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1. Keyence offered a demonstration of their package which was arranged and completed Friday the 15 of February Keyence s vision package looked promising at that time as it offers a multitude of capabilities During the demonstration the Keyence vision system s potential was clear and it became apparent that this system would provide a viable solution After establishing a promising cost analysis discussed later a formal recommendation was made to Continental Data label to purchase the Keyence vision system The purchase order consisted of two cameras one color and one monochromatic the controller and lens protectors The system was delivered and installed during the week of the 23 of March The vision system operates by capturing images of the web and then scanning those images for errors by running any combination of available inspection checks The controller has a very robust output capability as there are multiple input output lines that can be used to alert the operators in a number of ways or eventually be implemented into a feedback control system When the user set error threshold has been exceeded the system provides three outputs The first output consists of a simple visual ok no go display on a monitor The second output features an analog on off 12 signal The final output involves a 16 bit ribbon cable which allows for the transmission of a set of predefined user calibrated variables 4 5 Software Th
2. Workflow for Programming 1 2 P oo Create new program for specific product 10 up 20 up red or blue pg 1 oet up cameras that are in use by the system and adjust their shutter speeds focus and aperture to achieve a crisp clear image pg 3 Register example images on which to base future measurement windows pg 8 Create measurement window that adjusts for camera or product movement pg 10 Create measurement window that sets a tolerance for the amount of white pixels in the logo print pg 18 Create measurement window for both the horizontal die cut edge and an edge on the bar print pg 30 Create a calculation window that measures the distance between the aforementioned edges and sets a tolerance for this distance pg 41 Create additional calculation windows to establish a warning mode when either error has reached a certain percentage of its maximum threshold in this guide we use an approximate 60 tolerance level as an example pg 44 The overall goal is to have a program running that will output Screen output Light and buzzer output No errors Green OK Green Circles None for each type of error At least one type of error Flashing Red NG Red Flashing exceeds the warning circles for specific error At least one type of error Constant Red NG Red Constant exceeds the total circles for specific error Note Pages numbers referred to throughout this guide correspond to the Keyence User
3. MEN oom Limits Area Upper 511 479 F Save ay S g E 3u SCR Select Screen FNC Function Henu FNC Select image MENU More Options 1 9 Select Color to Binary The Color menu appears A 24 F C 3000 Series PC Simulator AndyC As Advertised 7 Selection E Center Hue Saturat ion As Advertised 7 Brightness i z 4 SCR Select Screen FNC Function Henu PNG Select image MENU More Options 20 Use the Pick tool to choose all of the colors on the product We want to choose the colors to stand out against the erroneous colors the white in the misalignment region In this example we selected the dark and light blue colors 7 C 3000 Series PC Simulator AndyC Color Type Color to Color to Binary w Color to Binary w As Advertised 7 EIER Back Black v Sens eee Selection L Center Hue Saturation As Advertised 4 Brightness 159 147 175 Detail Pe coe HELP a L L SCR Select Screen FNC Function Menu FNC Select image MENU More Options A 25 Cv 3000 Series PC Simulator AndyC Color Type Color to Binary w Hue z Saturation As Advertised 7 Brightness 152 132 203 P coe HELP oy 5 y SCR Select Screen FNC Function Menu FNC Select image MENU Hore Options 1234 21 Once the colors have been correctly distinguished from the erroneous colors save your specifi
4. Window menu and choose the Pos Adj menu F c 3000 Series PC Simulator AndyC 7 Prog002 Andy Try 2 amp Utility Display Global Edit Position Adjustment xYo Me Camera am aa Camera 1 001 Pattern search All windows Camera 2 None i Register g Camera 3 None Camera 4 None X Calc g Output 511 479 M Save F SCR Select Screen NC Function Menu FNC Select image X MENU More Options 24 In the Position Adj menu select a camera to be used for position adjustment 25 In Position Window select a window that will be used to adjust the inspection window s position In our case this will most likely be the pattern search window A 16 7 C 3000 Series PC Simulator AndyC t Prog002 Andy Try 2 S Utility Display A Global Edit F Camera 1 Position Window X Y O Inspection Window IENEUESS4 m murio es ww v Yv 511 479 Cance SS S d r E 35 SCR Select Screen FNC Function Henu NG Select image X MENU More Options 26 Select the items for which you want to perform adjustments and checkmark the box for each item Choose X Y and 0 X Adjusts position along the horizontal X axis Y Adjusts position along the vertical Y axis 0 Adjusts the horizontal X and vertical Y axes by Odegrees af Select All windows under Inspection Window 28 After completing the settings select OK m C 3000 Series PC Simulator
5. ate D GP utet Dutput me view View Bar Zoom in out Change display view MENU Hore Options F C 3000 Series PC Simulator AndyC Prog00 Andy Die Cut Rrutility Display Global Calculation C000 Diesrs uie sono E Jdps Ted dE dD pe m C IL 1E Tv ao on xo Crear C000 0000000 000 Standard Trig Geometry Date Time ent img Update base value kcii 1 478 view View Bar Zoom in out Change display view MENU Hore Options 1 Select Measure from the register calculations menu The Select Measurement Value menu appears 2 Under Window No select the window number with the measurement value to be used in the calculation 3 Under Value select the measurement value to be used in the calculation The items displayed vary depending on the items selected 4 Under Type select the type of measurement value to be used in the calculation The items displayed vary depending on the items selected A 42 5 After completing the settings select OK The selected measurement value is input into the register calculation screen Using Measurement Values in Equations F C 3000 Series PC Simulator AndyC F f Select Measurement Value Target No Wn Window No Tyo O W000 Pattern search Base Value O W001 Edge position 9 W002 Edge position Absolute Value O com Judge Value Upper Limit Lower Limit vew View Bar Zoom in out Change display
6. gt Close As Advertised 0 2x P SCR Select Screen FNC Function Menu FNC Select image MENU More Options 1 3 After completing the drawing select Close in the Edit field 1 4 Now we will specify what the actual pattern on the image to search for will be Select Pattern The Pattern menu appears A 13 7 C 3000 Series PC Simulator AndyC Prog002 Andy Try 2 Utility CoDisplay 3 Global Edit W Pattern search Name Pattern search Tool Pattern search Camera Camera 1 Regist Img 1 000 Search Area Heas Win Rotated Rect Mask CHULL Heas Win None cf Pos Adj wask hDI2EIEM Color Color to Gray x Calc Img Enhance Fitter On B Angle 33 000 25 000 raw scrn current img Nc 0 Count 01 Tenplate D0 ut ut 0 0 Parameters gt gt 511 479 Execute Always Execute F Save Limits Count Upper SCR Select Screen FNC Function Menu FNC mL Select image MENU Hore Options 15 Select Edit in the Measurement window field The Select menu appears Cv 3000 Series PC Simulator AndyC Pattern Measurement window As Advertised 7 As Ac Hask window As Advertised 4 Window memory Cance 5 SCR Select Screen FNC Function Menu FNC 4 Select image MENU More Options 1 6 Select the shape ROTATED RECTANGLE then select OK Do note choose regular RECTANGLE or else rotational data wi
7. AndyC Pesos gay Tey aii indem Tot Count Ae NG Cou te Jedi Prog Time mis dans r EN ma dVerised ccc caede eon PESADES That concludes the setup for a basic pattern search and position adjustment Now the machine should be able to track a specific feature of the product and adjust its measurements accordingly Decide what error to scan for A 17 Now we will set up measurement windows that will measure if errors have occurred and if they are of a great enough magnitude to notify the operators The two main types of errors that are encountered currently on the press fall into the categories of Erroneous color Distance between edges We need to set a separate measurement window for each error To measure erroneous colors such as the white that appears when there is a misalignment between the logo and bar print we will use the Area tool To measure the distance between edges we will use two instances of the Edge Position tool Programming the Area Tool 1 Select the Program No to record from the initial settings screen 2 Select Window The Edit Window menu appears Prog000 New000 ie Uti tity Ce Display 3 Global PROG Add Comy Delete Windowz Shift All Windows p Md Copy Delete Simul Larmous iy Shift All Windows ww Vies BarGoos in out Change DI JL JILONMM 1 Wore Options 3 Select Add Copy Del from the Edit Window menu A 18 Prog000 New000 Utility C2 Dise bay 1
8. Calculation C001 Name Flashing Indicator IoC Doe Le 1E Tos TE Jano or ror tear C001 0000000 000 vew View Bar Zoom in out Change display view MENU Hore Options The equation you input will be in the following form Judgement of the warning lower toleranced area tool OR judgement of the warning lower tolerance edge position calculation window Mod Count Flash frequency The Count function is found in the Date Time box and the upper limit of the function is set to 5 In our example the Flash frequency is set to 3 000 You can make the warning indicator flash at different frequencies by adjusting the Flash frequency value and the upper limit of the function s tolerance E cv 3000 Series PC Simulator Andycy 00 os CI xj t Prog001 Andy Die Cut amp Utility RTT X Global Calculation C002 Flashing Indicator Name Flashing Indicator COO JG OR COOU JG Hod CountO 3 000 i Le L5 Ees o p Io Lrest Upper JL Il JLz an or xon ctear C002 0000000 000 view View Bar Zoom in out Change display view MENU Hore Options The way that this function works is that when both errors have not exceeded the warning level a logical 0 will be multiplied against the rest of the function The function will activate however when either error breaches the warning tolerance sending a logical 1 to be multiplied against the Modulus functio
9. Edge pitch Edge counting view View Bar Zoom in out Change display view MENU Hore Options 7 C 3000 Series PC Simulator AndyC m mma Heasurement window Heasurement window Rotated Rect As Advertised mm As Aq AS Advertised view View Bar Zoom in out Change display view MENU Hore Options Remember that even though we are trying to check the distance between the die cut and the top of the bar print it is often more convenient to take the 2 edge measurement from the bottom of the bar print since sometimes the die cut perforation and the top of the bar print will overlap Adjustments to the tolerances can then be made accordingly in the next step where we calculate the distance between the edges A 40 E cY 3000 Series PC Simulator AndyC S 151 xl Adding Calculation Windows We need to add calculation windows that measure the distance between the two edge pairs Later we will add additional windows for the warning calculation t Prog001 Andy Die Cut amp Utility Display X Global Edit Calculation Add Copy Del X vew View Bar Zoom in out Change display view Mew Hore Options A 41 F C 3000 Series PC Simulator AndyC Prog001 Andy Die Cut Se Utility gt Display A Global Edit Calculation Add Copy Delete Calc Window Copy Delete m Window Add Calc Window Calc Window Number D00 x NEN sm filtered scrn current img Temp
