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Functional Specifications TCM

1. Video Terminal Processor OK Rel 2 010 Battery OK Machine Processor OK Rel 2010 Battery OK Flash Memor OK Test Flash Memo OK Flash cleared gt Test Parametri Card 0 SIGN PR OK Rel 2 010 Card 1 SIGN PR OK Rel 2 010 Card 6 MOTORS OK Rel 1 05 Card 7 DIGITAL VO OK Test Printer OK Press any key to continue Fig 3 3 Typical Self Test Screen TCM Functional Specifications 23 N9501FE1 DOC b Operating errors NN9501F ling The error messages are displayed in order to signal the wrong operation of fundamental parts of the machine that would not allow to correctly test the product The error messages listed here below preceded on the screen by the letter E are always associated with an automatic and immediate stop and a 3 second sound signal Consider them as serious alarms which require the intervention of technical personnel MESSAGE Lack of electronics 12VDC supply module x Power section CHINE CONDITION Lack of Telecamera 12VDC supply module x Power section Lack of Services 24VDC supply module x Power section Motor breakdown y module x Motor inverter belts encoder DM522 motor board Transmission error MP gt SP y Connections SP board Receive error MP lt SP y Motor speed too high Programme too long Phase error module x Encoder DM526 board
2. SP Signal Processor acquisition and processing circuit which processes the images coming from the telecameras and communicates the test result to the Machine Processor VTP Video Terminal Processor it is the computer section which handles the user interface screen and keyboard This permits the operator to program the SP processors to set and store the test parameters and to get the results of the production carried out TCM Functional Specifications 30 N9501FE1 DOC NN9S501F ling APPENDIX B Classes of Defects and Reject Priority Decs one e ape TA Son e a e ou oo 1 Burnings X AE et 2 Bumings X a C Each defect is assigned to a class if the corresponding cell is crossed Each defect must belong only to one class Classes are numbered in descending priority order TCM Functional Specifications Appendix B Page 1 emf a i on eee A 1900 130 P570 1000 A m Z n iT R b N 8 1 j li z RZ 2 o 1 a Yo L al 3 g a ee fe E APPROVED AS NOTED pe poun B CUSTOMER SIGNATURI A
3. Reject error y module x DM526 board DM532 board actuator sensor on actuator TCM Functional Specifications 24 N9501FE1 DOC c Operational warnings NN9501F ling The operational warnings preceded on the screen by the letter W do not stand for a bad operating of the machine but they advise the operator when some events occur which can alter the machine operating or when the operator himsel The simple operator s intervention is enough to restore normal condition MESSAGE Disconnected printer or printer OFF If gives an invalid command Printer connections SOUND SIGNAL MACHINE INDITION Function disabled Operator s error Inadmissible value Operator s error Parameter writing not enabled Parameter writing key not resent T O board on MANUAL module x Start with DM526 board on manual Motor board on MANUAL module x Start with DM522 board on manual 3 seconds Emergency stop module x Emergency push button emergency circuit Box y full module x Excessive number of ampoules out of seat box Stop box y full module x Excessive number of ampoules TCM Functional Specifications 3 seconds 3 seconds 25 N9501FE1 DOC NN9501F ling 4 INTERFACE All the operations described are performed using the machine s two keyboards Control keyboard located on the front wall of the machine Console k
4. To print the parameters the selection path is test parameters F7 F3 F5 Print Screen gt motor speed F7 F3 F5 Print Screen gt E Changing the active product GOAL PROCEDURE Change the type of product being tested The following parameters are associated with each type of product Name of product Sensitivity parameters Programs of the different SP sub systems Motor speed Parameters for timing the output boxes Changing the active product automatically changes all the parameters associated with that product Selection path lt F3 gt lt F1 gt Position the arrow located in the left part of the display on the row regarding the product to be activated using the up and down arrow keys AN and lt b gt Press the lt F2 gt key to select the product Note that to confirm acceptance of this command the name of the chosen product appears on the heading of the video screen To create and record a new product refer to the User Manual TCM Functional Specifications 28 N9501FE1 DOC NNOSOIF ling 4 1 2 Supervisor A Changing a parameter GOAL Change one or more parameters associated with the product To perform this operation it is necessary to own the parameter writing enable key and to insert it on the front panel of the DM503 board The change is possible only on the parameters of the active product PROCEDURE To make the product active follow the instructions de
