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iVu TG Sensor User`s Manual (Online Only

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1. Never use this device as a sensing device for personnel protection Doing so could lead to serious injury or death This device does not include the self checking redundant circuitry necessary to allow its use in personnel safety applications A sensor failure or malfunction can cause either an energized or de energized sensor output condition 7 1 Product Support Banner provides the following resources for quickly setting up and operating the device Documentation Online Help When setting up or monitoring inspections using the iVu sensor s integrated display you can get online help on any screen by clicking the Help icon in the upper right of the screen PDF Documentation The product documentation is available in a convenient printable format PDF on the installation CD or at www bannerengineering com Banner Website The most current product information documentation and software updates are available on the Banner website www bannerengineering com Warranty Service Contact Banner Engineering for troubleshooting of this device Do not attempt any repairs to this Banner device it contains no field replaceable components If the device or a device component is determined to be defective by a Banner Applications Engineer they will advise you of Banner s RMA Return Merchandise Authorization procedure a Important If instructed to return the device pack it with care Damage that occurs in return shipping is not covered by war
2. 2 On the sensor select System gt Firmware Update The name of the firmware file you copied on the USB Thumb Drive will be displayed 3 Choose correct file and click on the Load button 4 Follow the steps on the screen to update the firmware 5 2 How to Set or Modify a Device Name You can set a Device Name for your iVu Series sensor or modify an existing name on the sensor using the software keypad You can also change the device name this using the iVu Emulator as described below K NOTE If you are in a language other than English you cannot modify the device name using the software keypad Use the procedure described below w K NOTE If you have not set the device name previously then folders will be named using the first 8 characters of the device serial number 1 Plug a USB Thumb Drive into the device 2 Save Device Configuration to the USB Thumb Drive Main Menu gt System gt Sensor Configuration gt Save to USB The locaton of these files on the USB Thumb Drive will be displayed after the operation is complete the device configuration is saved in lt USB gt BANNER lt DEVICE_NAME gt For example if the device name is myName the path will be lt USB gt BANNER myName 3 Remove the USB drive from the device and insert it into an available USB drive on a Windows PC 4 If running the Emulator from the USB launch the iVuEmulator exe program If running the Emulator installed on a PC make sure the Emul
3. the Power LED is steady green and the Pass Fail is green or red depending on the triggered inspection 1 Power LED Green Power Red Error 2 Pass Fail LED Green Pass Red Fail m ee a ey The iVu also indicates abnormal conditions as described below 6 1 Errors Problem Indicator Solution The Pass Fail LED is blinking green a number Reboot the sensor of times separated by an LED red blink and the sensor repeats this pattern over and over This indicates that no inspections are occurring The Power LED is lit steady red These type of Do the following errors are reported in the System log and appear highlighted in red 1 Look in the System Log to see the error 2 Clear the LED that is go to the Main Menu gt Logs gt System Logs and press the Clear System Error button at the bottom of the screen a sensor reboot is not required If the error occurs again you can try rebooting the sensor to see if that fixes the problem If the problem persists contact Banner customer support 6 2 Warnings Warnings are atypical conditions that the sensor detects and fixes Warning are highlighted in yellow in the System Log and can typically be ignored 57 iVu Series Image Sensor 7 Product Support and Maintenance This section provides general Banner resources and specific documentation for installers and operators of this iVu TG Vision Sensor A WARNING Not To Be Used for Personnel Protection
4. Count The range bar at the bottom of the screen provides a zoomed view of the range so that you can fine tune the range Click on the bar and drag up to bring up the zoomed view as shown below 33 iVu Series Image Sensor Pass Count Main Menu gt Inspection gt Blemish gt Pass Count The Minimum Pass Count is the minimum number of pixels expected to fall within the specified criteria the Maximum Pass Count is the maximum number of pixels expected to fall within the specified criteria These settings are used to determine the pass or fail result of the inspection Lael 2 4 4 Motion Parameters Optionally Available for Area and Blemish Main Menu gt Inspection gt Motion Enable Motion when the part is expected to move or rotate Motion settings involve selecting the number of edges to locate adjusting sensitivity and selecting whether or not rotation is enabled These settings appear on the Inspection Menu when Blemish with motion or Area with motion is selected as a Sensor Type Number of Edges Main Menu gt Inspection gt Motion gt Number of Edges 34 iVu Series Image Sensor On the Number of Edges screen use the radio buttons to select One Edge or Two Edges If One Edge is selected motion is tracked in one direction by default horizontally if Two Edges is selected motion can be tracked horizontally and vertically Sensitivity Main Menu gt Inspection gt Motion gt Sensitiv
5. Emulator program All configuration changes will be saved to the CONFI G CFG file 10 Copy the sensor configuration that is CONFIG CFG from the PC working directory to the USB Thumb Drive for example lt USB gt BANNER myName CONFIG CFG 11 Remove the USB Thumb Drive from the PC and connect to the sensor 12 Restore the configuration to the sensor a Go to Main Menu gt System gt Sensor Configuration gt Load Configuration b Select the Configuration to restore c Click the Load button to start the restore sensor configuration You will need to reboot the sensor when the restore is complete 4 2 2 How to Debug Using the Emulator from the USB Flash Drive L 2 H 0 N Plug a USB Thumb Drive into the sensor Save Inspection Logs to the sensor a On the Main Menu gt Inspection Logs gt View Logs screen click the Save icon to save the inspection logs b When prompted select Yes to save sensor configuration along with the Inspection Logs The location of these files on the USB Thumb Drive will be displayed after the operation is completed the Inspection Logs are saved in lt USB gt BANNER lt SENSOR_NAME gt InspLog and the sensor configuration is saved in lt USB gt BANNER lt SENSOR_NAME gt For example if the sensor name is myName e Configuration File CONFIG CFG path lt USB gt BANNER myName e Inspection Logs path lt USB gt BANNER myName lnspLog it NOTE If the sensor has no name th
6. Exposure routine a second time or adjust Gain and Exposure manually e Main Menu gt Imager gt Gain 39 iVu Series Image Sensor e Main Menu gt I mager gt Exposure For Micro Video Lens Models Only 1 Use the supplied 1 16 in hex key to loosen the Focusing Window locking screw D then adjust focus on the iVu Series sensor using the clear Focusing Window B 2 Adjust focus while monitoring the focus number To ensure the best image adjust the focus until the Focus Number peaks Pe NOTE Turning the Focusing Window counter clockwise focuses on closer objects while turning the Focusing Window clockwise focuses on more distant objects 3 After the best image has been acquired lock the focusing window Micro Video Lens Models Lens Focusing Window Locking Clip Locking Screw Filter Cap optional Filter optional F NOTE Filter Kits are available separately 40 iVu Series Image Sensor For C Mount Models Only 1 Remove the Lens Enclosure 2 Adjust focus while monitoring the focus number To ensure the best image adjust the focus until the Focus Number peaks 3 Replace the Lens Enclosure on the camera C Mount Models C Mount Lens Lens Enclosure Retainer Ring optional Filter optional Filter Retainer Ring Tool K NOTE Filter Kits are available separately 3 3 Configuring an Area Sensor K NOTE By default the Trigger is set to I nternal and will continuou
7. If an integrated ring light is not used another light source is needed Various lights are available from Banner Operating in external trigger mode requires a triggering source for example the Banner WORLD BEAM QS18VN6D sensor iVu Series Image Sensor Focusing Window Focusing Window Locking Clip LED Green Ready Red Error BR WN e LED Green Pass Red Fail m a a os oy A USB Connector B Remote Display Connector C Power I O Connector Mounting Bracket Mounting Holes uses supplied three M4 x 4 mm screws 1 2 2 Installing and Connecting the Sensor The iVu TG sensor requires a bracket for mounting Three brackets are available from Banner The brackets allow the sensor to be mounted either perpendicular to the part or at an adjustable angle Thread three M4 x 4mm screws through the bracket into the mounting holes in the bottom of the sensor Tighten all three screws iVu Series Image Sensor Table 1 iVu Brackets SMBI VURAL SMBI VURAR SMBIVUU Installing a Filter on 1Vu Series Sensors Installing a Filter on the Micro Video Lens Model To install a filter on the iVu Series sensor with Micro Video Lens use the illustration as a guide and follow the steps listed below A CAUTION Failure to follow these instructions may cause damage to your iVu Series sensor Micro Video Lens Models Lens Focusing Window Locking Clip Locking Screw Filter Cap Filter 1 Remove the Focusing Window locking