10. Global Edit j Edit Winco Add Cooy Delete Windars Shift All Windows hdd md Camera Add Copy Del LOP Delete gt Register Simultaneously Shift All Windows CWindow ww tioy Bar ooe in out Change fisplay view More Oetions 4 select Add The Add Window menu appears 5 Select Window Number then specify the measurement window number Window numbers can be freely set at any value from 0 to 127 Prog000 New000 frutie Coil A Qlobal Edit Edit Winder 4dd Copy Delote Windae Shift All Windows Add Copy De hdd i Camera Copy z Delete r Register Simaltaneously Shift All Windows Add Window Window af Pos Adj fe VEW tice N25 in out Change ficnlav vice WA Moro Ontions 6 Select Measurement tool and then select Area rj Select OK The necessary settings for the Area window are added next 8 Select Window and then select an area measurement window The window setting menu appears A 19 Prog000 New000 f Utility Ce Display 3 Global 1 008 Aros LL IeL C Execute Limits ew View Dor Goos in out Chanzve dineplay view Woro Oetions 9 Select Camera then select a camera to take images Prog000 New000 Br Utility TS Disa bay Global Edit EU MILL Eo Rd B 1 JU Wi mL 5 nba n Execute Linits ww Vie BarGoos in out Change display view More Oetions A 20 digo Unt Ht Br Uti tity rh Disp lay 17008 Ares Execute Lini
11. The Above figure displays the intensity level selected in the Select Detection Conditions of Edges menu and the highest contrast if Regist Img is selected Display graph must be set to something other than OFF to show A 37 this when Current Img is selected The graph shows the intensity of the edge and how well the computer is picking out the edge from the rest of the sheet If the intensity is too low for the computer to recognize the edge you might want to play with using image filters until you find one that correctly highlights the edge 4 Select Edge Dir and then select the contrast change that will signify an edge Lght to Drk 2nd scan Default Detects an edge that changes from a bright area to a dark area Drk to Lght 1st scan Default Detects an edge that changes from a dark area to a bright area both Detects edges that change from a bright area to a dark area or from a dark area to a bright area BEZTES Dl Select Detection Conditions of Edges Display Image Regist Img Direction __ i Scan Dir Forward ua M AS Advartiseq Edge Dir Start Angle 000 000 Edge Strength Edge Sensitivity As Advertised Edge Filter Width Upper Edge Intensity Lower Edge Intensity 005 00 Counting Options Primary Target Count Angled Edge Det OFF 123 5 Choose both E cv 3000 Series PC Simulator Andycv E AEE Select Detection Conditions of Edges Display Image Regist Ing w I
12. arrow s direction is PERPENDICULAR to the edges If the arrow is parallel to the edges it will be unable to detect the edges 1 3 After completing the drawing select Close in the Edit field F C 3000 Series PC Simulator AndyC ams Heasurement window Heasurement window Rotated Rect As Advertised Wask window As Aq AS Advertise Window memory 0 9 HELP VEW View Bar Zoom in out Change display view X MENU Hore Options Note If you are using a monochrome camera for edge detection You probably are you do not need to worry about extracting the color in the next few steps Select Color The Color menu appears Select all of the colored areas until there is a clear difference between the two edges you are measuring A 35 7 C 3000 Series PC Simulator AndyC Color Type Color to Gray w As Advertised As Aq Selection Center As Advertised Ley m Saturation Brightness 159 145 174 Detail Pm taco HELP VIEW View Bar Zoom in out Change display view vew Hore Options 7 C 3000 Series PC Simulator AndyC Color Type Color to Gray w A gl A Omit Auto Sens Area Selection E Center Hue 156 162 Saturation 142 148 Brightness 1 177 Detail Copy EET HEL view View Bar Zoom in out Change display view fenu Hore Options Now we will specify conditions for edge search including search direction and edge direction 1 Selec
13. flash when the edges have reached 60 percent tolerance The Total Status dialogue controls the overall status icon that shows the red NG or the green OK in the upper right hand corner of the screen when the system is running This also controls the signal of the OR output in the output terminal of the Keyence CPU So once this program is complete you can simply attach an external warning beacon s input to the OR terminal and the beacon will correspond to the OK or NG indicator on the screen A 46 APPENDIX B B 1
14. in Figure 4 11 are already in operation on some of Datalabel s other presses and can readily connect to the Keyence computer s 24 volt programmable output de e c Saee I di Ba f E Figure 4 11 Allen Bradley Stack Lights with Optional Buzzer Attachment Due to their circular nature size and overall brightness the stack lights will be able to provide a long distance 360 degree visual indication of the status of the press For example the company 20 desires no signal to represent OK a flashing red light to being within the tolerance but approaching NG and a constant red light to ERROR The warning mode is established in section eight of the Operations Manual found in Appendix A On top of this an industry approved low pitched buzzer can be attached to the light stack to quickly alert the operator to error production even if he or she is focusing on another visually intensive part of the press Below in Table 4 2 is the overall alert output that has been programmed for this vision system Screen Output Light and Buzzer Output At least one type of error exceeds the Flashing Red NG Red circles for specific error Flashing warning tolerance At least one type of error exceeds the Constant Red NG Red circles for specific error Constant total tolerance Table 4 2 Alert Outputs 4 ECONOMIC ANALYSIS The following is an
15. in step 1 select OK NOTE Select Auto to automatically make the correct settings for the currently connected camera After changing the camera type save the settings then restart the device Specifying a Trigger for each Camera Trigger The trigger can be individually set for each camera 1 Select the camera port Camera 1 Camera 4 that you would like to configure the Individual Camera Settings for The Individual Camera Setting menu appears 2 Select Trigger The Trigger menu appears ProgO00 New000 MrUtitity CQdisplay Camera Specs Fu 512x4Hl Color Ir ioonr 1 60 16 67 aoc Register VEW View Bar 7ooe in out Cange EIL 1 711 2M BM CR Options 3 Select a trigger to be used as the camera input trigger then select OK f the global setting screen update mode Page 7 9 is Continuous trigger 2 cannot be used If this is the case trigger one will activate all cameras regardless of their trigger settings e If at least three color megapixel cameras CV 200C CV S200C are connected the cameras should be divided between trigger 1 and trigger 2 because one trigger cannot activate all cameras at the same time However by using sequential trigger Page 4 15 trigger 2 can be set to activate immediately after trigger 1 has activated Capturing Images Using External Triggers External trigger 1 Select Trigger from Common Settings on the Camera screen Page 4 6 2 Selec
16. inspection tools come in stock with the Keyence vision package and alone should allow for real time detection of any print alignment errors occurring in the process The next area of concern as discussed before is the die cut registration This involves the stage where the horizontal cuts are made that separate each label from the next To maintain consistent label dimensions each horizontal cut should be aligned with the top of the printed bar Thus an inspection tool must be able to determine if the die cut made to the underside of the sheet lines up with the printed bar Once again the Keyence software package comes with a stock inspection tool to do just this The edge 15 position tool can detect an edge or a line in any of the scanned samples even a line as faint as the die cuts done in the label process The edge position tool works by indicating with two parallel boxes where to look for an edge It then scans that area until a definite color change occurs determined by a user set threshold where it decides that an edge or line has been found Configuration of the tool can be seen below in Figure 4 5 as the boxes are positioned to first detect where the printed bar begins Figure 4 5 Configuration of the Edge Position Tool The system searches for the die cut in a similar fashion but because the color transition 1s more difficult to detect backlights can be used to amplify the die cuts Examples of this backlighting can be
17. menu appears A 33 7 C 3000 Series PC Simulator AndyC Prog001 Andy Die Cut amp Utility Display A Global Edit M00 Edge position Name Edge position Tool Edge position Camera Camera 1 f Regist Ins 1 000 Meas Win None Hask BI MI S J4 by Color None sf Pos Adj Ing Enhance Filter On gt gt Edge Filter are Calc Parameters gt gt B Execute raw sern Always Execute current img Limits Count U Temp ate D0 a Output T Lower en 479 Position dd Lower X Save VEW View Bar Zoom in out Change display view MEW Hore Options 1 0 Select Edit in the Measurement window field The Select menu appears F C 3000 Series PC Simulator AndyC o mmaa Heasurement window H IE rese Circle Oval Ring Window memory Arc 0 9 E Polygon Auto Adj Rect vEW View Bar Zoom in out Change MESI Auto Adj Circle SIZIS 11 Select ROTATED RECT then select OK 1 2 Draw the measurement area See Drawing a Measurement Window Page 3 13 for details A 34 7 C 3000 Series PC Simulator AndyC 29e ams Heasurement window As Advertised As Aq AS Advertised 0 9 VEW View Bar Zoom in out Change display view X MENU Hore Options IMPORTANT THE ARROW SHOULD BE PERPENDICULAR TO THE EDGE The computer will use the arrow in the rotated rectangle box to decide which direction to scan for edges Make sure that the
18. reference image using the PATTERN SEARCH tool 1 Select Add Copy Del from the Edit Window menu Prog000 New000 ft Uti tity Ce Display 8 Global Mdd Cooy Dolote Windors Shift All Windows LODY Delete Simultaneously Shift All Windows SIT NUS in out Change display view More Options 2 Select Add The Add Window menu appears 3 Select Window Number then specify the measurement window number Window numbers can be freely set at any value from 0 to 127 Prog000 New000 ir Utility C2 Display 3 Global PROG Edit Add Cooy Dolote Windars Shift All Windows ime Camera Copy Delete r Register Simultaneously Shift All Windows mw VEW tice BarCloos in out Change ficnlayv vice Wa here Ontions 4 Select Measurement tool and then select Pattern search 5 select OK A window with the specified number is added as a pattern search window The current window setting list is then displayed The necessary settings for the pattern search window are added next 6 select the PATTERN SEARCH window The window setting menu appears Prog000 New000 dr Utility ra Display 3 Global 19008 Pattern search Pattern search LLIeL CM Woas Win None ChLC hC ww View Dor oos in out Change diselay viov Mere Oetions T Select Camera then select which camera to take images A 11 Prog000 New000 uiy Cella Globe ww View Bar ooe in out Change displa
19. scrap rate even further this could be accomplished by attacking the error that results from the wasted time between operator recognition and error correction The addition of automation to the press would be the best way to decrease this correction time and would be possible to implement by using the digital and analog outputs of the Keyence machine vision controller This is the idea behind objective number 12 Control System Realization 25 The control system would be able to detect an error analyze the magnitude direction and type of error feed this information into a digital control program and then output appropriate values to the press s control panel to automatically correct the error that has occurred A digital signal processor or DSP could be used to implement a simple control program The outputs of the DSP could be then connected directly into the control panel of the printing press to allow for automatic adjustments The company originally wished for an automated control system to be implemented as part of the overall solution however since the company has more pressing issues and can save more money by first implementing error recognition systems on other presses Continental Datalabel no longer holds an immediate interest in automation Thus the automation portion of the project has been postponed indefinitely and the student group was asked to provide only a minimal amount of research in regards to the feasibil
