance.
5–4
Chapter 5
Auto Setup
NOTE 1: Changing the minimum area tolerance value after completing the
auto setup process will have no effect on the calculated area tolerance values.
You can, however, alter the calculated area tolerance values as explained on
page 6–10 under the Area Tolerance heading.
NOTE 2: Under some circumstances, a tablet may appear larger or smaller
than it actually is. Minor variations in lighting or tablet orientation may result
in identical objects presenting larger or smaller areas of a trained color. In
rare cases, slight differences in the actual size of a tablet or capsule may be
acceptable. Most often, however, you will seek minimum area tolerance
values that minimize false rejects and, at the same time, fail blisters
containing broken or malformed objects, and pockets containing multiple
objects.
Minimum Shape Tolerance
The minimum shape tolerance parameter sets the minimum value to which
the shape tolerance will be set during the “teach–in” process, even if the
observed shape variation is less. The default value is 10%.
During inspection, the system attempts to match the camera image of objects
with the stored image of those objects. In an ideal world, every object in
every pocket of every blister would appear to have exactly the same shape.
However, in the real world of production inspection, at least some variation
in shape is almost certain to occur.
For purposes of the Color CVIM BLISTER-PAK option, the shape of a
previously learned color (along with its area and relative position) determines
the definition of a tablet or blister. Shape is determined by examining the
area of a learned color and calculating
1
its “circularity.” This is a measure of
how circular an object is, with a perfect circle having a shape of 1.0 and less
circular objects having lower circularity values.
During the auto setup process, the Color CVIM BLISTER-PAK option
accommodates shape fluctuations by evaluating the variation in the
circularity of the sample objects and, on the basis of that evaluation,
automatically calculating shape tolerance values for each blister. These are
expressed as percentages.
It is possible, however, that a very small range of circularity values may be
encountered during the carefully controlled conditions of an application
“teach-in.” This could result in calculated tolerance values that are be much
lower than the actual circularity variations expected during production
inspection operations.
1 The formula used to calculate circularity has the effect of ignoring fuzziness or convolutions in the perimeter of
an object. Instead, the calculation measures how close the basic shape of the object is to being a perfect
circle, irrespective of variations in the perimeter.
5–5
Chapter 5
Auto Setup
If you expect that the values calculated by the auto setup process are likely to
be too low, you can use the Min. Shape Tolerance menu item (before the
auto setup process) to enter higher minimum values that will override any
calculated values that are lower. These higher minimum values can be based
on the known mechanical characteristics of your own installation, on
experience, or on other criteria.
When you select the Min. Shape Tolerance menu item, an onscreen
calculator appears, on which you can enter minimum shape tolerance values
between 0% and 100%. The value that you enter determines the minimum
acceptable range of shape variation.
For example, if you enter a value of 15, it establishes a minimum acceptable
shape range of 15% . If the auto setup process then calculates a shape
tolerance of +12% and –17%, the plus (+) value would be forced to 15% (the
minimum value), while the minus (–) value would remain at 17%, since it is
higher than the minimum shape tolerance.
NOTE 1: Changing the minimum shape tolerance value after completing
the auto setup process will have no effect on the calculated shape tolerance
values. You can, however, alter the calculated shape tolerance values as
explained on page 6–11 under the Shape Tolerance heading.
NOTE 2: Under some circumstances, a tablet may appear distorted. Minor
variations in lighting or tablet orientation may result in identical objects
presenting different profiles. Those different profiles appear more or less
circular to the system. In rare cases, slight differences in the actual shape of a
tablet or capsule may be acceptable. Most often, however, you will seek a
minimum shape tolerance value that minimizes false rejects, and at the same
time fails blisters containing broken or malformed tablets or pockets
containing multiple tablets.
Variation Scale
The variation scale parameter expands the tolerance range limits that the
system calculates during the auto setup process.
During auto setup, the Color CVIM BLISTER-PAK option gathers the
number of images determined by the value of the teach count parameter. It
then analyzes those images to identify a range of variation in position, area,
and shape for each object in the image. On the basis of those observed
ranges, it automatically calculates range values for position, area, and shape.
If a calculated range value is less than the corresponding minimum value that
appears in the Configure menu, the system will ignore the calculated value
and use the minimum value instead.
5–6
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