8. Reboot Sensor Main Menu gt System gt Reboot Sensor The Reboot Sensor screen allows you to force a reboot of the sensor K NOTE This option is not available on the Emulator 2 2 9 Firmware Update Main Menu gt System gt Firmware Update The Firmware Update screen is used to load the latest sensor firmware The Firmware Update screen lists the firmware versions it finds in the BANNER FIRMWARE folder on the USB flash drive When you receive a firmware update from Banner Engineering be sure to put it in the BANNER FIRMWARE folder on the USB flash drive K NOTE The Firmware Update menu is not available in the Emulator 23 iVu Series Image Sensor 2 3 I mager Menu Main Menu gt Imager The Imager menu icon is on the Main Menu and lists parameters that affect the characteristics of the captured image The Imager menu is used to access the Auto Exposure routine manually adjust Exposure and Gain set Trigger and Strobe options as well as the size of the field of view FOV 2 3 1 Auto Exposure Main Menu gt I mager gt Auto Exposure Auto Exposure optimizes the exposure time and gain for the current lighting conditions K NOTE The Auto Exposure option is not available on the Emulator 2 3 2 Exposure Main Menu gt I mager gt Exposure Exposure is the amount of time the sensor allows light to energize the imager Increasing the exposure time by moving the slider to the right allows more light to energize t
9. et bhnehoa gene Ga ire un enes 30 BAS BICMISHWIGINN geene tases eerie ate neces tdacte ean retort A aeons erty eer 32 2 4 4 Motion Parameters Optionally Available for Area and Blemish ccc cece cece cece eeeeeeeeeeeeeeeeeeeas 34 2 EOIN a E asain EE E A bade i eau ten E E E aaantnbemnes A eter eaeee 36 Za L SEON EOG aa A E a se ae oe 36 L V E O a a a aA a E E eer Tere E eee eee A EE 37 3 SELLING Up GN INSDSCEION ssssiienna a a a anand a a 39 Sal Selecting a Sensor TYDE erri onone anaE EEEE EE ETNEA KENIAN EEEE EERE AEAEE EEE ENEE 39 se AGUNG a Good iMag moree panes NAAN EAEE AEAN 39 S a COMMOUIING aN Area SENSO serno annae TAANE EEEE NEARE E EE A 41 324A COMMOUIINGa Blemish SenNSOr serrreiirersiosr r esaiar er nnNNK EEEN DEEE EENAA NENNE T EEANN EEA 45 DF CONMIuUrmMO a Match Senor secescindeendeeincatenin acne wae neroennmaam EAA AEE EE EEEE ENEE E 48 PLRO TE E A A EAA cena NEE E AANE E EE 51 A DEBUGGING INSPECEIONS QQ crisiiiccnewesenedeiesawwdciamsndsmwvenedeuhnemewacenennwesnwviedeesenenswndaeasabwimsisiied exis 52 ce IN MUON seer ceteceen cose oon enonce ss escer co E E sau e te ce cenoreesceues E AEE E 52 4 2 How to Round Trip Debug Using the Emulator oo cccccce cece ccceeee eee eee e ee eeee eens eeesseeaeneseeeneasaaananegs 52 4 2 1 How to Debug Using the Emulator from a PC a cece eee ecccce cece cece cece eee eens esses eeee nent eee seenaeneneennens 52 4 2 2 How to Debug Using the Emulator from the USB Flash Drive cece
10. feature of interest e Area Range or size of a feature of interest e Pass Count To see a working example of the sensor configured as an Area sensor see Demo Mode ROI Type Inspection gt Desired Sensor Type gt ROI Type Sensors The Region of Interest ROI is the user defined area on the screen that the sensor will analyze The ROI Type can be rectangular elliptical or circular From the menu at the bottom of the ROI Type screen select the ROI Type to use for the inspection Adjust the ROI as appropriate for your inspection An ROI can be as large as the entire Field of View FOV 30 iVu Series Image Sensor Intensity Range Main Menu gt Inspection gt Area gt Intensity Range Intensity Range is the range of gray scale values the sensor should look for To set the Intensity Range use the eye dropper on the left of the screen to select the target feature then use the slider bar at the bottom of the display to fine tune the selection As the slider bar is moved green highlighted areas indicate objects the sensor finds K NOTE Objects that are colored yellow are found but filtered out This is because the objects fall outside of the Area Range See Area Range to adjust this setting Area Range Main Menu gt Inspection gt Area gt Area Range The Area Range is used to set the size limits of a feature of interest Use the slider bar at the bottom of the display to select the range Areas are measured by cou
11. its manufacture which at the time it is returned to the factory is found to have been defective during the warranty period This warranty does not cover damage or liability for misuse abuse or the improper application or installation of the Banner product THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND WHETHER ARISING UNDER COURSE OF PERFORMANCE COURSE OF DEALING OR TRADE USAGE This Warranty is exclusive and limited to repair or at the discretion of Banner Engineering Corp replacement IN NO EVENT SHALL BANNER ENGINEERING CORP BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS EXPENSES LOSSES LOSS OF PROFITS OR ANY INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT WHETHER ARISING IN CONTRACT OR WARRANTY STATUTE TORT STRICT LIABILITY NEGLIGENCE OR OTHERWISE Banner Engineering Corp reserves the right to change modify or improve the design of the product without assuming any obligations or liabilities relating to any product previously manufactured by Banner Engineering Corp 59 Index A Advanced 23 annotations disabled 13 annotations enabled 13 area parameters area range 31 43 intensity range 31 42 area range 31 43 area sensor 30 Area sensor 17 auto exposure 24 bl
12. on the bottom right of the screen to see how the sensor detects edges on other images and adjust if necessary e Adjust the Edge Length Range The sensor counts all the edge pixels it detects in the ROI The bar at the bottom of the Edge Length Range screen shows all the different contiguous edge segments found Edge segments within the two brackets are highlighted in green and those outside the brackets are ignored and colored yellow as in the example You can move each bracket to add or remove more of the edge segments from consideration 1 Go to Main Menu gt Inspection and click the Edge Length Range option 2 Move the slider at the bottom of the screen to the to the desired Edge Length Range You can zoom in to refine the range 46 iVu Series Image Sensor e Adjust the Pass Count parameter The sensor aggregates all the edge pixels that fall within the Edge Length Range and indicates the value with a small colored bar at the bottom of the page If within the range brackets the bar is green otherwise it is yellow 1 Goto Main Menu gt Inspection and click the Pass Count option 2 Use the brackets to set a tolerance for the pass fail 3 Test the complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad parts 4 To complete the Blemish application setup set triggering as appropriate for the application K NOTE Remote Teach does not work with the Blemish Sens
13. screw D using the 1 16 in hex key NOTE The Locking Clip C inserts in a groove near the top of the Focusing Window B When removing the window the Locking Clip will be loose Be careful not to lose the clip while removing the window 2 Unscrew the Focusing Window by turning it clockwise approximately 5 complete turns or until the Focusing Window disengages from the light lens assembly NOTE The light lens assembly may include an integrated ring light or a blank disk if an integrated ring light is not used Be careful that the light lens assembly does not pull out when removing the Focusing Window Give a slight tug on the Focusing Window when you think you ve unscrewed it far enough If the lens assembly moves with the window continue to rotate the window clockwise until the lens assembly does not move Set the Focusing Window aside Be careful not to get any debris on the window s O ring If present remove the protective covering on the filter Place the filter into the Filter Cap and press the cap onto the lens After the filter is installed place the Focusing Window back into the housing while inserting the Locking Clip into the groove as shown SS at iVu Series Image Sensor Groove 7 Press the Focusing Window onto the housing to make sure that it seats correctly no gap between the window and housing Rotate the window counter clockwise at least two turns 8 Replace the locking tab screw but do not tighten unti
14. the user defined area on the screen that the sensor will analyze The ROI Type can be rectangular elliptical or circular From the menu at the bottom of the ROI Type screen select the ROI Type to use for the inspection Adjust the ROI as appropriate for your inspection An ROI can be as large as the entire Field of View FOV 32 iVu Series Image Sensor DP my a rt ji Sensitivity Main Menu gt Inspection gt Blemish gt Sensitivity Sensitivity is used to fine tune how sensitive the sensor is to finding blemish or other edges within the ROI The Sensitivity value helps account for light variations that might affect how well the sensor detects edges on inspected parts The Sensitivity scale is from O to 100 where 0 means least sensitive and 100 means most sensitive If set near 0 the sensor will only find very sharp edges with strong contrast If set near 100 the sensor will find very dim or blurry edges and may be unstable Edge Length Range Main Menu gt Inspection gt Blemish gt Edge Length Range The sensor counts all the edge pixels it detects in the ROI The bar at the bottom of the Edge Length Range screen shows all the different contiguous edge segments found Edge segments within the two brackets are highlighted in green and those outside the brackets are ignored and colored yellow Use the slider bar to specify the edge length range in pixels Edges found within this range will be considered to calculate the Pass