20. such as the W logo shown in Figure 1 9 Then the second tower fills in the darker colored bar that both outlines the words As Advertised and provides a hole knockout region for the lighter colored logo to show through The most common registration error noted during our plant trip is the misalignment of the W logo and the dark colored bar shown in Figure 1 10 Color registration errors such as this have been the leading cause of scrap in the production of these labels accounting for nearly 80 percent of total scrap Ww As Advertised As Ad tu As Advertised As Ad Figure 1 9 Stacking Order of Print Layers and Correct Registration As Advertised 77 As Advertisedf 77 d Figure 1 10 Registration Error between Print Stations The second leading cause of scrap in the manufacturing process comes from a misalignment between the printed colors and the cuts that divide the sheet into individual labels To separate the labels small perforations are made across the web and down the center of each sheet It is desired that these perforations are made as close to the top of the dark colored bar as possible without cutting into the bar itself The correct alignment for the die cut perforations is illustrated by the dark red bars in the left half of Figure 1 11 and an incorrect alignment is shown on the right As Advertised As Advertised As Advertised AS Aavertisear Figure 1 11 Correct and
21. the software disregards every color but white and then counts those white pixels within the designated area indicated by the red box les Enhance Filter n Binary Lvl PTT Figure 4 1 Configuration of the Area Inspection Tool 13 Figure 4 2 Area Tool Counting White Pixels Failing NG For this sample too many white pixels have been detected and so this sheet has been failed as indicated by the NG in the top right corner In manufacturing NG is the buzzword for a failed test indicated that the product is no go In the following Figure 4 3 it can be seen that no white pixels are detected within the indicated blue box and so the sample passes the inspection no alignment error is detected and the sample is determined to be acceptable as indicated by the OK Figure 4 3 Area Tool Counting No White Pixels Passing OK In order to use the area tool discussed above the scanning box needs to always fall over the printed logo making sure the correct region is being scanned Thus a landmark somewhere on the image is first needed to reference where the scan box will always be This is where the next tool comes in the pattern recognition tool This tool searches for and detects a specific pattern Once this pattern is found it can then be used as a landmark to reference other scanning tools such as the area tool The pattern recognition tool functions by first storing an image of the desired pattern This sto
22. vetture uidet A reissue putos A ds tuatonaadbted 12 Dy OU A stus ice cce erase deu crear i eL a cadena et eth LSU 13 4 6 Operations MODUS ssseko osea Eee uos tia adere RROA 18 A cd Permanent MOUBLS soas t os EDet e page ebet a uta Te et Denedet ban snes ak J aint Anat Goo ber edet be eei Ue 18 4 5 ARE Output Enhance cme Esa erotica Era M Eton A Ares dest cated 20 2 TE COMOMMCATIALY SIS eucct Sec tisb bolsos osque a E aE 21 O Sensi Mim 24 Jo EREC OIC ndatrons ssa hei Gare tle ail ocr inen nonnul ease al bacc tu e Pda au anie uM ease uM 24 7 1 Mirror Implementation at California Plant eese nennen 24 7 2 Implement Machine Vision on Other Presses ccccccccsescceeseeeseccenecesescesensceeenseeseseeaaees 25 L9 Pp ture Control System AXutoriatiOb 5 1 Peer eeu a ubt bae eer ovatae Dok E Edd 25 dado Il Spo ed DC at IODS sx ono adoner tetuer AA nose uS MS 26 Me LT 21 Appendix A Operations Manual Ad Create New Procrain 2x55 oue dod tpe edebat ential sasecdapauecsshonemmentd e ane A I 227 det OEE T e EE E E EAA A AAA E AT te A 3 ARES ister Example aoe Seeon e a E E taetaieeaens A 8 A 4 Create Measurement Window for AdjUustMent ccccccesecccsescceeeeceeeceeaeeeseneesseneeeeases A 10 A 5 Create Measurement Window for Pixel Tolerance eee A 18 A 6 Create Meas
23. 5 17 0 39318174 4669990 164585 soo 164085 1621706 113596 Table 5 2 Two Camera System with Expansion Unit for Additional Cameras The only difference between Tables 5 1 and 5 2 is the initial added cost of 2 000 for the expansion unit CameraSystem Capitalization Production sheets Production Scrap Savings Maintenance Cash Flow ROI IRR Payback 0 17458 1 0 o 17458 17458 0 104 years BE 38101604 4525499 5 167387 149929 O O 39382204 4677602 50 39382204 4677602 173529 50 OJo eo O O 5 1015076 50 173029 1534164 173029 1707193 9 Table 5 3 Three Camera System l O ce c co N O O Ol C1 9 re 19 59 19 e 8 e os ds 8 ds 8 3s 8 38 6 96 E LB 9 coc ojo ojojo o po 322958 93 PE 4 39382204 4677602 173529 5 669017 96 5 0 39882204 4677602 50 842046 o o pO o pO o 96 6 c O NIR a c O 23 The three camera system follows the same calculations as the two camera system with the exception that it accounts for 100 of total errors 6 CONCLUSIONS The main goal of this project was to incorporate a video monitoring and alert system in order to decrease the overall scrap rate of this printing press from the current rate of 5 5 to at most 2 75 Preliminary research found several developer software packages as well as some potential vision system vendors Due to in
24. CONTINENTAL DATALABEL INC WEB MONITORING SYSTEM DEVELOPMENT Andy Quitmeyer Bryana Yergler Aaron Beal GE 494 Spring Semester 2008 WEB MONITORING SYSTEM DEVELOPMENT Project Team Project Advisor Company Sponsor Company Contacts Andy Quitmeyer Bryana Yergler Aaron Beal Angelia Nedich Continental Datalabel Inc 1855 Fox Lane Elgin IL 60123 Steve Solberg Ron Kassal Brian Zimmerman John Kassal GE 494 Spring Semester 2008 Department of Industrial and Enterprise Systems Engineering University of Illinois at Urbana Champaign ABSTRACT Continental Datalabel manufactures a variety of labels for many commercial and industrial uses One of their leading products is the repositionable adhesive label which is responsible for 3 million dollars of annual profit However the pre existing manufacturing method for these labels includes a scrap rate comprising approximately 5 5 of all raw material costs The press these labels are produced on has inherent flaws that cannot be easily corrected Quality control originally consisted of human inspection which allowed for significant delays before errors in production were recognized It is this delay before errors are detected and then corrected that accounts for the egregious scrap rate To minimize this scrap rate a video monitoring system is implemented to perform real time checks against production errors Monitoring cameras are placed in specific locations to watc
25. Incorrect Die cut Registration The center cut is made by either the third or fourth die cut tower The variation of cuts made depends on whether it is desired to cut the web into sheets of ten with one vertical cut or sheets of 20 with three vertical cuts Scrap problems in connection to these vertical cuts have been virtually non existent due to little movement in the across the web direction Finally as seen in Figure 1 12 a fifth cutting station provides solid cuts across the web into individual sheets and feeds each sheet into the inspection region of the press Figure 1 12 The Final Cutting Stage 10 labels per sheet The web moves through the press at an average of 250 feet per minute This means that if a registration error occurs at one of the above stages anywhere from 300 500 unusable sheets may be produced before an operator has time to notice and then correct the error For this reason the printing process has a scrap rate of approximately 5 5 of all finished product To minimize this scrap rate Continental Datalabel desires that a video system be implemented to monitor each station and perform real time error checking When this system discovers an error at a point on the production line the operators can immediately be signaled and informed of the magnitude and location of the error This will help reduce operator response time from 30 60 seconds to 5 to 20 seconds per error After this error recognition system is in place it
26. NC Select image MENU More Options 1 3 Select the shape ROTATED RECTANGLE then select OK Do note choose regular RECTANGLE or else rotational data will be lost 7 C 3000 Series PC Simulator AndyC am me Measurement window H Rectangle As Advertised lia Oval Arc 0 5 Polygon Cance a 0K Cancel MM Mu iudi cilc Auto Adj Circle image MENU Hore Options 1 4 Draw the area to measure the amount of errored pixels A 23 Ec 2000 Series PC simulator Andy EE P mmm Heasurement window Heasurement window w H 0059 0055 cx v C 0306 0074 EI O 000 0 D gt Close As Advertised 4 0 5 de r 35 SCR Select Screen NC Function Henu FNC Select image MENU More Options 1 5 After completing the drawing select Close in the Edit field 1 6 Hit OK to save your settings 1 T Because area measurements require a binary image set a threshold and create a binary black and white image 1 8 Select Color The Color menu appears E C 3000 Series PC Simulator AndyC t Prog002 Andy Try 2 amp Utility b Disp lay A Global Edit W000 Area Name md Camera Tool Camera Register CICER Meas Win Heas Win Rotated Rect Mask jit jet JL 4 sf Pos Adj Img Enhance Filter On Binary Lvl Upper Lower t Calc Detect Black B Parameters gt gt Current Did c Output Bote
27. R Select Screen FNC Function Menu FNC Select image MENU Hore Options 24 Select Upper and set the tolerance The unit of tolerance is the number of pixels inside the measurement area This is a measure of the number of BAD pixels inside our measuring region In order to come up with this number use a product sample that is as misaligned as possible yet could still be considered GOOD product This will allow you to set the upper limit on how large of an errored region you will allow 25 After completing the settings select OK 26 Test the program with a sample of GOOD product and BAD product to check if it is correctly distinguishing the two If not go back and debug your Limits setting Prepare an additional window for the warning system 2f Name your program something like Print Alignment 100 tolerance The 100 part is important E cY 3000 Series PC Simulator AndyC el xj t Prog002 Andy Try 2 amp Utility PTS X Global Edit M000 Area Print Alignment 100 tolerance Ed Camera Tool z Area Camera Camera 1 Register Regist Ing 1 000 Heas Win Meas Win Rotated Rect Mask Jif jet sp ja Color Color to Binary gi Pos Adj Ing Enhance Filter On Binary Lvl Upper 255 Lower 128 Ys Calc Detect Black 2 gt raw scrn Parameters current img Execute Always Execute Template 00 oe Output i 0 0 Limits Area Upper 511 479 F Save VEW Vie
28. Wa More Ootions The necessary settings for the edge position window are added next 6 Select Window and then select the Edge pairs window The window setting menu appears 7 C 3000 Series PC Simulator AndyC t Prog001 Andy Die Cut Utility o Disp lay A Global Edit W001 Edge position Test EE En position WO00 Pattern sea Camera Camera 1 Register 1 gt Regist Ing 1 000 gt Meas Win None Color None Img Enhance Fitter On Execute Always Execute Fai gi Pos Adj Linits Count pen ower Position Upper X X Calc LIBI y Sarre fug Tes p ate 00 OF Output G11 879 fl Save VEW View Bar Zoom in out Change display view X MENU More Options rj Select Camera then select a camera to take images A 32 Prog000 New000 Sr Utility 2 Display 3 Global 10000 Edse position 1 Register dit x4 ki gt 6 ww Vie BarGoos in out Change display view O Moro Options Prog000 New000 fr Uti tity C2 Display 3 Global EIU NET C NOCUIT Edge position RS a 8 i x4 ki Execute Linitc 6 L AIL Bar Goos in out Change display view More Oe ions 8 Select Regist Img then specify the number of the registered image to be used REMEMBER you will probably want to use the same registered image to take measurements from as the image that you used with the pattern search function 9 Select Meas Win The Measurement window
