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2804-ND001, Bulletin 2804 Smart Linear Sensor User`s Manual

1. 5 2 6 2 3 LEDs Operational Status Functions 2 7 3 1 SLS Connectors Side View 00 2 2 00 e eee 3 1 3 2 SLS Connectors Rear View 2 0 2 005 3 1 3 3 Cable Connectors and Wire Color Codes 3 2 3 4 AC Terminal Block Wiring a 3 4 3 5 DC Terminal Block Wiring 005 3 5 3 6 LEDs Diagnostic Status Functions 3 6 4 1 Aiming Target ma pawa hnd ee ee re NG MANA eee 4 2 4 2 SES Staging awa nag NG WA an hate Daa hand PDA 4 3 5 1 Field of View Orientation 2 0000005 5 1 6 1 Standoff Distance From Inspected Object 6 2 6 2 FOV Orientation and Inspection Direction 6 3 B 1 Measuring Distance to Inspected Object B 1 B 2 Lens Focusing Details aaan aa naron n ran B 2 B 3 Timing Relationships 2a ps3 eed bee Peaks B 3 B 4 Side View SLS 2804 SLS2 a B 4 Table of Contents Figure Title Page List of Figures continued B 5 Exploded View of Lens Filter and O Ring B 5 B 6 O Ring Installation aa B 6 B 7 I O Connections Na fetes es con shu fondue KABAYANG B 7 B 8 Using Both Set Points on One Result B 10 Table Title Page List of Tables 2 1 Analysis Functions Objectives and Switch Settings 2 5 3 1 SLS Connectors Pin Functions and Wire Color Codes 3 2 3 2 Electrical Specifications for Pin Functions 3 3 3 3 Poweru
2. Table of Contents eo mar a AA PAA PAA Chapter Title Page 5 SLS Analysis Functions Chapter Objective Uu 5 Analysis Functions Lana Anna bw i eda eek 5 1 D Spatial Measurement 5 Object Width Measurement 5 Object Void Measurement Largest Object Width 0 1 D Object Recognition Included Object Texture Recognition Full Field Texture Recognition Binary Object Size Binary Object Count Parts COUNTING aaa aan Taka ka Teach Function mandin bamba RUN FUNCTIONS aah exon paa Bank NANG anag Ka ba 2 D Object Size oo os AA dee A eee Uhm aed TeaCMEUNCHON 5 nbd oaks eet nmete ANA Run Function lees cus ea sad bade vee Bees MAMMA ANN LA Am 6 SLS Site Installation Requirements and Procedur Chapter Objective a Site Preparation Requirements Staging and Installation Procedures Determining FOV Width Focusing the SLS 5 mGA td pias parecer Positioning Ideal ObjectinFOV Mounting and Positioning SLS Mounting and Positioning Light Source SLS Connection Procedures Connecting J1 Cable Connecting J2 Cable Connecting J3 Cable Before Applying AC Power Performing Powerup Check Fine Tuning SLS AIM a Setpoint Adjustment Controls LEDs D PA i IYO YO
3. Appendix A Definition of Terms Appendix Objective Definition of Terms The objective of this appendix is to define briefly some terms used in this manual that have a special meaning for machine vision and or the SLS Access Panel The access panel is the means by which you the user interact with the SLS while configuring the SLS The panel contains as set of 12 switches in a dual inline pack DIP seven LEDs and two setpoint controls Analog Outputs The SLS has two analog outputs A and B that correspond to the discrete A and B outputs These lines carry inspection results to your production equipment in the form of a current that can vary from 4mA to 20m The level of the analog current corresponds to either a percentage of the field of view or a percentage of match to a reference image stored in the SLS memory In either case 4mA represents 0 and 20mA represents 100 Analysis Function This is one of the eight inspection operations for which the SLS can be configured An analysis function is selected by the specific settings of four switches on a 12 switch DIP on the SLS access panel Discrete Outputs The SLS has two switched outputs A and B that correspond to the analog A and B outputs These outputs carry two state inspection results to your production equipment that is they are either open or closed according to the specific inspection results the setting of the Output
4. Function Select See Function Table These switch functions are printed on the nameplate inside the access panel 2 2 Configuration Switches continued Chapter 2 SLS Access Panel Each switch can be rocked to the left or right with a small screwdriver or similar instrument Left corresponds to the Off 0 position right corresponds to the On 1 position Thus rocking a switch to the left selects the function on the left side and vice versa Here is a description of each configuration switch function e Targeting Light Off Targeting Light On This switch turns the targeting light on and off The targeting light emits a line of light that shows you where the SLS is aimed This line indicates the location of the SLS field of view FOV Thus by aiming the targeting light at the inspected object you can align the FOV with that object Note that while the targeting light is on the SLS suspends all image processing Since the targeting light is designed for intermittant use the SLS turns the light off after it has been on for two minutes or when the lens head gets too warm After the lens head cools you can turn the light on again by setting the switch to off then on NOTE You should not attempt to focus the SLS using the targeting light since it may cause an incorrect focus Run Mode Setup Teach Mode When you set this switch to setup teach mode and position an ideal ob
5. Using the burst acquisition mode the SLS can acquire and store a rapid succession or burst of images before processing any of them This capability can be useful when a series of images must be acquired more rapidly than the normal cycle time for the specified analysis function allows For example if an application required a series of four images spaced at 10ms intervals but the normal cycle time for an object width measurement were 25ms then 25ms is the minimum time that the SLS requires between trigger signals Using the burst acquisition mode however the SLS can be configured to acquire from 2 to 9 images at intervals ranging from 6ms to 25ms B 10 Appendix B Reference Information Burst Acquisition Mode continued The burst acquisition mode can be configured using one of the following two methods 1 Using one trigger to acquire a specified number of images 2 to 9 having a specified interval 6ms to 25ms between them or 2 Using multiple triggers to acquire a specified number of images 2 to 9 The interval must be specified as 0 In the second method the SLS evaluates the time interval between the first and second triggers and uses that as the baseline for the intervals between the remaining triggers For example if the SLS expects seven triggers but the interval between trigger 3 and trigger 4 exceeds twice the interval between triggers 1 and 2 the SLS assumes that a missed trig
6. AA ALLEN BRADLEY U 4 ROCKWELL INTERNATIONAL COMPANY User s Manual Bulletin 2804 Smart Linear Sensor Cat No 2804 SL51 SLS2 40062 209 01 B Catalog No 2804 ND001 Series B Important User Solid state equipment has operational characteristics differing Information from those of electromechanical equipment Application Considerations for 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 Allen Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment 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 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 permissi
7. During the Run function the SLS examines each orange one at a time Thus when the first medium size orange crosses the FOV the percentage of match is 50 indicating that this orange is the same size as the reference orange Thus the Analog A output current is 50 of the difference between 4mA and 20mA or 12mA When the second large size orange crosses the FOV the percentage of match is 65 indicating that this orange is larger than the reference orange Thus the current is 65 of the difference between 4mA and 20mA or 14 4mA When the third small size orange crosses the FOV the result is a proportional decrease in current Chapter 4 SLS Analysis Functions 5 49 2 D Object Size continued Your Action Set the lower four function switches as shown Set these mode switches as required for your application Set the operating mode switch to Setup Teach Mode After a few seconds or 10 to 20 image acquisitions set the switch to Run Mode Use the following steps to configure the SLS for the 2 D Object Size Teach and 2 D Object Size Run functions Comments SW1 through SW4 must be off to enable the 1 D Spatial Measurement function 1 D Spatial Measurement High Resolution 7 E High Speed sw o sw2 Function Select Sw3 eat See Function Table sw4 ile olf Object trigger lighting remote configuration outputs and speed resolution Refer to Chapter 2 for information
8. Ideal Object Varying Texture _ ____ The SLS learns the recognition signature by acquiring images of the texture at several points along the object and thus seeing several slight variations of the ideal texture NOTE You can determine the proper number of image acquisitions by trial and observation In general if too many images are acquired the SLS may fail to indicate real flaws if too few images are acquired the SLS may indicate flaws where none exist Example Refer to the example in the discussion of the Included Object Texture Recognition function Chapter 5 SLS Analysis Functions po Full Field Use the following steps to configure the SLS for the Full Texture Recognition Field Texture Recognition function Assume that the SLS is continued already staged for its application and is powered up and the ideal object is properly positioned in the FOV Assume also that you have used the SLS Configuration Support Software and have determined that your application is feasible Your Action Comments Set the lower four function SW1 through SW4 must be off to enable the 1 D Spatial switches as shown Measurement function 1 D Spatial Measurement High Resolution High Speed SW1 SW2 SW3 SW4 Function Select See Function Table Set these mode switchesas Object trigger lighting remote configuration outputs and required for your application speed res
9. Set this switch to remote configuration enable to enable a personal computer PC using the optional SLS Configuration Support Software to download a stored configuration to the SLS and monitor SLS operations In this mode the configuration and setpoint settings specified in the stored configuration can override the physical switch and control settings on the SLS and control its operation Set this switch to remote configuration disable to inhibit the PC from downloading a configuration to the SLS but still allow the PC to monitor SLS operations In this mode the physical switch and control settings in the SLS control its operation 2 4 Configuration Switches continued Chapter 2 SLS Access Panel Outputs N O Outputs N C This switch determines the operation of discrete output lines A and B relative to the settings of their corresponding setpoint adjustment controls N O means normally open and N C means normally closed When you set this switch to Outputs N O discrete output line A or B opens if an inspection result such as object width is lower than the setting of setpoint control A or B Conversely the output line closes when the inspection result is higher For example if an inspection result such as object width is 40 and setpoint control A is set to 50 discrete output line A opens and current cannot flow in the external circuit NO
10. 1 Targeting Light Off Run Mode Dark Object Targeting Light On Setup Teach Mode ight Object The SLS can now begin operating in the run mode during which it acquires images according to the trigger mode setting analyzes these images and sends the results to the analog and discrete outputs Largest Object Width This analysis function available only in the Series B SLS is similar to the Object Width Measurement function except that the SLS measures the width of the largest inspected object and locates the center of that object When two or more objects are wholly within the FOV the SLS measures the width between the two edges of the largest object and locates the center position of that object halfway between the two edges relative to the FOV Chapter 5 SLS Analysis Functions Largest Object Width continued The SLS measures the width of the largest object as a percentage of FOV regardless of its position along the FOV and locates the center position relative to the FOV as shown in the following illustration Largest Object Width 35 of FOV 100 of FOV Object Center h 60 of FOV t Field of View 0 of FOV Largest Object Since the SLS cannot determine whether the objects in the FOV are several individual objects or are one object with holes voids in it the SLS assumes that the objects are separate It regards each pair of edges to be another object Example Here is a si
11. 2801 P4 Provides 24 VDC 1 6A requires 170 to 270 VAC 47 to 63H7 The SLS can also operate from any NEMA NEC Class 2 power supply that provides 20 to 28 VDC 20W Cables The SLS uses standard Brad Harrison Micro Change or equivalent connecting cables for signal interfacing The specific cables to use are shown in the following table Brad Harrison Cables SLS Connectors Cable Part Numbers Cable Length 6 Feet 1 8m 70632 70621 70432 12 Feet 3 7m 70634 70623 70434 20 Feet 6 1m 70635 70624 70435 Cables continued Optional Configuration Support Software Chapter 1 introduction Smart Linear Sensor Allen Bradley does not supply the connecting cables for the SLS however these cables are available from your local Allen Bradley photoswitch distributor or a Brad Harrison cable distributor The optional SLS Configuration Support Software Catalog No 2804 SW1 is a menu driven IBM PC compatible application program that enables you to store upload and retrieve download SLS application configurations using your personal computer PC In addition it enables you to monitor SLS inspection operations and it can accumulate and log runtime statistics The software contains online help messages At any point in the program you can call up a help screen to learn more about the corresponding program functions and requirements Allen Bradley provides the support software package as Catalog No 28
12. Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Targeting Light On Setup Teach Mode Bright Object The SLS learn the lighting compensation parameters ina few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each high to low transition of the trigger signal to learn the parameters The SLS saves the lighting compensation parameters Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Dark Object Targeting Light On Setup Teach Mode ight Object 5 50 2 D Object Size continued Your Action Remove the ideal object from the FOV Set the lower four function switches as shown Set the trigger mode switch as required for your application Pass the ideal object across the FOV When the ideal object has crossed the FOV set the lower four function switches as shown SW1 and SW2 must be on and SW3 and SW4 must be off to Chapter 4 SLS Analysis Functions Comments enable the 2 D Object Size Teach function High Resolution SW1 SW2 SW3 SW4 NOTE If your conveyor system moves at a variable rate set the trigger mode switch to Edge Triggered and synchronize 2 D Object Size Teach H igh Speed Function Select See Function Table the triggers to the conveyor system s
13. and J3 It also shows the corresponding Brad Harrison numbers for each cable Table 3 1 SLS Connectors Pin Functions and Wire Color Codes Pin 1 Function 24 VDC power input Trigger input RS 232 Transmit data Wire Color Code Red with white tracer Red with white tracer Red with black tracer Pin 2 Function Analog output A Trigger input RS 232 Receive data Wire Color Code Red Red with white tracer Pin 3 Function Discrete output common Reserved Wire Color Code Red Pin 4 Function Analog output B Discrete output A Wire Color Code Red with yellow tracer Red with yellow tracer Pin 5 Function Strobe trigger output Discrete output B Wire Color Code Red with black tracer Red with black tracer Cable No 6 Foot 1 8M 12 Foot 3 7M 20 Foot 6 1M Figure 3 3 shows the connectors on the three cables along with the color codes corresponding to the pins and sockets on each connector Figure 3 3 Cable Connectors and Wire Color Codes Red w White Red w Black Red w Black Tracer Red w White Tracer Red w White Tracer Red w Yellow Tracer Red w Yellow Tracer To J1 Female To J2 Male To J3 Female Pin Socket Connector Pin Pin Socket Chapter 3 Hardware Connection and Powerup Check y5 Cable Connections continued Table 3 2 shows the electrical specifications for the various connector pin functions Table 3 2 Electrical Specifications for Pin Functions Pin and Function El
14. and also carries the strobe trigger output and the analog A and B outputs Table 6 2 lists the specifications for those output signals Table 6 2 J1 Specifications Strobe and Analog Outputs J1 Signal Specifications Strobe Trigger Strobe trigger signal pin 5 Red wire with black Output tracer Signal return through the DC power common pin 3 Green wire Active state 5V typical inactive state OV Current is limited to IMA Compatible with all Allen Bradley strobe light sources Output is not isolated Analog AandB JAnalogA output signal pin 2 Red wire Outputs Analog B output signal pin 4 Red wire with yellow tracer Signal return through the DC power common pin 3 Green wire High side sourcing 4 20mA Maximum load resistance 500 Ohms Chapter 6 SLS installation Requirements and Procedures Connecting J1 Cable continued Connecting J2 Cable 6 5 Chapter 3 showed you how to connect the AC and DC power cables to their respective terminal blocks on the 2801 P3 or 2801 P4 power supply Use that same information to make power connections to the power supply and SLS at their permanent location if you have not already done so If your application requires the analog B output connect the analog B output wire and common return wire to your process equipment If your application requires the analog A output connect the analog A output wire and common return wire to your process equipment If
15. mm FOV Width Inches mm 71178 15 9 403 60 1524 153 0 3880 118 3 3005 8 203 22 6 575 17 8 452 70 1778 178 0 4516 137 7 3498 Chapter 6 SLS Installation Requirements and Procedures Focusing SLS continued Positioning Ideal Object in FOV Mounting and Positioning SLS 6 3 For an FOV width lying between those listed in the table use interpolation to determine the corresponding standoff distance Using the calibrated markings on the SLS lens set the lens to the apropriate standoff distance Use the set screw to lock the lens at that setting Manually position an ideal object exactly where it should be when the SLS acquires an image Secure the object in that position Note that the SLS inspects an object starting from one end of the FOV and stopping at the other end In effect the inspection begins at the bottom and ends at the top of the SLS when it is positioned as shown in Figure 6 2 Figure 6 2 FOV Orientation and Inspection Direction lt Inspected Object ES Inspection Direction Start of FOV With most analysis functions you must take the inspection direction into account For example if your application requires using the 1 D Spatial Measurement function to locate the first edge of a dark object against a light background and the dark object extends beyond the FOV you must position the SLS so that the start of the inspection is in t
16. the SLS inspects the sheet at close intervals For this example assume that all areas with good texture result in a percentage of match of 85 At the Analog A output the current in this case is 85 of the difference between 4mA and 20mA or 17 6mA Asa consequence the process equipment is instructed to continue the processing of the sandpaper At the Analog B output the current reflects the object width which is 80 of the FOV This becomes 80 of the difference between 4mA and 20mA or 16 8mA The illustration below shows the good texture and its signature which the SLS learns during the setup teach mode Object Width 100 of FOV 80 of FOV O KK ITAAS IS NG O PP NY BY 0 KNINA ONG 9252S IL NO KZ O KA Po KAKA AH SA x gt oO SA o 0505 ents Ni no KO oe x K Ng 55 N Ses re rer e 7 KAKA o IBA SASA 2x Cc KY o o lt gt O o oe Te C9 CS er res o 9 KO Q o 9 2 C9 na a X9 KO ora ato 0 4 KO o o one SS AKO pt fe 5 KA 55 NS oS KS RS nanan votes NS Co OOOO oo Cc x oO SRR KC lt gt C Oo C RK Sx KI o 9 Ng to lt 5 KO 001008 gt o o KO Oe ro 2 29 55 5 ava Sato te a O x a o Nyo res
