iVu Plus Quick Start Guide
Contents
1. 4 Start Guide Bee BP owe be ee Contents Contents VINTOQUCUON sorene pR 3 2 iVu Plus Major Features asssessssssususnnnnsusnnnnsnnnnnnnnnnunnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnanannnn nna 4 POMC NIOGE a E magnate ier E eaten 4 DEOENSOl TYDES aia cect ca desea acces fasten A atten uae catia s echt matacnatatares 4 2 21 SCIECING A Sensor TYPES aranna aaa teite eetioeaianGian 5 Zero WNUNUDICIINGDCCUONG E EE AN E E coated A atone daa AT 6 2 3 1 Adding a New Insp ction accs secs som httt cesta saseecctes hte ecelabecachnestt cada cectestergedeu ai ia 6 2 3 2 Changing RUNING INSPECIONS cipascecatieenuest de taateek E E ao E E EEE T 2A NUPUS COmMMUNCAIONS dete wietincahieGatetebeasid caietenind icine cccantiensilocnise lela ca seem i bane aie S 8 ZA A COMMUNICAMOMGMARMGIS sairia Ma hither a e tat gtt Plt titeer sett uuaaat shales iacnaseheaead 8 3 Installing and Connecting the Sensor ou eeessessesseseeseeseeseesessessensessensaesaesaesaesaesaeeaeesetaaeas 9 3 1 Cable Connections for the iVu Plus Sensor with a Remote Display o eciccsccseseesesesessteessseesseerseeeees 10 4 Overview of Configuring a Sensor ue ceesescscseeseseseeessessecseeseeseesensessessaesetsessessensansaeeaes 11 4 TAcgumng animaag arcticabtsrtaiissteatiases feaaceitalddnatnidaccachan teak tip ANa a Micleewaoeadtoeks ilvectas 11 4 2 CONMMOUNNGA Sensor Type seinsta atrcdeacete a aE E evade ae Gonads 12 4 2 1 S2. the sensor reboots with a single inspection with a Match sensor type by default To change the Sensor Type 1 Goto Main Menu gt Inspection gt Properties gt Sensor Type This displays the Sensor Type menu options 2 Select either Area Blemish Match or Sort 3 Click the Home Screen icon in the upper left corner of the screen to return to the Home screen P N 154721 rev A www bannerengineering com tel 763 544 3164 5 iVu Plus Quick Start Guide 2 3 Multiple Inspections The iVu Plus supports multiple inspections that facilitate storing and controlling up to 30 inspections of different Sensor Types 2 3 1 Adding a New Inspection To Add a new stored inspection 1 Go Main Menu gt Inspection gt Stored Inspections and click Add New Select Sensor Type Area Blemish Match Sort Tip Name and Sensor Type can be moditied under Properties within the Inspection menu Dione 3 Click Done 6 www bannerengineering com tel 763 544 3164 P N 154721 rev A iVu Plus Quick Start Guide 2 3 2 Changing Running Inspections To change the running inspection 1 From the Home screen click the Yellow button in the top center of the screen that displays the currently running inspection to display all the stored inspections P N 154721 rev A www bannerengineering com tel 763 544 3164 iVu Plus Quick Start Guide 2 4 iVu Plus Communications The iVu Plus provides for communicati
3. 4mm screws through the bracket into the mounting holes in the bottom of the sensor Tighten all three screws P N 154721 rev A www bannerengineering com tel 763 544 3164 9 iVu Plus Quick Start Guide 3 1 Cable Connections for the iVu Plus Sensor with a Remote Display The cable connections on the iVu sensor are shown below and power I O connections B are defined in the Power I O Connections table below 10 www bannerengineering com tel 763 544 3164 P N 154721 rev A 4 Overview of Configuring a Sensor 4 1 Acquiring an 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 The flow chart at left provides an overview of the steps to acquiring a good image 1 Run the Auto exposure routine Main Menu gt Imager gt Auto Exposure 2 Check the lighting e Make sure that the lighting is constant and consistent unchanging over time no shadows or hot spots 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 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 run the Auto exposure routine a se
4. Sensitivity is used to fine tune how sensitive the sensor is to finding blem ishes or other edges within the ROI The Sensitivity value helps account for light varia tions that might affect how well the sensor detects edges 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 find very sharp edges with strong contrast if set near 100 the sensor will find very dim or blurry edges and may be unstable fEg NOTE Make sure you test a range of samples check ing that the worst good part passes and the best bad part fails 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 contigu ous edge segments found Edge segments within the two brackets are highlighted in green and those outside the brackets are ignored and colored yellow You can move each bracket to add or remove more of the edge segments from consideration Pass Count 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 with in the range brackets the bar is green otherwise it is yellow P N 154721 rev A www bannerengineering com tel 763 544 3164 13 iVu Plus Quick Start Guide Use the Manual Trigger located in the lower right corner of the screen to test good an