5. have a value below this threshold and assignes the value 1 to the ones which have a value above the threshold Just to make an example if the object monitored has a middle grey colour the image will be a table full of 127 values corresponding thus to the middle of the range 0 255 If the binarization threshold is set at 128 the resulting binarized image will be a table full of 0 values if the threshold is set at 126 the table will be full of 1 values In this way we obtain one or more binarized images consisting only of 0 and 1 values If we test a vial and succeed in lighting it up so that the defects to be detected look darker than the vial glass we will set the binarization threshold at such a value that in the resulting binarized image the defect becomes a completely black spot on a completely white background that is a group of 0 values surrounded by 1 values The system can be programmed to look for defects in definite zones of the image to detect bigger defects than the ones whose dimensions was preset by the user to make measurements to detect presence or absence of particulars TCM Functional Specifications 18 N9501FE1 DOC NN9SOI1F ling A second technique is the one based on the differences that is used for the search of particles inside the fluid The container rotates and then abruptly stops so that the particles move inside the fluid while the container stays in front of the telecamera The SP s
6. for a standard format of the video signal Digitizing or analog to digital conversion Conversion of an analog signal into a series of numbers At first the analog signal is sampled in order to have istantaneous values later converted into a number sequence describing the signal amplitude step by step The accuracy of the signal translation into numbers depends on the sampling and conversion frequency and on the resolution of the converter circuit The higher is the frequency the higher is the resolution and thus the accuracy Image Image stands for the whole numbers resulting from the analog to digital conversion it is a table of numbers each of them representing the luminosity value in a definite point of the field focused by the telecamera MP Machine processor it is the processor which controls the machine movements and the correct operating of all parts After receiving the results of the SP boards tests it actuates the reject device if the container is considered defected Pixel Contraction of Picture Element each element composing the image In the telecamera image a pixel corresponds to what was picked up by one of the photosensors contained in the CCD sensor Sampling Acquisition process of an analog signal a circuit measures at regular intervals the analog signal applied at its input and at output it gives a sequence of istantaneous values picked up in the different moments of sampling
7. in first out as the first container which enters the line is the first to get out too The lines are equipped with belts powered by motors which are used for the correct operating of the lines themselfs The transportation method guarantees a uniform movement of the containers without sudden shifts This mechanism is built with materials which cannot damage or dirty the containers TCM Functional Specifications 15 N9501FE1 DOC NN9501F ling 2 4 TECHNICAL NOTES 2 4 1 Performances Tested containers Ampoules Dimensions of tested containers 10 5mm tot h 50mm ampoules 16 5mm tot h 67mm ampoules Machine speed 300 pes min for 1 2 ml ampoules 250 pes min for 6 ml ampoules Inspection stations 2 inspection stations Loading from boxes or in line from the upstream machine Unloading accepted in first in first out line rejected standard CEA steel boxes 130x345x50mm WxDxH 2 4 2 Services required Electric supply 220V 5 60Hz 1Ph Power 1 5 KW TCM Functional Specifications 16 N9501FE1 DOC 2 4 3 Limits Dimensions WxDxH Weight Loading unloading height Minimum height above floor Noise acoustic pressure level continuous equivalent A weighted Protection level 2 4 4 Working environment Operating temperature Relative humidity Electromagnetic compatibility Pressure NN9501F ling 2465 x 1250 x 1800 1100 Kg 900mm 30mm mechanic module 150mm 75dB A mec
8. their effect without original programs and parameters which are stored in a non volatile memory being changed 5c possibility of activating the Manual mode MANUAL menu this is useful for instance for format changeover it permits to disable lamps and motors without the machine diagnosing operating errors 5d possibility of acquiring an image from any station and immediately execute different processing for testing purposes TEST SP menu the gray scale image and the binarized one are shown in separate windows The user can change the binarization threshold and see the effects on the binarized image Furthermore it is possible to copy the image in a new window and process it using algorithms as subtraction between two images or convolution Se possibility of activating an oscilloscope function OSCIL menu a window 59 complete with a reference grid shows a real time oscilloscope like display of the light intensity along a row or a column of the image The user can examine the desired row or column simply by using the four arrow keys A red line indicates the level of binarization by changing this level with the lt gt lt gt keys the red row moves and gives a help to look for the more appropriate binarization threshold possibility of testing the inputs and outputs with the machine stopped TEST HW menu TCM Functional Specifications 13 N9501FE1 DOC NN9501F ling 6 includes a complete programm