15. three Sensor Types Area Sensor An Area type sensor is used to ensure that a feature or multiple features are present on a part When setting up the sensor for an Area inspection a feature such as a drilled hole is identified as well as the size area expected If there is more than one of the identified features on a part the number expected can be set as well During the inspection the sensor verifies that each part or package includes the specified number of features Some example applications include e Inspections that check for drilled holes on a part e Inspections that check for correctly stamped parts e Inspections that ensure proper packaging for example check that a packing slip exists in or on a box test whether a vial is properly capped e Inspections of blister packs Blemish Sensor A Blemish type sensor can be used to find flaws on a part for example scratches on a disc or it can be used to make sure a feature exists on a part Although verifying a feature is present on a part is more commonly an Area sensor application a Blemish sensor may be a better option when dealing with variable materials or uneven lighting Some example applications include e Inspections that check for scratches on a part and reject parts where the scratches are too numerous or larger than acceptable e Inspections that check for the presence of some label or marking on a part that may vary in color Match Sensor A Match type sensor is
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17. Move the slider from 0 to 180 degrees Note that the smaller the rotation range the faster the inspection will run To set the Rotation Range 1 Go to Main Menu gt Inspection and click the Rotation Range option A INER 2 Move the slider at the bottom of the screen to the desired rotation If you are verifying that a label is correctly applied to a container that is on straight you will want to set a small rotation If you want to make sure that the correct label is present no matter how the part is oriented in the Field of View then the rotation range will be set to its maximum 180 which is the setting for the Demo Ek f rA i bi oF Set the Pass Count parameter The Minimum Pass Count is the minimum number of parts labels or features expected to fall within the specified criteria the Maximum Pass Count is the maximum number expected to fall within the specified criteria These settings are used to determine the pass or fail result of the inspection 1 Goto Main Menu gt Inspection and click the Pass Count option 50 iVu Series Image Sensor 2 Set the Minimum Pass Count and Maximum Pass Count as appropriate In the Demo both are set to 1 6 Test the complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad 7 To complete the Match application setup set triggering as appropriate for the application K NOTE When running a Match inspection the s
18. Outputs 1 3 Home Screen The Home screen on the iVu Series sensor display is used to monitor inspections and to configure the sensor Normally the part being inspected is centered on the screen with the feature of interest bounded by the Region of Interest ROI a rectangle as shown below The ROI can be rotated and resized and is highlighted when selected for adjustment 12 iVu Series Image Sensor Main Menu Field of View Display Modes Region of Interest Help button Zoom In Zoom Out Manual Trigger 1 3 1 Display Modes The iVu Series sensor has three Display Modes Annotations Enabled Annotations Disabled and Inspection Statistics Annotations Enabled Annotations Enabled shows the image of the part with highlighting over the pattern or objects that the sensor finds within the ROI Green highlighting indicates good objects that is passes based on all parameter settings yellow highlighting indicates filtered objects that is the object does not meet size requirement or is slightly below the acceptance level red highlighting occurs if the sensor can find no object or pattern in the Field of View FOV that matches the reference object or pattern or meets threshold requirements Annotations Disabled Annotations Disabled shows the image of the part without any annotations 13 iVu Series Image Sensor 1 3 2 Inspection Statistics To access the Inspection Statistics click the Display
19. ages of a range of samples to set up from the worst good part to the best bad part The Demo application shows how the sensor when configured as a Blemish sensor can accept or reject parts based on the range of edge pixels the sensor detects in the ROI Start the setup with a good part Normally each part to be tested will be centered in the Field of View FOV 1 Adjust the Region of Interest ROI Resize the ROI so that it surrounds just the feature of interest In the Blemish Demo example the feature of interest includes the two irregular shapes below the Banner logo 2 Adjust the parameters of the sensor by clicking inside the ROI then click the sensor name button e Adjust the Sensitivity parameter Sensitivity is used to fine tune how sensitive the sensor is to finding blemish or other edges within the ROI The Sensitivity value helps account for light variations that might affect how well the sensor detects edges The Sensitivity scale is from O to 100 where 0 means least sensitive and 100 means most sensitive If set near 0 the sensor will only find very sharp edges with strong contrast If set near 100 the sensor will find very dim or blurry edges and may be unstable 1 Go to Main Menu gt Inspection and click the Sensitivity option 45 iVu Series Image Sensor 2 Use the slider on the bottom of the screen to adjust the sensitivity watching as the sensor detects more or fewer edges 3 Click the Trigger button
20. ain Menu gt Inspection and click the Intensity Range option 42 iVu Series Image Sensor 2 Click on the eye dropper icon on the left of the screen and then click anywhere in one of the white letters Now any white area will be highlighted in green Use the slider bar at the bottom of the display to fine tune the selection As the slider bar is moved green highlighted areas indicate objects the sensor finds and counts The objects colored yellow are found but filtered out that is not counted because the objects fall outside of the Area Range ae NOTE To get to the other parameters click the back arrow then click inside the ROI and then click the sensor name button e Adjust the Area Range The Area Range is used to set the size limits of a feature of interest Use the slider bar at the bottom of the display to select the range Areas are measured by counting pixels For example a rectangular feature that is 100 pixels wide by 200 pixels tall has an area of roughly 20 000 pixels 1 Goto Main Menu gt Inspection and click the Area Range option 2 Move the slider at the bottom of the screen to the to the desired area range In the Demo example the Area Range is adjusted so that each letter is identified as a found object indicated by the green highlight and the blue 43 iVu Series Image Sensor e Set the Pass Count parameter The Minimum Pass Count is the minimum number of parts labels or features expec
21. ation is saved in lt USB gt BANNER lt SENSOR_NAME gt For example if the sensor name is myName e Configuration File CONFIG CFG path lt USB gt BANNER myName e Inspection Logs path lt USB gt BANNER myName InspLog NOTE If the sensor has no name then the folder is the first 8 characters of the serial number 3 Remove the USB drive from the sensor and insert it into an available USB port on a Windows PC that has the iVu Emulator installed a 4 Copy the Sensor Configuration from the USB Thumb Drive to the folder where the Emulator is installed on the PC For example if the sensor name is myName and the iVu Emulator is installed in the default location on the PC copy the file lt USB gt BANNER myName CONFIG CFG to C Program Files Banner Engineering iVu Series 5 Copy the Inspection Logs from the USB Thumb Drive for example lt USB gt BANNER myName InspLog to the InspLog folder on the PC for example C Program Files Banner Engineering iVu Series InspLogs 6 Start the emulator 7 Set the Trigger option to Internal Important Make sure the iVu Emulator is NOT running before going to the next step a Goto Main Menu gt Imager gt Trigger and select Internal b Set the Trigger Interval as desired The iVu Emulator will run with the saved configuration from Step 6 using the saved Inspection Logs from Step 7 as images 8 Make the desired adjustments 52 9 iVu Series Image Sensor Close the iVu
22. ator is not running and copy the Device Configuration from the USB Thumb Drive to the folder where the Emulator is installed on the PC For example if the device name is myName and the iVu Emulator 54 iVu Series Image Sensor is installed in the default location on the PC copy the file lt USB gt BANNER myName CONFIG CFG to C Program Files Banner Engineering iVu Series Launch the iVuEmulator exe program Go to the Information screen Main Menu gt System gt Sensor Information Click the white box next to the Device Name label and enter the desired Device Name Click the Back button on the lower left corner of the screen to save the Device Name Close the Emulator program and the Device Name will be saved to the CONFIG CFG file 0 If running the Emulator on the PC copy the CONFIG CFG file back to the original folder on the USB drive lt USB gt BANNER lt DEVICE NAME gt for example lt USB gt BANNER myName NOTE The device will look in the original folder for example myName for the CONFIG CFG file 11 Remove the USB Thumb Drive from the PC and connect to the device 12 Restore the configuration to the device a Goto Main Menu gt System gt Sensor Configuration gt Load from USB b Select the Configuration to restore c Click the Load button to start the restore device configuration F NOTE Once the new device name is restored in the device all files saved to USB will now reside in the folder corr