5. for Percent Match will be colored yellow 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 0 to 180 degrees Note that the smaller the rotation range the faster the inspection will run Repeat these steps for subsequent patterns and store each pattern in an empty pattern stor age slot www bannerengineering com tel 763 544 3164 15 iVu Plus Quick Start Guide 5 Set the Pass Criteria assuming only two stored patterns Any Saved Pattern Pass condition if the sensor matches either Pattern_1 Pattern_2 or both All Saved Patterns Pass condition if the sensor matches both Pattern _1 AND Pat tern_2 Single Saved Pattern Pass condition if the sensor matches either Pattern_1 OR Pat tern_2 but NOT both Specific Save Pattern Must also select the saved pattern to match for example select Pattern_2 Pass condition any time the sensor matches Pattern_2 Use the Manual Trigger located in the lower right corner of the screen to test good and bad parts Adjust settings as necessary and retest www bannerengineering com tel 763 544 3164 P N 154721 rev A
6. its normal operating mode with default settings K NOTE You may return to Demo Mode any time by going to Main Menu gt System gt Sensor Mode and selecting Demo 2 2 Sensor Types The iVu Plus sensor includes four Sensor Types An Area sensor type that is used to ensure that some feature or features are present on a part When setting up the sensor for an Area inspection some feature such as a drilled hole is identified as well as the size area expected If there is more than one of the identified feature on a part the number expected can be set as well During the inspection the sensor will verify 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 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 A Blemish sensor type that 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 application for an Area sensor 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
7. parts where the scratches are too numerous or larger than acceptable Inspections that check for the presence of some label or marking on a part that may vary in color A Match sensor type that is used to verify that some 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 Date Lot code inspections e Label inspections e Part etching inspections e Part orientation inspections e Part shape inspections A Sort sensor type that can recognize and sort up to ten different patterns within the same inspection Each reference pattern is taught during setup and stored in one of ten pattern memory locations A reference pattern might include alphanumeric characters logos or any other shapes and the pass criteria can be set for any or all of the patterns Some example application include Identify and sort parts on a production line Ensure that several different parts are present in a package 4 www bannerengineering com tel 763 544 3164 P N 154721 rev A iVu Plus Quick Start Guide 2 2 1 Selecting a Sensor Type When you exit Demo Mode
8. Help built into the sensor itself WARNING Not To Be Used for Personnel Protection Never use this product as a sensing device for personnel protection Doing so could lead to serious injury or death This product 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 denergized sensor output condition Consult your Banner Safety Products catalog for safety products that meet OSHA ANSI and IEC standards for personnel protection 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 P N 154721 rev A www bannerengineering com tel 763 544 3164 3 iVu Plus Quick Start Guide 2 iVu Plus Major Features 2 1 Demo Mode The first time you power up the iVu Plus 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 working with the four sensor types while observing how the adjustments affect the sensor results To exit Demo Mode go to Main Menu gt System gt Sensor Mode and select Live from the drop down list When you exit Demo Mode the sensor reboots into
9. cond time or adjust Gain Main Menu gt Image gt Gain and Exposure Main Menu gt Image gt Exposure manually 4 Adjust the focus while monitoring the Focus Number Main Menu gt Imager gt Focus a Use the supplied 1 16 hex key to loosen the Focusing Window locking screw D then adjust focus on the iVu Series sensor using the clear Focusing Window B foe A Bo Focusing Window ia Locking Clip K NOTE Use Internal Trigger for 4 O 4 D TEA Auto Exposure Main Menu gt E Filter Cap optional Image gt Trigger Filter optional NOTE Filter Kits are available separately b Adjust focus while monitoring the focus number To ensure the best image adjust the focus until the Focus Number peaks Ea NOTE Turning the Focusing Window counter clock wise focuses on closer objects while turning the Fo cusing Window clockwise focuses on more distant objects c Once the best image has been acquired lock the focusing window P N 154721 rev A www bannerengineering com tel 763 544 3164 11 iVu Plus Quick Start Guide 4 2 Configuring A Sensor Type 4 2 1 Setting External Trigger Mode By default the Trigger on the iVu Plus sensor is set to Internal To maintain control over triggering before configuring any of the Sensor Types change this setting to External Main Menu gt Imager gt Trigger Then use the Manual Trigger in the lower right corner of the sreen to trigger the sensor whi