17. 1 in Appendix B These values pertain to results expected from a high contrast object and nearly ideal lighting conditions Inspection Results Results These terms refer to the consequences of an SLS inspection measurement or comparison as indicated by the condition of the discrete outputs and the level of current in the analog outputs Learn Function The Learn function is the first of the two switch selections required when configuring the SLS for the parts counting or two dimensional object analysis function The second switch selection is the Run function When performing the Parts Counting Learn function the SLS learns the object width and the maximum number of objects to be counted When performing the 2 D Object Size Learn function the SLS learns the object size in two dimensions Lighting Compensation Lighting compensation is an automatic function that enables the SLS while operating in the setup teach mode to adjust to the light level within the image field The SLS can adjust to wide range of light levels SLS This is the abbreviation for Smart Linear Sensor The SLS is a linear machine vision system in which the lens linear sensor and image processing electronics are all contained in a single NEMA 4X housing Object Inspected Object These terms refer to any item that the SLS inspects measures or compares Reference Object Ideal Object These terms refer to an object whose image the SLS stores in i
18. 80 of FOV 25 of FOV 100 of FOV Field of View Object Void 2 0 of FOV 20 of FOV Inspected f Objects Total Void 20 25 45 of FOV Since the SLS cannot determine whether the objects in the FOV are several individual objects or are one object with holes voids in it the SLS locates edges and voids in the same manner for either situation When two objects lie wholly within the FOV and a third object lies partially outside the FOV the SLS measures the width between the first edge of the first object and the last edge of the second object and the void between these two objects but ignores the third object Chapter SLS Analysis Functions 5 14 Object Void Measurement In the following illustration two objects lie within the FOV continued but one object lies partially outside the 100 of FOV point Ignored 100 of FOV Object Object Width 40 of FOV 4 Field of View Object Void 0 of FOV 20 of FOV Inspected Objects Total Void 20 of FOV Ifa single object overlaps the FOV entirely or if no object appears in the FOV the width and total void both default to 0 of FOV Example Here is a simple example of using the Object Void Measurement function to detect a missing pin in a connector The SLS is positioned so that its FOV lies across the pins as shown in the following illustration Field of View 100 of Object Width 90 of
19. Center 80 of FOV 50 of FOV Field of View 100 of FOV 0 of FOV Use the following steps to configure the SLS for the Object Width Measurement function Comments SW1 through SW3 must be off and SW4 must be on to enable the Object Width Measurement function Object Width Measurement NAT High Resolution High Speed SW1 swe Function Select SW3 See Function Table Chapter 5 SLS Analysis Functions 5 12 Object Width Measurement continued Your Action Set these mode switches as required for your application Set the operating mode switch to Setup Teach Mode After a few seconds or 10 to 20 image acquisitions set switch to Run Mode Comments Object trigger lighting remote configuration outputs and speed resolution Refer to Chapter 2 for information Configuration Switches Off 0 On 1 Targeting Light Off Targeting Light On Setup Teach Mode Run Mode Bright Object The SLS learns the lighting compensation and other parameters in a few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each high to low transition of the trigger signal to learn the parameters The SLS saves the parameters Confiquration Switches Off 0 On 1 Targeting Light On Setup Teach Mode ight Object Targeting Light Off
20. FOV Each Void 7 of FOV 0 of FO Total Void 49 of FOV In this example each void between the pins occupies 7 of FOV and each pin occupies 5 of FOV When all pins are present the total void is 7 X 7 49 of FOV Chapter 5 SLS Analysis Functions kae Object Void Measurement The total void results appear at the Analog A output continued onthe SLS Since the analog range is 4 to 20mA the 49 of FOV value represents 49 of the difference between 4mA and 20mA Using this formula Analog Current of FOV x 16 4 the Analog A current is 49 X 16 4 11 84mA This is the current when all pins are present If a pin is missing however the current will change If an end pin is missing the total void decreases by 7 since there are now only six voids Thus the total void decreases to 6 X 7 42 and the Analog A output delivers less current 42 X 16 4 10 72mA If a middle pin is missing the total void increases by 5 the width of the missing pin Thus the total void increases to 54 and the Analog A output delivers more current 54 xX 16 4 12 64mA The object width results appear at the Analog B output on the SLS Since the object width in this example equals 90 of the FOV with both end pins present the normal Analog B current is this 90 X 16 4 18 4mA If an end pin is missing however the current changes For example if one end pin is missing the width dec
21. FOV and the current is 20mA If one bottle were missing the cumulative current would be 18 67mA instead of 20mA thereby indicating a count of 11 When this occurs the process equipment rejects the carton and resets the SLS part count in preparation for the next carton Chapter 5 SLS Analysis Functions Parts Counting continued Your Action Set the lower four function switches as shown Set these mode switches as required for your application Set the operating mode switch to Setup Teach Mode After a few seconds or 10 to 20 image acquisitions set the switch to Run Mode 5 43 Use the following steps to configure the SLS for the Parts Counting Teach and Parts Counting Run functions Comments SW1 through SW4 must be off to enable the 1 D Spatial Measurement function 1 D Spatial Measurement High Resolution High Speed SW1 SW2 Function Select Sw3 See Function Table SW4 Object trigger lighting remote configuration outputs and speed resolution Refer to Chapter 2 for information Configuration Switches Off 0 On 1 Targeting Light Off Targeting Light On Setup Teach Mode Run Mode Bright Object The SLS learns the lighting compensation and other parameters in a few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each
22. N O Output N C function switch and the setting of the corresponding setpoint control Edge Within the SLS field of view an edge is the location of a significant transition from light to dark or dark to light Most of the SLS analysis functions determine edge locations as part of their overall inspection objective Field of View FOV The FOV is what the linear one dimensional sensor in the SLS sees Compared to the FOV of a two dimensional sensor which has both length and width the linear sensor s FOV is a thin line its has only length The length of the FOV is a function of the lens standard or wide angle and the distance from the lens front plate to the inspected object Increasing distance increases the length of the FOV For any given distance a wide angle lens results in a longer FOV than a standard lens In practice the SLS must be physically oriented so that the FOV which is parallel to the bracket mounting surface lies across the inspected object at the correct point for the intended inspection measurement or comparison A 2 Appendix Definition of Terms Definition of Terms continued Gray Scale Image The linear sensor in the SLS sees an inspected object in varying shades of gray Image Resolution Image resolution indicates the ability of the SLS to resolve the edge position of an object in the FOV The actual values rated in terms of percent of FOV can be seen in Table B
23. Nato cones rese S 2 oe O Pe saree 9 KO 2 oO ret KO KZ NG o y te Na 0S S06 e 5 gt 5 Ng gt oO es ae Ng 8 SK SSCS KIKI KO KN NG es co 5 e 2 lt gt o pe ox ox KO KI NG Ka no o O gt X9 O o e S KY e SIL C9 2 5 KO oe ox KY Z gt S505 KP KZ KY KK re rer ZI SR LA vO KO Stationary Ideal Object 4 ar echt S05 RAIN HK When the operating mode switch is set to run the SLS saves the lighting compensation parameters in its memory The analysis function switches are then be changed to the Full Field Texture Recognition function The ideal object remains in the FOV Chapter 5 SLS Analysis Functions 5 34 Full Field With the operating mode switch set to setup teach an ideal Texture Recognition object such as a strip of coarse sandpaper is moved across continued the FOV as shown in the illustration below rare eran Ware se aM 2 gt ote Kei a tg o lt gt rates tato o LS o KAO S63 RS o SI NS 0 od SES SILL ILG SWRI SEK X Field of View o KN KI KA KAMA Q 4 en XO o stat 4 x o 5 KG SINK KO KI ros a Ng CRS Ng RS mene Ss p Psg bs o o Os
24. Quick Start Setu and Checkout continued Figure 4 1 Aiming Target TOP 1 NOTE USE THE SPECIAL AIMING TARGET PRINTED ON THE INSIDE OF THE BACK COVER Chapter 4 SLS Quick Start Operation Staging SLS Figure 4 2 SLS Staging 4 3 Staging involves connecting and positioning the hardware and mounting the object to be inspected in this case the Aiming Target Figure 4 2 is an example of a staging layout lt Aiming Target Your Action Place the SLS power supply on or under the table Connect the cable to connector J1 on the SLS Fasten the Aiming Target to the vertical surface Attach the mounting bracket to the SLS Position the SLS on the table with the lens facing the target Connect the light source to the AC outlet turn iton and position it to maximize the light on the target 5 E 4 Targeting Light Coincides With Field of View x Mounting Bracket EESNDE Output 24 VDC Power Supply Use the following steps to stage the SLS for the quick start operation Comments Use care when aligning the connectors The Aiming Target is at the back of this manual Figure 4 2 shows the Aiming Target orientation Figure 4 2 shows the bracket orientation Refer to Figure 4 2 4 4 Focusing and Aiming SLS Your Action Use the tape measure to position the SLS 20 inches from the Aiming Target Turn the focus ring to 20 inches Remove the panel acc
25. are available Both functions require setting a binary threshold using the CSS View Image option in order to determine the point above which the SLS can detect objects in the FOV The SLS ignores or masks off all objects in the FOV that are below the selected binary threshold For more information refer to the SLS Configuration Software Support User s Manual Catalog No 2804 ND002 Series B The binary threshold can be fixed or absolute and remain at the same value regardless of background light level changes or it can be light compensated and change its value according to background light level changes detected by the background light probe Both the binary threshold level and the background light probe can be adjusted as required in the View Image display option Once adjusted their values can be stored in a configuration record for later use When an SLS Series B only is connected to a personal computer using the Series B SLS Configuration Support Software CSS the SLS can be configured to use the burst acquisition mode with any analysis function The burst acquisition mode can be enabled and configured only within a configuration record Also since the timing of the analog and discrete outputs is indeterminate when using the burst mode only the RS 232 results should be used For more information refer to the SLS Configuration Software Support User s Manual Catalog No 2804 ND002 Series B
26. count objects in FOV and measure object size 0 Off 0 Off o o Pam Pama o O O O 3 3 o O para a Null Function 1 N A Parts Counting Teach Learn reference object and 1 On 0 Off 1 On number of objects to count 2 D Object Size Teach Learn reference object 2 D Object Size Run Measure relative 2 D size of 1 On object Null Function 2 wa ftom 100m ion on Nor ea QO 3 Cammi O D Oo O _ O 3 o O pawis h Null Function 3 1 On 0 Off 0 Off o paa O a S Note that 16 different switch settings are possible however only 13 are currently used Chapter 5 SLS Analysis Functions explains the 13 analysis functions in greater detail 2 6 Setpoint Adjustment Controls Chapter 2 SLS Access Panel The setpoint adjustment controls determine the switching points for the discrete outputs These are the points at which the discrete outputs open or close according to the setting of the Outputs N O Outputs N C switch Setpoint controls A and B determine the switching points for discrete outputs A and B Inspection results are expressed as percentages from 0 to 100 For example a one dimensional spatial measurement result that is an edge location can range from one side of the field of view 0 of FOV to the other side 100 of FOV Similarly an object wid
27. error condition one or more LEDs will flash continuously Table 3 3 shows the meanings of the flashing LEDs In each case except the EEPROM checksum failure the error is fatal and the SLS must be replaced If any of the error indications occur contact your local Allen Bradley sales office for assistance Table 3 3 Powerup Error Indications Number of 7A ul Flashing LEDs Cause of Error Indication a Hardware revision failure EEPROM checksum failure flashes twice then testing continues After the SLS powers up successfully and begins normal operations the LEDs that turn on depend on a number of factors such as lighting contrast and function switch settings Notice that one of the LEDs is labeled Fault Error Condition When the SLS is in operation this LED turns on in any of the following eight situations 1 Changing an SLS switch setting while the SLS operates using a configuration program downloaded from the SLS Configuration Support Software The switch change however has no effect on SLS operation The LED turns on for a few seconds then off 2 Changing a setpoint control setting while the SLS operates using a configuration program from the SLS Configuration Support Software The control change however has no effect on SLS operation The LED turns on for a few seconds then off 3 Exceeding the lighting compensation limits Typically this results from extremely low or hig
28. gt o KO o KIA Ng to o S S e ASS 2 SICK bu tg o KS o lt o 2 KO O KO jea KO S KY Patar 22 Ng o Ko x 0 tae O o to ef S BS J Ko o Xs KI rates KO lt gt POVaYAYOTO PO YATA TODA PAYO aT ToNeTeToe e e eTa eo e a e e e s e e eNe erere eTe eNa a ee etoheerererereterererentetareetetatae TCR KK NH RK KOK I 8 90 8K O BOBO HK OO NS sA oO O Chapter SLS Analysis Functions Included Object Texture Recognition continued 5 29 The next illustration shows flaws in the sandpaper and in the corresponding signature Since the flawed signature is not like the stored signature it should result in a low percentage of match such as 50 in this example 100 of FOV gt SS Ng KI rarer SO o lt 0 OR Ko 2 AKI O 020 2 0 ua RS Field of View 0 of FOV Signature of Bad Area 7 TALO TATAYO LLII EZELI SLCHI FS TIG US OO At the Analog A output the current in this case is 50 of the difference between 4mA and 20mA or 12 0mA Asa consequence the process equipment is instructed to stop the processing so that the cause of the flaws can be determined and corrected At the Analog B output since the object s width remains unchanged the current remains 80 of the difference between 4mA and 20mA or 16 8mA 5 30 Included Object Texture Recognition co
29. high to low transition of the trigger signal to learn the lighting compensation and parameters The SLS saves the lighting compensation parameters Confiquration Switches Off 0 On 1 Targeting Light Off Run Mode Dark Object Targeting Light On Setup Teach Mode ight Object Chapter 5 SLS Analysis Functions 5 44 Ka E RT wer NP SSS SSS Parts Counting continued Your Action Comments Remove the ideal object from the FOV Set the lower four function SW1 and SW3 must be on and SW2 and SW4 must be off to switchesasshown enable the Parts Counting Teach function Parts Counting Teach High Resolution High Speed Function Select See Function Table Set the trigger mode switchas NOTE If your conveyor system moves at a variable rate set required for your application the trigger mode switch to Edge Triggered and synchronize the triggers to the conveyor system speed Pass the ideal object The SLS counts the ideal object and learns its size During across the FOV first the Parts Counting Run function the SLS counts only those objects whose size is within 50 of the ideal object s size Pass the remaining objects The SLS learns the maximum number of objects to be across the FOV counted during the Parts Counting Run function Be sure that each object passes completely across the FOV single file NOTE Since the spacing of the image acquisitions must be the same during the Teach func
30. must be mounted within reach of the cable between the power supply and the SLS 20 foot maximum when using standard Brad Harrison cables Mounting Fixtures Prepare all required fixtures platforms and or surfaces for mounting the SLS and light source Plan the field of view FOV and the relative mounting position for the SLS The SLS mounting bracket is compatible with Unistrut mounting techniques Cables Prepare a path for the SLS cable s Plan to route the cables as far away as practicable from moving machinery excessive heat and strong RF emissions In general the SLS must be positioned so that it sees the inspected objects properly according to the application s requirements The light source must be positioned to provide optimum contrast between the inspected objects and their background Staging involves measuring the required FOV and then determining the optimum positions for the SLS and light source relative to the objects to be inspected Installation involves securing the SLS and light source in their optimum positions and connecting the SLS to the power supply and the production equipment The FOV width is primarily a function of the width of the objects to be inspected For most analysis functions the FOV must be wide enough to include the inspected objects yet allow for some object shifting and or width variations For analysis functions that require the inspected objects to lie completely with
31. of origin of the signal that starts an inspection cycle while the SLS operates in either the setup teach mode or the run mode The trigger source depends on the setting of the Level Triggered Edge Triggered switch on the SLS When the set to the level triggered mode the SLS uses its internal trigger so long as the trigger input is either high or open If so the SLS operates at the maximum rate for the selected analysis function If the trigger input is low SLS operation is inhibited When the set to the edge triggered mode the SLS requires an external trigger The SLS performs one inspection cycle with each falling edge high to low of the trigger signal up to the maximum rate for the particular analysis function The external trigger rate is dictated by events at the presence sensing switch or other source Appendix Appendix Objective Using Appendix B Focusing SLS B Reference Information The objective of this appendix is to provide easy access to specific information and procedures under alphabetically arranged topic headings Information and procedures in this appendix appear under the following topic headings Focusing the SLS Exposure time cycle time and lighting compensation Speed vs resolution The side view SLS 2804 SLS2 Lens filter maintenance and replacement e O connections Mounting brackets e Trigger input modes e Binarization and background light probe Burst acqui