29. a Settings menu appears Prog000 New000 frutitity CoDisply Global Camera Sotiings Casora l IPOE Camera Specs Aog 512408 Color Mos Camra iplrigver Irisgert Boy Camra 2 Stutter Speed 1 68 16 67 mec A Sensitivity Origin X Orisin Start Line End Line D Parameters ww iow Bar oos in out Change jisplay view More Options When multiple cameras are connected to the CV you can specify the shutter speed gain adjustment process area image area trigger and camera type for each camera With setting items that can be individually configured for each camera be sure to specify a camera in Camera before selecting the individual setting item Camera Settings Configuration 1 Select the camera port Camera 1 Camera 4 that you would like to configure the Individual Camera Settings for A 4 The Individual Camera Setting Prog000 New000 MrUtility CQdisplay Global menu appears Bing 512x480 Color Ir hoped VEO 15 67 uoc Sersitivity 5 0 Origin X n Origin Y 6 Stirt Line 0 Enc Line 479 Sem ww View Bar 7ooe in out Change display view More Options 2 Select Camera Specs The Camera Specs menu appears ProgQ00 New000 fe Util ity Ce Display 1 Global Color Ir oper VU 16 67 uoc 1 O 16061200 Grav 512480 ts Cale w el Output VEW Vice Rar Coos in out Chango dicnlay view WA Moro Ontions 3 After selecting the camera type for the camera selected
30. adley stack lights with optional buzzer attachment sesesesessse 24 Pisure 7 Photo DIOd6uueiieo EE SEE d REID bleu u expeti bien oko e boue elect 26 LIST OF TABLES Fables MistoOtb y ster DISICIDULOES Se osiavesiacsaraewsonses Leo UC on co too ae debeas T don aed sei a aired 12 Maple Irt OUUDULS ces deeem ePaper beta cease bert e Detenido n rab tese oso S Oen med dM 21 Hable s P QAO Cameri oystein e r E E 22 Table 5 2 Two Camera System with Expansion Unit for Additional Cameras 23 Japleo Three Cameras VySLe Hc soda roa RC det vars dived etu Debo Fase tut ctetu ovd rola duelo Cae 23 1 Introduction Continental Datalabel located in Elgin Illinois is one of the largest label manufacturers nationwide with sales exceeding 60 million dollars annually The company was started in 1950 by Roy Flynn as a distributor of early computer office products such as key punch cards When Roy s son Timothy took over for his father in 1979 the business began to shift its emphasis strictly to labels While at first offering only a few different types of labels the company has since expanded to offer its customers more than 700 different products for home commercial and industrial uses In order to reduce lead times for customers nationwide Continental Datalabel now includes four separate branches in Illinois California and New Jersey Some examples of Continental Datalabel products include press
31. and labor costs etc 2 Development of specifications for the performance of the video system and potential feedback of data or other inputs to the system for registration control 3 Investigation of suitable components for the system taking into account size resolution sample speeds scrap reduction capability and performance in an electro mechanical environment etc Robustness of the system is a chief concern 4 Selection of the proper components system integration plan for remote monitoring in one or more locations and the possible integration of feedback control system 5 Full implementation of final design system specification and operations Desired Results Deliverables 6 Complete system implementation of specifications with report and presentation including all items mentioned in the scope of work 7 Release of all drawings data schematics software vendor information presentations reports etc to Continental Datalabel at the completion of the project 8 Performance of an economic analysis to justify all recommendations 3 TEAM OBJECTIVES The following objectives were determined to be necessary for the successful completion of this project Goals 1 Scrap Rate Reduction Reduce scrap from 5 5 to 2 75 2 Process Speed Improvement Lower error rates will allow higher run speeds 3 Print Quality Improvement Improve both print alignment and die cut registration Tasks 4 Alternative Solution Rese
32. ap With the new loss of only 72 92 ft per error the annual scrap count will drop from approximately two millions sheets to less than 775 000 sheets The overall cost to produce a sheet is 9 3 cents while a sheet is sold for 13 11 cents To calculate the annual savings the current amount of annual sheets of scrap minus the improved annual sheets of scrap was multiplied by the cost of a sheet plus the profit of a sheet This calculation changes the difference of the current total to the improved total of annual scrap sheets into profitable sheets The final calculation made was the estimated new scrap rate the current 187 5 ft loss per error produces a 5 50 scrap rate while the improved 72 92 ft loss per error will produce only a 2 14 scrap rate 2 Camera Systemwith Expansion Unit for Additional Cameras 0 3 00 14050 14050 0 088 years 3 0 38101604 4525499 159492 500 158992 144942 932 2 0 39918174 4669990 164585 500 164085 309027 1113 3 O 39318174 4669990 164585 500 164085 473112 1132 4 0 39918174 4669990 164585 500 164085 637197 113496 5 0 39318174 4669990 164585 soo 164085 801282 1135 6 0 39318174 4669990 164585 soo 164085 965367 113596 7 0 39918174 4669990 164585 500 164085 1129451 1135 8 0 39918174 4669990 164585 500 164085 1293536 113596 9 0 39318174 4669990 164585 500 164085 1457621 113
33. arch Research possible solutions in technology and video related control systems 5 Economic Analysis Provide an analysis of the best solutions in financial terms meeting the mandatory one year payback 6 System Purchase Make a formal recommendation to Datalabel to purchase the preeminent machine vision system 7 Installation Work with plant mechanic to install cameras and work out any issues concerning mounting and positioning the vision system on the press 8 Training Collaborate with Datalabel designated personnel in becoming familiar with the operation and programming of the machine vision system software 9 Implementation Initially configure vision system software to perform error detection as needed by the current process 10 Debugging Fine tune and further configure the programs in place from initial implementation 11 Operations Manual Creation Create a detailed step by step instruction manual for operator reference and the training of future operators 12 Control System Realization Incorporate machine vision equipment s output to be used as an automated feedback control system 13 Conclusions Provide a summary of the findings obtained from testing that are related to project goals and objectives including financial and technical benefits as well as further considerations 4 PROJECT ANALYSIS 4 1 Metrics During the initial plant trips a thorough investigation of the process was completed Key metrics c
34. ate the use of different printing and cutting templates As Advertised As Advertised As Advertised As Advertised As Advertised As Advertised As Advertised As Advertised As Advertised As Advertised Figure 1 3 10 Labels per Sheet Figure 1 4 20 Labels per Sheet Each sheet begins as part of a long continuous roll of vinyl material called the web that is fed through multiple printing and cutting stations before it is sliced into 9 by 12 5 inch sheets and packaged As seen in Figures 1 5 and 1 6 the errors occurring in the direction that the web is fed are referred to as along the web and those in the perpendicular direction are noted as being across the web Figure 1 5 Along the Web Figure 1 6 Across the Web The entire press that produces these repositionable labels can be divided into four main sections as seen in Figure 1 7 The tension rolling and paper splicing section feeds rolls of vinyl material into the press at a constant tension while also providing the ability to operate continuously by splicing on new rolls of vinyl Tension Rollers Paper Splicing Print Towers Die Cut Stations Inspection Figure 1 7 Propheteer Press 1313 Layout The press operates constantly Monday through Friday from 7 a m to 12 a m and is rarely halted at any point during its operation The printing and die cut stations consist of multiple towers that are each respon
35. ation of Cameras on Permanent Mounts 19 4 8 Alert Output Enhancement Since the primary purpose of the machine vision system lies in informing the press operators about errors being produced the sooner the machine alerts the operator the more efficiently the entire process will run Currently the system is easily able to convey information about the press s functioning directly on the monitor with the OK and NG symbols shown in Figures 4 3 and 4 4 By altering the current programming of the system this visual alert system on the monitor can be enhanced by creating larger symbols that are context sensitive to a particular error For example there could be a small green circle in the corner that says OK when the system is functioning properly and a large red triangle could flash on the screen with the words PRINT ERROR DIE CUT ERROR or both depending on what type of error has occurred on the press This type of alert system would of course only be able to function when the operator is looking directly at the monitor The operators who run the press however have many other duties to attend to at the various stations comprising the printing process For this reason the company has asked for an alert system that will provide 360 degree audio and visual stimuli concerning the functioning of the press To meet these needs a set of Allen Bradley stack lights will be incorporated into the error detection system These lights
36. cameras light enough for simple removal and assembly and easily adjustable so that camera positions can be changed for different product lines While researching various vendors of general mounting accessories the team found Frame World a company that specializes in building and assembling frames made of structural aluminum extrusions After further investigation it became clear that Frame World would solve the desired mounting needs Frame World works closely with customers in designing custom framing for any mounting project After sending in sketches and pictures of the desired kind of mounting system Frame World created a design and met with Continental Datalabel managers about installation A rough sketch resembling the desired assembly can be seen below in Figure 4 9 18 Figure 4 9 Desired Mounting Assembly The assembly will consist of members attached together with adjustable knobs for easy repositioning There are two support members one on each side mounted to the press not shown in sketch with a single crossbar going over the webbing where the camera is mounted The camera is able to rotate on two axes allowing for a wide range of repositioning and compensates for vibrations along the press The framing assembly was installed on April 18 The mounting assembly consists of parts purchased from Frame World Photographs of the installed mounting brackets for the cameras are shown below in Figure 4 10 Figure 4 10 Install