23. ccc cccceeceeeeeeeeeeaeeeeeeeeeeeeenanes 53 5 Updating the Sensor ssiniinio E tented 54 SLU PTO a A E sired celia eaten 54 5 2 How to Set or Modify a Device Name nassssssussssnsrnnsrersrrrrrrrerrrerrrerrrsrrrsrrrorrrorrroerrrerrrrerrrrrrrrrerrrrrerrene 54 5 3 How to Reset the Sensor Password as asssssssssrsssrrnesrrnnrrnrrrrrrrrrrrsrrrsrrrornrerrrrsrrrsnrrsrrrsrrrerererrrerrrenrrene 55 5 4 How to Use Bitmap Image Files with the iVu Emulator n sssesssssrnssrrnsrrnsrrrsrrrsrrrerrrerrrerrrrrrrrrrrrrrrsrrrne 55 6 LED Indicator Troubleshooting 3 seassiiiniinciitewarecwtewnnsaeseannacsnecwtewdduatentiaws aa 57 O LENTOS ee a a a a E E A 57 iVu Series Image Sensor CEAN I aaa E NE A AA Onde ae canine wade cient raat E OEEO enacts Matec 57 7 Product Support and Maintenance sssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 58 Jal ProdUCE SUDDPOE dxcseatewwreinnie cilncrncesad EREA miad cna tuie EOO ied sence dtegdeubk inte matdenavens 58 T2 MaintenanGe irrien ARO nncusaelae T E ESE ERAO EA rnin hashes 58 7 3 Banner Engineering Corp Limited Warranty ssssssssssssssesrrssrrrsrersrrrerrrerrrenrrrrrrsrrrsrrrsrrrsrrrerrrerrrerrrene 59 iVu Series Image Sensor 1 Overview of the Sensor The iVu TG Image Sensor sensor is used to monitor parts for type size orientation shape and location No PC is required to configure the sensor Instead the sensor has a color touch screen display either integrated
24. d inspections and configuration from an iVu sensor then modify its parameters on the emulator and restore the updated configuration back to the sensor When you install the iVu Emulator by default it is installed in the following folder C Program Files Banner Engineering iVu Series You can run the Emulator from this folder but you will need to move files between the USB drive and PC To avoid moving files you can copy the Emulator executable to the USB drive and run the Emulator directly from the USB drive This how to describes the procedures for doing round trip debugging either using the iVu Emulator installed on a PC or using it directly from the USB Thumb Drive K NOTE This document refers to saving configuration and inspection logs in folders based on the sensor name If you have not yet named the sensor then folders will be named using the first 8 characters of the sensor serial number 4 2 1 How to Debug Using the Emulator from a PC 1 Plug a USB Thumb Drive into the sensor 2 Save Inspection Logs to the Thumb Drive a On the Main Menu gt Inspection Logs gt View Logs screen click the Save icon to save the inspection logs b When prompted select Yes to save sensor configuration along with the Inspection Logs The location of these files on the USB Thumb Drive will be displayed after the operation is completed The Inspection Logs are saved in lt USB gt BANNER lt SENSOR_NAME gt InspLog and the sensor configur
25. d the inspection will continue normally This time delay is just for the screen You can set this parameter from 0 to 3600 seconds using the slider at the bottom of the screen 22 iVu Series Image Sensor LCD Timeout Main Menu gt System gt Display Settings gt LCD Timeout The LCD screen dims after a user selectable period when the device is not being used Use the arrow keys or slide the bar at the bottom of the screen to set the LCD screen time out nr K NOTE This screen is not available in the Emulator Touch Calibration Main Menu gt System gt Display Settings gt Touch Calibration Touchscreen Calibration may be necessary if the software does not correctly respond when an icon on the screen is pressed The calibration routine aligns the touch screen s coordinates to the display behind it Be sure to follow the prompts on the screen when executing the Touchscreen Calibration function re K NOTE This screen is not available in the Emulator Advanced Main Menu gt System gt Display Settings gt Advanced The Advanced Display screen allows you to enable the Optimize Display Response option This feature helps to make the display more responsive when the sensor is busy either inspection times are long and or no idle time exists between inspections Disable this feature if Missed Triggers occur due to touchscreen presses With this setting disabled the display may become sluggish when the sensor is busy 2 2 8
26. e folder name is the first 8 characters of the serial number Remove the USB drive from the sensor and insert it into an available USB port on a Windows PC that has the iVu Emulator installed Copy the iVuEmulator exe program file to the USB Thumb Drive in the same location as the CONFIG CFG file for example lt USB gt BANNER myName Launch the lt USB gt BANNER myName iVuEmulator exe program Set the Trigger option to Internal a Go to Main Menu gt I mager gt Trigger and select Internal b Set the Trigger Interval as desired The iVu Emulator will run with the saved configuration using the saved Inspection Logs as images Make the desired adjustments Close the iVu Emulator program All configuration changes will be saved to the CONFIG CFG file Remove the USB Thumb Drive from the PC and connect to the sensor 0 Restore the configuration to the sensor a Goto Main Menu gt System gt Sensor Configuration gt Load Configuration b Select the Configuration to restore c Click the Load button to start the restore sensor configuration You will need to reboot the sensor when the restore is complete 53 iVu Series Image Sensor 5 Updating the Sensor 5 1 Update Process Banner Engineering may release new versions of the sensor firmware in the future New firmware releases can be downloaded from Banner s website or can be obtained by ordering the latest Product CD The following steps will guide you through the p
27. em Configuration Main Menu gt System gt Sensor Configuration The Sensor Configuration menu options are e Save sensor Configuration to the USB flash drive e Load sensor Configuration from the USB flash drive e Reset the sensor Configuration to defaults e Set Pass Fail Output Save to USB Main Menu gt System gt Sensor Configuration gt Save to USB The Save to USB screen allows the sensor Configuration to be saved to a USB flash drive The saved configuration information can be used as a backup or as a way to clone configuration information for other sensors K NOTE On the Emulator this option is Save Configuration Load from USB Main Menu gt System gt Sensor Configuration gt Load from USB The Load from USB screen allows the sensor Configuration to be restored from a USB flash drive This operation removes all existing inspections and replaces them with inspections contained in the configuration file on the USB flash drive K NOTE On the Emulator this option is Load Configuration 18 iVu Series Image Sensor Match Time Limit Main Menu gt System gt Sensor Configuration gt Match Time Limit When the sensor is configured as a Match sensor this screen provides for adjusting the amount of time allotted for the sensor to determine if a pattern is good This is essentially a timeout value If set too high the sensor can miss triggers while trying to match a bad pattern K NOTE This menu option is o
28. emish sensor 32 Blemish sensor 17 C Configuration menu 18 D debugging 52 display modes annotations disabled 13 annotations enabled 13 statistics 13 Display Settings menu 22 emulator 52 exposure 24 external strobe 26 F fail hold time 22 field of view 27 firmware update 23 focus number 25 G gain 24 H home screen 12 imager auto exposure 24 exposure 24 gain 24 trigger 25 imager menu 24 Information 19 Inspection Logs 36 inspection menu 28 intensity range 31 42 internal strobe 27 iVu emulator 52 L LCD Timeout 23 Load from USB 18 lock sensor 20 logs inspection 36 system 37 M match parameters percent match 29 49 rotation range 29 50 match sensor 28 Match sensor 17 Match Time Limit 19 maximum pass count 30 32 34 44 50 menu Display Settings 22 Configuration 18 Sensor Type 17 System 17 minimum pass count 30 32 34 44 50 motion parameters area range 31 43 intensity range 31 42 motion settings 20 34 number of edges 35 rotation 35 sensitivity 35 motion settings 20 34 number of edges 35 P pass count parameter 30 32 34 44 50 percent match 29 49 R rotation parameter 35 rotation range 29 50 S Save to USB 18 sensitivity 35 sensor display 12 Sensor Type menu 17 statistics 13 strobe external 26 internal 27 System Logs 37 System menu 17 T Touchscreen Calibration 23 trigger 25 U USB loading from 18 saving to 18
29. en lock the focus ring A K NOTE For the Focus Number to work the sensor must be triggering and the images must be similar over time 25 iVu Series Image Sensor 2 3 6 Strobe Main Menu gt I mager gt Strobe The Internal Strobe configures the operation of the integrated ring light The External Strobe configures the operation of an external light External Main Menu gt Imager gt Strobe gt External The External Strobe is a 5V output that can be used for an external light Setting options are Always ON Always OFF or Exposure Based If Exposure Based is selected then the external light is on during the time the sensor is capturing an image Internal Main Menu gt Imager gt Strobe gt Internal 26 iVu Series Image Sensor The Internal Strobe setting configures the operation of the integrated ring light Strobe options are Always ON Always OFF or Exposure Based If Exposure Based is selected then the ring light is on during the time the sensor is capturing an image For UV models the Always ON option is not available 2 3 FOV Field of View Main Menu gt Imager gt FOV The field of view FOV is the area that the sensor can see at a given working distance The working distance is the distance from the sensor s lens cover to the part being inspected By default the sensor uses the entire FOV in its operation The effective FOV can be reduced in order to speed up the processing time o