32. showing the access panel cover removed Figure 1 3 SLS Access Panel Cover Installed and Removed Access Panel A Focusing Ring Cover Installed Focus Set Lens Filter Lens SLS Power and Signal Housing Connectors Lens Front Plate Access Panel Cover Removed Setpoint Adjustment Controls Configuration DIP Switches Access Panel The access panel contains the configuration switches setpoint adjustment controls and LEDs The panel access cover is secured by four slotted screws 4 40 x 3 8 It uses a neoprene seal to maintain the NEMA 4X rating Chapter 1 Introduction Smart Linear Sensor ihe SLS Housing continued The configuration switches are arranged in a 12 switch DIP package These switches select the analysis parameters and functions for an inspection application The setpoint adjustment controls set the switching points for the discrete outputs The LEDs indicate the operating status of the SLS and the discrete outputs Lens Allen Bradley provides two lenses for the SLS e Catalog No 2804 NL1 A standard lens focal length 35mm viewing angle approximately 19 Catalog No 2804 NL2 A wide angle lens focal length 28mm viewing angle approximately 30 These lenses are designed especially for the SLS Power Supplies Sues provides two 24 VDC power supplies for the LS Catalog No 2801 P3 Provides 24 VDC 1 6A requires 85 135 VAC 47 to 63Hz Catalog No
33. your application requires a strobe light source connect the strobe trigger output wire to the strobe trigger input signal Connect the common return to the strobe trigger return signal The J2 cable carries the trigger input signal and return and the discrete A and B outputs Table 6 3 lists the specifications for those input and output signals Table 6 3 J2 Specifications Trigger Input and Discrete Outputs Trigger Input Trigger signal pin 1 Red wire with white tracer Signal return pin 3 Green wire Voltage level 5Vto 30VDC Output isolation from other I O 300V Maximum source off state leakage IMA Response time for triggered image acquisition 75uS maximum Discrete Outputs Discrete A output signal pin 4 Red wire with yellow tracer Discrete B output signal pin 5 Red wire with black tracer Signal return pin 3 Green wire 30VDC or 30VAC max peak Class 2 supply Maximum current 100mA Isolation from other I O 300V Polarity insensitive A NEMA NEC Class 2 power limited type supply should be used for both control and I O power to preserve internal transient and overload protection functions of SLS If your application requires the trigger input connect the trigger signal input wire and trigger signal return wire to your process equipment Connecting J2 Cable Connecting J3 Cable Before Applying AC Power Performing Powerup Check Chapter 6 SLS Insta
34. 04 SW1 This includes the following items Two 5 1 4 inch diskettes and one 3 1 2 inch floppy diskette containing the support software One 12 foot 3 7m connecting cable Catalog No 2804 CSC1 for attachment to your PC s serial port One User s Manual for the support software Catalog No 2804 ND002 The user s manual provides information for installing the support software in your PC and using it In order to use the support software your PC must have the following minimum configuration An IBM PC AT XT PS2 or compatible PC with at least 475K bytes of free memory MS DOS 2 1 or later Disk drive systems Two 5 1 4 inch floppy disk drives any density or One 3 1 2 inch floppy disk drives any density or One hard disk drive any size and one floppy disk drive An RS 232 communication port A Catalog No 2804 CSC1 cable to connect the SLS to the PC supplied with the support software A video monitor A graphics display adapter Chapter 1 Introduction Smart Linear Sensor Optional Configuration Support Software continued Here is a list of recommended hardware An IBM AT or compatible PC A PC based on the 80286 80386 or 80486 microprocessor operates much faster than an 8088 based PC A hard disk drive This enables you to store the SLS Configuration Support Software and operate the software faster and more efficiently e A math coprocessor This enable
35. 5 Configuration Switches continued Table 2 1 Analysis Functions Objectives and Switch Settings marannan retour an so an oa 1 D Spatial Measurement Locate position of first and last 0 Off f 0 Off 0 Off 0 Off edges of object Object Width Measurement Measure width of object 0 Off 0 Off 0 Off 1 On Find center position of object Object Void Measurement Measure width of object ff 0 Off 1 On 0 Off Measure cumulative total of voids within object Largest Object Width Measure width of largest object 0 Off 0 Off 1 On 1 On Series B SLS only Find center position of object 1 D Object Recognition Determine percentage of match 0 Off 1 On 0 Off 0 Off to learned reference object Measure object width Included object Texture Recognition Determine percentage of match 0 Off 1 On 0 Off to learned reference object Measure object width Full field Texture Recognition Determine percentage of match 0 0f 1 On 1 On to learned reference object Binary Object Size Use binary thresholding to Series B SLS only Can be used only with identify objects and measure SLS Configuration Support Software cumulative object size pa O O 3 3 o O o 2 Binary Object Count Series B SLS only Can be used only with SLS Configuration Support Software Use binary thresholding to identify and
36. Action Comments After a few seconds or 10 t020 The SLS saves the lighting compensation parameters image acquisitions set the switch to Run Mode Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Dark Object Targeting Light On Setup Teach Mode ight Object Set the lower four function SW1 and SW3 must be off and SW2 and SW4 must be on to switchesas shown enable the Included Object Texture Recognition function included Object Texture Recognition High Resolution High Speed sw1 swe Function Select SW3 See Function Table SW4 Set the operating mode switch to Setup Teach Mode Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Begin moving the object The SLS learns the recognition signature of the ideal slowly across the FOV to object by acquiring images at several points along its length enable the SLS to learn the recognition signature NOTE As previously discussed you can determine the proper number of images to acquire by trial and observation 5 32 Included Object Texture Recognition continued Your Action When the SLS has learned the object signature set the switch to Run Mode Full Field Texture Recognition Chapter 5 SLS Analysis Functions Comments The SLS saves the object signature Configuration Switches Off 0 Targeting Light Off Run Mode Dark Object The SLS can now begin operating in the run mode duri
37. Background LBY Contrast Fault Error Condition Yellow waren ERR ERS ESS KA P RR Output B Active KS Operating Duty Cycle Green Maximum Speed Red Waiting for Trigger SEER K SILI Green Steady Remotely Configured paasa Flashing Communicating Note that the brightness LED is now red since the light level is quite low Also the fault error LED turns on red because the lighting compensation limit has been exceeded an error condition The other LEDs should remain the same as they were before you covered the lens Unblock the lens The brightness LED should turn green again and after a few seconds the fault error LED should turn off Conclusion This completes the quick start operation You have just performed all the basic steps required to set up and operate your SLS You have also verified its operational readiness Your SLS is now ready to be set up at its permanent operating site Set up the SLS at that location using the same method described for the quick start operation If your application requires a different analysis function than the one used in the quick start operation refer to Chapter 5 SLS Analysis Functions for descriptions of all analysis functions and procedures for using them Refer also to Chapter 6 SLS Site Installation Requirements and Procedures for information about installing your SLS at its permanent site and connecting it to your equipment Chapter 5 SLS Analysis F
38. E EAST ASIA PACIFIC HEADQUARTERS CANADA HEADQUARTERS LATIN AMERICA Allen Bradley AFRICA HEADQUARTERS Allen Bradley Hong Kong Limited Allen Bradley Canada Limited HEADQUARTERS 1201 South Second Street Allen Bradley Europe B V Room 1006 Block B Sea View Estate 135 Dundas Street Allen Bradley Milwaukee WI 53204 USA Amsterdamseweg 15 2 8 Watson Road Cambridge Ontario N1R 5X1 1201 South Second Street Tel 414 382 2000 1422 AC Uithoorn Hong Kong Canada Milwaukee WI 53204 USA Telex 43 11 016 The Netherlands Tel 852 887 4788 Tel 519 623 1810 Tel 414 382 2000 FAX 414 382 4444 Tel 31 2975 43500 Telex 780 64347 FAX 519 623 8930 Telex 43 11 016 Telex 844 18042 FAX 852 510 9436 FAX 414 382 2400 FAX 31 2975 60222 Catalog No 2804 ND001 Series B 40062 209 01 B ED
39. Run Mode Dark Object The SLS can now begin operating in the run mode during which it acquires images according to the trigger mode setting analyzes these images and sends the results to the analog and discrete outputs Chapter 5 SLS Analysis Functions Object Void Measurement 5 13 This analysis function requires two or more objects wholly within the FOV or one object with one or more holes The SLS regards the spaces between objects or the holes in a single object as voids When the inspected objects are dark relative to their background a void is any occurrence of the light background between the first and last edges The opposite is true for bright objects Using this function the SLS measures the total void between the first edge of the first object and the last edge of the last object as a percentage of the FOV The SLS also measures the width between these edges as a percentage of the FOV When only one solid object lies wholly within the FOV the SLS measures the width of that object but does not measure the void between that object and another object lying partially outside the FOV The void size in this case is 0 The following illustrations show you how the SLS measures voids and object width When two or more objects lie wholly within the FOV the SLS measures the width between the first and last edges and the total void between these edges as follows Object Width Object Void 1
40. SLS sees the inspected object along the length of the FOV line 5 Chapter 5 SLS Analysis Functions AAAA SS 1 D Spatial Measurement This analysis function requires at least one object that lies partly within the FOV In this case the SLS can locate the first or last edge of the inspected object If the object lies wholly within the FOV the SLS can locate both edges The following illustrations show you where the SLS locates the first and last edges in a variety of object positions relative to the FOV When one object lies wholly within the FOV the SLS locates the first and last edges as follows 100 of FOV Last Edge Inspected Object 65 of FOV Na First Edge oe lt Field of View 35 of FOV 0 of FOV When two or more objects lie wholly within the FOV the SLS locates the first edge of the first object and the last edge of the last object as follows 100 of FOV Last Edge 75 of FOV Na Inspected First Edge i Objects 40 SI FOV lt FField of View 0 of FOV Chapter 5 SLS Analysis Functions 5 3 1 D Spatial Measurement continued Since the SLS cannot determine whether the objects in the FOV are several individual objects or are one object with holes voids in it the SLS locates edges in the same manner for either situation as follows 100 of FOV Last Edge 75 of FOV Na Single Object with Void Paf First Edg
41. Strobe Light Source Strobe Trigger 24 VDC Power Supply Trigger Input Device Trigger See next page B 8 Appendix B Reference Information llO Connections continued Mounting Brackets Trigger Input Modes The following analog and discrete input modules are available from Allen Bradley and are recommended for use with the SLS Discrete input modules Catalog No 1771 IB IBD IBN IQ IT IV and IVN Analog input modules Catalog No 1771 IE IF IF and IL Installation and connection procedures for these modules are beyond the scope of this manual Refer to the instruction and or data sheets included with each module for specific connection and installation information Allen Bradley supplies two types of brackets for mounting the SLS A stainless steel bracket Catalog No 2804 BR1 and an aluminum bracket Bulletin 880 N12 The 2804 BR1 provides an extra axis of motion and is required to maintain the NEMA 4X rating Both the SLS and the mounting brackets are shipped with 10 32 screws that are suitable for mounting the bracket to the SLS Full dimension details are provided in the instruction sheet shipped with the SLS CAUTION When mounting the bracket to the SLS observe the following cautions 1 Do not exceed 30 inch pounds of torque 10 when tightening the bracket mounting screws Otherwise the screw inserts in the SLS case may pull out and destroy the cas
42. TAAMUBBBWWN 2 NYOMATTA MTMDA a Appendix Title Appendix A Definition of Terms Table of Contents 3 S ne py fcct Appendix Title Page Appendix B Reference Information Appendix Objective maana d ASAL kda eee wees B 1 Using Appendix Br Xa sn c dead susie dnaes ees B 1 FOCUSING SES ANNA GAAN Lovie ee ward Beads B 1 Exposure Time Cycle Time and Lighting Compensation B 2 Speed vs Resolution 2 20 cee eee eee B 4 Side View SLS 2804 SLS2 0 00200 5 B 4 Lens Filter Maintenance and Replacement B 5 VO CONnNECHONS 65455 sheen Seige tome aes B 7 Mounting Brackets waa cia aoe oes ees Abad ee B 8 Trigger Input Modes 0 2 022 eee B 8 Binary Threshold Background Light Probe B 9 Burst Acquisition Mode B 9 Set Point Methods Hasan RNGA ans ig deeae dee B 10 Invert Discrete OutputB 2 00 06 B 11 Disable Lighting Compensation B 11 Power Loss Recovery aa B 11 Connector Covers on J2 and B3 B 12 Gr u nding 3 24 5 sees Kan Ata DFA a na AB ga a B 12 Figure Title Page List of Figures 1 1 SLS Components and Connections 1 2 1 2 SLS Models Front View Lens and Side View Lens 1 3 1 3 SLS Access Panel Cover Installed and Removed 1 4 2 1 Configuration Switches 2 2 2 2 aa sla e208 Sees eae ews 2 1 2 2 Setpoint Adjustment Controls
43. TE In the Output N O mode the output line defaults to open during powerup and whenever certain types of errors occur When you set this switch to Outputs N C discrete output line A or B close if an inspection result such as first edge is lower than the setting of setpoint control A or B Conversely the output line opens when the inspection resultis higher For example if an inspection result such as first edge is 20 and setpoint control A is set to 40 discrete output line A closes and current can flow in the external circuit NOTE In the Output N C mode the output line defaults to closed during powerup and whenever certain types of errors occur e High Resolution High Speed When you set this switch to high resolution the SLS produces the highest possible image resolution at some sacrifice in operating speed Use high resolution for most applications When you set the switch to high speed the SLS produces the highest possible operating speed at some sacrifice in image resolution Select this mode when the high resolution mode is not fast enough for your application e SW1 SW2 SW3 SW4 These four switches select the SLS analysis function The specific function selected depends on the combined settings of the four switches Table 2 1 below lists the analysis functions by name function objective and specific switch settings Chapter 2 SLS Access Panel 2
44. The SLS can now begin operating in the run mode during which it acquires images according to the trigger mode setting analyzes these images and sends the results to the analog and discrete outputs This analysis function requires at least one object lying wholly within the FOV When two or more objects appear in the FOV the SLS interprets them as one object from the first edge of the first object to the last edge of the last object Using the 1 D Object Recognition function the SLS compares the gray scale pattern of an ideal object with the gray scale pattern of the object currently in the FOV These gray scale patterns are the recognition signatures of the two objects and they indicate the variations in brightness Unat is shades of gray of the object along the length of the Chapter SLS Analysis Functions 5 20 1 D Object Recognition During the setup teach mode the SLS learns the gray continued scale pattern of an ideal object This is the recognition signature At the start of the run mode the SLS stores the recognition signature in its memory During operation in the run mode the SLS compares the signature of an inspected object regardless of its position along the FOV with the stored signature of the ideal object and reports the results of this comparison as the percentage of match of the two signatures These results appear on the Analog A output When the inspected object is exactly the sam
45. The cycle time increases in steps as the exposure time increases For example a base cycle of 20mSec increases to 25mSec when the exposure time passes 16mSec The Brightness LED turns solid red just before the cycle time increases above the base value It indicates that the present light intensity may not be sufficient to maintain the cycle time at its base value If the base cycle time is not required for a particular application the increased exposure time may not affect the application The maximum exposure time however is 200mSec as noted earlier Figure B 3 indicates the basic timing relationships Figure B 3 Timing Relationships Trigger n 1 Cycle Time n 1 Exposure Time n 1 Image Acquisition Time n 1 Image Acquisition Time n Processing Time n Results Output Valid Inspection Cycle n 1 Results Output Valid Inspection Cycle n Time from Trigger n to Results Output n Appendix B Reference Information Speed vs Resolution When youselect the High Speed mode or High Resolution mode your choice affects the resolution and accuracy of the SLS and the cycle time of the selected analysis function In general high resolution increases both the resolution and accuracy but requires a longer cycle time than high speed Also the more complex functions require longer cycle times Table B 1 lists these effects for each analysis function Table B 1 High Resolution vs High Spe
46. ation Switches Off 0 On 1 Targeting Light Off Run Mode Targeting Light On Setup Teach Mode Bright Object The SLS learns the lighting compensation and other parameters in a few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each high to low transition of the trigger signal to learn the parameters Chapter Ey SLS Analysis Functions 5 7 1 D Spatial Measurement continued Your Action After a few seconds or LO to 20 image acquisitions set switch to Run Mode Object Width Measurement Comments The SLS saves the parameters Configuration Switches Off 0 Targeting Light Off Run Mode Dark Object The SLS can now begin operating in the run mode during which it acquires images according to the trigger mode setting analyze these images and sends the results to the analog and discrete outputs This analysis function requires at least one object that lies wholly within the FOV Using this function the SLS measures the width of the inspected object and locates the center of the object The following illustrations show you how the SLS measures object width and locates the center position with a variety of object positions relative to the FOV When one object lies wholly within the FOV the SLS measures the width of that object as a