10. d bad parts Adjust settings as necessary and retest 4 2 4 Configuring a Match Sensor The flow chart at left provides an overview of the steps to setting up an inspection on the iVu Plus sensor as a Match sensor 1 Make sure you use a good part for the inspection setup Normally the part will be centered in the field of view with the feature of interest surrounded by the Region of Interest ROI a blue rectangle The ROI can be rotated and resized and is red when selected for adjust ment 2 Select the ROI by clicking inside it Move it resize it and rotate it by dragging the ROI or its corners Once the feature of interest is within the ROI click the Teach button The feature will be highlighted in green K NOTE When running a Match inspection the sensor will look for any possible pat terns to match anywhere within the field of view 3 Configure the following parameters The Percent Match setting adjusts how closely the inspected part or label needs to match 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 to adjust the setting For the best results use a value from 50 to 90 NOTE When running a Match inspection the sensor will highlight in green any pattern matches that are within the specified Rotation Range and meet or exceed the value specified for Percent Match Patterns that are with
11. etting External Trigger Mode s s sssnsnsnssnsnsnsnsrnrsinirsnsrsnsrsnsnnaninansrsrsrsrsnnunnrurnnsnsrsnnrnnnnnnnnnnnsnnnnnnna 12 4 2 2 Configuring an Area Sensor sesasisesciseccastoanstewisbcasdeaevansudenscssdpacabhussesevels saul sceeateuhalesaedetanteeideuesds 12 4 2 3 Configuring a Blemish Sensor s esssnssssssnsnsnsnsrsrnrnsrarsrsrsnsrsnsrsnsinnninnrsrsnnrsrsnsnnnnunununnrsrnnsnsrsnsrnnnnna 13 4 2 4 Configuring a Match Sensor stnssiesnion denen adscensedce Geese siaace raceme nedcetades 14 42o COMMOUMMG OOM OCMSOR an cic t ere ae etch cies ae a a a 15 2 P N 154721 rev A 1 Introduction The iVu Plus is used to monitor labels parts and packaging for type size orientation shape and location The sensor has an integrated color touch screen display making installation setup and configuration easy without requiring a PC Quick Start Overview This guide is designed to provide the necessary information to get the iVu Plus sensor up and running quickly It provides an overview of the sensor and illustrates how to set up the sensor to inspect a label part or packaging The flow chart at left provides an overview of the process Related Information The following documentation is available on the Product CD e Datasheets iVu Plus for Use with Remote Display Vu Series Remote Display Other iVu Plus Software Reference iVu Plus Communications Guide iVu Plus User s Manual In addition there is integrated
12. in the specified Rota tion Range and within approximately 20 below the specified value for Percent Match will be colored yellow F NOTE Under normal opera The Rotation Range sets the expected rotation of parts or labels during an inspection tion any parameter modifica For example a value of 45 means that the part may rotate 45 degrees in either direction tions take effect on the next from the reference part and still pass Move the slider from 0 to 180 degrees Note that trigger the smaller the rotation range the faster the inspection will run 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 Use the Manual Trigger located in the lower right corner of the screen to test good and bad parts Adjust settings as necessary and retest 14 www bannerengineering com tel 763 544 3164 P N 154721 rev A iVu Plus Quick Start Guide 4 2 5 Configuring a Sort Sensor The flow chart at left provides an overview of the steps to set up and inspection on the iVu Plus 2 3 fEg NOTE Under normal opera tion any parameter modifica tions take effect on the next trigger 4 P N 154721 rev A sensor as a Sort sensor 1 Make sure you use good parts for the inspection setup Nor