9. N9501FE1 DOC Order Customer Reference Version Date NNO9501F ling Brevetti C E A S p a Via del Commercio 28 36050 Sovizzo VI ITALY corr ne 3 Tel 0444 551988 Fax 0444 536241 Functional Specifications TCM N9501 Connaught Canada NNO9S01F 1 February 2 1996 This document contains 30 pages one page of Appendix B and an enclosure Author Review Approval Customer s review Customer s approval V Maruzzo EI Aa pis Name Position Signature Date A Signorelli Project Responsible ego EL A ASE EE D Dal Bello Q A Manager DA A3 2 S6 TCM Functional Specifications 1 N9501FE1 DOC NN9501F ling TABLE OF CONTENTS 1 INTRODUCTION 1 1 REFERENCES 2 GENERAL DESCRIPTIO 2 1 PROCESS DESCRIPTION 2 1 1 Process diagram Sheets 1 4 2 1 2 Mechanics layout 2 2 COMPUTER DESCRIPTIO 2 2 1 Hardware architecture 2 2 2 Software architecture 2 4 TECHNICAL NOTE 2 4 1 Performances 2 4 2 Services requir 2 4 3 Limits 2 4 4 Working environment 2 4 5 Expandability interface option 3 FUNCTIONS esssssessssees 18 3 1 ACQUISITION SYSTEM 18 3 1 2 PROCESSING SYSTEI 18 3 2INSPECTIONS 20 3 2 1 Station TV1 Station TV2 20 3 3 MECHANICS 21 3 3 1 Loading 21 3 3 2 Transportation metho 21 3 3 3 Output 22 3 3 4 Protections 22 3 4 SAFETY ERRO 22 SAN GO evosisssssasisasssssesasansssin 22 3 4 2 Error and al
10. air flow keeps An airflow keeps the container on the the container on the Ant van accepted star wheel rejected star wheel an ka gere and it can proceeds it proceeds to the is generat to the good channels rejected box Y Reject device position is checked s programmed aximum different from 0 Machine stops Machine stops Error message Error message is displayed is displayed 95013 oa TCM Functional Specifications 8 N9501FE1 DOC Process diagram sheet 4 The container is inserted on one of accepted channels Container position is checked container on the correct channel 2 Machine stops Emor message is displayed Process complete n9501pr cdr TCM Functional Specifications NN9501F ling N9501FE1 DOC NN9501F ling 2 1 2 Mechanics layout See enclosure 1 2 2 COMPUTER DESCRIPTION The computer is housed in a standard 19 inches rack enclosure containing the computer hardware the power supply section the power section and the signal processors for the telecameras The monitor for the data display and the keyboard are placed externally on a machine table The rack can be reached by a door which is placed on the left side of the machine 2 2 1 Hardware architecture The control system is multiprocessor architecture based with high speed serial connection among the different processors to a
11. arm messages 23 4 INTERFACE 26 4 1 ACCESS LEVEL 26 4 1 1 Operator 27 4 1 2 Superviso 4 1 3 Maintenance technician 5 GLOSSARY erer APPENDIX B Classes of Defects and Reject Priority ENCLOSURES Enclosure 1 LAY CONNAUGHT 13 1 sheet rev 2 TCM Functional Specifications 2 N9501FE1 DOC NN9501F ling 1 INTRODUCTION This document is prepared by Brevetti C E A S p A in order to define functional criteria of TCM machine as required by the Customer in the User Requirement Specification 1 This document is prepared in accordance with what foreseen in 14 15 Instruction Standard Format of Machine Documentation 2 This document is produced by the System Analysis Department and approved by Quality Assurance and then submitted to the Customer s approval as foreseen by the Quality Plan 3 1 1 REFERENCES When there is a reference to another document only the number is reported into square brackets as indicated in the following table N RIF DOCUMENTO 1 N A SPECIFICATIONS FOR BREVETTI AUTOMATIC INSPECTION MACHINE AND BREVETTI JUPITER LEAK DETECTOR dated June 26 1995 2 14 15 Standard Format of Machine Documentation 3 NN9S01Q Quality Plan 4 NN9S501U TCM User Manual 5 NN9501V TCM Maintenance Manual 6 NN9501Z Software Configuration SP Programs and Parameters TCM Functional Specifications 3 N9501FE1 DOC NN9501F ling 2 GENERAL DESCRIPTION TCM machine is designed
12. ays the corresponding level code The user can select the Logout command keys lt F7 gt lt F6 gt lt F2 gt lt F2 gt to temporarily disable all functions To access them again a password must be re entered TCM Functional Specifications 26 N9501FE1 DOC NN9501F ling 4 1 1 Operator 4 1 1 1 Machine operations A Starting and stopping Machine START green and STOP red commands are given by illuminated push buttons present on the control keyboard Command activation and acceptance are signalled when the push button lights up These commands only permit start up and stop with the machine in phase B Emergency stop Immediate machine stop is obtained by pressing one of the self retaining EMERGENCY push buttons red mushroom shaped push buttons located around the machine in easily accessible positions When the EMERGENCY RESET push button is illuminated it signals the condition of emergency stop At power up the machine is set in emergency for safety reasons C Reset after an emergency stop To restore normal operation you must release the emergency push button which caused the machine stoppage and press the interested EMERGENCY RESET push button This sequence of operations Release emergency button press Reset press Start guarantees and protects the machine operator against the possibility of accidental machine start up after an emergency stop 4 1 1 2 Operations on the console keyboard A Display of motor speed GOAL Di