47. ches to the Parts Counting Run function Run Function The Parts Counting Run function isa separate function switch setting whose purpose is to enable the SLS to count the specified number of learned objects During the Run function the SLS counts objects passin through the FOV The size of an object must be within 50 of the size of the ideal object to be included in the count Otherwise the SLS will ignore the object For each object that the SLS counts it increments the analog outputs by the percent that the single object bears to the number taught For example if the number of objects taught were 12 the analog output current would increase by 8 33 for each object counted 1 12 0 0833 0 0833 x 100 8 33 Using Edge Triggered Mode When the SLS is counting parts while operating in the edge triggered mode the trigger signals must be synchronized with the conveyor The SLS restarts the parts count when the next object crosses the FOV after the maximum count is reached and the outputs reach 100 For example if the learned maximum count were 20 the SLS would restart the parts count after the 21st object crossed the FOV Thus the SLS would count the 21st object as the first object of the next lot and the outputs would indicate 5 This capability is useful in an application that count objects to be placed in a package where the lot size must always equal the maximum count Using Level Triggered Mod
48. chronize it with the SLS The SLS is shipped with metal access covers on SLS connectors J2 and J3 Be sure to leave these covers in place if your application does not require using J2 and or J3 When these connectors are not used the covers must be installed to maintain the NEMA 4X rating by sealing the SLS maintain ESD electrostatic discharge isolation and protect the unused connectors The AC power source s must all be properly grounded in accordance with applicable local codes For information about of wiring and grounding for your SLS system refer to the Allen Bradley publication Grounding and Wiring Guidelines Publication No 1777 4 1 Aiming Target Ca NG AB ALLEN 5 B RAD L EY A subsidiary of Rockwell International one of the world s largest technology companies Allen Bradley meets today s automation challenges with over 85 years of practical plant floor NAA ce naa BEBMPANN experience More than 12 000 employees throughout the world design manufacture and apply a wide range of control and automation products and supporting services to help our customers continuously improve quality productivity and time to market These products and services not only control individual machines but also integrate the manufacturing process while providing access to vita plant floor data that can be used to support decision making throughout the enterprise With offices in major cities worldwide WORLD HEADQUARTERS EUROPE MIDDL
49. cognition During the setup teach mode the SLS learns the signature continued of a representative ideal sample of the 8 pin connector on which all eight pins are in their proper positions and are intact In the preceding illustration A shows the ideal connector and its signature which the SLS learns during the setup teach mode During the run mode this connector and all connectors like it should result in a high percentage of match such as 85 At the Analog A output the current is 85 of the difference between 4mA and 20mA or 17 6mA As a consequence the process equipment is instructed to accept the connector and pass it to the next process stage At the Analog B output the current reflects the object width which is 90 of the FOV This becomes 90 of the difference between 4mA and 20mA or 18 4mA In the same illustration B shows a bad connector and the corresponding signature Since this connector s signature is not like the stored signature it should resultin a low percentage of match such as 15 At the Analog A output the current is 15 of the difference between 4mA and 20mA or 6 4mA As a consequence the process equipment is instructed to reject this connector At the Analog B output the current remains 90 of the difference between 4mA and 20mA or 18 4mA Use the following steps to configure the SLS for the 1 D Object Recognition function Your Action Comments Set the lower f
50. e 4 Field of Vi 40 of FOV AIOE VIEW 0 of FOV When part of an inspected object lies outside the FOV so that the SLS cannot locate a first edge or last edge the SLS defaults to 0 of FOV for the location of the first edge or 100 of FOV for the last edge In the following illustration the inspected object is shown lying partially outside the 0 of FOV point 100 of FOV Field of View gt Inspected Last Edge Object 50 of FOV First Edge 0 of FOV P 0 of FOV Similarly if the object overlaps the FOV entirely the SLS defaults to 0 of FOV and 100 of FOV for the locations of the first and last edges respectively If no object appears in the FOV the SLS also defaults to 0 of FOV and 100 of FOV for the locations of the first and last edges respectively Chapter SLS Analysis Functions 5 4 j 5 1 D Spatial Measurement When one of two objects lies partially outside the FOV the continued SLS disregards the partial object Instead it locates the first and last edge on the object lying wholly within the FOV In the following illustration the first object lies partially outside the 0 of FOV point In this case the SLS ignores the first object and locates the edges of the second object as follows Last Edge 100 of FOV 85 of FOV ak First Edge Il Field of View Inspected 75 of FOV Object Ignored Object 0 of FOV When th
51. e When the SLS is counting parts while operating in the level triggered mode the conveyor must be moving at a predictable uniform speed The SLS can restart the part count when the trigger input rises momentarily before the next object enters the FOV For example if the learned maximum count were 10 and the trigger input rose momentarily after the 5th object crossed the FOV the SLS would restart the part count after the 6th object crossed the FOV Thus the SLS would count the 6th object as the first object of the next lot and the outputs would indicate 10 This capability can be useful in an application that counts objects in a package to determine whether the correct number of objects that is the taught count is present Chapter Sy SLS Analysis Functions mai Parts Counting The following illustration shows you how the SLS performs continued the Parts Counting Run function 100 of FOV 4 Field of View 0 of FOV Objects in FOV ty AE lt gt The specified number of objects are shown moving as a group across the FOV When an object enters the FOV the SLS keeps track of it and does not count the object until it leaves the FOV The gap between successive objects must be sufficient for the SLS to acquire at least one image in the gap To accomplish this the conveyor speed and distance between the objects and the SLS must be considered The objects rate of movement during the Run f
52. e P3 the source voltage must be 85 to 135 VAC For the P4 the voltage must be 170 to 270 VAC If you are unsure about the source voltage check it with a voltmeter The SLS has an internal diagnostic program that checks the status of the SLS whenever power is first applied The program operates for about 7 seconds During that time the on off pattern of the LEDs changes as the program enters each test phase Apply AC power to the power supply at this time If you are using the 2801 P3 or P4 power supply the DC power turns on within ten seconds as indicated by the POWER LED turning red Initially all seven LEDs are on briefly then offagain Then the top LED 1 in Figure 3 6 turns on followed by 2 3 and so on as each test phase is completed Figure 3 6 LEDs Diagnostic Status Functions Image Brightness Level Green Bright Light Level Red Low Light Level Insufficient Object to Background j Contrast Fault error Condition Output A Active Output B Active Operating Duty Cycle Green Maximum Speed Red Waiting for Trigger a Green Steady Remotely Configured Flashing Communicating Chapter 3 Hardware Connection and Powerup Check 3 7 2 i EE E AP TAGAS LS SIT EE EE Powerup Check After the SLS passes all seven test phases the LEDs turn continued off briefly and one or more LEDs wll turn on again as the SLS begins normal operations If the diagnostic program detects an
53. e Recognition continued PG Va Yang SONS AN RENN SORES 0 of FOV Stationary Ideal Object With the operating mode switch set to setup teach an ideal object such as a strip of coarse sandpaper is moved across the FOV as shown in the illustration below 100 of FOV Field of View gt S2 NA RG SOP RRR See lt Moving Ideal Object Acquisition Varying Texture 5 28 Included Object Texture Recognition continued Chapter SLS Analysis Functions The SLS learns the recognition signature by acquiring images of the texture at several points along the object and thus seeing several slight variations of the ideal texture NOTE You can determine the proper number of image acquisitions by trial and observation In general if too many images are acquired the SLS may fail to indicate real flaws if too few images are acquired the SLS may indicate flaws where none exist Example In this example the SLS uses the Included Object Texture Recognition function to inspect a continuous sheet of coarse sandpaper for flaws such as areas on which the sand granules did not adhere to the paper During the setup teach mode the SLS learns the signature of good texture on the sandpaper To accomplish this you must set up the SLS to acquire images of the sandpaper at several points along its length During run mode operations
54. e analysis functions that are available to configure the SLS for inspection applications Where appropriate the user manual provides one or more simple examples to help you understand the concepts involved in a particular feature or function Following an example the user manual provides the step by step instructions for configuring the feature or function This manual and the SLS are intended for persons with no vision training or experience but who have some familiarity with the installation and use of industrial sensing devices such as photoelectric switches and proximity switches It is assumed that the user is familiar with the intended application and that the application is within the capabilities of the SLS Chapter 1 Introduction Smart Linear Sensor 1 2 Smart Linear Sensor The SLS is an easy to configure high performance machine Product Overview vision system that can be used for a variety of process control and manufacturing inspection applications The SLS and lens are housed in a NEMA 4X compatible package Three cable connectors are provided for connecting DC power and signal lines to the SLS The SLS can be mounted using an aluminum bracket Bulletin 880 N12 Photoelectric Switch mounting bracket or a three axis stainless steel bracket Catalog No 2804 BR1 The 2804 BRI1 is required to maintain the NEMA 4X rating An optional SLS Configuration Support Software package can be used to upload and download SLS conf
55. e as the ideal object the percentage of match is 100 When something in the inspected object is not the same such as one of the component objects is a different shade of gray or is missing the percentage of match is less than 100 How much less depends on the magnitude of the change NOTE The inspected objects must be consistently fixtured during both the setup teach mode and the run mode so that they always have the same orientation in the FOV Also the lighting must be consistent in both position and intensity The object width results appear on the Analog B output The term object width has the same meaning here as it does for the Object Width Measurement function In the illustration below the SLS sees the three separate objects in the FOV as one composite object with gray scale variations Object Width 100 of FOV 80 of FOV Field of View gt 0 of FOV Object Width and Recognition Signature Chapter 5 SLS Analysis Functions oe 1 D Object Recognition The following illustration is a graphical depiction of the continued shades of gray within the preceding recognition signature Object Width and Recognition Signature Med Gray Dark Black FOV Example 1 In this example the SLS uses the 1 D Object Recognition function to inspect uncut gear blanks ona gear grinding machine The main purpose of the inspection is to determi
56. e object size and the object count number by acquiring multiple images as the object moves across the FOV at right angles At this time the Analog A output remains a 4mA The Analog B output indicates the object s width at the instant of each image acquisition thus it is likely to change as the object moves across the FOV During the Parts Counting Run function when inspected objects move across the FOV the SLS counts each object and reports the cumulative count result as a percentage of the maximum count on both analog outputs Before the SLS learns the parts counting parameters it must learn lighting compensation parameters using the 1 D Spatial Measurement function With the ideal object positioned in the FOV as shown in the illustration below and the operating mode switch set to setup teach the SLS learns the lighting compensation parameters within a few seconds 10 to 20 image acquisitions 100 of FOV Stationary Ideal Object w Field of View 0 of FOV Object OM 0000000 ng When the operating mode switch is set to run the SLS saves the lighting compensation parameters in its memory Chapter 5 SLS Analysis Functions Parts Counting continued 5 39 The analysis function switches are then be changed to the Parts Counting Teach function and the ideal object removed from the FOV Teach Function The Parts Counting Teach function is a separate function switch setti
57. e or cause it to leak 2 Do not exceed 11 foot pounds of torque 10 when tightening the 5 16 18 friction pivot bolt on the 2804 BR1 mounting bracket 3 If you use other means to mount the SLS do not use mounting screws that are long enough to strike the bottom of the screw inserts The SLS provides two trigger input modes Level triggering and edge triggering One of these is selected during the configuration operation Level triggering requires the trigger input to be either high 5 VDC to 30 VDC or low 0 VDC When the input is high the SLS cannot acquire images When the input is low the SLS acquires images at the maximum rate using an internal trigger The maximum rate is determined by the inspection cycle time which depends on the analysis function in use and the exposure time Appendix R Reference Information B 9 Trigger Input Modes continued Binary Threshold Background Light Probe Burst Acquisition Mode Edge triggering requires the trigger input to transition from high 5 VDC to 30 VDC to low 0 VDC When this occurs the SLS acquires one image The maximum trigger repetition rate is determined by the inspection cycle time which depends on the analysis function in use and the exposure time When an SLS Series B only is connected to a personal computer using the Series B SLS Configuration Support Software CSS the Binary Object Size and Binary Object Count analysis functions
58. e second object lies partially outside the 0 of FOV point the SLS ignores that object and locates the edges of the first object as follows 100 of FOV ignored Object Last Edge 25 of FOV lt Field of View First Edge 15 of FOV 0 of FOV Inspected Object Example Here is a simple example of using the 1 D Spatial Measurement function to track one edge of a continuous sheet product such as paper cloth or sheet metal and control the lateral position of the sheet as it moves through the processing equipment Chapter 5 SLS Analysis Functions es 1 D Spatial Measurement The SLS is positioned so that its FOV lies across one edge of continued the sheet with the first edge location at the 50 of FOV point The last edge is not used in this example Direction of Sheet Movement N 100 of FOV First Edge weer 50 of FOV Moving Sheet Lateral Field of View gt Drift 0 of FOV The location results for the first edge appear at the Analog A output Since the analog range is 4 to 20mA the 50 of FOV point represents 50 of the difference between 4mA and 20mA or 12mA You can use this formula to determine the analog current Analog Current of FOV x 16 4 If the sheet drifts laterally the Analog A output increases or decreases proportionally Thus if the sheet drifts so that the first edge location moves to the 55
59. e the width of a disc brake rotor and check it for runout The SLS is positioned so that its FOV lies parallel to the rotor axis and perpendicular to the friction surfaces of the rotor The illustration on the following page shows the FOV relative to the brake rotor Note that A shows the complete brake rotor assembly while B shows the FOV located across the rotor near the edge The object width results appear at the Analog A output on the SLS Since the Analog A output represents the 80 of FOV point in this example using the formula Analog Current of FOV x 16 4 the current is 16 8mA If the rotor thickness varies as the rotor rotates the object width results will vary up or down from the 80 of FOV point and the Analog A output current will increase or decrease proportionally The object center results appear at the Analog B output on the SLS Since the Analog B output represents the 50 of FOV point in this example using the formula above the current is 12mA If the object center position varies as the rotor rotates the center position results will vary up or down from its 50 of FOV point and the Analog B output current will increase or decrease proportionally This indicates the degree of rotor runout Chapter SLS Analysis Functions Object Width Measurement continued Your Action Set the lower four function switches as shown 4 Rotation Axis Object Width Object
60. ectrical Specification Pin 1 24 VDC power input Usea 20 to 28 VDC NEMA NEC class II power supply in 2 Analog output A High side sourcing 4 20mA max load resistance 500 Ohm Pin 3 Common Common return for pins 1 2 4 and 5 in 4 Analog output B Same as Analog output A 3in 5 Strobe trigger output 5VDC active current limited non isolated Compatible with all Allen Bradley strobe light sources in 1 Trigger input 5 to 30 VDC isolated max off state leakage 1mA max response time 75uSec Trigger return Common return for discrete outputs Max 30 VDC or AC peak NEMA NEC class II power supply max current 100mA 300V isolation from other I O Same as Discrete output A in 2 Trigger input Pin 3 Common 2in 4 Discrete output A Pin 5 Discrete output B Pin 1 RS 232 Transmit data Pin 2 RS 232 Receive data Pin 3 Common Pin 4 24VDC output RS 232C non isolated RS 232C non isolated Common return for pins 1 2 and 4 24VDC routed from power supply input J1 pin 1 3 4 Chapter 3 Hardware Connection and Powerup Check POWG GN PS Ba Connecting to AC Power Source The 2801 P3 requires an input voltage of 85 to 135 VAC at 47 to 63Hz and the 2801 P4 requires 170 to 270 VAC at 47 to 63Hz Their output voltage is 24 VDC at 1 6A This section shows you how to connect AC and DC wiring to these
61. ed Mode Resolution Accuracy and Base Cycle Time High Resolution High Speed Analysis Function Resolution Accuracy Resolution Accuracy of FOV of FOV of FOV of FOV 1 D Spatial Measurement 0 125 0 25 0 250 0 50 20ms Object Width Measurement 0 125 0 25 0 250 20ms 0 25 0 250 0 50 20ms Binary Object Count 0 125 0 5 Object Void Measurement 0 125 0 25 0 250 20ms Largest Object Width 0 125 1 D Object Recognition 0 125 0 25 0 250 30ms Included Object Texture Recognition f 0 125 0 25 0 250 30ms Full Field Texture Recognition N NA NA 20ms Binary Object Size 0 125 0 25 0 250 15ms 0 25 0 250 15ms A A N N Parts Counting Teach N NA NA 2 D Ob ect Size Teach 0 125 0 25 0 250 0 50 25ms 2 D Object Size Run 0 125 0 25 0 250 0 50 25ms Series B SLS only Binary functions require connecting the SLS to a personal computer using the SLS Configuration Support Software Side View SLS The side view SLS is intended for inspection applications 2804 5L52 where space limitations prevent using the front view SLS As Figure B 4 shows the lens is on the same side as the access panel Figure B 4 Side View SLS 2804 SLS2 00606600 Appendix B Reference Information B 5 Lens Filter Maintenance and Replacement The lens filter has two functions It protects the lens and it seals the SLS against moisture and dirt As Figure B 5 s