37. cations by selecting OK For your information we will have just set the selected colors to WHITE and the unselected colors to BLACK Meaning the errored region will now appear BLACK to the computer and the good regions will appear WHITE 7 C 3000 Series PC Simulator AndyC t Prog002 Andy Try 2 amp Utility Display X Global Edit WODO Area Name Area Camera Camera 1 Regist Img 1 000 Meas Win Meas Win Rotated Rect Mask EEEE Color Color to Binary sf Pos Adj Ing Enhance Filter On Binary Lvl Upper Lower tz Calc Parameters D Execute oy HORDES Linits 3 E p A E Li SCR Select Screen FNC Function Henu PNG Select image MENU Hore Options 22 Select Detect and then select BLACK to detect the errored region that is now set to BLACK by the previous step 23 Select Limits The Enter Limits menu appears You can set the tolerance upper and lower limits for the measurement value as follows If the measurement value meets or exceeds the specified tolerance an NG message appears If it is within the specified tolerance an OK message appears A 26 7 C 3000 Series PC Simulator AndyC t Prog002 Andy Try 2 amp Uti lity o Display A Global Edit WOOO Area Name md Camera Tool Camera Register Enter Limits gf Pos Adj cu r End E img Og Always Execute Temp ate 00 ut ut 0 0 Area Upper 511 478 F Save ER S r E E SC
38. e Disolay 3 Global Edit Edit Window hdd Coey Delete Windows Shift All Windows md Camera Copy Delete i Register Simultaneously Shift All Windows gf Pos Adj xz Calc cj Output M Save ww Vie Aat in out Change display view M CR 24117 2 Select Add The Add Window menu appears 3 Select Window Number then specify the measurement window number Window numbers can be freely set at any value from 0 to 127 A new Window number will be automatically generated A 30 Prog000 NewO00 f Utility 2 Display 1 Global Eng Windows a LMLS e n e i 9 k f T Addy m s el i f iw i PEON M E NE ww View BarC ooe in out Change display view W More Options mr Utility _oUisplay 1 Global Edit Winder Add Cooy Delote Windars Shift All Window Pere KATAA X BITE ET rente ett Loy Delete Simultaneously Shift All Windows r Register Add 9 TT wi 2E SN LI j m r AN AL eme a Aros Pattern search 2 Pattern sort FI Quel ran gt Edo position Edge width t Eda pitch ww iow Bar ooe in out Change fisplay view More Oetions 5 select OK A window with the specified number is added as an edge pair measurement window The current window setting list is the displayed A 31 Prog000 New000 fruti Coil A Qlobal Edit Window LL Edge position Edge position Exe position VW iow Nat in out Change fisplay view
39. e left of the scanned image is the desired threshold The red line that jumps around represents the measured intensity of the image as the software scans down the box Once the intensity jumps above the threshold as it does here when it detects the die cut the tool knows that it has found a line or edge With these inspection tools the system should be able to identify any registration errors that are associated with the process Using a two camera system with one to scan and sample the print alignment and the other scan for the die cut registration 95 of all errors should be identified in real time 4 6 Operator Education In order to ensure that the machine vision system is always able to function even in the absence of the employees directly in charge of its programming the plant managers have requested that a full operations manual be constructed The operations manual located in Appendix A consists of detailed and illustrated step by step instructions to help with operator training and to allow anyone to quickly service or reprogram the machine vision system The operations manual will be kept at the press and will serve as a quick reference guide for the operators 4 7 Permanent Mounting Continental Data Label requested that permanent framing to mount the Keyence cameras onto the press be designed After discussion it was determined that the framing was to be rigid enough such that vibrations of the press would not move the
40. e system comes with a long list of pre established stock inspection tools that can be customized to fit the needs of the customer In order to meet Continental Datalabel s demands only a specific few of these tools are needed to establish accurate error recognition for both printing alignment and die cut registration The three error checks that will be of most use are the area pattern search and edge position inspection tools The area inspection tool is a simple program that counts the number of pixels in a desired area such as a box determined by the user The tool then checks the color of each pixel and counts how many pixels there are of each color The user sets a threshold for an allowable number of pixels of a certain color and then the tool will pass or fail the image by comparing the threshold to the counted number For Continental Datalabel this tool would be used to check the print alignment of the bar around the logo An area drawn as a box around the logo is defined and the pixels inside are counted The tool is configured to only count the white pixels within this area A threshold of allowable white pixels is determined by what the tolerance should be for an acceptable print The scanned image is then passed or failed dependent on how much white is showing if it 1s outside the acceptable tolerance The next two Figures 4 1 and 4 2 illustrate the configurability of the area tool as well as the tool in action Figure 4 2 shows how
41. economic analysis concerning the purchase of the various machine vision kits offered by the Keyence representative A two camera system with the capability of adding an expansion for additional cameras 1s referred to as the two camera system in Table 5 1 Figure 5 1 is a visual aid to help interpret the information found in Table 5 1 Shown in Table 5 2 an expansion kit can be purchased along with the two camera system that will allow for two more cameras to be added as needed in the future Table 5 3 represents the costs associated with buying the two camera system the expansion kit along with a third additional camera 21 2CameraSystem 0 700 J 20 0 0 of 12050 12050 0 076 years pif 0 38101604 4525499 159492 500 158992 146942 1119 2 0 39918174 4669990 teases 500 164085 311027 1303 3 O 39318174 4669990 164585 500 164085 475112 182176 4 of 39918174 4669990 164585 500164085 639197 132275 5 0 39318174 4669990 164585 soo 164085 803282 1322 6 0 39318174 4669990 164585 500164085 967367 1322 7 0 39918174 4669990 164585 500 164085 t131451 1322 8 1 0 39918174 4669990 164585 500 164085 1295536 132296 9 0 39918174 4669990 164585 500 164085 1459621 1322 pio 0 39918174 4669990 teases 500 164085 1623706 132296 Table 5 1 Two Camera System Cash Flow NPV and IRR
42. enu Page 4 18 A 8 F C 3000 Series PC Simulator AndyC Register Image Select Image Source Image Camera Save image Saved to LC Compression i Free area 14 3GB 97 76B Adjust Image Position AS Adv artised 0000 000 j Li E SCR Select Screen FNC Function Henu FNC Select image MENU Hore Options 2 Select the camera to use next to Camera The image and inspection windows of the camera are displayed 3 Press the TRG button on the remote control console The image captured by the camera selected in step 3 is displayed 4 Select Save to register the displayed image The displayed image is saved to the CV as the reference image for measurement and judgment settings 5 Repeat steps 2 and 4 to register an image for another camera Create Measurement Windows 1 Select the Program No to record from the initial settings screen 2 Select Window The Edit Window menu appears A 9 Prog000 New000 f Utility 2 Display 3 Global PROG Edit Pinde Madi Coy Do lete Windows Shift All Windows Add Copy De fp Adi Copy Delete Simul tarmeousiy Shift All Windows ww View BarGoos in out Change display viov D Wore Options Choose a tool to correct for the camera s position In case the camera shifts slightly or the position of the labels changes it is necessary to set a reference point The easiest way to do this is by selecting a simple recurring pattern on the
43. figuration the Area Inspection Tool ccccccccccssecccceeeeeneeeeecseeeeceseeeceeseeeeneeeeeas 13 Figure 4 2 Area Tool Counting White Pixels Failing NG eee 14 Figure 4 3 Area Tool Counting No White Pixels Passing OK ccccccesscccseseceeeeeeeseeeeeeeeseees 14 Figure 4 4 Pattern Recognition Tool Demonstrating Skew Capability seeessssse 15 Figure 4 5 Contieuration of the Edge Position Tool E ER Estee en eee 16 Figure 4 6 Use of Backlights for Die cut Detection cecccccsececeeeeceeeeeeecnseeeceeseeeeeneeeeeas 16 Figure 4 7 Die cut Detection Using the Edge Position Tool cc cccceeccceececeeeeeeeeeceeneeeeeseeaaenes 17 Figure 4 8 Light to Dark Filter for the Edge Position Tool eese 17 Lieure d 9 Desired Mounting ASSeIHDIS 2 eec ttu pete one be ecu Pet dee e us scm Rees nea arene dee Hid 19 Figure 4 10 Installation of Cameras on Permanent Mounts eeeesseeseeeseeeeeeeenneeeem eee 19 Figure 4 11 Allen Bradley stack lights with Optional Buzzer Attachment eeeesssse 20 Figure 5 1 Cash Flow NPV and IRR vs Year for a Two Camera System eesesss 22 Figure 6 1 Excerpts from the Machine Vision Operation Manual eese 22 Figure 6 2 Excerpts from the Machine Vision Operation Manual ccccecsseeeceeeeceeeeeeeeeeeeeeens 23 Figure 6 3 Allen Br
44. g menu appears 2 Select Shutter Speed The Shutter Speed menu appears A 7 Camera Shutter Speed w 0016 67 ese LAIT Msc in out Change jisplay view More Options 3 Select a shutter speed then select OK As you select different shutter speeds the image in the background changes accordingly Reference To enter shutter speed numerically select Custom then enter the shutter speed The range of values you can specify is from 0 05 9000 00 ms When using a fast shutter speed it may be necessary to open the lens aperture to let in more light However allowing an intense light into a wide open aperture may cause a smear affect vertical streaks on the image To compensate for this close the lens aperture as much as possible Register a Reference Image This will let you choose a sample image of the product from which to take measurements and create error recognition programs For ease of programming later on you will want to register an image that serves as an example of a product that is on the border between passing and failing in all errors This means that for the current labels you will want to capture a reference image of product with errors in the logo registration and in the die cut registration You may want to capture additional images of good product for comparison but try to use one reference image for all calculations 1 Select Current Img from Source Image on the Register Image m
45. h problematic areas in order to quickly identify any errors and reduce delays in correction Ideally the output of this vision system will eventually be linked to the press control panel in order to provide a feedback control system for automatic corrections With this system in place production errors should be minimized press speed should be increased and scrap rates should drop below the target of 2 75 KEYWORDS repositionable adhesive labels registration errors video monitoring system vision processing quality control ACKNOWLEDGEMENTS We would like to thank Steve Solberg Ron Kassal and Brian Zimmerman for all of their advice and cooperation throughout this project They were very helpful and made themselves available whenever necessar y Thanks to Professor Leake and Professor Wozniak for all of their encouragement and feedback throughout the course of this project Thanks to Professor Nedich for all of her valuable advice and input for reports presentations and all other aspects of this project TABLE OF CONTENTS is lt Loic e iitenlo ppt re E 1 25 Properes uenen an a e aa tata ad uode 7 De Wea ODICCUIVES NNI TU URN 8 4 Project Analysis and Work Completed sess nennen 9 ZW Us UNIS RU ET E UELUT 9 2 2 PIOCeSS AMAL YSIS shana sctestoan daa ana Desde loinc otdactes anda wo acd Sedat Les rope a Con Teac B au pusu Lee caet aou ee 9 Ao Reseda LINE o D o mE 10 AA IRC VENICE S SUG UN E E