13. box If the container was accepted it proceeds and is put on the output channel of accepted As there are two output channels for accepted containers these are sent alternatively towards the two channels by means of a third star wheel They pass from one star wheel to the other by using the same air principle used for the rejects Then by means of belts are addressed to the downstream machine ATM18 3 3 4 Protections a All parts in contact with the product are made of stainless steel or of plastic material which does not produce dust and can be removed to permit cleaning b The transportation zone of the containers is separated from the mechanical and electrical parts so that the product residues can not reach them c The parts in movement are protected by covers equipped with safety switches which stop the machine in case of opening d Access panels to parts that require maintenance can be opened only using a proper tool 3 4 SAFETY ERROR AND ALARM MESSAGES 3 4 1 Safety a The cover of the loading star wheel is equipped with a device which in case of opening stops the machine When the machine is running the access to moving parts is possible only after actuating a key switch which cuts out the safety switches b Mushroom shaped emergency push buttons are located around the machine in easily accessible positions The machine stops in emergency for the following reasons 1 amushroom shaped push button was pressed 2 ac
14. created in memory and it is filled with the numbers coming from the conversion stage Each one of these numbers represents the quantity of light present in a definite point of the image at the moment of sampling This method is called analog to digital conversion or digitizing At this moment there is a 144 x 416 table whose cells contain all information necessary to understand if the object acquired as an image presents some defects This map therefore can be called image or more precisely digitized image The present system permits to acquire up to 8 images while the container stands in front of the telecamera The container can be monitored 8 times while it is rotating around its own axis covering thus the whole lateral surface In case of flip off or bottom test a unique image is sufficient 3 1 2 PROCESSING SYSTEM In all the application programs both using the difference method or the binarized one a test is pesrformed in order to check if the quantity of light is enough for the correct execution of the program itself In the negative the container is rejected termining the program execution Moreover if four consecutive rejects occur for lack of light the machine stops and displays the message Station breakdown The first processing the image undergoes is the binarization the user defines a threshold between 0 and 255 so that the system assignes the value O to all the elements of the digitized image which
15. e of the machine is logically subdivided in 1 Machine handling software 2 Programming software 2 2 2 1 Machine handling software The machine handling software executes the functions typically used by the product manager and the operator that is 1 provides the machine normal operation 2 provides production data operating warnings and error messages The rejects are counted according to a structure consisting of four elements 1 Defects 2 Stations 3 Classes of Defects 4 Reject Priority Each Station can detect up to four Defects for example the station x can detect at the same time total height and burnings Defects can be grouped in Classes A class can include both the defects detected by the same station and the defects detected by different stations for example the Burning class can include burnings on the tip and on the neck which are defects detected by separate stations In this case a container presenting one or both the defects will be counted as reject under the Burning class A class however can consist of a single defect as well Each inspection or defect must belong only to one class The number of available classes is 16 Classes are arranged according to a Reject Priority order for example if the Burning class is a priority respect to the Height class the container with both defects will be counted only as reject for cracks Fig 2 2 In the HOME page the number of r
16. ejects for each class is displayed If lt ENTER gt is pressed when the cursor is positioned on a class a window pops up which displays the number of rejects for each defect belonging to that class this display also includes the indication of which stations have detected the defects The subdivision into classes of defects can be configured according to different types and priority of defects For the Classes of Defects and Reject Priority configuration see Appendix B TCM Functional Specifications n N9501FE1 DOC NNO9501F ling Station 1 Station 2 Dete perc oeo Z Def F Priority 4 Priority 2 aaan aaa Priority 3 Priority 4 Priority 5 Priority 6 Fig 2 2 A separate window displays the following data Rejects for Machine Stop Total Rejected Total Accepted Total Inspected 3 permits to store and recall the inspection parameters for the products 4 features some display and print functions useful for monitoring the production and for system operation such as 4a on line that is in real time detailed display of the inspection result for each station ON LINE menu while the machine is operating the screen displays up to four values of measures performed on the container by the selected station together with the time taken by the inspection program for processing the image s Furthermore some symbols appear which indicate the presence or absence of the co