62. ess cover from the SLS Connect the power supply cord to the AC outlet Turn off the light source Set the targeting light switch to Targeting Light On Chapter 4 SLS Quick Start Operation Focusing the SLS involves measuring the distance from the lens front plate to the object to be inspected the Aiming Target and setting the lens to that distance Aiming the SLS involves using the targeting light to ensure that the SLS sees the object to be inspected the Aiming Target in this case at the correct location Use the following steps to focus and aim the SLS Comments Refer to the following figure Front Plate Tee SEES SEES sibs Aiming Target 0000000 20 Inches 508mm This sets the focus No further adjustment is necessary The cover is secured by four captive screws Be sure the SLS completes its power up cycle as described in Chapter 3 Use a small screwdriver or similar device to set the switch Configuration Switches Off 0 Targeting Light Off NOTE The targeting light turns off after two minutes or when the lens head becomes too warm To turn it on again set the switch to off then on If the light does not turn on wait for the lens head to cool then cycle the switch again Chapter 4 SLS Quick Start Operation Focusing and Aiming SLS continued Your Action Aim the SLS so the targeting light crosses the black bars If necessary reposition the Aiming Target Careful
63. fect match would be 50 for an object exactly the size of the reference object This allows for measuring objects that are larger as well as smaller than the reference object The following illustration shows you how the SLS performs the Run function 100 of FOV Field of View 0 of FOV Instantaneous Object Width NOTE All objects must cross the FOV single file and they must be spaced far enough apart for the SLS to acquire at least one image in the gap between objects at the applicable rate of movement The objects rate of movement during the Run function must be the same as their rate during the Teach function unless synchronized triggering is used as mentioned earlier Thus if the SLS learned an oblong reference object along its short axis the SLS can determine the object s size along the long axis so long as the image acquisition spacing remains the same ete Chapter 5 SLS Analysis Functions 2 D Object Size Example Here is an example of using the object size continued function to sort oranges The objective is to determine the size of each orange and the appropriate size category i 100 of FOV Oranges Direction of Orange Movement ATIN NANA KOS KA rates SEEEN Ky oS Ne 2 Medium v Orange field of View During the Teach function the SLS learns the size of the reference orange which in this example is a medium size orange
64. fficient Object to Background j Contrast gt Fault Error Condition Output A Active Yellow O Output B Active Operating Duty Cycle Green Maximum Speed Red Waiting for Trigger OR KITA Green Steady Remotely Configured bass Flashing Communicating i Chapter 4 SLS Quick Start Operation 4 1 Performing Run Operation continued Your Action Comments Set the output mode switch This instructs the SLS to close a discrete output when a toOutput N C result value is less than the value determined by the corresponding setpoint control Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Dark Object Level Triggered Targeting Light On Setup Teach Mode Bright Object Edge Triggered Strobe Lighting Remote Conf Disable Outputs N C Normal Lighting Remote Conf Enable Outputs N O Observe the LEDs The LEDs should now appear as follows Image Brightness Level Green Bright Light Level Red Low Light Level RD Insufficient Object to Background Ig Contrast Yellow Output B Active Operating Duty Cycle Green Maximum Speed Red Waiting for Trigger ES Ka Green Steady Remotely Configured Ry Flashing Communicating The output active A LED should now be on and the output active B LED should be off discrete output A is now closed discrete output B is now open Chapter 4 SLS Quick Start Operation Performing Run Operation continued Your Action T
65. ger has occurred It then times out processes the images already acquired 1 2 and 3 sends the results data to the PC and resets the burst count Set Point Methods Discrete output A closed q2 Discrete output B Discrete pa AG ba a nA closed output B inverted open When an SLS Series B only is connected to a personal computer using the SLS Configuration Support Software CSS the SLS can be configured to enable both set points A and B to operate on the same inspection result that is both can operate on output A or output B This has the effect of setting two range limits for one result such as object width For example assume that output A indicates an object width and the desired width is represented by 40 at output A with the lower range limit being 38 and the upper range limit being 42 With set point A set to 38 set point B set to 42 the Outputs N O Outputs N C switch set to N C and the Invert Output B option selected both discrete outputs are open only between 38 and 42 Above or below that range one or the other discrete output is closed This is shown in the following figure Figure B 8 Using Both Set Points on One Result Discrete outputs N C Set pointA Set point B 38 of FOV 42 of FOV Discrete output A open Discrete output B open Discrete output B inverted closed t 1 i i t ij l i We ee Both di
66. ger mode setting analyzes these images and sends the results to the analog and discrete outputs Included Object This analysis function requires at least one object lying Texture Recognition wholly within the FOV When two or more objects appear in the FOV the SLS interprets them as one object from the first edge of the first object to the last edge of the last object Using the Included Object Texture Recognition function the SLS compares the texture frequency pattern of an ideal object stored in its memory with the texture pattern of each inspected object These texture patterns are the recognition signatures of the two objects 5 26 Chapter SLS Analysis Functions Included Object Texture Recognition continued NOTE In order to determine the feasibility of your application you must be sure that the SLS can see the texture on your inspected objects The only way to be sure of that is to use the SLS Configuration Support Software and observe the View Image display of your object If the texture ts not visible in the display your application is not feasible During the setup teach mode the SLS learns the texture frequency or granular characteristic of the ideal object s surface This is the recognition signature At the start of the run mode the SLS stores the recognition signature in its memory During operation in the run mode the SLS compares the signature of an inspected
67. gnature of the ideal slowly across the FOV to object by acquiring images at several points along its length enable the SLS to learn the recognition signature NOTE As previously discussed you can determine the proper number of images to acquire by trial and observation Chapter 5 SLS Analysis Functions Full Field Texture Recognition continued When the SLS has learned the recognition signature set the switch to Run Mode Binary Object Size Binary Object Count 5 37 The SLS saves the recognition signature Configuration Switches Off 0 Targeting Light Off Run Mode Dark Object The SLS can now begin operating in the run mode during which it acquires images according to the trigger mode setting analyzes these images and sends the results to the analog and discrete outputs These analysis functions are available only in the Series B SLS when it is connected to a personal computer using the Series B SLS Configuration Support Software CSS The functions are mentioned here for reference only If either function is selected without using the CSS the SLS performs a null function and flashes the error LED continuously These two functions provide an adjustable binary threshold that can be used to mask off unwanted visual clutter in the FOV This enables the SLS to ignore everything in the FOV below the binary threshold and to look for the inspected objects only in the area above the thre
68. h light levels The LED stays on as long as the extreme light condition continues Chapter 3 Hardware Connection and Powerup Check Powerup Check 4 Selecting the Run function before selecting and continued performing the corresponding Teach function This applies only to the Parts Count and 2 D Object Size analysis functions The LED stays on until the Teach function is performed or a different analysis function is selected 5 Selecting the Run function along with a different setting of the speed resolution switch than was used during the Teach function This applies only to the Parts Count and 2 D Object Size analysis functions The LED stays on until the Teach function is performed or a different analysis function is selected 6 Selecting one of the two binary analysis functions from the DIP switches when the remote configuration switch is set to Remote Conf Disable The SLS can use the binary functions only when the remote configuration DIP switch is set to Remote Conf Enable 7 Selecting the burst acquisition mode Configuration Support Software only but not providing enough light on the inspected objects The result is that the SLS clips the exposure time in order to maintain the selected burst spacing For example if the selected burst spacing were 10ms and the required exposure time were 8ms the SLS would clip the exposure time to 5ms in order to keep the total of the exposure time plus the acquis
69. he SLS trigger mode switch can be set to Level Triggered which enables the SLS to acquire images at its maximum rate If the conveyor speed varies however the trigger mode switch should be set to Edge Triggered and the trigger signals synchronized with the conveyor The illustration below shows the movement of the ideal object as it crosses the FOV during the Teach function 100 of FOV TU laa a ee ee EERE Moving Ideal Object 0 of FOV Field of View Instantaneous Object Width After the object passes the FOV the SLS learns its size and records it at 50 of its actual size This enables the SLS to aN size variations of 50 from the size of the ideal object Chapter 5 SLS Analysis Functions 2 D Object Size continued 5 47 The Teach function is complete when the ideal object has passed completely across the FOV At this point you must set the function switches to the 2 D Object Size Run function Run Function The 2 D Object Size Run function isa separate function switch setting whose purpose is to enable the SLS to measure objects crossing the FOV by comparing them to the ideal reference object stored in memory During the Run function the SLS compares the size of each object crossing the FOV with the size of the reference object The SLS indicates the result as a percentage of match to the reference object divided by two Thus a per
70. he light background area Figure 6 2 shows this 6 4 Mounting and Positioning SLS continued Mounting and Positioning Light Source Chapter 6 SLS Installation Requirements and Procedures Assuming that you have prepared all the necessary fixtures and or mounting surfaces for the SLS mount the SLS but do not completely tighten the fasteners at this point Refer to the Mounting Brackets section in Appendix B for information about the Allen Bradley mounting brackets Aim the SLS so that the FOV lies approximately across the object as required for your application Tighten the fasteners lightly at this point You will be fine tuning the aim later Assuming that you have prepared all the necessary fixtures and or mounting surfaces for the light source mount the light source but do not completely tighten the fasteners at this point Turn on the lamp and aim it at the inspected object in the FOV Adjust the light source so that it illuminates the object uniformly and produces good contrast between the object and its background When you have optimized the object s illumination tighten the fasteners SLS Connection Procedures Connecting J1 Cable Connection involves connecting the J1 J2 and J3 cables as required between the SLS and the power supply and process equipment Note that all SLS applications require the J1 cable since it carries DC power to the SLS The J1 cable carries DC power to the SLS
71. hows the filter is threaded and can be removed for cleaning or replacement Figure B 5 Exploded View of Lens Filter and O Ring Lens Filter B ma Lens Housing You should clean the filter periodically especially in dirty environments The filter is made of polycarbonate plastic however use care when handling and cleaning it to avoid finger prints and scratches To clean the filter use a soft lint free tissue dampened with glass cleaner If the filter appears excessively scratched replace it with a new one You can obtain a package of ten new filters from your local Allen Bradley distributor using Catalog No 2804 FL1 CAUTION The O ring is used to seal the lens housing and maintain the NEMA 4X rating When you replace the filter be sure to install the O ring around the shoulder in the lens housing as shown in Figure B 6 not on the filter If you attempt to mount the O ring on the filter it may be damaged when you screw the filter into the lens housing ae Appendix B Reference Information Lens Filter Replacement and Maintenance continued Figure B 6 O Ring Installation Lens Filter Lens Housing Appendix B Reference Information T 10 Connections Figure B 7 shows the SLS connected to the various input and output devices Figure B 7 O Connections 24 VDC Analog Input Device Output B Discrete Input Output Device Output B t24 VDC Power Supply
72. ial Aiming Target as shown in Figure 4 1 in which the black bars are the objects to be inspected A special copy of the Aiming Target printed on card stock is located in the back of this manual Figure 4 2 shows the staging layout Focusing measuring the distance from the lens front plate to the Aiming Target and setting the lens focus to that distance Aiming positioning the SLS so that its linear sensor element can see the objects Performing Setup Teach Operation operating the SLS in the setup teach mode During this time the SLS acquires images in order to learn lighting compensation and other parameters e Performing Observing Run Operation operating the SLS in the run mode and observing the LEDs During this time the SLS acquires images of the objects analyzes the images and indicates the inspection results and SLS status in the LEDs For the purposes of the quick start operation prepare your SLS staging area as follows Obtain a table workbench or other horizontal surface suitable for staging the SLS Place the table next to a wall or other vertical surface suitable for mounting the Aiming Target A source of AC power of the correct voltage must be close by Obtain a small incandescent lamp that you can position close to the Aiming Target without obstructing it e Poa a small tape measure You will need it to focus the LS Chapter 4 SLS Quick Start Operation
73. igurations and can also monitor SLS operations and accumulate statistics Figure 1 1 identifies in symbolic form the basic SLS components and shows the connections between these components Figure 1 1 SLS Components and Connections Ka LOV Personal Computer RS 232 Optional Strobe Light Discrete Outputs Optional To User p Production ARGI Equipment nalog Outputs Strobe Trigger 24 VDC Input 24 VDC Power Supply Chapter 7 Introduction Smart Linear Sensor T SLS Hardware The basic SLS hardware includes the sensor lens mounting bracket power supply and cables The lens mounting bracket and power supply are ordered separately Connecting cables are provided by the user SLS Housing The SLS is available in two models that are identical except for the lens Catalog No 2804 SLS1 Front view lens Catalog No 2804 SLS2 Side view lens Figure 1 2 shows the two SLS models Figure 1 2 SLS Models Front View Lens and Side View Lens 2804 SLS1 Front View Lens 2804 SLS2 Side View Lens Chapter 7 Introduction Smart Linear Sensor 1 4 al SLS Housing continued The SLS electronics are completely contained in a NEMA 4X compatible housing The SLS lens is in a separate unit attached to the front of the SLS housing An access panel is under a cover on the side of the housing Figure 1 3A is a side view of the SLS showing the access panel cover in place Figure 1 3B is the same view
74. in the FOV measure the object s width then add 20 to allow for object shifting and or width variation This will be the FOV width for your application Chapter 6 SLS Installation Requirements and Procedures 6 2 Determining FOV Width For analysis functions that require only one edge of an object continued 1 D Spatial Measurement or a portion of the object Full Field Texture Recognition place the SLS as close as practicable to the inspected objects in order to maximize the image resolution yet provide an FOV that is wide enough to accommodate any anticipated shift in the object s position Focusing SLS Focusing the SLS includes two main steps measuring the standoff distance the distance from the inspected object to the front plate of the SLS lens as shown in Figure 6 1 and setting the focusing ring Figure 6 1 Standoff Distance From Inspected Object lt Inspected Object Standoff Distance Using the FOV width for your application refer to Table 6 1 to find the corresponding standoff distance for the standard lens 2804 NL1 or wide angle lens 2804 NL2 Table 6 1 Standoff Distance Determination FOV Width vs Standoff Distance Standoff Distance Inches mm Standoff Distance Inches mm StandardLens Wide Angle Lens Standard Lens Wide Angle Lens 2804 NL1 2804 NL2 2804 NL1 2804 NL2 1 5 38 1 6 8 173 BEN 10 254 27 6 702 21 6 550 FOV Width Inches
75. ition time from exceeding 10ms 8 Selecting the burst acquisition mode Configuration Support Software only without specifying the burst spacing and configuring the SLS for Level Triggered operation When selecting burst mode without specifying the burst spacing you must configure the SLS for Edge Triggered operation Observe the LED powerup sequencing as described above After the SLS appears to have powered up successfully continue with Chapter 4 SLS Quick Start Operation This chapter enables you to familiarize yourself with basic SLS configuration procedures and at the same time check the SLS for proper operation Chapter Chapter Objective 4 SLS Quick Start Operation The objectives of this chapter are to show you the basic steps for configuring the SLS and at the same time enable you to check your SLS for normal operation after performing the powerup check described in Chapter 3 Quick Start Setup and Checkout The quick start operation includes the basic steps used to configure the SLS for most applications Note that this operation does not use the optional SLS Configuration Support Software For information about the software refer to the SLS Configuration Support Software User s Manual Catalog No 2804 ND002 The quick start operation includes these procedures Staging positioning the SLS the light source and the object s to be inspected The quick start operation uses a spec
76. ject in the FOV the SLS calibrates learns the internal automatic lighting compensation function This process requires the SLS to acquire several images thus it takes only f few seconds if the SLS is operating at maximum speed When you set the switch to run mode the calibration process terminates and the SLS stores the learned configuration parameters After you set the switch to run mode the SLS begins performing its normal inspection operations NOTE If you attempt to operate certain analysis functions in the run mode without first using the setup teach mode the Fault Error LED turns on Dark Object Bright Object Set this switch to dark object when the inspected objects are darker than the background Conversely set the switch to bright object when the inspected objects are brighter than the background NOTE The terms dark and bright refer to the relative light intensity or contrast not color between the object and its background If the contrast is not great enough for the analysis function to perform reliably the Low Contrast LED turns on Chapter 2 SLS Access Panel Configuration Switches continued 2 3 e Level Triggered Mode Edge Triggered Mode When you set this switch to level triggered mode and the external trigger input is either low or not connected the SLS acquires images continuously at maximum speed using an internal trigger source The maximum speed depe