46. itial system costs ranging from 10 000 to ten times that the most cost effective system was provided by the Keyence vendor Based on trial runs the amount of scrap has been successfully reduced by monitoring the two locations on the press that produce the largest number of errors The video monitoring system is capable of cutting the error detection time in half therefore reducing the scrap rate significantly The plant managers have seen the system in action and have agreed that our calculations are a good projection for the future Observations along with calculations have shown the probability of a more than fifty percent reduction in scrap as well as an annual savings of approximately 160 000 can be achieved 7 RECOMMENDATIONS 7 1 Mirror Implementation at California Plant 24 In addition to the repositionable adhesive label being produced at the Elgin IL plant on press number 1313 there is identical product being produced at the Redwoods CA facility Since the two processes are identical the current machine vision error detection system that has been implemented at the home plant should be replicated and added to the press in California immediately The California plant can use the documentation provided by the student group to the company concerning all details of the machine vision system integration into press 1313 to quickly mirror the error detection system in place at the Illinois plant These details include informatio
47. ity of appending such a control system to the error recognition system 7 4 Mill Splice Locations Recently the raw material has been determined as another possible error location Continental Datalabel purchases the initial raw material web in rolls of 9 by 7800 through a vinyl material vendor Within one of these rolls one could find anywhere three to five mill splices made by the vendor Due to tension issues test runs show that mill splices can produce an error anywhere from ten feet prior to the splice till nearly one hundred feet after the splice The operator has the general knowledge of when a mill splice is coming through because as the roll depletes the splices become more noticeable However if the operator does not see it then an error of large magnitude can occur To attack this problem a simple detection device can be used to help alert the operator of a splice The sensor shown in Figure 7 1 could be connected to the 24 volt Keyence power supply through a simple wire and amplifier connection 26 Figure 7 1 Photo Diode 8 REFERENCES www keyence com 2008 http www quadtech com 2007 http www photosonicsinternational co 2008 www mathworks com 2008 www ni com 2008 www maxprog com 2008 www frame world com 2008 www ab com 2008 http www goldmine elec products com prodinfo asp number G 14442 amp variation 2008 2l APPENDIX A Programming the Machine Vision system
48. ll be lost A 14 7 C 3000 Series PC Simulator AndyC Pattern Heasurement window As Advertised 7 Delete F Retasle Rectangle amp 4 A 47 amp Circle As Advertised 7 EM Ring Window memory f Arc 0 2 Polygon HELP LJ E B LI SCR Select Screen NC Function Henu FNC 4_ Select image X MENU More Options 1 T Draw the pattern area 7 C 3000 Series PC Simulator AndyC Pattern y H C 0059 0049 cx 0363 oroa E O 000 0 D gt Close As Advertised 7 As Ad Window memory 0 2 P x SCR Select Screen FNC Function Menu FNC Select image MENU More Options 1 8 After completing the drawing select Close in the Edit field 1 9 Now we will allow for possible rotations Select Angle The Select Angle Range menu appears A 15 Proa000 NewOO00 i Utility Ca Display 3 Global dit 10000 Pattern search j tz Calc Output ww View BarGoos in out Change display view More Options 20 Select Range clockwise rotation and set the maximum range of the angle in which angle measurement can be made Usually a value of 30 45 degrees will work fine 21 Select Range counter clockwise rotation and set the maximum range of the angle in which angle measurement can be made Usually a value of 30 45 degrees will work fine 22 After completing the settings select OK 23 Escape from the
49. n thus activating the overall calculation window Once activated this function will then output the sequence 0 1 Flash frequency 1 everytime the system is triggered Since the tolerance level is set to 5 everytime the function produces an output greater than 5 the calculation window will output a NG Thus a system operating in the warning mode with a Flash Frequency of 3 would output OK NG NG OK NG NG A 45 Next we will want to make sure that only the pertinent functions are considered in the overall output of the system Go to the output section select Total Status F cY 3000 Series PC Simulator AndyC t Prog001 Andy Die Cut amp Utility RTI X Global Edit Total Status Me Camera C W000 Pattern search _ 001 Edge position __ 002 Edge position Hy Register W003 Print Alignment 100 tolerance 004 Print Alignment 60 judgment Window C C000 Difference Function and 60 judgment C001 Difference Function and 100 judgment PA C002 Flashing Indicator s Pos Adj 4 x Cale Hold Mode OFF vew View Bar Zoom in out Change display view MENU Hore Options Select the Area tool that you used to check the print alignment that is set at 100 of the tolerance the 100 difference function of the two edge positions and the flashing indicator This means that the alert will sound when either the edges or the print alignment have broken tolerance and that the alert will
50. n about pricing parts delivery times installation locations light camera computer and monitor mounts alert systems operator training programming and troubleshooting These actions could be duplicated as soon as the functionality of the current implementation is ascertained This would in turn multiply the savings offered by the machine vision error detection system detailed in this report 7 2 Implement Machine Vision on Other Presses Along with replicating the error detection system on presses producing identical products the robustness of the machine vision will allow for implementation on many of the plants various other presses Economic analyses should be performed on all the presses to determine which processes would benefit from the addition of a real time error recognition system i e which processes are currently producing the greatest amount of correctable scrap The documentation provided by the student group can be used as a template for other presses Only minor adjustments to the overall installation and programming will be needed to adapt the current system to perform real time inspection on a variety of other products 7 3 Future Control System Automation Once the video monitoring system has been successfully implemented the scrap production resulting from the delay between error formation and operator recognition should be reduced to an inconsequential amount At this point if it is desired to reduce the overall
51. ng system was needed to provide such real time error recognition It was evident that cameras are necessary to watch certain areas of the process and then provide some sort of output that would alert the operators It was found desirable that the cameras be as small as possible while still maintaining a high enough resolution for robust image acquisition Also as desired by Datalabel the shutter speed of the cameras must be fast enough to capture an image every time a sheet goes past it Thus shutter speeds of at least 1 6 s are required as a maximum of 6 sheets will pass in one second Higher quality cameras are able to provide shutter speeds as high as 1 1000 1 2000 s which enables faster and more accurate product sampling 10 Once the cameras have captured the image data the data must be processed to determine the presence of errors Initial investigation of vision processing software determined that the industry standard is much more expensive than writing one s own software Thus investigation into do it yourself vision developer kits was initiated Preliminary research found quite a few potential developer software packages including 1 Matlab 2 Processing 3 Eyesweb 4 Labview 5 MAX Further investigation determined that Labview s vision developer kit was the most user friendly and straightforward It was also discovered that learning the software would require a large amount of time Becoming sufficiently proficient to do
52. nsidered an edge inside the measurement window e Edge Sensitivity Specifies the relative threshold value for recognizing edges 0 to 100 Default 30 e Edge Filter Width Specifies the width of the smoothing filter applied to the derivative wave to detect edges 0 to 100 Default 5 e Upper Edge Intensity Specifies the upper limit for the absolute intensity of edges 0 000 to 255 000 Default 255 000 Lower Edge Intensity Specifies the upper limit for the absolute intensity of edges 0 000 to 255 000 Default 5 000 A 39 Reference Adjusting the highest and lowest edge intensities which are shown to the left of the graph based on the highest intensity in the segment currently being displayed allows noisy edges to be excluded Now a function detailing the position of the first edge the die cut perforation will be complete Next repeat the above steps to measure the position of an edge on the printed bar 7 C 3000 Series PC Simulator AndyC i Prog001 Andy Die Cut amp Utility gt Display A Global Edit Edit Window Add Copy Delete Windows Shift All Windows cd Camera Copy W000 Pattern sea Delete j W001 Edge positi i Register Simultaneously Shift All Windows Add Window Window Number r J ef Pos Adj Measurement tool rs zi Area Calc Pattern search z nm filtered scrn E3 Pattern sort current img ING aa diy D aer e 479 bad Edge width F Save bi
53. og002 Andy Try 2 Bad Gel ovp Edit W002 Area Name md Camera Tool Camera Register Regist Img Meas Win Color gf Pos Adj Ing Enhance Binary Lvl zr Calc Detect Parameters Execute a Output F Save Print Alignment 60 tolerance Area Camera 1 1 000 Meas Win Rotated Rect Mask CHEJL 4 Color to Binary Filter 0n Upper 255 Lower 128 Black am CI Always Execute oe Area Upper 511 479 view View Bar Zoom in out Change display view MENU Hore Options 30 Now take the copied version of the area tool whose limits had been set to 100 percent of the allowed tolerance and decrease the tolerance settings so that they reflect the desired warning tolerance and change the name of this window to reflect its tolerance A 29 Programming the Edge Position Tool F C 3000 Series PC Simulator AndyC Register Image Select Image Source Image Camera As Advertised f Save image AsA s Saved to L Compression As Advertised Il Free area 9 76B 97 76B x Adjust Image Position VEW View Bar Zoom in out Change display view MENU More Options We will be using TWO instances of the Edge Position Tool to measure the locations of the die cut perforation as compared to the edges of the printed bar In the pictures the red bar represents the horizontal die cut perforation 1 Select Add Copy Del from the Edit Window menu Prog000 New000 i Utility C
54. ogram Nos can be used for measurement once they have been added Reference Selecting Close will cancel all actions up this point and will not create a new Program No Camera Calibration NOTE Most of the Camera settings have already been correctly set for the Keyence System implemented at the Elgin IL plant The following information concerning the Camera settings should mostly only be used for initializing additional Machine Vision systems NOTE The only reason to alter the camera settings on a system that has already been initialized would be to adjust the shutter speed to increase or decrease the brightness and contrast of the captured images Overview of CAMERA Settings Specify settings for capturing an image The camera settings that can be altered are as follows Note pages refer to Keyence User s Manual Camera Settings Camera Specs Page 4 7 e Trigger Page 4 8 e Shutter Speed Page 4 8 CCD Parameters Gain Adjustment Image Area Scan Method Page 4 9 Camera Common Settings e Trigger Setting Page 4 14 e Multi Image Capture Page 4 17 To Display the Camera Settings menu 1 Select the Program No from the initial settings screen EProg000 No000 aene enne vf ean PROG Now Ecit Del settings I Pr o008 Howe I Pr onb Novnb rog Time gt Register _ Window M Save vew tios Bar Goos in out Change jisplay view More Options 2 Select CAMERA The Camer