30. ensor will look for any possible patterns to match anywhere within the Field of View 3 5 1 Remote Teach The Remote Teach function is a method of remotely updating inspection parameters while the iVu sensor is running Remote Teach is only available when the iVu is configured as a Match sensor The sequence of events for executing a Remote Teach are 1 With the sensor Ready see Installation on page 6 pulse the Remote Teach line 2 The sensor recognizes that the Remote Teach line has been pulsed and waits for the next valid trigger 3 At the next valid trigger Ready goes inactive the Green Ready LED shuts OFF and the sensor acquires a new image 4 The sensor learns the new pattern and performs the analysis 51 iVu Series Image Sensor 4 Debugging Inspections 4 1 iVu Emulator The iVu Emulator is a Windows application that allows you to operate in a Windows environment exactly as you would on the iVu Series sensor itself In general the Emulator is an inspection debugging tool where you can 1 Import stored inspections and configuration from an iVu TG sensor 2 Modify inspection parameters on the emulator 3 Restore the updated configuration back to the sensor 4 2 How to Round Trip Debug Using the Emulator The iVu Emulator is a Windows application that allows you to operate in a Windows environment exactly as you would on the sensor itself In general the Emulator is an inspection debugging tool you can import store
31. esponding to the new device name You will need to reboot the device when the restore is complete K NOTE If a Device Configuration from one device is loaded onto another device the Device Name from the Device Configuration will not be stored in the device 5 3 How to Reset the Sensor Password If you forget the password for your sensor you can remove the current password using a reset key that is generated by the Password Reset Utility which is located on the Product CD The following steps will guide you through the specific steps to reset the password L 2 3 4 5 6 7 8 9 1 On your iVu Series sensor click the Forgot button located on the bottom of the Enter Current Password screen Write down the 6 digit Device Key On a Windows PC insert the iVu product CD into the CD ROM drive From the product CD menu started upon inserting the CD launch the Password Reset Utility Enter the Device Key into the text box in the Utility identified as Step 1 in the Password Reset Utility Click the Generate Reset Key button Write down the four digit Password Reset Key identified as Step 2 in the Password Reset Utility On the iVu Series sensor check the Next button on the Password Reset screen Enter the 4 digit reset key on the Enter Reset Key screen 0 Click Apply The password is now cleared 5 4 How to Use Bitmap I mage Files with the iVu Emulator You can use bitmap bmp image files with the iVu Emulator for deve
32. f an inspection or to decrease background noise Maximize FOV Main Menu gt Imager gt FOV gt Maximize FOV If the FOV has been modified and you want to quickly get back to the default click the Maximize FOV menu option to restore the FOV to the entire sensor display 27 iVu Series Image Sensor Modify FOV Main Menu gt Imager gt FOV gt Modify FOV Use this option to reduce or alter the size of the FOV 2 4 Inspection Menu Main Menu gt Inspection The Inspection menu icon is located on the Main Menu and is where settings for inspection can be adjusted Each type of sensor has specific settings that are available 2 4 1 Match Menu Main Menu gt Inspection gt Match When the sensor is configured as a Match sensor set the ROI Type Percent Match Rotation Range and Pass Count for the inspection To see a working example of the sensor configured as a Match sensor see Demo Mode ROI Type Inspection gt Desired Sensor Type gt ROI Type Sensors The Region of Interest ROI is the user defined area on the screen that the sensor will analyze The ROI Type can be rectangular elliptical or circular From the menu at the bottom of the ROI Type screen select the ROI Type to use for the inspection Adjust the ROI as appropriate for your inspection An ROI can be as large as the entire Field of View FOV 28 iVu Series Image Sensor Percent Match Main Menu gt Inspection gt Match gt Perce
33. g or incorrectly positioned then the sensor sends a fail output to the line iVu Series Image Sensor 1 2 Installation 1 2 1 Components iVu with Integrated Display The iVu Series sensor comes fully assembled with the lens and an integrated ring light if so ordered The integrated touchscreen display has a plastic cover to protect the display Remove this cover when setting up the sensor When the display is not in use be sure to keep the display covered to protect it If an integrated ring light is not used another light source is needed Various lights are available from Banner Operating in external trigger mode requires a triggering source for example the Banner WORLD BEAM QS18VNE6D sensor Focusing Window Focusing Window Locking Clip LED Green Ready Red Error LED Green Pass Red Fail Mm BB U N e Integrated Display E i l 1 F i I i i i f i i ie ee es ee A 8 pin Euro style M12 female USB Cable Connector 8 pin Euro style M12 male Power and I O Cable Connector C Mounting Bracket Mounting Holes uses supplied three M4 x 4 mm screws faa ae ee E p iVu with Remote Display The iVu sensor for use with a Remote Display comes fully assembled with the lens and an integrated ring light if so ordered Although the Remote Display is not required for normal sensor operation it is needed to set up the sensor and to monitor inspections
34. he imager which brightens the image K NOTE This feature is not effective on the emulator 2 3 3 Gain Main Menu gt Imager gt Gain Gain is an electronic boost to the image signal Increasing Gain by using the right arrow key or moving the slider to the right increases image brightness without increasing exposure time Note that Gain brightens both the light pixels and dark pixels and may reduce the image quality 24 iVu Series Image Sensor r K NOTE This feature is not effective on the emulator 2 3 4 Trigger Main Menu gt I mager gt Trigger A Trigger is a signal that makes the sensor capture an image and inspect it Use the radio buttons to select External Trigger Internal Trigger default or Free Run e If Internal Trigger is selected triggers are based on timed intervals and you need to select a trigger interval between 10 and 10000 milliseconds NOTE If the interval is less than the inspection time then missed triggers will occur e If External Trigger is selected inspections are triggered in response to an electrical signal on the Trigger input line e f Free Run is selected the sensor automatically runs continuous inspections 2 3 5 Focus Main Menu gt Imager gt Focus The Focus Number displayed at the bottom of this screen is used to fine tune image focus Loosen the lock on the lens cover turn the focus ring on the sensor until the Focus Number peaks or the image appears sharp th
35. iVu Series Image Sensor Instruction Manual Original Instructions 143372 REVSG Qe 31 July 2014 SSN SSr 143372 iVu Series Image Sensor Contents T OVEFVIEW OF ENG SENSOM siciiisincietevcscadsnniaiecaccsnsneiateeeneeasnsistecaniiusinaredeeesweewanistesdamiensmeteiveeswenes 4 Tok PYDICELIVUAODIICATIONS statcesdecexcecduncetnhenaancanaandels s ene E EEEN EAE EE cians ecanostencas 4 Tel PADEIIWMSDCGHOMN acstenpacncmacutebpiceciedatacasdieneacdencinceiadueteccunaides sicnsdeccadacintansnceiatadesewessecoenccceians 4 11 2 Blister Pack IASPECHOM xauteswnnmeccocsseceunatacacichousansuneniattdnenrnemsadnadGnsd onaneniecscdddazemencascchorsasane 5 11 3 Vial Stopper Inspeccion sidisxnnecenverestaransmnnancsadragunancuadebattaawnentndeddbaskmendaccntehensenencasadsseeesasc 5 Le a ON are E AAEE ENEE O EEE se eudone tects a ent necstehesannmmesress are cen coc 6 Dees COMIDONEMES wetecseceqepseanecothatonnacutatarietcaxesnenacetususansmmmatadsssenesydadmencebutvesemaniaccesecesseceansc tate 6 1 2 2 Installing and Connecting the Sensor on eee eeececccc cece cece eee e eee eee nee eee eee D DEES EERE Eee dG e EEE E EEE EE EES 7 1 2 3 iVu Trigger Remote Teach and I O WavefOrmMs un eccccccccccccccee cece ee eeeeeeeeeeeeeeeeeeeenaeeeeeeeeeegaaas 10 Peo TIOMMGSCSCN serine AR ENA E ATE E muesacseresssuccens tbe reodementetadenes seosenes 12 Dao eD DEY POGO EAE EE EEEE A E AEE A E E AATAS 13 E32 Mope On Stat speiniear EAEE EE EOE 14 L
36. ity Sensitivity is used to fine tune how sensitive the sensor is to finding a reference edge The Sensitivity value helps account for light variations that might affect how well the sensor detects edges on inspected parts The Sensitivity scale is from 0 to 100 where 0 means least sensitive and 100 means most sensitive If set near 0 the sensor will only find very sharp edges with strong contrast If set near 100 the sensor will find very dim or blurry edges and may be unstable due to noise within the image Rotation Main Menu gt Inspection gt Motion gt Rotation Rotation can be Enabled or Disabled Select Enabled if the part can be expected to rotate during the inspection 35 iVu Series Image Sensor 2 5 Logs Menu Main Menu gt Logs The Logs menu icon is on the Main Menu and is used to set up view and save Inspection and System Logs 2 5 1 Inspection Logs Main Menu gt Logs gt Inspection Logs This menu provides for configuring and viewing Inspection Logs Inspection Logs are stored inspection records that include a captured image the parameters used to inspect it and the results of that inspection Up to ten Inspection Logs can be held in memory on the sensor The next ten overwrite the previous Inspection Logs can be saved to the USB flash drive so that the logs can be imported to the emulator View Logs Main Menu gt Logs gt Inspection Logs gt View Logs Inspection Logs appear a
37. l you have set up and focused the sensor again Installing a Filter on the C Mount Lens Model To install a filter on the iVu Series sensor with C Mount Lens use the illustration as a guide and follow the steps listed below A CAUTION Failure to follow these instructions may cause damage to your iVu Series sensor C Mount Lens Models C Mount Lens Lens Enclosure Retainer Ring optional Filter optional Filter Retainer Ring Tool a NOTE Filter Kits are available separately Remove the Lens Enclosure and Lens Install filter behind the retainer ring Make sure it is fully seated Using the provided retainer ring tool thread the retainer ring into the sensor until it firmly seats the filter Replace the Lens and Lens Enclosure on the camera AUNE A CAUTION Electrostatic Discharge Avoid the damage that electrostatic discharge ESD can cause to the Sensor Always use a proven method for preventing electrostatic discharge when installing a lens or attaching a cable Cable Connections for iVu TG with Integrated Display The power and I O cable for the iVu TG sensor is available in 2 5 9 and 15 m 6 15 30 50 ft lengths The connector on the sensor is shown below B Li i Liv B Power I O Connector K NOTE Micro video lens model shown C Mount model connections are identical iVu Series Image Sensor Power I O Connections Wire Color Description Direction White Output 1 Output Brown 10 30V dc Inpu