77. llation Requirements and Procedures If your application requires the discrete A output connect the discrete A output wire and common return wire to your process equipment If your application requires the discrete B output connect the discrete B output wire and common return wire to your process equipment The J3 cable carries the RS 232 data input and output signals and signal return Table 6 4 lists the specifications for those input and output signals Table 6 4 J3 Specifications RS 232 Data I O and 24VDC Output RS 232 Serial O Transmit data signal pin 1 Red wire with black tracer Receive data signal pin 2 Red wire with white tracer Common return pin 4 Green wire Serial VO is used with Allen Bradley 2804 SW 1 Configuration Support Software only If your application requires only the RS 232 serial I O use the special 12 foot J3 cable supplied with the SLS Configuration Support Software package This cable hasa 25 pin D type connector already attached You can order it separately as Catalog No 2804 CSC1 Before applying AC power to the power supply be sure that the source voltage lies within the range appropriate for the power supply Refer to the instruction sheet supplied with the power supply for specific ratings and requirements Refer to Chapter 3 and perform the SLS powerup check as described Chapter 6 SLS Installation Requirements and Procedures Fine Tuning SLS Aim 6 7 Yo
78. ly set the switch to Targeting Light Off Setting Configuration Switches Your Action Set the object switch to Dark Object 4 5 Comments Refer to Figure 4 2 The targeting light produces a thin line of light corresponding to the SLS field of view The useful range of the light depends on the ambient light level NOTE Do not use the targeting light to fine tune the focus Use only the measuring method described earlier Your objective is to center the black bars within the targeting light Do not disturb the SLS position Configuration Switches Off 0 Targeting Light Off Run Mode Dark Object In the next steps you will use the configuration switches to select the 1 D Spatial Measurement analysis function and several configuration parameters The SLS will use the 1 D Spatial Measurement function to locate the first and last edges of the black bars in the Aiming Target Use the following steps to set the configuration switches Comments This instructs the SLS to recognize the black bars on the the Aiming Target as the objects to be inspected Configuration Switches Off 0 _ On 1 Targeting Light Off Run Mode Dark Object Targeting Light On Setup Teach Mode Bright Object po Chapter 4 SLS Quick Start Operation Setting Configuration Switches continued Your Action Comments Set the trigger mode switch This enables the SLS to acquire images continuously so to Level Triggered
79. ly the LED indicates that communication activity is taking place between the SLS and the PC When itis off the LED indicates that the SLS is controlled by its physical switch and control settings For additional details about the SLS support software refer to the SLS Configuration Support Software User s Manual Catalog No 2804 ND002 Chapter Hardware Connection and Powerup Check Chapter Objective The objective of this chapter is to show you how to connect the SLS to the power supply and I O devices and perform a powerup check Cable Connections The SLS connects to the power supply and all I O devices through three connectors on the back of the case labeled J1 J2 and J3 They are arranged as shown in Figure 3 1 Figure 3 1 SLS Connectors Side View Power and Signal Connectors Jlis a 5 pin male connector J2 is a 5 pin female connector and J3 is a 4 pin male connector Figure 3 2 shows the connectors as they appear from the rear of the SLS Figure 3 2 SLS Connectors Rear View J1 Male J2 Female J3 Male Connector Pin Pin Socket Connector Pin Figure 3 2 shows the pin numbering on the three connectors The actual orientations of the connectors on your SLS may be rotated from the orientations shown in the figure Chapter 3 Hardware Connection and Powerup Check Cable Connections Table 3 1 identifies the signal function and wire color code continued for the cables that connect to J1 J2
80. mode long as the trigger input in connector J2 is open or low Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Dark Object Level Triggered Targeting Light On Setup Teach Mode Bright Object Edge Triggered Set the lighting mode switch This enables the SLS to acquire images using a continuous to Normal Lighting mode lighting source such as the one you are using Configuration Switches Off 0 Targeting Light Off Run Mode Dark Object Level Triggered Normal Lighting Set the remote configuration This enables the physical switches on the SLS to control its mode switch to Remote operation Also it prevents the optional SLS Configuration Configuration Disable Support Software from downloading a configuration to the Configuration Switches Off 0 Targeting Light Off Run Mode Dark Object Level Triggered Edge Triggered Normal Lighting Strobe Lighting Remote Conf Enable Remote Conf Disable Chapter 4 SLS Quick Start Operation Setting Configuration Switches continued Your Action Comments Set the output mode switch This instructs the SLS to open a discrete output when an toQutputN O inspection result value is less than the setpoint value determined by the corresponding setpoint control Configuration Switches Off 0 Targeting Light Off Run Mode Dark Object Lavel Triggered Normal Lighting Remote Conf Enable Outputs N O Set the resolution speed s
81. mory Chapter SLS Analysis Functions 5 33 Full Field During operation in the run mode the SLS compares the Texture Recognition signature of an inspected object regardless of its position continued along the FOV with the stored signature of the ideal object and reports the results of this comparison as the percentage of match of the two signatures These results appear on the both the Analog A and B outputs When the inspected object is exactly the same as the ideal object the percentage of match is 100 When something in the inspected object is not the same such as a flaw in the surface texture the percentage of match is less than 100 How much less depends on the size of the flaw Before the SLS learns the recognition signature of the ideal object it must learn lighting compensation parameters using the 1 D Spatial Measurement function With the FOV positioned over the ideal object as shown in the following illustration and the operating mode switch set to setup teach the SLS learns the lighting compensation parameters within a few seconds 10 to 20 image acquisitions naa 225 0A Hy Potato Va Va o ra AK SS SS o O O C3 SSE RoR RR HD PAP NAGO c OOO AWRA se lt 2 KY CKD a ONG 0 EADY Ng Sato KAKO S nao Og SENS K CI KO i O o Xo ree o roe Na o OO
82. mple example of using the Largest Object Width function to measure the width of objects that are normally accompanied in the FOV by several smaller objects Since these objects are in effect visual noise the Largest Object Width function can act as a filter to eliminate the noise The SLS is positioned so that the FOV is perpendicular to the path of the inspected objects as shown in the illustration on the following page The SLS analyzes each pair of edges along the FOV and identifies the largest object as the pair of edges that has the greatest distance between them The SLS ignores the smaller objects The largest object width results appear at the Analog A output on the SLS Since the Analog A output represents 40 of the FOV in this example using the formula Analog Current of FOV x 16 4 the current is 10 4mA The object center results appear at the Analog B output on the SLS Since the Analog B output represents 35 of the FOV in this example using the formula above the current is 9 6MA Chapter 5 SLS Analysis Functions 5 1 Largest Object Width continued Field of View Largest Object Width 40 of FOV Smaller Objects 100 of FOV LLL dd Object Center 777 35 of FOV 0 of FOV NOTE For optimum results the contrast between the largest object and the background luminance should equal or exceed the contrast of all other objects expected t
83. nds on the cycle time of the selected analysis function the exposure time and the setting of the High Resolution High Speed switch When the trigger input goes high the SLS discontinues image acquisition When you set this switch to edge triggered mode the SLS acquires one image with each high to low transition of the external trigger signal up to its maximum rated speed The color of the Duty Cycle LED indicates the trigger signal repetition rate Thus red indicates that the SLS is waiting for a trigger orange indicates triggers arriving at less than the maximum rate and green indicates triggers arriving at or close to the maximum allowable rate NOTE Be certain that external trigger signals do not recur at shorter intervals than the cycle time of the selected analysis function otherwise the SLS will not process all of them The Duty Cycle LED turns orange if the interval is much shorter than the cycle time Normal Lighting Strobe Lighting Set this switch to normal lighting mode if you are using continuous lighting to illuminate the inspected objects In this mode the exposure time varies according to the intensity of the light thus the lighting compensation is effective over a wide range of light intensities Set the switch to strobe lighting if you are using a strobe light to illuminate the objects In this mode the exposure time is fixed at 0 5mSec e Remote Conf Enable Remote Conf Disable
84. ne whether a gear blank is acceptable for grinding Another purpose is to determine whether a finished gear has somehow remained on the grinder If so action would be necessary to prevent the grinder from operating on the finished gear and damaging both the gear and the cutter In the illustration below the SLS learns the signature of an ideal gear blank during the setup teach mode as follows Object Width 50 of FOV 100 of FOV Ideal Object gt Gear blank Field of View gt 0 of FOV Object Width and Gear Blank Signature During the run mode the SLS compares the signature of each inspected object with the stored recognition signature of the ideal object Chapter 5 SLS Analysis Functions 5 22 1 D Object Recognition For this example assume that the first inspected object is a continued gear blank not a finished gear its signature is like the stored signature the gear blank is not flawed in shape or appearance and the percentage of match is 85 At the Analog A output the current is 85 of the difference between 4mA and 20mA or 17 6mA As a consequence the grinding equipment is instructed to perform its cutting operation on the gear blank At the Analog B output the current reflects the object width which is 50 of the FOV This becomes 50 of the difference between 4mA and 20mA or 12mA Now assume that the second inspected object is a finished gear tha
85. nfigured Before operating in the run mode however the SLS must operate briefly in the setup teach mode in order to learn the correct lighting compensation parameters Use the following steps to configure and operate the SLS in the setup teach mode Your Action Comments Set the mode switch to This enables the SLS to learn the appropriate parameters Setup Teach Mode Configuration Switches Off 0 Targeting Light Off Run Mode Chapter 4 SLS Quick Start Operation 4 9 Performing Run Operation Your Action Set the operation mode switch to Run Mode Observe the LEDs After learning parameters in the setup teach mode the SLS is ready to perform its assigned inspection measurement or control task When the SLS performs the 1 D Spatial Measurement function it will locate the first and last edges of the black bars the objects in the Aiming Target Use the following steps to configure and operate the SLS in the run mode Comments This instructs the SLS to enter the run mode and perform the 1 D Spatial Measurement function the one you selected Configuration Switches Off 0 Targeting Light Off Run Mode Dark Object The brightness and duty cycle LEDs should be on and the output active B LED should be on discrete output B is ia discrete output A is open The other LEDs should be off Image Brightness Level Green Bright Light Level Red Low Light Level 3 Insu
86. ng which it acquires images according to the trigger mode setting analyzes these images and sends the results to the analog and discrete outputs This analysis function does not require an object that is an identifiable first and last edge to lie wholly within the FOV Instead the SLS assumes that the entire FOV is occupied fully with the surface texture of the object to be inspected The Full Field Texture Recognition function does not perform an object width measurement Beyond that this function operates the same as the Included Object Texture Recognition function Using the Full Field Texture Recognition function the SLS compares the texture frequency of an ideal object with the texture frequency of the object currently in the FOV These patterns are the recognition signatures of the two objects NOTE In order to determine the feasibility of your application you must be sure that the SLS can see the texture on your inspected objects The only way to be sure of that is to use the SLS Configuration Support Software and observe the View Image display of your object If the texture ts not visible in the display your application is not feasible During the setup teach mode the SLS learns the texture frequency or granular characteristic of the ideal object s surface This is the recognition signature At the start of the run mode the SLS stores the recognition signature in its me
87. ng the inspected object Exposure time is measured in milliseconds and it starts with the triggering event and ends when the SLS acquires the image data During operation in the setup teach mode the SLS uses the light from the image area to compute or learn the lighting compensation parameters The SLS stores these parameters when it enters the run mode During operation in the run mode the SLS uses the stored lighting compensation parameters to compute the proper exposure time If the light intensity in the image area changes the SLS changes the exposure time accordingly Thus if the light intensity increases the SLS decreases the exposure time and vice versa The SLS can vary the exposure time from 0 5mSec to 200mSec the limits of the lighting compensation function Appendix B Reference Information B 3 Exposure Time Cycle ime and Lighting Compensation continued Cycle Time n Exposure Time n 4 75ySec Delay Cycle time is the minimum interval in milliseconds that the SLS requires before it can respond to the next trigger signal It includes exposure time image acquisition time image processing time and lighting compensation computation time Cycle time also reflects the maximum triggering rate Thus for a cycle time of 20mSec the maximum triggering rate is 50 triggers per second Increased exposure time can increase the minimum base cycle time of an analysis function
88. ng whose purpose is to enable the SLS to learn the object size and the number of objects to be counted NOTE 1 During the Teach function the spacing of the image acquisitions must be consistent Thus if the conveyor moves at an unvarying speed the SLS trigger mode switch can be set to Level Triggered which enables the SLS to acquire images at its maximum rate If the conveyor speed varies however the trigger mode switch should be set to Edge Triggered and the trigger signals synchronized with the conveyor In the following illustration the specified number of objects are shown moving single file across the FOV 100 of FOV Moving Direction of Object Objects Motion q Field of View gt 0 of FOV Object Currently in FOV NOTE 2 The first object to cross the FOV must be the ideal object The SLS learns this object s size then records it at 50 of its actual size This enables the SLS to accept size variations of 50 from the size of the ideal object NOTE 3 All objects must cross the FOV single file and they must be spaced far enough apart for the SLS to acquire at least one image in the gap between objects at the applicable rate of movement 5 40 Parts Counting continued Chapter SLS Analysis Functions The Teach function is complete when the specified number of objects have passed completely across the FOV At this point you must set the function swit
89. ntinued Your Action Set the lower four function switches as shown Set these mode switches as required for your application Set the operating mode switch to Setup Teach Mode Chapter 5 SLS Analysis Functions Use the following steps to configure the SLS for the Included Object Texture Recognition function Assume that the SLS is already staged for its application and is powered up and the ideal object is properly positioned in the FOV Assume also that you have used the SLS Configuration Support Software and have determined that your application ts feasible Comments SW1 through SW4 must be off to enable the 1 D Spatial Measurement function 1 D Spatial Measurement High Resolution High Speed Swi sw2 Function Select SW3 See Function Table SW4 Object trigger lighting remote configuration outputs and speed resolution Refer to Chapter 2 for information Configuration Switches Off 0 Targeting Light Off Run Mode The SLS learns the lighting compensation parameters in a few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each high to low transition of the trigger signal to learn the parameters Chapter SLS Analysis Functions mmm hm GC C SAAR aQ ddksoeogoeeeeeer6eecccrriiil Included Object Texture Recognition continued Your
90. nued that the SLS cannot measure the full width of the object the width defaults to the part of the object that the SLS can see starting with the 0 of FOV point or ending with the 100 of FOV point 100 of FOV Field of Vie Object Center paaa E 15 of FOV Inspected Object Width Object C 30 of 0 of FOV If the inspected object overlaps the FOV entirely or if no object appears in the FOV the width and center position both default to 0 of FOV When one of two objects lies partially outside the FOV the SLS disregards the partial object Instead it measures the width of the object lying wholly within the FOV and locates the object s center position In the following illustration the first object lies beyond the 0 of FOV point In this case the SLS locates the edges of the second object as follows 100 of FOV Object Width 15 of FOV f Inspected Object Object Center a Field of Vi 80 of FOV EAEAN Ignored Object 0 of FOV 5 Chapter 5 SLS Analysis Functions 5 1 Object Width Measurement Ifthe second object lies beyond the 100 of FOV point the continued SLS locates the edges of the first object as follows Ignored Object Object Width Object Center C 15 of FOV 25 of FOV lt Field of View 0 of FOV Inspected Object Example Here is a simple example of using the Object Width Measurement function to measur
91. o appear in the FOV with the largest object Use the following steps to configure the SLS for the Largest Object Width function Your Action Comments Set the lower four function SW1 and SW must be off and SW3 and SW4 must be on to switches as shown enable the Largest Object Width function Largest Object Width a l ka High Resolution High Speed SW1 sWw2 sw3 swa Function Select See Function Table Set these mode switchesas Object trigger lighting remote configuration outputs and required for your application speed resolution Refer to Chapter 2 for information Chapter Ey SLS Analysis Functions Largest Object Width continued Your Action Set the operating mode switch to Setup Teach Mode After a few seconds or 10 to 20 image acquisitions set switch to Run Mode 1 D Object Recognition 5 19 Comments Configuration Switches Off 0 Targeting Light Off Run Mode The SLS learns the lighting compensation and other parametersin a few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each high to low transition of the trigger signal to learn the parameters The SLS saves the parameters Configuration Switches Off O On 1 Targeting Light Off Targeting Light On Run Mode Setup Teach Mode Dark Object t Object