55. oncerning product formation were recorded and each component of the press was critically analyzed 1 Final sheet size of 8 5 by 12 2 Two variations of labels per sheet 10 or 20 3 Two color schemes for each variation red or blue 4 Continuous process average operating speed of 250 ft min with a maximum speed of 360 ft min E Overall annual scrap rate of 5 5 6 Annual loss of approximately 175 000 due to scrap a 150 000 in lost raw material b 25 000 in lost press time opportunity cost labor and other expenses 7 Error recognition delay of 30 seconds to 1 minute 8 Average loss of 300 500 sheets per error detection and correction 9 Production cost of 9 3 cents per sheet 10 Sale price of 13 11 cents per sheet 11 Label design cannot be altered in any way 4 2 Process Analysis The process itself was found to be composed of four major sections Tension rolling Printing towers Cutting towers cs de Jes dos Packaging Inspection Each station has multiple components that serve a particular purpose and determine the quality of the finished product Further analysis and discussion of the process including the plant managers and process operator s inputs concluded that only certain sections should be considered for reduction of scrap Variations in tension account for some registration errors but the Datalabel plant managers have made it clear that addressing tension problems is beyond the scope of
56. red pattern 14 is then used as a template that is searched for throughout the entire image Once this pattern is found the other tools that are tied to it then become referenced such that the desired orientation is realized For example with the label process the desired scanning location for the area tool is always around the W logo The easiest way to reference the location of the logo is to locate the large prominent exclamation mark next to it The area inspection tool box 1s then referenced to the exclamation mark such that the geometry 1s always the same This can be seen in both Figures 4 2 and 4 3 as the green box around the exclamation mark indicating that the pattern has been found and that the area tool is now functioning It can be seen in both figures that even though they are separate samples the geometry of the area inspection tool box is in the exact same orientation This is because the software first establishes the exclamation mark as a landmark and then uses it to reference where the logo scan should be taking place Even when the scanned image is skewed as seen in Figure 4 4 the software still first finds the landmark and then adjusts the area scan box accordingly This is not a large concern with the label process as there is rarely a skewing issue however this ability demonstrates the robustness of the software LES SUM Il ev b Hs Figure 4 4 Pattern Recognition Tool Demonstrating Skew Capability These two
57. s Manual which Is always available for further instruction Create a new program 1 Select the Prog No field in the upper left corner of the screen The Program No menu appears A 1 E Prog000 New000 Now Edit Del settings EE LIT 4 J n5 7 Register _ Window gf Pos Adj I Calc ww View Baroo in out Change display view More Options 2 Select New Edit Del settings The New Edit Del settings screen appears Prog000 New000 rUtility CQDdisplay 3 Global View Bar Goos in out Change display view O More Ootions 3 Select Add 4 When adding a Program No set Location to either Internal memory or Memory card Reference Location cannot be set to amemory card if no card has been inserted into the machine When assigning a Program No to amemory card be sure to first insert a memory card into the unit 5 Select Prog No then select the desired number The name of the newly created program defaults to New where represents the No of the program Prog000 NewO00 r Utility Ce Display d Global New Edit Del settings Location u Internal wewory Y Pros Wo 401 NM HORE RERUM EMI Vies Bar Goos in out Change display view O More Options 6 Select Name The Add menu appears F After entering the name for the new program select OK See Inputting Characters Page 3 7 for details on entering text 8 Select Execute Pr
58. seen in Figure 4 6 as the Keyence sales representative demonstrates the software s capability Figure 4 6 Use of Backlights for Die cut Detection The edge position tool also comes with filters that can be applied to enhance the image processing Instead of looking for a color transition the software can be configured to only perceive an image as 16 black and white and then detect an edge by looking for simple shade transition Figure 4 7 below shows what the system sees when this sort of filter is implemented and a die cut is viewed This filter makes the die cut clearly visible The position of the die cut can now be compared to the position of the bar to determine whether misalignment has occurred Select Image Regist i MN 0n etait L taii Petani petit Un Tom Prose Vindoy rve Int SO Mory 0 6 Contrast Cony I Bar 7 Con in out Change display y EM adl Im Opt i traction Figure 4 7 Die cut Detection Using the Edge Position Tool In the right panel of Figure 4 7 other filters are seen that can be applied to any edge position scan Figure 4 8 illustrates the use of one of these filters where instead of checking for a dark to light transition the software inverts the shades and looks for a light to dark transition Figure 4 8 Light to Dark Filter for the Edge Position Tool 17 Figure 4 8 also displays the current threshold setting The yellow bar to th
59. sible for a particular print or cut on the label This central region of the process is where a majority of registration issues propagate At the end of the press the labels are hand checked against a master template and packed into boxes Label creation mostly takes place in the printing and cutting regions of the press which consist of three individual print stations as well as five separate die cut stations At the first print tower a clear substrate the flood coat is applied across the entire surface of the web This coat allows the water based inks to attach to the hydrophobic vinyl backing material The flood coat is applied to the surface of the web by a large roller that is partially submerged in the flood coat substrate If part of this roller dries too quickly or the clear ink levels are too low streaks will form along the web leaving sections of the labels without the flood coat as illustrated by Figure 1 8 This will result in a non adherence of the colors that is visible as streaks across the labels Product with this streaking would be considered scrap and discarded Fortunately interviews with plant managers and operators have indicated that such errors are extremely rare and do not merit further consideration at this point in time Figure 1 8 Example of Flood Coat Streaking The next two print towers can have registration issues regarding the color alignment along the web The first tower creates a light colored pattern
60. st scan Scan Dir Forward v Edge Dir Lght to Drk w Start Angle 000 00 Edge Sensitivity Edge Filter Width Upper Edge Intensity ce HER As Advertised Lower Edge Intensity 005 00 s AS Ad Skip Edges Counting Options Max Edge Gap Min Edge Gap Primary Target j e gt 7 Count Angled Edge Det 6 If necessary adjust the settings in the Edge Strength field to help refine what the computer views as an edge A 38 7 C 3000 Series PC Simulator AndyC Select Detection Conditions of Edges As Advertiseg ASA o 7 C 3000 Series PC Simulator AndyC Select Detection Conditions of Edges Ces AS Advertised As Advertised ASA 9 Display Image Direction Scan Dir Forward v Edge Dir both v Start Angle Edge Strength Edge Sensitivity Edge Filter Width Upper Edge Intensity Lower Edge Intensity Counting Options Primary Target Count Angled Edge Det Display Image Direction Scan Dir Forward Edge Dir both Start Angle Edge Strength Edge Sensitivity Edge Filter Width Upper Edge Intensity Lower Edge Intensity 005 00 Counting Options Primary Target Count Angled Edge Det OFF Notice how the green bar indicating the edge position is correctly moved on top of the die cut line by raising the sensitivity and lowering the edge filter width The items in the Edge Strength field allow you to set the conditions that indicate what will be co
61. t Edge Filter The Select Detection Conditions of Edges menu appears A 36 7 C 3000 Series PC Simulator AndyC t Prog001 Andy Die Cut m Utility gt Display X Global Edit W001 Edge position Name md Camera Tool Camera Register TET Meas Min Color Img Enhance PA N gf Pos Adj r Ca C Parameters Execute Edge position Edge position Camera 1 1 000 Meas Win Rotated Rect Mask Jif T2L SL 4 Color to Gray Fitter 0n Always Execute Count Upper Lower current img Temp ate 00 0 0 511 479 Limits cj Output Position Horari Lower X F Save VEW View Bar Zoom in out Change display view MENU Hore Options 2 Select Edge Filter The Select Detection Conditions of Edges menu appears 3 Select Display Image and then specify an image to display on the Select Detection Conditions of Edges menu Regist Img Displays the image selected in Specifying a registered image to use Page 4 119 Current Img Displays the current image from the camera selected in Selecting a Camera to Take Images Page 4 119 7 C 3000 Series PC Simulator AndyC Select Detection Conditions of Edges Display Image Direction Scan Dir Forward Edge Dir both Start Angle Edge Strength Edge Sensitivity Edge Filter Width Upper Edge Intensity Lower Edge Intensity Counting Options Primary Target Count Angled Edge Det
62. t Trigger Global A 6 t Prog000 New000 Prutitity CeDiselay Global PROG Camera Soetcings Trigger Toso Erternal bd Sequential Trigger Active Camera Can Irgl Ira Irgl 2 Multiple ww AIT Na in out Change jisplay view O More Options 3 Check the trigger you want to use by applying checkmarks in the corresponding checkboxes You can select more than one type of trigger Terminal Triggers that are input to the terminal block I O Console Triggers that are input using the TRIGGER button on the remote control console Page 1 3 e RS 232C Triggers that are input via RS 232C Ethernet Triggers that are input via Ethernet USB Triggers that are input via USB 4 After completing the settings select OK Selecting a Shutter Speed Shutter Speed NOTE Adjust the shutter speed and aperture controlled by a ring physically on the camera to the point where the image is crisp clear free of streaking and bright enough to view as much detail as possible in the image Select a shutter speed suitable for the line speed and lighting conditions If you select a fast shutter speed to match a fast line make sure you have enough light intensity to produce a quality image NOTE The Shutter speed can be individually set for each camera 1 Select the camera port Camera 1 Camera 4 that you would like to configure the Individual Camera Settings for The Individual Camera Settin
63. the sort of vision processing required for this problem appeared to be rather difficult After consulting Datalabel about performing in house programming it was determined that the direction to proceed in was to go with a third party vision system distributor At this point further research was done in exploring vision system vendors Potential vendors included 1 Quadtech 2 Photosonics 3 Keyence After comparing quotes and offered systems from each vendor it became clear that Keyence was the best choice They provide a capable system at a price that is significantly less than their competitors Table 4 1 displays a list of vision system distributors and the cost of each respective system 11 Photosonics 50 000 90 000 Keyence 10 000 Table 4 1 Vision System Distributors Keyence provides the least expensive system by an extremely large margin The more expensive systems have capabilities that Continental Datalabel does not need Some of these capabilities include press speeds of over 5000 sheets per second automation for tension adjusters and very expensive cameras Continental Datalabel s press only runs between 200 and 400 sheets per minute does not possess tension adjusters and only needs cameras with a much lower resolution than the cameras quoted by the more expensive vendors Therefore the system provided by Keyence addresses all of Continental Datalabel s needs at a much lower cost 4 4 Keyence System