17. eset by the user For each distribution shown the mean and standard deviation are displayed Furthermore a zoom function is available to expand the graph on the x axis to make it more readable 4e possibility of displaying a list of the last 256 alarms occurred during a production lot 45 5 features Each alarm is displayed complete with date and time Only the alarms with codes 1 1999 Operating errors are listed These alarms usually involve intervention of a technician to be recovered see par 3 4 2 The user can browse the alarm list using lt Pg Up gt and lt Pg Dn gt Keys The contents of the screen can be sent to the printer using lt Print Screen gt key When the counters are reset at the beginning of a new lot the alarm list is cleared possibility of entering product and batch data two 80 character lines available which is displayed in the Home screen lt F7 gt key If the machine is switched off this data remain stored in a non volatile memory some test functions useful for performing trials on each single test station and on the total efficiency of the machine such as Sa utility for Knapp test execution with print out of graphical and numerical report KNAPP menu 5b possibility of acquiring an image from any station and immediately execute with the machine stopped any processing program for testing purposes PROGRAM menu It is possible to change parameters and instructions to check
18. eyboard All information is furnished by the computer screen by the telecamera monitor and by an optional printer 4 1 ACCESS LEVELS Operational Functions are accessed via passwords The system has two access levels 1 Operator 2 Supervisor Two passwords are available for each level A two character field which is constantly displayed in the video screen heading shows the current level code The level codes which can be displayed are listed below no level is active therefore no operational function can be accessed Operator level is active under password No 1 Operator level is active under password No 2 Supervisor level is active under password No 1 Supervisor level is active under password No 2 When Operator Level is active access is restricted to the following operational functions 1 Start and Stop 2 Counter Reset 3 Active Product Selection When Supervisor Level is active access to operational functions is extended and includes 1 Access to Operator Level Functions 2 Inspection Parameter and Program Modification 3 Password Modification When the machine is switched on no level is active therefore no operational function is enabled By pressing keys lt F7 gt lt F6 gt F2 Fl the Login command is selected and the system requests the user to enter a password After a password is entered the user accesses the functions reserved to that password and the video screen heading displ
19. hanic module within the CEI standard IP22 cabinet within the CEI standard IP54 5 35 C max 90 no condensation emission within the CEI EN5008 1 1 standard limits 0 5 2 bar 2 4 5 Expandability interface options Software reserve space Cabling reserve space Interface Options Prearrangements 20 10 spare terminals serial RS232 C parallel Centronics not applicable not applicable TCM Functional Specifications 17 N9501FE1 DOC NN9501F ling 3 FUNCTIONS 3 1 ACQUISITION SYSTEM The system of image acquisition and processing is explained into detail in the User Manual This chapter sums up its operating in order to give an overall view of the techniques used and facilitate the understanding of the tests performed by the machine The telecamera has a CCD type matrix sensor Charge Coupled Device The sensor consists of thousands of single elements each of them supplies a quantity of electric energy proportional to the quantity of luminous power it receives The circuits of the telecamera measure all voltage values supplied by the single elements of the sensor and build a standard CCIR video signal This signal is sent by means of a cable to the SP acquisition and processing board This board samples the signal at a sampling rate of 8MHz that is it measures the signal level each 125ns then it converts the detected value into a number from 0 to 255 i e 0 black 127 gray 5096 255 white A table is
20. ich accumulates them against the transportation star wheel or automatically draws them by means of a worm screw from a line coming from the upstream machine and directly insert them on the transportation star wheel The belt made of a synthetic material is dragged by a roller connected through a timing belt to a gear motor The motor speed is controlled by the computer and is preset and stored in the test parameters of the product The transportation star wheel rotates with continuous motion and makes the ampoules directly pass in front of the test stations 3 3 2 Transportation method The container is transported along the path by a unique star wheel which beyond making the container pass in front of the inspection stations moves it to the reject device too Fig 3 2 During the transportation the containers flow along a steel profile which follows the star wheel circumference Automatic loading Mahdal iit N501132 CDR Fig 3 2 Containers path TCM Functional Specifications 21 N9501FE1 DOC NN9501F ling 3 3 3 Output At the output of the transportation star wheel the container is drawn by a smaller star wheel This star wheel moves the container towards the output channels If the container must be rejected a proper air actuator moves it to a second star wheel which addresses it towards the output channel of rejects ending in a