13. le configuring the sensor 4 2 2 Configuring an Area Sensor The flow chart at left provides an overview of the steps to setting up an inspection on the iVu Plus sensor as an Area sensor 1 Make sure you have a good part to use for the inspection setup Normally the part being in spected is centered in the field of view with the feature of interest surrounded by the Region of Interest ROI the blue rectangle The ROI can be rotated and resized and is red when selec ted for adjustment 2 Adjust the ROI so that the part is within the ROI The pattern will be highlighted in green F NOTE When running an Area inspection the sensor will only find objects within the ROI 3 Set the following parameters 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 a NOTE Make sure you test bar is moved green highlighted areas indicate objects the sensor finds and counts The a range of samples check objects colored yellow are found but filtered out that is not counted because the objects ing that the worst good fall outside of the Area Range part passes and the best bad part fails The Area Range is used to set the size limits of a feature of interest Use the slider bar at the bottom of
14. mally each part will be centered in the field of view with the feature of interest surrounded by the Region of Interest ROI a blue rectangle The ROI can be rotated and resized and is red when selected for adjust ment For the first part select the ROI by clicking inside it Move it resize it and rotate it by drag ging the ROI or its corners Once the feature of interest is within the ROI click the Teach button The feature will be highlighted in green Tip For better results make sure that the ROI bounds the image of the pattern as tightly as possible K NOTE When running a Sort inspection the sensor will look for any possible patterns to match anywhere within the field of view Click the Save button to save the pattern to the first empty pattern storage slot Set match criteria The Percent Match setting adjusts how closely the inspected part or label needs to match any of the ten stored patterns 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 to adjust the setting For the best results use a value from 50 to 90 Ki NOTE When running a Sort inspection the sensor will highlight in green any pat tern matches that are within the specified Rotation Range and meet or exceed the value specified for Percent Match Patterns that are within the specified Rotation Range and within approximately 20 below the specified value
15. ng with other devices via Ethernet or a UART serial communicatoins port RS 232 In order to establish an Ethernet connection the external device must be configured with the correct IP address and correct TCP port to communi cate with the sensor If planning to use the serial communications connection port settings for baud rate data bits parity and stop bits are configured on the iVu Plus to match the settings of the external device 2 4 1 Communication Channels The iVu Plus supports up to three communications channels e Command Channel which is a bi directional communication protocol that currently supports ASCII and enables other devices to remotely control the iVu Plus sensor and to access sensor results Data Export which is used to export selected inspection data to a remote device e Image Export which is used to export inspection images to a remote device Data export and command channel can be configured for either Ethernet or Serial I O but not both image export is only available over Ethernet The table below briefly summarizes valid communication channel configuration options 8 www bannerengineering com tel 763 544 3164 P N 154721 rev A 3 Installing and Connecting the Sensor The iVu Plus sensor requires a bracket for mounting Four brackets are available from Ban ner The brackets allow the sensor to be mounted either perpendicular to the part or at an adjustable angle SMBIVURAL Thread three M4 x
16. 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 will have an area of roughly 20 000 pixels 12 www bannerengineering com tel 763 544 3164 P N 154721 rev A iVu Plus Quick Start Guide 4 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 ts Use the Manual Trigger located in the lower right corner of the screen to test good and bad parts Adjust settings as necessary and retest 4 2 3 Configuring a Blemish Sensor The flow chart at left provides an overview of the steps to setting up an inspection on the iVu Plus sensor as a Blemish sensor 1 Make sure you have a good part to use for the inspection setup Normally the part being inspected is centered in the field of view with the feature of interest surrounded by the Re gion of Interest ROI the blue rectangle The ROI can be rotated and resized and is red when selected for adjustment 2 Adjust the ROI so that the part is within the ROI The pattern will be highlighted in green K NOTE When running a Blemish inspection the sensor will only find edges within the ROI 3 Configure the following parameters Sensitivity
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