64. this project Of the types of errors that occur on the press prime consideration has been given to errors occurring between the logo and bar prints and errors occurring between the die cut and bar print This is because these two errors account for roughly 80 and 18 percent of total scrap respectively Further analysis revealed that negligible scrap can be attributed to misapplication of the flood coat less than 0 5 Thus the company is not interested in monitoring the flood coat at this time With this understanding of where most of the scrap is generated it is clear that the print towers and the die cut towers are to be the primary focus Currently the Packaging Inspection station is the only implemented quality check for the process When an error occurs at one of the previously mentioned stations it may take as long as one minute before either the operator or the packager recognizes the issue and then additional time is required to compensate for it During this time 300 500 sheets are lost since the process is continuous With this understanding of the process it 1s clear that implementing a monitoring system that will provide real time error recognition will greatly reduce the delay before an error 1s recognized and corrected This will directly decrease the amount of scrap since if the delay can be cut in half then the overall scrap rate will be reduced by half 4 3 Research Brainstorming was done as to determine what sort of monitori
65. ts ww View Dor Goos in out Change dinplay view Woro Oetions 10 Select Regist Img then specify the number of the registered image to be used Prog000 New000 f Utility mi 1 119008 Ares Execute Limits wW View Bar U ooe in out Change display view More Options 1 Global 3 Global A 21 Prog000 NewO00 fr Utility ra Display 3 Global PROG Edit 11W008 Aes Window Camera Regi z Calc VEW View BarGoos in out Chanm display view O More Ootion 1 1 Select Meas Win The Measurement window menu appears 7 C 3000 Series PC Simulator AndyC Prog002 Andy Try 2 Sr Utility Display X Global Edit WOOO Area Name md Camera Tool Camera Register Besisi Ina Color Img Enhance Binary Lvl r Calc Detect Parameters 0 Execute utput F Save SCR Select Screen NC Function Menu Area z Area Camera 1 1 000 Heas Win Rotated Rect Mask 1 H jal n Color to Binary Fitter On Upper Lower Black gt Always Execute E rea Upper 511 479 4 FNC 45 Select image MEW Hore Options 12 Select Edit in the Measurement window field The Select menu appears A 22 E C 3000 Series PC Simulator AndyC am am Measurement window Measurement window SM Mask window As Advertised 7 Window memory 0 5 j Li SCR Select Screen FNC Function Henu F
66. ure sensitive tape paper packaging material address labels and thermal transfer labels as shown in Figure 1 1 Figure 1 1 Product Examples Each product that Contintental Datalabel produces is created on its own dedicated press at the manufacturing plant One press in particular produces repositionable adhesive labels for commercial use and is responsible for 3 million dollars of annual profit These labels as seen in Figure 1 2 can be applied to products for sale advertising and then be removed without leaving behind a sticky residue As Advertised As Advertised As Advertised As Advertised Figure 1 2 Sample of Label with Repositionable Adhesive This product is widely distributed among the specific customer s retail chain and is used for price displays as well as advertising The product not only comprises one of the largest sources of income for Continental Datalabel but is also the most complicated label that they have ever produced Unlike many of Datalabel s other products which use either no color or only one color and simple geometric shapes the repositionable adhesive label formed on this press requires three printed colors precise lettering and accurate cutting These items are manufactured on sheets containing either 10 or 20 labels available in two color schemes as seen in Figures 1 3 and 1 4 Only one specific variation of the label can be produced per day since the alterations necessit
67. urement Window for the Die Cut cc cccccceccccseseceeeeceseccaeseeseneeesenseeaeges A 30 A 7 Create Calculation Window for the Die Cut Tolerance seeeeeereeeeeese A 41 A 8 Create an Additional Calculation Window to Establish a Warning Mode A 44 Appendix B AutoCAD Drawing of Mounts ccc ecccccesccceeeeceeseceeneecaeseeeeeceeseseeseeseaeseesenseeees B 1 LIST OF FIGURES Powe il Product Example 5269 ehe E a Pda tec aaa eae eut au a MU iunt I Figure 1 2 Sample of Label with Repositionable Adhesive eese 2 Proure dlo I0 Eabels per SIeebu ois aan aa a O 2 Foure kA 20 Labels pet SBeeLouieistonatules euo ina aaron hase cabiaa tare eo ainda ed eee al EI ccc a CLE etiaan 2 Foue ko Alone the WeD esaea dtc op Oeo Ms tab eephea a dt du edad Dh do and 3 Peur EO AOS te WV CO caste gen ies senescence eet ear arene tee atur ieee ene eae 3 LIieure Le Propheteer Press 1515 Lay OU eso de veiacchvasaucetaneceaendent desta asume audis eren teagan Hed 3 Figure 1 8 Example of Flood Coat Streaking 200 inast E na E E E EEA E 4 Figure 1 9 Stacking Order of Print Layers and Correct Registration ccceecccccnseeeeeeeeeeeeeeeens 5 Figure 1 10 Registration Error between Print Stations esses 5 Figure 1 11 Correct and Incorrect Die cut Registration sessin a nennen 5 Figure 1 12 Final Cutting Stage 10 labels per sheet asnarin E 6 Figure 4 1 Con
68. view MENU Hore Options Prog00 Andy Die Cut tility DIE IE Global Hea leilation cooo Le L5 lles c Io Lrest Upper HOR e e mmm view View Bar Zoom in out Change display view MENU Hore Options Subtract one edge position from the other and set the tolerance to the maximum amount of distance allowable between the two edges A 43 E cv 3000 Series PC Simulator AndyCY Pd Prog001 Andy Die Cut zt Utility gt Display X Global Calculation C001 Difference Function and 60 judgment Ee o nam view View Bar Zoom in out Change display view MENU Hore Options Name this function as having 100 of the tolerance cutoff Next create another calculation window but with a lower warning tolerance 60 was used in the examples that follow F C 3000 Series PC Simulator AndyC t Prog001 Andy Die Cut amp Utility 6 Display A Global Calculation C000 Difference Function and 60 judgment Le L5 lles foe p Io test Upper JL Il JLz ano or xon clear C000 0000000 000 view View Bar Zoom in out Change display view MENU Hore Options Create one last calculation window that will be used to provide a flashing output when the warning tolerances have been exceeded Name this calculation window something like Warning Indicator or Flashing Indicator A 44 Ec 3000 Series PC Simulator Andycy E Dl t Prog001 Andy Die Cut amp Utility Display A Global
69. vs Year 1300 1250 1 1550 1500 o 2 S 4 145096 S 1 o Oo P 140096 o mmm NPV D 6 1350 ge Cash Flow 5 s IR 0 Z o 2 c x 0 1200 Year Figure 5 1 Cash Flow NPV and IRR vs Year for a Two Camera System The initial cost of a two camera system is 10 448 however a recurring maintenance cost has been added to account for any unforeseen annual needs This system will monitor both the printing alignment and the die cut alignment which account for 95 of total errors according to Continental Datalabel So 95 of the annual scrap cost of 175 000 is 166 250 Continental Datalabel stated that producing 57 000 ft of scrap costs them approximately 4 760 Therefore if 4 760 is the cost of producing 57 000 ft of scrap then the current scrap cost of 166 250 produces approximately two million sheets of scrap annually The implementation of a video monitoring system will cut error detection time drastically leading to a reduction in scrap The current error detection time is on average 45 seconds thus accounting for a loss of 187 5 ft before an error is noticed by the operator With the help of this monitoring system the detection time should drop to an average of 17 5 seconds This will lower the loss to only 72 92 ft per error So another proportion has been created 22 to determine the improved sheets of annual scrap produced loss per error to annual sheets of scr
70. w Bar Zoom in out Change display view MENU Hore Options A 27 28 Add a new area window 7 C 3000 Series PC Simulator AndyC Prog002 Andy Try 2 BEd Gorad E Edit Edit Window cud Camera WO00 Print Align aa ge Register W001 Pattern sea Add Window Window Number f Pos Adj Measurement tool z e Qutput Add Copy Delete Windows Shift All Windows Copy Delete Simultaneously Shift All Windows EN Pattern search Pattern sort f Edge position 611 479 bod Edge width bod Edge pitch Ie Edge counting view View Bar Zoom in out Change display view MENU Hore Options 7 C 3000 Series PC Simulator AndyC Prog002 Andy Try 2 poe ed Lol ES Edit Edit Window md Camera Add Copy Delete Windows Shift All Windows Delete Simultaneously Shift All Windows view View Bar Zoom in out Change display view T More Options 29 Copy your 100 tolerance area tool to the area tool that has just been created A 28 El cv 3000 Series PC Simulator Andycy 0 sl Ici xl t Prog002 Andy Try 2 amp Utility o Display A Global Edit Window Copy Windows Add Copy Delete Windows Shift All Windows Copy from W Print Alignment 100 tolerance WO000 Print Alignment 100 tolerance W001 Pattern search 7 w002 Area woos won woos woos VIEW View Bar Zoom in out Change display view MENU Hore Options 7 C 3000 Series PC Simulator AndyC Pr
71. would then be possible to augment its efficacy by linking its output to a control system and into the press operation panel to allow for automated mechanical adjustment of the process However the primary goal is simply to reduce the scrap to half as many sheets which would be accomplished by focusing on real time error recognition 2 PROBLEM STATEMENT Continental Datalabel s current press operation maintains an undesirable level of scrap production It is desired that a monitoring system be designed and integrated into the press using available video and computer components to allow continuous real time monitoring of problematic locations on the press The primary goal of the system will be to significantly reduce the delay in error recognition thereby limiting the amount of scrap produced The data from this system will ideally be implemented into a feedback control system that will allow for real time automatic registration adjustment It is hoped that the current scrap rate for this process of 5 6 will be reduced to less than 2 5 after implementation Most likely this is a conservative approximation and the achieved scrap rate will in all probability be significantly less than the 2 5 goal All recommendations must satisfy a one year payback requirement Scope of Work 1 Analysis of the current press operation the recommended six desired monitoring locations equipment mounting locations alignment and registration issues scrap
72. y view More Options 8 select Regist Img then specify the number of the registered image to be used REMEMBER you will probably want to use the same registered image for the pattern search function as you will to measure errors from in the later steps ProgO00 New000 MrUtitity CQBisplay Global Edit 19008 Pattern search e LR 7 Search Area Woas Win None Camera wx OOO Pattern Moas Win None Sion Color Nono t Calc Ivo Enhance Filter On Output ww Vie Nato in out Change display view O More Options 9 Select Search Area This is where you will specify a range on the screen where the computer should search for the pattern The Search Area menu appears A 12 7 C 3000 Series PC Simulator AndyC Search Area Heasurement window As Advertised 7 As Ac ER Mask window As Advertised 7 Window memory Cance SCR Select Screen NC Function Menu FNC Select image MENU More Options 10 Select Edit in the Measurement window field The Select menu appears 11 Select the shape ROTATED RECTANGLE then select OK Do note choose regular RECTANGLE or else rotational data will be lost 1 2 Draw a box covering the entire area that the pattern could be located F C 3000 Series PC Simulator AndyC BJ 12 x og A m Search Area As Advertised MMT N w H 0425 0283 cx 0225 Coras 000 0 D

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