21. ing environment reserved to technical personnel this permits to write the image processing programs and change the existent ones These operations are performed by using an integrated editor the programs can be saved on non volatile memory and on removable memory card 2 2 2 2 Application software The application software consists of the image processing programs or SP programs The programs are written using a language developed by Brevetti C E A which has specific functions for image processing Each program is assigned to one or more SP systems and executes on the acquired images the sequence of operations and measures required by the inspection to be performed SP Program listings are included in the document 6 TCM Functional Specifications 14 N9501FE1 DOC NN9SOIF ling 2 3 MACHINE DESCRIPTION The machine consists of the following main parts 1 Keyboard and VGA Monitor 2 Machine body 3 Loading table 4 Connecting table with ATM18 The containers loaded on a conveyor belt or coming in line from the upstream machine are drawn by a star wheel which at first makes them pass in front of the inspection stations and then addresses them towards the device which divides them into accepted or rejected ones according to the inspection result The device beyond separating goods from rejects sends the accepted containers to two different channels which are connected in line with the ATM18 machine This line is named first
22. instantaneous way that is only taking one image TV1 while the ampoule is passing with continuous motion in a station which is Station placed on the transportation star wheel TV2 Each telecamera placed above the transportation level of the ampoule frames Fig 3 1 the tip by means of a mirror a lighting unit with halogen lamp and diffuser filter illuminates sideways the tip of the ampoule making the outlines and the possible black points present on the tip appear black on white background Number 1 points out the test zone of the black points By measuring the whole area of the defects and the symmetry of the ampoule tip and comparing these measures with the reference parameters the system defines if the container must be rejected The minimum detectable defect as regards the black point is a square with a 190um side when the contrast between defect and background is equal to 100 N B The two telecameras frame the container with a 90 angle the one respect to the other permitting the check of the whole tip development DIFFUSED LIGHT ILLUMINATOR HALOGEN BULB DIFFUSION FILTER MIRROR TELECAMERA TRANSPORTATION STAR WHEEL so1F31 coR Fig 3 1 Station TV1 TV2 Tip test Symmetry and burnings TCM Functional Specifications 20 N9501FE1 DOC NN9501F ling 3 3 MECHANICS 3 3 1 Loading The containers are manually loaded by means of proper boxes on a conveyor belt wh
23. ntainer and whether the container was or was not rejected by the other stations 4b comprehensive on line graphical display of the inspection result of all stations HISTORY menu a map of the positions the container fills while it is transported from input to output is displayed in correspondence to each inspection station a small square appears If it is green it will indicate that the station accepted the container if it is red it will indicate that the station rejected the container in case it appears light blue it will indicate that the station is disabled and did not perform any inspection 4c graphical and numerical display of the amount of rejects for each turret spindle SPINDLES menu the reject percentage of each spindle is shown with a histogram By selecting a spindle it is possible to obtain the total containers which it loaded the total rejected and their percentage These data is useful to point out possible malfunction of the spindles TCM Functional Specifications 12 N9501FE1 DOC NN9501F ling 4d graphical and numerical display of the distribution of the values measured by each station on the last 1000 inspections performed GAUSS menu once a station has been selected four quadrants appear Each quadrant shows the values distribution of one of the quantities analyzed by the program on a max of 1000 samples the samples are the last inspections performed by the station the number of samples can be pr