38. log changes 38 iVu Series Image Sensor 3 Setting up an Inspection To set up for an inspection 1 Acquire a good image 2 Configure the sensor s in the inspection 3 Configure multiple sensors in the inspection 3 1 Selecting a Sensor Type When you exit Demo Mode the sensor reboots with a single inspection with a Match sensor type by default To change or for Plus models to add the Sensor Type 1 Go to Main Menu gt System gt Sensor Type This displays the Sensor Type menu options 2 Select either Area Blemish or Match 3 Click Apply 3 2 Acquiring a Good Image The iVu Series sensor needs to capture a good image of each part to ensure that it correctly passes good parts and fails bad parts 1 Go to Main Menu gt Imager gt Auto Exposure to run the Auto Exposure routine 2 Check the lighting e Make sure that the lighting is constant and consistent unchanging over time no shadows or hot spots e Capture the shape and form of the target object with lighting that optimizes its contrast and separates it from the background Depending on the target this may mean the integral ring light is not the best choice and other Banner lights should be considered e Adjust the mounting angle to provide the clearest image of the part features you are monitoring The mounting bracket lets you easily position and adjust the sensor on your line 3 If needed go to Main Menu gt I mager gt Auto Exposure to run the Auto
39. loping and simulating iVu inspections The iVu Emulator only accepts image files in bmp format If you have other image file formats use an image viewer editor program such as PhotoShop Gimp or Paint to convert the files to 8 bit grayscale bmp format K NOTE Images smaller than 640 x 480 will be black filled starting in the upper right Images larger 1 than 640 x 480 will be cropped starting in the upper left Copy the bmp files into the InspLog folder in the iVu Emulator install folder For example copy bmp files into the C Program Files Banner Engineering iVu Series IlnsLog folder 55 iVu Series Image Sensor NOTE Remove any existing omp or Log files in that folder to avoid confusion because the Emulator automatically runs all omp Log files sequentially according to filename 2 Launch the iVu Emulator program 3 Select Internal Trigger on the Trigger Selection screen Main Menu gt I mage gt Trigger and select Internal 4 Set the Trigger Interval as desired The iVu Emulator will be running using the bmp files from Step 1 K NOTE Banner does not recommend setting up inspections using these 8 bit grayscale images because you will always end up modifying the configuration after loading it on the sensor on the line A better choice would be to set up the inspection on the emulator using Inspection Logs from the sensor 56 iVu Series Image Sensor 6 LED Indicator Troubleshooting In normal operation
40. low to high and Remote Teach behaves electrically like trigger NPN High to Low Trigger and Remote Teach Input Waveforms Power up Wire Color Function Pink Trigger Remote Gray Teach The sensor triggers from high to low and Remote Teach behaves electrically like trigger K NOTE If the device used to trigger or remote teach the iVu TG is a sinking device these are the options regarding the use of a pull up resistor Option 1 Put a pull up resistor rated approximately 1k ohm between the sensor s positive voltage and the sensor s input as shown below Sinking VCC iVu Trigger Input Pullup Resistor 1k ohm Remote Teach Input gt 1 gt VV NPN 11 iVu Series Image Sensor iVu Output Waveforms Function Ready i Outputs 1 2 and 3 Pass Fail Pass Set as Active Pass Outputs 1 2 and 3 Set as Active Fail Strobe Out Configure as External amp Expose Based Pass Fail Pass Figure 4 PNP Outputs Function Ready Outputs 1 2 and 3 Pass Fail Pass Set as Active Pass Outputs 1 2 and 3 Pass Fail Pass Set as Active Fail Strobe Out Configure as External amp Expose Based Figure 5 NPN
41. mode icon The Inspection Statistic mode has two pages e History e Inspection Result Click the arrow to access the other page History The History screen shows inspection history from sensor reboot or the last time the statistics were reset including e Frame Range e Count Range minimum and maximum number of objects observed e Passed running total of parts that passed inspection e Failed running total of parts that failed inspection e Missed triggers running total of missed triggers e Percent Match e Time Range minimum and maximum inspection times observed Click the Reset button to reset statistics Inspection Results The Inspection Result screen shows data about the current inspection being viewed 1 4 Major Features 1 4 1 Demo Mode The first time you power up the iVu TG sensor it starts in Demo Mode Demo Mode uses stored images and inspection parameters that demonstrate how the sensor is set up without having to worry about focus lighting or triggers In this mode you can learn how to make adjustments while working with the different sensor types and observing how the adjustments affect the sensor results When you exit Demo Mode the sensor reboots into its normal operating mode with default settings 14 iVu Series Image Sensor K NOTE You may return to Demo Mode any time by going to Main Menu gt System gt Sensor Type and selecting Demo Mode 1 4 2 Sensor Types The iVu TG sensor includes
42. n icon provides access to parameters that need to be set for an inspection Parameters are dependent on Sensor Type Imager icon lists parameters that affect the characteristics of the captured image System icon used to manage the sensor Logs icon used to set up view and save Inspection and System Logs 2 2 System Menu Main Menu gt System The System menu icon is on the Main Menu and is used to manage the sensor The System menu provides for selecting Sensor Type updating sensor firmware backing up and restoring sensor Configuration and other general system level operations 2 2 1 Sensor Type Main Menu gt System gt Sensor Type The Sensor Type menu allows you to select one of the following as a Sensor Type e An Area sensor that detects if a particular feature or features is present e A Blemish sensor that either detects flaws or determines if a particular feature or features is present when conditions are not optimal for using an Area sensor e A Match sensor that determines whether a part or label matches some reference part or label 17 iVu Series Image Sensor K NOTE The first time you start up the sensor it starts in Demo Mode Demo Mode uses canned images to demonstrate how the sensor operates as a Match Area and Blemish sensor If in Demo Mode Sensor Type will have an option to exit Demo Mode If in normal running mode there is an option to enter Demo Mode 2 2 2 Syst
43. nly available when the Sensor Type selected is Match sok D mS e Reset to Defaults Main Menu gt System gt Sensor Configuration gt Reset to Defaults Resets all sensor configurations to the factory defaults This operation will remove all existing inspections and replace them with factory default settings 2 2 3 System Information Main Menu gt System gt Sensor Information The Information screen displays the following sensor information e Serial Number e Firmware Version e Boot Number e Up Timer the time elapsed since last boot of the sensor e Hour Count the total hours of operation in the sensor s lifetime e Model Number e Device Name Click the right arrow next to the Sensor Name field to display a software keyboard that allows you to change the Sensor Name 2 2 4 Lock sensor Main Menu gt System gt Lock sensor 19 iVu Series Image Sensor This option provides for locking the sensor to prevent accidental modification of settings When locked the sensor only provides access to pass fail statistics as well as the ability to view logs and to save them to a USB device A lock icon in the upper left corner of the sensor display indicates that the sensor is locked Note that the sensor can be locked with or without a password If a password is not used unlock the sensor by clicking on the Unlock sensor menu When a password is used it must be 4 digits entered using the software keypad If the password is lost
44. nt Match The Percent Match setting adjusts for how closely the inspected part or label matches the reference part or label The Percent Match scale is from 0 to 100 where 0 is the most tolerant and 100 is the least tolerant Move the slider to the left or to the right a ok DO oS a Rotation Range Main Menu gt Inspection gt Match gt Rotation Range The Rotation Range sets the expected rotation of parts or labels during an inspection For example a value of 45 means that the part may rotate 45 degrees in either direction from the reference part and still pass Move the slider from O to 180 degrees K NOTE The smaller the rotation range the faster the inspection will run 29 iVu Series Image Sensor Pass Count Main Menu gt Inspection gt Match gt Pass Count The Minimum Pass Count is the minimum number of parts labels or features expected to fall within the specified criteria the Maximum Pass Count is the maximum number expected to fall within the specified criteria These settings are used to determine the pass or fail result of the inspection L iii 2 4 2 Area Menu Main Menu gt Inspection gt Sensors gt Area When configured as an Area sensor the sensor is used to ensure that one or more features of interest are present on a part To configure as an Area sensor set four parameters e ROI Type Rectangle Elliptical or Circle and size e Intensity Range range of gray scale values of a