92. object regardless of its position along the FOV with the stored signature of the ideal object and reports the results of this comparison as the percentage of match of the two signatures These results appear on the Analog A output When the inspected object is exactly the same as the ideal object the percentage of match is 100 When something in the inspected object is not the same such as a flaw in the surface texture the percentage of match is less than 100 How much less depends on the size of the flaw The SLS also uses the Included O bject Texture Recognition function to measure the width between the first and last edges of the object The object width results appear on the Analog B output Before the SLS learns the recognition signature of the ideal object it must learn lighting compensation parameters using the 1 D Spatial Measurement function With the ideal object positioned within the FOV as shown in the first illustration on the next page and the operating mode switch set to setup teach the SLS learns the lighting compensation parameters within a few seconds 10 to 20 image acquisitions When the operating mode switch is set to run the SLS saves the lighting compensation parameters in its memory The analysis function switches are then be changed to the Included Object Texture Recognition function The ideal object remains in the FOV Chapter 5 SLS Analysis Functions bay Included Object Textur
93. objects with reflections or bright areas that are either brighter than the background for a dark object with a light background or are brighter than the object for a light object with a dark background In either case disabling the lighting compensation maximizes the contrast between the object and the background and enhances the edge detenction capability of the SLS The SLS contains an electrically eraseable read only memory EEPROM for storing learned configuration data This data transfers to the EEPROM when you change the operating mode switch from setup teach to run The transfer requires two to three seconds maximum If a power loss occurs immediately after you set the operating mode switch to run the configuration data may not transfer correctly to the EEPROM Subsequently when power is restored the LEDs may indicate an EEPROM checksum failure You can correct this condition by resetting the switch to setup teach and enabling the SLS to relearn the configuration data B 12 Appendix R Reference Information Power Loss Recovery continued Connector Covers on J2 and J3 Grounding If a power loss occurs while the SLS is operating in the run mode the configuration data remains in the EEPROM Thus after power is restored the SLS can continue its inspection operations without relearning the configuration data However you may have to restart your process in order to re syn
94. of FOV point the Analog A output delivers more current 55 X 16 4 12 80mA Direction of Sheet Movement gt 100 of FOV First Edge 55 of FOV Moving Sheet Original Sheet Position 5 Lateral Drift Field of View gt 0 of FOV Z Chapter 5 SLS Analysis Functions 5 1 D Spatial Measurement The 0 30mA increase in current could be used directly by the continued servo mechanism that controls the sheet position In this case the mechanism moves the sheet until its edge is again at the 50 of FOV point and the current is once again 12mA Alternatively the current can be converted to digital values by an A D converter connected to a programmable logic controller PLC In this case the PLC could use the digitized current values in its program that controls the sheet positioning servo mechanism Use the following steps to configure the SLS for the 1 D Spatial Measurement function Your Action Comments Set the lower four function SW1 through SW4 must be off to enable the 1 D Spatial switches as shown Measurement function 1 D Spatial Measurement High Resolution swi SW2 sw3 SW4 High Speed Function Select See Function Table Set these mode switchesas Object trigger lighting remote configuration outputs and required for your application speed resolution Refer to Chapter 2 for information Set the operating mode switch to Setup Teach Mode Configur
95. olution Refer to Chapter 2 for information T Set the operating mode switch to Setup Teach Mode Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Targeting Light On Setup Teach Mode Bright Object The SLS learns the lighting compensation parametersin a few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each high to low transition of the trigger signal to learn the parameters pag Chapter 5 SLS Analysis Functions Full Field Texture Recognition continued Your Action Comments After a few seconds or 10 to20 The SLS saves the lighting compensation parameters image acquisitions set the switch to Run Mode Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Dark Object Targeting Light On 3 Setup Teach Mode ight Object Set the lower four function SW1 and SW4 should be off and SW2 and SW3 should be on switches as shown to enable the Full Field Texture Recognition function Full Field Texture Recognition High Speed sw swe Function Select SW3 See Function Table SW4 Set the operating mode switch to Setup Teach Mode Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Targeting Light On Setup Teach Mode Bright Object Begin moving the object The SLS learns the recognition si
96. on of the Allen Bradley Company is prohibited 1991 Allen Bradley Company Chapter 1 Table of Contents Title introduction Smart Linear Sensor Chapter Objective d6 strat bie pase waded cndon Bat User Manual Objective 0 5 User Experience idn Kana ain dad wae eu Oa cee eet Smart Linear Sensor Product Overview SUS Hardware pana an data eee cis eee ous SLS HOUSING 24ce geencceedieiak rene teeta LENS tenbide dee naan ae aes ee eee ha GA LA POWerSUDDIIGS akan ete aeek Cables kaa tact Gate AN ie oh NG et Optional Configuration Support Software Aree oo er os es os es a I Mi WI VIT WIT W WO NO ma SLS Access Panel Chapter Objective nwala seed aes SLS Access Panel Overview 00 255 Configuration Switches 02 0 05 Setpoint Adjustment Controls LEDs Hardware Connection and Powerup Check Chapter Objective 0 00022 Cable Connections SLS Quick Start Operation Chapter Objective 1 ca paaa AG NEGA ee kaees Quick Start Setup and Checkoit Staging SLS Performing Run Operation Power Supply 2801 P3 P4 a Connecting to ACPower Source Connecting DC Cable Xp a Nka RG Powerup Check lt tacs sass pana pdn ee ewes cated Focusing and Aiming SLS Setting Configuration Switches Performing Teach Operation
97. open Chapter 2 SLS Access Panel LEDs 2 7 The seven LEDs signify the operating status of the sensor Figure 2 3 shows the LEDs and the labels as they appear on the access panel nameplate Figure 2 3 LEDs Operational Status Functions Image Brightness Level Green Bright Light Level Red Low Light Level Insufficient Object to Background l Contrast FaultError Condition Output A Active Output B Active HE Operating Duty Cycle Green Maximum Speed Red Waiting for Trigger gt Green Steady Remotely Configured Flashing Communicating Here is a brief explanation of the labels alongside each LED Image Brightness Level Solid green indicates that the image is bright enough for the SLS to use a short exposure time Solid red indicates that the image is so dim that the SLS must use a long exposure time A mixture of red and green orange indicates that the image is somewhere between bright and dim In practice the image should be bright enough so that the Image Brightness LED ranges from orange to green e Insufficient Object Background Contrast When it is on red this LED indicates that the contrast between the object to be inspected and its background are not sufficient for the SLS to inspect the object When the LED is off the contrast is sufficient pr Chapter 2 SLS Access Panel ata EE ggg I rr r LEDs continued Fault Error Condition When it is on
98. our function SW1 SW3 and SW4 must be off and SW2 must be on to switches as shown enable the 1 D Object Recognition function 1 D Object Recognition pos L J ae High Resolution High Speed Swi sw Function Select SW3 See Function Table SW4 Set these mode switchesas Object trigger lighting remote configuration outputs and required for your application speed resolution Refer to Chapter 2 for information Chapter SLS Analysis Functions noe 1 D Object Recognition continued Set the operating mode switch to Setup Teach Mode Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Targeting Light On Setup Teach Mode Bright Object The SLS learns the lighting compensation parameters and the object s signature in a few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each high to low transition of the trigger signal to learn these parameters After a few seconds or 10 to20 The SLS saves the lighting compensation parameters image acquisitions set and object signature switch to Run Mode Confiquration Switches Off 0 On 1 Targeting Light Off Run Mode Dark Object Targeting Light On Setup Teach Mode ight Object The SLS can now begin operating in the run mode during which it acquires images according to the trig
99. p Error Indications 3 7 6 1 Standoff Distance Determination 6 2 6 2 J1 Specifications Strobe and Analog Outputs 6 4 6 3 J2 Specifications Trigger Input and Discrete Outputs 6 5 6 4 J3 Specifications RS 232 I O and 24 VDC Outputs 6 6 B 1 High Resolution vs High Speed Mode B 4 Chapter Chapter Objective User Manual Objective User Experience 1 Introduction Smart Linear Sensor The objectives of this chapter are to introduce you to the Allen Bradley 2804 SLS1 SLS2 Smart Linear Sensor and to explain the overall objective of this manual The objective of the Smart Linear Sensor User Manual is to provide the information and procedures you need to prepare your Smart Linear Sensor SLS for inspection applications The user manual is intended to complement the instruction sheet included with the SLS The instruction sheet may be sufficient for those who have experience with machine vision or whose applications are fairly simple Chapter 2 introduces you to the SLS access panel Chapter 3 steps you through the procedures for connecting the signal and power cables powering up the SLS and checking the SLS operational status Chapter 4 steps you through a quick start procedure which uses a simple example to show you the basic steps for setting up and using the SLS At the same time you can check the SLS in operation Chapter 5 describes th
100. peed The SLS learns the size of the ideal object During the 2 D Object Size Run function the SLS compares the size of all inspected objects with the size of the ideal object NOTE Since the spacing of the image acquisitions must be the same during the Teach function as during the Run function you should move the objects using either the actual conveyor system or a device that can simulate the conveyor rate SW1 SW2 and SW4 must be on and SW3 must be off to enable the 2 D Object Size Run function High Resolution SW1 SW2 SW3 SW4 2 D Object Size Run igh Speed Function Select See Function Table The SLS is now ready to begin comparing inspected objects with its stored reference object and sending the results to the analog and discrete outputs Chapter 6 SLS Site Installation Requirements and Procedures Chapter Objective The objective of this chapter is to describe the requirements and procedures for installing the SLS at its permanent operating site Site Preparation Four site preparation tasks must be completed before you Requirements install the SLS Staging and Installation Procedures Determining FOV Width AC Power If necessary install an AC power source near the DC power supply Be certain that the AC voltage is within the range that the power supply requires DC Power Prepare a mounting platform or surface for the DC power supply Keep in mind that the power supply
101. percentage of FOV regardless of its position along the FOV and locates the center position relative to the FOV as follows 100 of FOV A Inspected Object Object Width amp 35 of FOV Object Center Field of View 50 of FOV 0 of FOV 5 Chapter 5 SLS Analysis Functions 5 Object Width Measurement Note that in the preceding illustration the center of the continued inspected object is located at the 50 of FOV point while in the following illustration it is located at the 25 of FOV point The width of the inspected object however remains the same in each case 100 of FOV Object Center lt Field of View 25 of FOV Inspected Object Object Width k 35 of FOV 0 of FOV When two or more objects are wholly within the FOV the SLS measures the width from the first edge of the first object to the last edge of the last object and locates the center position halfway between the two edges relative to the FOV 100 of FOV Inspected Object Width Objects G 45 of FOV Object Center 55 of FOV 4 Field of View 0 of FOV Since the SLS cannot determine whether the objects in the FOV are several individual objects or are one object with holes voids in it the SLS locates edges in the same manner for either situation Chapter 5 SLS Analysis Functions ag Object Width Measurement When part of an inspected object lies outside the FOV so conti
102. power supplies If you are using a power supply other than the 2801 P3 or P4 follow the power supply manufacturer s instructions for connecting these cables The AC power source connects to the AC terminal block on the power supply as shown in Figure 3 4 Figure 3 4 AC Terminal Block Wiring 115 VAC White Wire NEUTRA R 230VAC Blue Wire 115 VAC Black Wire 230VAC Brown Wire 115VAC Green Wire 230VAC Green Yellow Wire WARNING Before attaching AC power wiring to the power supply 1 Be certain that the wires are disconnected from the AC power source 2 Be certain that the AC power source has a ground connection that conforms to local electrical codes Remove the cover from the AC terminal block For the P3 unit when using standard 3 wire line cord or cable connect the wires as follows 1 Connect the green wire to the GND terminal 2 Connect the white wire to the NEUTRAL terminal 3 Connect the black wire to the LINE terminal Chapter 3 Hardware Connection and Powerup Check 3 5 a RA AAP Connecting to AC For the P4 unit when using a European line cord or cable Power Source continued Connecting DC Cable connect the line cord wires as follows 1 Connect the green yellow wire to the GND terminal 2 Connect the blue wire to the NEUTRAL terminal 3 Connect the brown wire to the LINE terminal Replace the cover on the terminal block Do not apply AC power yet DC power enters the SLS a
103. reases by 12 the combined width of one pin and one void to 78 and the Analog B output delivers less current 78 X 16 4 16 48mA Use the following steps to configure the SLS for the Object Void Measurement function Your Action Comments Set the lower four function SW1 SW2 and SW4 must be off and SW3 must be on to switches as shown enable the Object Void Measurement function Object Void Measurement High Speed High Resolution swi sw2 a Function Select SW3 E a See Function Table swa E Set these mode switchesas Object trigger lighting remote configuration outputs and required for your application speed resolution Refer to Chapter 2 for information Chapter 5 SLS Analysis Functions 5 16 Object Void Measurement continued Set the operating mode switch to Setup Teach Mode Configuration Switches Off 0 On 1 Targeting Light Off Run Mode Targeting Light On Setup Teach Mode 3 Bright Object The SLS learns the lighting compensation and other parameters in a few seconds when the triggering mode switch is set to Level Triggered and the trigger input is low When the switch is set to Edge Triggered the SLS requires 10 to 20 image acquisitions one for each high to low transition of the trigger signal to learn the parameters After a few seconds or 10 to20 The SLS saves the parameters image acquisitions set switch to Run Mode Confiquration Switches Off 0 On
104. red this LED indicates a lighting compensation error a configuration error or a changed switch setting while the SLS operates under the control of a downloaded configuration Chapter 3 Hardware Connection and Powerup Check explains these conditions in more detail Normally the LED is off Output A Active Output B Active When one of these LEDs is on yellow it indicates that the corresponding discrete output is closed active that is current can flow in the circuit to which the output is connected Conversely when the LED is off it indicates that the discrete output is open and current cannot flow NOTE The term Active always refers to the LED being on and the output closed Operating Duty Cycle When it is green this LED indicates that the SLS is operating at or near its maximum rated speed When it is red the LED indicates that the SLS is waiting for a trigger signal When it is some shade of orange the LED indicates that the SLS is operating at less than its maximum rated speed e Communication When it is on green this LED indicates all of the following conditions The remote configuration switch is set to enable The SLS is using a configuration downloaded from the optional SLS Configuration Support Software The SLS is controlled by the settings specified in the downloaded configuration The SLS is ignoring the physical switch settings When it flashes brief
105. s a 6 inch FOV and the first edge of the object must be 1 5 inches from the start of the FOV You will use the analog A output to determine the position of the first edge along the FOV The analog A reading at the start of the FOV is always 4mA and the reading at the end of the FOV is always 20mA thus the range across the FOV is always 16mA Since the first edge position in this example must be 1 5 inches from the start of the FOV using the following formula Output Yo Output mA 100 x 16MA 4mA the meter will indicate a reading that corresponds to the 25 of FOV point Thus the meter should read 8mA if the first edge is exactly where it should be Ifit isn t you can reposition the SLS until the reading is exactly 8mA then tighten the mounting fasteners hig Chapter 6 SLS Installation Requirements and Procedures Table 6 1 Standoff Distance Determination FOV Width vs Standoff Distance Standoff Distance Inches mm Standoff Distance FOV Width inches mm FOV Width Inches mm Inches mm Standard Lens Wide Angle Lens 2804 NL1 2804 NL2 3 76 8 3 211 4 102 10 2 259 5 127 12 1 307 6 152 14 0 356 7 178 15 9 404 8 203 17 8 452 9 229 19 7 500 21 6 549 StandardLens Wide Angle Lens 2804 NL1 2804 NL2 52 7 1339 77 6 1971 102 6 2606 ee ee 11 279 20 508 30 762 40 1016 50 1270 60 1524 70 1778 80 2032 90 2286
106. s your PC to perform mathematical calculations faster than the same PC without a coprocessor An EGA or VGA graphics adapter This enables your PC to display images in color with greater resolution A printer This enables you to print hard copies of reports Chapter Chapter Objective SLS Access Panel Overview 2 SLS Access Panel The objective of this chapter is to describe the functions of the SLS access panel As shown in Chapter 1 the SLS access panel is located under a protective cover on one side of the SLS housing Here are the components included on the access panel Configuration Switches These are 12 switches in a dual inline pack DIP They select the operating parameters and inspection function for your SLS application s Setpoint Adjustment Controls These are two screwdriver adjustable controls They set the point at which inspection results change the state of the discrete outputs e LEDs These are seven LEDs They signify the status ofa number of parameters during SLS operation Configuration Switches As noted above the configuration switches are arranged ina 12 switch DIP package on the access panel Figure 2 1 shows the functions assigned to each of the 12 switches Figure 2 1 Configuration Switches Off 0 Targeting Light Off f Run Mode Dark Object Level Triggered Normal Lighting f Remote Conf Enable Outputs N O High Resolution swi sw2 sw3 swa