24. over was opened When an emergency stop occurs all parts of the machine stop After an emergency stop the operator must press the emergency reset push button to start the machine again c Access panels to parts that require maintenance can be opened only using a proper tool d Parts directly in contact with mains voltage are shielded by insulating panels in order to avoid accidental contacts The equipment features protections against overloads and earth leakage TCM Functional Specifications 22 N9501FE1 DOC NN9501F ling 3 4 2 Error and alarm messages a Start up diagnostic test At power up the machine control system performs a series of self diagnostic tests in order to check the operating condition of the boards and of the printer The test results are shown on the screen until the user does not make any selection from the keyboard The tests performed are in this order Memory test Parameter test Back up battery test Board test Printer test The following information is displayed for each test Test description Result Note where result corresponds to OK if the test passed FAIL if the test failed According to the kind of test there can be an additional note in particular for the electronic boards equipped with software the note reports the software release if the test of the program checksum is negative the note reports FAIL or Rel 000 The typical self test screen is shown in figure 3 3
25. s if inspection is enabled the images are processed and the result is stored as an active reject or accept flag in the shift register The acquired scans are processed while the machine is carrying the container to the next station If this container is ready for the image acquisition but the processing of the previous images was not completed the machine stops and the container is indicated as reject This happens when the machine speed is too fast or the test program is too long The diagram shows from the functional point of view the main functions performed by the system during operation A more detailed explanation of the routines the software executes to test the various sections of the machine is given in the Software Design Specification Fig 2 1 shows the layout of the stations to which we refer in the process diagram TCM Functional Specifications 4 N9501FE1 DOC NN9501F ling E m n l a JOX Ampoule sensor NS01F21 CDR Fig 2 1 Inspection station layout TCM Functional Specifications 5 N9501FE1 DOC 2 1 1 Process diagram Sheets 1 4 NN9501F ling Acquire images Process images Process diagram sheet 1 acquisition routine Each station assigns its Good reject flag to the container to be inspected If the station is disabled the flag always as
26. scribed previously To make modifications refer to the User Manual B Print outs It is enough to select the desired page and press the lt Print Screen gt function key 4 1 3 Maintenance technician The maintenance technician has a key for safety exclusion which actuates a switch to disable the safety switches mounted on the machine covers This permits the machine operating with open covers in order to perform maintenance or repairing operations The condition of disabled safety is signalled by the lighting up of a yellow lamp on the panel of the operating keyboard Each of the two modules has got its own key switch and its own yellow signal lamp TCM Functional Specifications 29 N9501FE1 DOC NN9501F ling 5 GLOSSARY Analog Quantity or signal which can continuously change The video signal supplied by the telecamera is analog because it changes in a continuous way analog to the variations of the luminosity of the framed object Binarization Image processing consisting in the conversion of the value of luminosity of each pixel into a binary value that is 0 or 1 based on a threshold This permits to obtain an image composed of black and white colours only CCD Charge coupled device it is a solid state photosensor where the received luminous energy produces a variation of the electric charge which is picked up and amplified by the telecamera circuits CCIR International Radio Consultative Committee It stands
27. splay the speed of the machine motors for the active product This speed is expressed in pieces hour for the main motor in RPM for the rotation motors and in cm second for the belt motor PROCEDURE Selection path F7 F1 F3 B Display of production data Counters GOAL Display of the following data number of tested containers number of rejects number of rejects divided by test station percentages PROCEDURE Selection path lt F7 gt Press the Print Screen key to get a print out of the video page TCM Functional Specifications 27 N9501FE1 DOC NN9501F ling C Start of production batch GOAL PROCEDURE Set the machine up to test a new production batch This corresponds to zero the counters and if necessary put in the name or the code of a new batch To zero the counters press the following keys lt F7 gt F2 FI FI and when required confirm with Y Two lines with 80 alpha numeric characters each one are available to enter batch name batch number or comments by pressing the keys lt F7 gt lt F2 gt lt F1 gt and F5 INFO The Esc key deletes a complete line D End of production batch GOAL PROCEDURE Record the data relative to the inspected batch It corresponds to print the data referring to the counters and the parameters with which the inspection was carried out To print the counters the selection path is lt F7 gt lt Print Screen gt