45. nting pixels For example a rectangular feature that is 100 pixels wide by 200 pixels tall will have an area of roughly 20 000 pixels 31 iVu Series Image Sensor Pass Count Main Menu gt Inspection gt Area gt Pass Count The Minimum Pass Count is the minimum number of parts labels or features expected to fall within the specified criteria the Maximum Pass Count is the maximum number expected to fall within the specified criteria These settings are used to determine the pass or fail result of the inspection L iii 2 4 3 Blemish Menu Main Menu gt Inspection gt Sensor gt Blemish When configured as a Blemish sensor it can be used to find flaws on a part for example scratches on a disc It can be used to make sure the a feature exists on a part Although this is more commonly an application for a sensor configured as an Area sensor a Blemish sensor may be a better option to find a feature when dealing with variable materials or uneven lighting Some sample applications include e Inspections that check for scratches on a part and reject parts where the scratches are too numerous or larger than acceptable e Inspections that check for the presence of some label or marking on a part that may vary in color To configure as a Blemish sensor select the ROI type and set the Sensitivity Size Filter and Pass Count ROI Type I nspection gt Desired Sensor Type gt ROI Type Sensors The Region of Interest ROI is
46. oducts have labels To verify each product an iVu Series sensor is configured for a Match inspection An image of a good product package is captured When the inspection is running if the sensor detects a package with a different or missing label the sensor sends a fail output to the line and the product is rejected iVu Series Image Sensor 1 1 2 Blister Pack Inspection Figure 2 Blister Pack Inspection Because of tightened federal regulations that make the quality of pharmaceutical packaging increasingly critical when tablets are inserted into a blister pack manufacturers need to verify that all the blisters in a pack have been filled with unbroken tablets To verify each blister in the pack use an iVu Series sensor configured for an Area inspection The sensor inspects each blister pack to make sure that each blister contains an unbroken tablet 1 1 3 Vial Stopper Inspection Figure 3 Vial Stopper Inspection In the pharmaceutical industry where vials are filled with tablets in a high speed application as soon as each vial is filled a stopper must be properly inserted into the vial To ensure that a stopper is properly inserted as each vial leaves the filling station an iVu Series sensor set up for an Area application and motion parameters enabled verifies that the vial has a stopper inserted into its neck and that the stopper IS positioned correctly to provide a proper seal on the glass vial If the stopper is missin
47. or type 47 iVu Series Image Sensor 3 5 Configuring a Match Sensor om K NOTE By default the Trigger is set to I nternal and will continuously trigger based on a time interval setting This may make it more difficult to make adjustments while setting up the sensor The best practice is as follows e Go to the Main Menu gt Imager gt Trigger menu and select External e Make sure there is no external trigger input e Use the Trigger icon in the lower right of the screen to manually trigger the sensor to capture an image as you set up and test e Capture images of a range of samples to set up from the worst good part to the best bad part Start the setup with a good part Normally each part to be tested will be centered in the Field of View FOV Teach the sensor a good reference part 1 Adjust the Region of Interest ROI The ROI is a dotted box as shown The color of the box depends on the inspection parameters red for fail green for pass 2 Click Anywhere within the ROI to select it When selected the ROI is bolded with resize and rotational icons in the corners 48 iVu Series Image Sensor 3 Resize the ROI so that it surrounds just the feature of interest In the Demo example the feature of interest is the Banner logo 4 Click the Teach icon to teach the sensor this good reference part With Annotations Enabled the screen will highlight in green the pattern found 5 Set sensor
48. parameters e Adjust the Percent Match parameter The Percent Match setting adjusts for how closely the inspected part or label matches the reference part or label The Percent Match scale is from 0 to 100 where 0 is the most tolerant and 100 is the least tolerant Move the slider to the left or to the right Es NOTE When running a Match inspection with annotations enabled the sensor will highlight in green any pattern matches that meet or exceed the value specified for Percent Match Patterns that are below the specified value for Percent Match down to approximately 20 or out of the Rotation Range see below will be colored yellow 1 Using a bad part click the Manual Trigger icon in the lower right of the screen to capture an image For this example one of the stored images is missing the letter N yet the sensor initially sees this as a good label 2 Goto Main Menu gt Inspection and click the Percent Match option 49 iVu Series Image Sensor 3 On the adjustment at the bottom of the screen adjust the slider and click the Manual Trigger button When adjusted correctly the annotations should turn yellow and the icon in the upper right of the screen should indicate fail Adjust the Rotation Range The Rotation Range sets the expected rotation of parts or labels during an inspection For example a value of 45 means that the part may rotate 45 degrees in either direction from the reference part and still pass
49. ranty Factory Support To help Banner better assist you be ready to provide the following information e iVu firmware version to find the version number click Main Menu gt System gt Sensor Information e Device Model Number and Date Code which are found on the bottom of the device e Exact wording of any messages that appeared on your screen e A description of what you were doing and what happened e A description of how you tried to solve the problem e Error Codes see LED Indicator Troubleshooting on page 57 7 2 Maintenance Maintenance tasks include keeping the hardware free of dust and dirt and possibly updating the iVu firmware as new versions become available Cleaning the Sensor Regularly remove any dust or dirt from the device using a soft cloth If needed slightly dampen the cloth with a weak solution of neutral detergent Avoid getting dirt on the imager the area behind the lens If the imager is dirty use anti static compressed air to blow off the dust Updating the iVu firmware The current version of iVu firmware is available for download from the Banner website See the Banner Website for the firmware download link 58 iVu Series Image Sensor 7 3 Banner Engineering Corp Limited Warranty Banner Engineering Corp warrants its products to be free from defects in material and workmanship for one year following the date of shipment Banner Engineering Corp will repair or replace free of charge any product of
50. rocess of updating the iVu firmware Step 1 Copy firmware of desired product to USB Thumb Drive 1 Launch the iVu Series software From Product CD e Place the latest Product CD into your CD ROM drive The iVu Series Software will automatically start e If your computer is not set for Auto Play you may start the iVu Series Software by browsing to the CD drive from My Computer screen and double clicking on iVuSeries exe From Banner Website e Visit Banner s Website http www bannerengineering com e Browse to Vision Products page and select the iVu product you are using e Click on the Software tab to view software releases e Determine which version you want to download Current Version recommended for example iVu Series Software Version 2010R4 e Click on the circular Download button This will initiate the download process Depending on your browser settings you may be asked to confirm or provide a location to save the file Choose to download on yoru desktop Note the file name e Double click the file to start extracting the files and run the iVu Series Software 2 Select the product you are using and browse to Firmware Update page 3 Click on Run Firmware Update Wizard and program will start 4 Follow on screen instructions Clicking on Copy firmware to USB will copy the selected firmware to the USB Thumb Drive Step 2 Install firmware on iVu 1 Remove the USB Thumb Drive from the PC and plug it into the sensor
51. s a strip of film You can select a frame to view a specific image Use the icon in the lower right of the screen to save the logs to the USB flash drive Logs saved to the USB flash drive can be imported into the emulator Click the Clear button to clear Inspection Logs 36 iVu Series Image Sensor mi I ES AN O The View Inspection Log screen is used to debug an inspection and shows one inspection in read only mode Click the upper left icon to cycle through views When in Statistics view the table title has arrows to switch between Inputs and Results of the Inspection Use the left and right arrow keys at the bottom of the screen to navigate through the all stored Inspection Logs Setup Main Menu gt Logs gt Inspection Logs gt Setup Use the radio buttons to Disable Logging to log Passed Inspections Failed Inspections or All Inspections 2 5 2 System Logs Main Menu gt Logs gt System Logs The System Log contains configuration change information other notifications and any errors or warnings that may be encountered e Click the icon in the upper left corner of the screen to show hide the time column e Click Clear Log button at the bottom of the screen to clear the System Log e Click the icon at the lower right of the screen to save the System Log to the USB flash drive 37 iVu Series Image Sensor K NOTE System log will not log changes while in Demo mode Additionally the Emulator does not