107. screte outputs open Appendix B Reference information Invert Discrete Output B Disable Lighting Compensation Power Loss Recovery When an SLS Series B only is connected to a personal computer using the SLS Configuration Support Software CSS the SLS can be configured to invert the output from discrete output B This function can be used as described in the discussion of Set Point Methods Thus when the discrete output would normally be open because of the setting of the Outputs N O Outputs N C switch inverting the output causes it to be closed When an SLS Series B only is connected to a personal computer using the SLS Configuration Support Software CSS the SLS can be configured to disable the automatic lighting compensation function in order to accommodate special lighting situations such as backlighting Generally you would first enable the lighting compensation long enough to permit it to adjust to the existing luminance level then disable it to prevent further automatic adjustments from occurring when intended or unintended changes occur in the background luminance level One example is to disable lighting compensation when using bright backlighting so that the background luminance reaches saturation This intensifies the contrast between the object and the background and enhances the edge detection capability of the SLS Another example is to disable lighting compensation in order to accommodate
108. shold After the SLS has been configured with one of the binary object functions the binary threshold can be adjusted using the View Image option the Configure option version in the CSS When the proper threshold setting has been achieved itis transferred to the appropriate configuration record for subsequent downloading to the SLS The Binary Object Size function measures the cumulative size of all objects dark or light whichever is selected in the FOV Thus if three dark objects are in the FOV and they measure 15 20 and 25 of the FOV the SLS returns a binary object size of 60 The Binary Object Count determines the number of objects dark or light whichever is selected within the FOV The outputs reflect the object count on the basis of a fixed maximum of 50 Thus if 10 objects are in the FOV the SLS returns an object count of 20 5 38 Chapter 5 SLS Analysis Functions Parts Counting This analysis function enables the SLS to count objects parts moving on a conveyor belt or similar device Two or more objects can be in the FOV at the same time but cannot contact each other The SLS must be positioned so that the FOV spans the conveyor at right angles to the direction of movement Two function switch settings are required One is for teaching the parts counting parameters and the other is for performing the actual parts counting During the Parts Counting Teach function the SLS learns th
109. sition mode Set point methods invert discrete output B Disable lighting compensation Covers on J2 and J3 connectors Power loss recovery Grounding Use these three steps to focus the SLS 1 Measure the distance to the inspected object 2 Set the focusing ring 3 Lock the focusing ring Step 1 Measure the distance between the front plate of the lens assembly to the inspected object as shown in Figure B 1 below Fi ure B 1 Measuring Distance to Inspected Object Inspected Measure this distance B 2 Focusing SLS continued Exposure Time Cycle ime and Lighting Compensation Appendix B Reference Information Step 2 Loosen the three locking screws on the focusing ring until the ring turns freely Then turn the ring until the front plate to object distance that you measured in Step 1 is aligned with the index mark on the front plate For example if your measured distance is 13 inches 0 33M set the focus ring so that the index mark is about halfway between 14 and 12 as shown in Figure B 2 below Fiqure B 2 Lens Focusing Details Index Mark Focusing Ring Locking Screw Step 3 Lock the focusing ring by carefully tightening one of the three locking screws Use a small screwdriver such as the one supplied with the SLS Do not over tighten Exposure time is the period during which the linear sensor element in the SLS accumulates light from the image area includi
110. t connector J1 through one the cables listed in Table 3 1 Two wires in the cable connect to the DC terminal block as shown in Figure 3 5 Figure 3 5 DC Terminal Block Wiring Green Wire from J1 Pin 3 Red Wire with White Tracer from J1 Pin 1 24V Note that the terminal block provides four connection points Ke both 24VDC and common COM Connect the wires as ollows 1 Remove about one half inch of insulation from the red wire with the white tracer from J1 pin 1 2 Remove about one half inch of insulation from the green wire from J1 pin 3 Insert the red wire with the white tracer into any connection point labeled 424V oo NG Tighten the screw to clamp the wire securely 5 Insert the green wire into any connection point labeled COM 6 Tighten the screw to clamp the wire securely Observe the orientation of the polarizing keys on the cable connector then carefully align the cable connector with connector J1 on the SLS Turn the collar to engage the aan on J1 then tighten the collar Avoid using excessive orce 3 6 Chapter 3 Hardware Connection and Powerup Check Powerup Check After connecting the AC and DC cables to the power supply check the AC power source then perform a powerup check on the SLS to verify that it initializes properly CAUTION Before applying AC power Be sure that the source voltage lies within the range appropriate for the power supply For th
111. t somehow remained in the cutting fixture In this case the gear s signature is not like the stored signature Object Width 50 of FOV 100 of FOV Inspected Object Finished Gear Field of View gt 0 of FOV Object Width and Finished Gear Signature N Ss es Se f EE WC S Since the gear s signature is not like the stored signature the percentage of match is now 30 At the Analog A output the current is 30 of the difference between 4mA and 20mA or 8 8mA As a consequence the grinding equipment is not be instructed to cut the gear thereby averting likely damage to both the gear and the cutting wheel At the Analog B output the current remains 50 of the difference between 4mA and 20mA or 12mA Chapter 5 SLS Analysis Functions 1 D Object Recognition continued 5 23 Example 2 In this example the SLS uses the 1 D Object Recognition function to inspect the pins on an 8 pin connector and verify that all eight pins are in place If the pins are all there the connector will be allowed to continue to the next assembly process if not the connector will be rejected Object Width 90 of FOV 100 of FOV 8 Pin Connector Signature of Ideal Connector LEA Ea Ea ET EES CET HA PU 8 Pin Connector Signature of Defective Connector FH EH EX BEA Ea OES Ed Chapter 5 SLS Analysis Functions 5 24 1 D Object Re
112. th measurement result can range from very narrow greater than 0 of FOV to very wide less than 100 of FOV You can adjust a setpoint control to switch the corresponding discrete output at any point from 0 and 100 In Figure 2 2 the circular wedge shape indicates that turning a setpoint control clockwise CW increases the percentage of measurement range and vice versa Figure 2 2 Setpoint Adjustment Controls Here s an example Suppose that you ve configured the SLS to perform one dimensional spatial measurements Specifically you re interested in monitoring the location of the first edge of an object If the edge moves beyond the 40 of FOV point you want an alarm to be activated Suppose further that you ve selected the Outputs N O mode for the discrete outputs The SLS sends first edge results to discrete output A In this example you want discrete output A to remain open so long as the first edge location does not extend beyond the 40 point and close if the edge extends beyond that point To accomplish this you would adjust setpoint control A so that discrete output A closes when the edge location passes the 40 point In a practical situation you could perform that adjustment by moving the object s edge to or just beyond the 40 point then adjusting control A slowly to avoid overshooting until output A closes When you move the edge back below the 40 point output A should
113. tion as during the Run function you should move the objects using either the actual conveyor system or a device that can simulate the conveyor rate When all objects have crossed SW1 SW3 and SW4 must be on and SW2 must be off to the FOV set the lower four enable the Parts Counting Run function function switches as shown Parts Counting Run High Speed High Resolution SW1 Sw2 Function Select sw3 See Function Table SW4 The SLS is now ready to begin counting objects and sending the results to the analog and discrete outputs Chapter 53 SLS Analysis Functions 2 D Object Size 5 45 This analysis function enables the SLS to evaluate the two dimensional size of an object moving across the FOV by comparing its size with the size of a learned ideal object stored in the SLS memory Two function switch settings are required One is for teaching the object size parameters and the other is for performing the actual object measurement During the 2 D Object Size Teach function the SLS learns the size of an ideal object by acquiring multiple images as the object moves across the FOV at right angles The Analog A output remains a 4mA until the object has crossed the FOV then it indicates 50 of the full scale The Analog B output indicates the object s width at the instant of each image acquisition thus it is likely to change as the object moves across the FOV During the 2 D Object Size Run f
114. ts memory learns for use with those analysis functions that perform comparisons Run Function The Run function is the second of the two switch selections required when configuring the SLS for the parts counting or two dimensional object analysis function The first switch selection is the Learn function When performing the Parts Counting Run function the SLS compares the size of each object it inspects to the size of the stored reference object then counts the number of objects having the correct size When performing the 2 D Object Size Run function the SLS compares the size of each inspected object to the size of the stored reference object then reports the percentage of match to the reference object Appendix Definition of Terms Definition of Terms continued A 3 Run Mode When the Run Mode Setup Teach Mode switch is set to the run mode the SLS inspects measures or compares the inspected object according to the selected analysis function Setup Teach Mode When the Run Mode Setup Teach Mode switch is set to the setup teach mode the SLS accumulates lighting compensation and other parameters This step is required for all analysis functions before operating the SLS in the run mode Standoff Distance Standoff distance is the distance from the inspected object to the front plate of the SLS lens This is the distance used to focus the SLS lens Trigger Source The trigger source is the point
115. u can use both the targeting light and the analog outputs to fine tune the SLS aim so that the FOV lies across the inspected objects exactly where it is required Check the position of the ideal object in the image area It should be in the optimum position for your intended application Turn off any light source that you are using to illuminate the inspected objects If the image field is still quite bright because of high ambient light you may need to shield it before performing the next step Set the targeting light switch to on and aim the SLS so that the line of light that is the FOV lies across the object as required for your application NOTE After being turned on for two minutes the light will automatically turn off to avoid overheating To turn the light on again wait a few moments to allow the light to cool Turn the switch to off then on again Tighten the SLS mounting fasteners then turn off the targeting light Turn the light source on again To verify the aim using the analog outputs configure the SLS for 1 D Spatial Measurement by operating the SLS in the setup teach mode for a few seconds then operating in the run mode Use the appropriate triggering and object color mode Connect the analog A output line to an accurate milliammeter and look at the reading The reading will show you exactly where the edge of the object is in the FOV Example Assume that your application require
116. unction when an inspected object moves across the FOV the SLS calculates the object size then calculates the value to be placed on the Analog A output using the following formula Measured Object Size 2 x Taught Object Size The Analog B output is the same as during the Teach function Analog OutputA Before the SLS learns the object size parameters it must learn lighting compensation parameters using the 1 D Spatial Measurement function With the ideal object positioned in the FOV as shown in the illustration below and the operating mode switch set to setup teach the SLS learns the lighting compensation parameters within a few seconds 10 to 20 image acquisitions 100 of FOV Stationary Ideal Object Field of View gt 0 of FOV Object P Chapter 5 SLS Analysis Functions aa E AA AA E E EEE 2 D Object Size When the operating mode switch is set to run the SLS continued saves the lighting compensation parameters in its memory The analysis function switches are then changed to the 2 D Object Size Teach function and the ideal object removed from the FOV Teach Function The 2 D Object Size Teach function is a separate function switch setting whose purpose is to enable the SLS to learn the size of the ideal object NOTE During the Teach function the spacing of the image acquisitions must be consistent Thus if the conveyor moves at an unvarying speed t
117. unction must be the same as their rate during the Teach function unless synchronized triggering is used as mentioned earlier Note that more than one object can occupy the FOV at any given time The spacing must be sufficient for the SLS to acquire at least one image in the gap between objects at the applicable rate of movement 5 42 Parts Counting continued Chapter SLS Analysis Functions Example Here is an example application that uses the parts counting function to count bottles in a carton The objective is to determine whether the carton has 12 bottles in it by counting the bottle caps If not the process equipment rejects the carton and resets the SLS part count Since the SLS part count must be reset when a short count occurs this example requires level triggering and consequently requires a constant speed conveyor system 100 of FOV Bottle Caps Direction of Object Motion Field of View gt 0 of FOV Carton Objects in FOV es ty ey During the Teach function the SLS learns the size of an individual bottle cap and the count number 12 During the Run function the SLS counts three objects at one time Thus when the first three bottle caps cross the FOV the analog output current increases by 25 of the difference between 4mA and 20mA to 8mA When the second three caps cross the FOV the current increases to 12mA This continues until all 12 bottle caps have crossed the
118. unctions Chapter Objective The objective of this chapter is to show you the details of the SLS analysis functions Analysis Functions An analysis function determines the operation of the SLS for a specific application You can configure the SLS with any one of the analysis functions selectable in the lower four configuration switches two of these functions require two switch selections one for learning and one for running After being configured the SLS can acquire an image of the object to be inspected or measured analyze the image according to the selected analysis function and issue the inspection measurement results on its analog and discrete output lines Results always appear as a percentage For example object width results appear as a percentage of the field of view FOV while texture recognition results appear asa percentage of likeness to a previously learned object This chapter provides detailed descriptions of the analysis functions listed in Table 2 1 and provides simple application examples to help you understand them All illustrations used with these descriptions show a vertical FOV orientation with the inspected object s positioned across the FOV as shown in Figure 5 1 Figure 5 1 Field of View Orientation Field of View Smart Linear Sensor 100 of FOV Inspected Object 0 of FOY 7 Start of FOV The FOV is vertical when the SLS is positioned as shown in Figure 5 1 The
119. urn off the light source Observe the LEDs Turn on the light source again Without disturbing the SLS block the light entering the lens Comments This forces the SLS to use its lighting compensation The LEDs should now appear as follows 7 image Brightness Level Orange orRed Green Bright Light Level 7 Red Low Light Level KO Insufficient Object to Background 9 Contrast 3 Output B Active Operating Duty Cycle Green Maximum Speed Red Waiting for Trigger SA Green Steady Remotely Configured Flashing Communicating Color depends on room light level Note that the brightness LED may now be orange or red This color change is likely to occur when the light level is reduced The dimmer the room light the more red the LED becomes The orange color effect occurs when the LED transitions from solid green to solid red The other LEDs should remain the same as they were before you turned off the light The brightness LED should turn green again This once again forces the SLS to use its lighting compensation function This time however the SLS will not be able to compensate for such a large change in light level 5 Chapter 4 SLS Quick Start Operation 4 1 Performing Run Operation continued Your Action Comments Observe the LEDs The LEDs should now appear as follows Image Brightness Level Green Bright Light Level Red Low Light Level LI Insufficient Object to
120. witch This instructs the SLS to operate at its highest speed as to High Speed opposed to its highest resolution For the quick start operation this setting doesn t matter Configuration Switches Off 0 On 1 Targeting Light On Setup Teach Mode Bright Object Edge Triggered Strobe Lighting Remote Conf Disable Outputs N C High Speed Targeting Light Off Run Mode Dark Object Level Triggered Normal Lighting Remote Conf Enable Outputs N O High Resolution pr Chapter 4 SLS Quick Start Operation Setting Configuration Switches continued Your Action Comments Set the four function select This setting instructs the SLS to perform the 1 D Spatial switches SW1 4 tothe Measurement function which looks for the first and last Off O position edge of the object within the sensor s field of view The SLS is now operating in the setup teach mode A few seconds of operation is all that is necessary for the SLS to earn the parameters In the level triggered mode with its J2 trigger input open or high the SLS acquires images continuously at the maximum rate swt MOI aen mfa Eee sw3 SW4 See Function Table Turn the two setpoint controls This initializes the setpoint settings for the purposes of the to the mid point of their ranges quick start operation Performing Teach Operation During the run mode the SLS performs the inspection measurement or control task for which it is co

2804-ND001, Bulletin 2804 Smart Linear Sensor User`s Manual

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