28. ssure real time process control Itis composed of 1 visual display terminal interface Video Terminal Processor or VTP 2 amachine handling unit Machine Processor or MP 3 various signal processing sub systems for the inspection stations Signal Processor or SP The power section provides the power supply to control electronics to the motors and to the various lighting systems The telecameras are equipped with a CCD matrix sensor and use standard TV lenses Operating VTP manages the user interface programmes the SP sub systems sends test parameters to the SP sub systems stores production data MP manages movements collects the results of SP sub system tests synchronizes movements and tests checks the correct operating of all parts and stops the machine in case of malfunction SPs process the images coming from telecameras and communicate the results of the tests performed to the Machine Processor TCM Functional Specifications 10 N9501FE1 DOC NN9501F ling 2 2 2 Software architecture The software of different processing units is stored on solid state components instead of magnetic media to avoid the risk of accidental erasure or modification A program editor with copy and modify functions and a powerful set of macro instructions makes Signal Processor programming easier a special test page permits to acquire an image and to execute the program in order to check it The control softwar
29. sumes the Good value If the station is enabled and it did not detect defects beyond the tolerance allowed the flag assumes the Good value The container is accepted if the flags of all stations have the Good value at the moment when it reaches the machine output N B The aim of this diagram is to show the process from a functional point of view Actually the functions shown here are performed by different processors The acceptireject flag in set to reject The accept reject flag in set to reject The accept reject flag in set to accept Stop the machine Display error The accepl reject flag in set to accept n9801pri ede TCM Functional Specifications N9501FE1 DOC NN9501F ling Process diagram sheet 2 Container is loaded on conveyor Container is picked up by star wheel Container is detected by proximity sensor Shift register is updated with container present flag Station TV1 Station TV2 Tip test Tip test see par 3 2 1 see par 3 2 1 Image acquisition Image acquisition and processing and processing see sheet 1 see sheet 1 Container is loaded on worm screw n8501pr2 cdri TCM Functional Specifications N9501FE1 DOC NN9SOIF ling Process diagram sheet 3 Has reject box activated limit switch No v An
30. to be inserted in modern pharmaceutical product lines It is installed downstream from filling and freeze drying lines and before the line for particle inspection TCM machine is manually loaded with boxes or directly in line from the ampoule filling machine the output of rejected containers occurs on standard stainless steel C E A boxes while the accepted containers are addressed to the downstream machine ATM18 by means of two linear guides The TCM machine consists of a mechanic part charged with transporting the containers along the test path an electric and electronic part which handles the mechanic part management and its interface with the production line Furthermore it permits the user s monitoring of the process external keyboard and monitor used as user machine interface 2 1 PROCESS DESCRIPTION Process control is totally automatic Each container undergoes a series of inspections performed by telecameras It is enough that only one of the tests results negative for the container to be rejected Containers are transported along the test path including the tests which are listed here below Inspection Ref U R S 1 Tip symmetry and burnings Tip symmet i The specifications of the different inspection stations and of the image processing method are present in Chapter 3 Functions of this document The process diagram is shown in the next pages Sheet 1 shows the process flow chart for all inspection station
31. ystem is designed to detect only the particles set in movement so it acquires the first image that is the one with a value between 0 and 255 for each pixel then acquires the following ones comparing at every new acquisition the value of each pixel with the one it had in the first image In memory a new table called map of differences is built in this table is inserted a value 1 when in any image a pixel presents a variation respect to the first image equal or above the threshold difference threshold preset by the user In this way only the particles set in movement are marked parts of the image such as the silk screen on an ampoule even though they are very bright or reflecting they do not produce luminosity variations in time and so they are not detected The difference method is used also for the alu cap inspection and the one concerning the lateral surface of the container This permits to detect while the container is rotating little differences of light due to the presence of cracks or dents The Signal Processor can be programmed to process the map of differences in order to look for defects in certain zones of the image or in order to eliminate little disturbances present in the image TCM Functional Specifications 19 N9501FE1 DOC NN9501F ling 3 2 INSPECTIONS What follows is a description of all inspection stations installed in the machine 3 2 1 TIP SYMMETRY AND BURNINGS Station The test is performed in

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