52. sly trigger based on a time interval setting This may make it more difficult to make adjustments while setting up the sensor The best practice is as follows e Goto the Main Menu gt I mager gt Trigger menu and select External e Make sure there is no external trigger input e Use the Trigger icon in the lower right of the screen to manually trigger the sensor to capture an image as you set up and test e Capture images of a range of samples to set up from the worst good part to the best bad part Start the setup with a good part Normally each part to be tested will be centered in the Field of View FOV To adjust the Region of Interest ROI follow the steps listed here The ROI is a blue dotted box as shown below 41 iVu Series Image Sensor 2 Resize and move the ROI to surround the feature of interest In the Demo example the feature of interest is the Banner logo as shown here It is still red because the parameters need to be set Ea NOTE When running an Area inspection the sensor finds objects only within the ROI 3 Click the sensor name button to go to open the Area sensor parameters menu 4 Set sensor parameters e Adjust the Intensity Range This is the range of grayscale values the sensor should look for Use the eye dropper on the left of the screen to select the target feature then use the slider bar at the bottom of the screen to fine tune the selection to set the intensity range 1 Go to M
53. t Green Output 2 Output Yellow Strobe Out 5V dc only Output Gray Remote Teach Input Pink External Trigger Input Blue Common Signal Ground Input Red Ready Output Cable Connections for the iVu TG with a Remote Display The cable connections on the iVu TG sensor are shown below and power I O connections B are defined in Table 2 on page 10 Remote Display Connector Power I O Connector USB Connector K NOTE Micro video lens model shown C Mount model connections are identical Table 2 Power I O Connections Wire Color Description Direction m White Output 1 Output Brown 10 30V dc Input Green Output 2 Output Yellow Strobe Out 5V dc only Output Gray Remote Teach Input Pink External Trigger Input Blue Common Signal Ground Input Red Ready Output Oo oOo N oO UU A UWU N Orange Not used N A Light Blue RS 232 TX Output Black RS 232 Signal Ground Output Violet RS 232 Rx Input 1 2 3 iVu Trigger Remote Teach and I O Waveforms The iVu has two input signals Trigger and Remote Teach The default setting is to detect the low to high transition This setting can be changed in the Main Menu gt System gt Discrete I O gt Input Polarity screen on the sensor 10 iVu Series Image Sensor PNP Low to High Trigger and Remote Teach Input Waveforms Power up Wire Color Function Pink Trigger i Remote Gray Teach The sensor triggers from
54. t to active state This signal will be reset up on resetting the History on the statistics page e A System Error condition occurs when a fatal error is detected on the sensor This output signal will be set to active state This signal can be reset upon resetting the History on the statistics page or executing a ClearSystemError command through command channel The default setting is Pass and Latched for Output 1 If Pulsed is selected the default Pulse width is 50 ms K NOTE For Latched the signal is active until the results of an inspection cause a change in the signal output Output2 Main Menu gt System gt Discrete I O gt Output 2 21 iVu Series Image Sensor Output 2 can be configured in a similar way as Output 1 The default setting for Output 2 is Fail and Latched For Latched the signal is active until the results of an inspection cause a change in the signal output If Pulse is selected the default Pulse width is 50 ms 2 2 Display Settings Main Menu gt System gt Display Settings The Display Settings menu is for setting the Fail Hold Time LCD Timeout and doing a Touch Screen Calibration Display optimization can be enabled in the Advanced menu Fail Hold Time Main Menu gt System gt Display Settings gt Fail Hold Time The Fail Hold Time determines how long a failed image is displayed on the LCD so that you can see what failed The sensor will continue to process any triggers an
55. ted to fall within the specified criteria the Maximum Pass Count is the maximum number expected to fall within the specified criteria These settings are used to determine the pass or fail result of the inspection ae NOTE Start with the Maximum Pass Count the Minimum will not allow it to be more than the maximum 1 Goto Main Menu gt Inspection and click the Pass Count option 2 Set the Minimum Pass Count and Maximum Pass Count as appropriate In the Demo both are set to 6 since the inspection should find six letters 5 Test the complete range of good and bad samples to make sure that the sensor accepts good parts and rejects bad The green check in the upper left corner indicates the inspection passed 6 To complete the Area application setup set triggering as appropriate for the application K NOTE Remote Teach does not work with the Area Sensor type 44 iVu Series Image Sensor 3 4 Configuring a Blemish Sensor n K NOTE By default the Trigger is set to I nternal and will continuously trigger based on a time interval setting This may make it more difficult to make adjustments while setting up the sensor The best practice is as follows e Go to the Main Menu gt Imager gt Trigger menu and select External e Make sure there is no external trigger input e Use the Trigger icon in the lower right of the screen to manually trigger the sensor to capture an image as you set up and test e Capture im
56. use the Password Reset Utility software provided on the CD to obtain a Reset Key K NOTE This menu option is not available in the Emulator 2 2 5 Motion Main Menu gt System gt Motion Motion settings involve selecting the number of edges to locate adjusting sensitivity and selecting whether or not rotation is enabled Motion settings are only available for Area or Blemish sensor types 2 2 6 Discrete I O Main Menu gt System gt Discrete I O The Discrete I O options are used to adjust iVu input and output settings I nput Polarity Main Menu gt System gt Discrete I O gt Input Polarity The iVu has two input signals Trigger and Remote Teach The operation of these signals is dependent on the Input Polarity setting e Low To High The Trigger and Remote Teach are detected on a low to high transition of the signal e High To Low The Trigger and Remote Teach are detected on a high to low transition of the signal The default setting for a PNP sensor is Low To High and for an NPN sensor it is High To Low The user can change the setting on the Input Polarity screen 20 iVu Series Image Sensor Output 1 Main Menu gt System gt Sensor Configuration gt Discrete I O gt Output 1 Output 1 can be configured for Pass Fail Missed Trigger or System Error e A Missed Trigger condition occurs when a trigger is received while sensor is busy inspecting the previous image This output signal will be se
57. used to verify that a pattern shape or part in any orientation matches a reference pattern The reference pattern is taught during setup A reference pattern might include alphanumeric characters logos or any other shapes During an inspection the sensor checks that each part or package being inspected matches the reference pattern Additionally if there is more than one of the identified pattern the number expected can be set Some example applications include e Date Lot code inspections e Label inspections e Part etching inspections e Part orientation inspections e Part shape inspections Selecting a Sensor Type When you exit Demo Mode the sensor reboots with a single inspection with a Match sensor type by default To change or for Plus models to add the Sensor Type 1 Go to Main Menu gt System gt Sensor Type This displays the Sensor Type menu options 15 iVu Series Image Sensor 2 Select either Area Blemish or Match 3 Click Apply 1 4 3 Trigger Modes The iVu TG has three trigger modes that determine how the sensor captures and processes images e External e Internal e Free Run Select one of the trigger modes by accessing Main Menu gt I mager gt Trigger on the iVu touch screen display Trigger on page 25 describes these trigger modes in more detail 16 iVu Series Image Sensor 2 Main Menu Reference 2 1 Main Menu Icons Main Menu icon used to access the Main Menu Inspectio
58. with the sensor or available as a remote display that you can use to set up and monitor inspections The following features are available e Self contained image sensor no PC required e Easy configuration install connect iVu acquire image set inspection parameters e Intuitive interface and sophisticated features make powerful inspection capabilities simple e Multiple sensor configuration e GUI available in multiple languages English French German Italian Spanish Japanese Simplified Chinese Portuguese and Turkish e 68 5 mm 2 7 in touch screen LCD display or separate touch screen display that mounts remotely from the sensor to allow easy access to the user interface and to view inspection images e Robust IP67 housing with integrated lighting red blue green or infrared e M12 connector with 10 to 30 V dc for power supply and PNP or NPN output e External trigger input remote TEACH input and external strobe output available e USB port for uploading and downloading of inspections and log files for easy updating and diagnostics e Software emulator for PC available to evaluate inspections offline based on bitmap images or inspection logs 1 1 Typical iVu Applications 1 1 1 Label Inspection i H d Figure 1 Label Inspection A manufacturer packages a number of products in similar packaging and needs a cost effective way to ensure that only like products are packaged together Additionally they want to verify that all the pr

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