Cadbury MCE720 Training Mar08

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    MC-E720 Autosort

    A Training Guide

    for

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    Why an Autosort ?

    Camera

    Inspection

    Electronics

    Software

    Pneumatics

    Autosort

    Reject

    Dark

    Light

    Small

    Large

    Misshapen

    Accept

    Improved Product

    Added Value

    Customer Satisfaction

    Increased Margin

    Automated

    Processing/Packaging

    Raw

    Product

    Natural Imperfections - specks, diseased...

    Production Faults - burnt, uncoated...

    Foreign Bodies - plastic, wood...

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    MC-E720

    Purpose built for whole formed products

    Fitted to new or existing lines

    Encoder for accurate measurement and

    rejection

    Product passes under a pair of red, infrared and

    blue LEDs for colour check

    Additional pair of red + infrared LEDs for

    Heightcheck

    Top camera only (250mm inspection width)

    Control and electronics enclosures integral to

    sorter

    Separate pneumatic Reject station positioned tosuit

    Acceptable product continues along belt to

    packaging, reject blown by one or more nozzles

    sideways

    Customised accept and reject take-offs

    Defects from 0.5mm in size

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    General View of MC-E

    PneumaticCabinet

    Camera

    Enclosure

    Electronics

    Cabinet

    Main Isolator

    Switch

    on Electronics

    cabinet

    Beacon

    Green OK

    Red-AlarmTouchscreen

    Inspection

    area

    Air reservoir

    Power On

    Lamp (on

    both sides)

    Password

    Keyswitch

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    Inspection Area

    2 outer LED

    bars for

    Heightcheck

    (red + infrared)

    2 inner LED bars

    for colour and size

    check (red, infrared

    & blue)

    Heightcheck

    adjustment

    (detects under

    height bars)

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    Camera Enclosure

    Camera Window

    Mounting plate with

    positional adjustments

    Camera lens (50mm)

    focus & aperture

    adjustment

    Signal Connector

    (CameraLink)

    Line Scan Camera

    12V powerConnector

    (Hirose)

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    Camera Adjustments

    Power Supply Lead

    Focus adjust

    Aperture adjust

    Range adjust

    Pan adjust

    Roll adjust

    Tilt adjust

    Baseplate

    Signal Lead

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    Electronics Enclosure

    Power Supply 24V

    for I/O boards and

    touchscreen

    Camera Power

    Supply 12V

    Industrial PC

    With Snapshot

    PCI control card

    HeightCheck LED

    Switch 3 posn -

    A, B, Both

    Input boardHeightCheck LEDbars (outer pair)

    Output board

    Power socket

    for servicing

    Signal to Valve

    Island

    LED ITG Driver

    Board

    Power Supply 15V

    for LED Driver board

    Colour LED Switch2 posn - On/Off

    Colour LED bars

    (inner pair)

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    Mechanical Enclosure

    Air to

    valves via

    reservoir

    (4 5 bar)

    LED bars (inner pair

    colour; outer pair

    heightcheck

    Valve Island

    PCB

    Pneumatics control;

    isolator, regulator,

    filter, drain

    Signal to EjectorValves

    Pressure Switch

    (~3.5 bar)

    Air inlet (~6 7 bar)

    5V PSU forValve Island

    24V PSU for

    valves

    Signal from

    Snapshot to

    Valve Island PCB

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    Valves

    Electrical

    Connection

    from Valve

    IslandValve Body

    Hood

    support

    frame

    Air In from

    reservoir

    Nozzle jets

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    Principle of Operation

    Camera basedCCD Line scan up to 10,000 scans/sec (0.1ms exposure)

    2048 pixels/camera

    3 wavelength illumination (red, infrared, blue)

    Optional Heightcheck illumination (red + infrared)

    ElectronicImageProcessingSnapshot PCI card

    Valve Island

    RejectionPneumatic

    Fast acting valves

    Defect removed. Good product undisturbed

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    Principle of Operation

    Direction of travel

    Overhead

    Camera

    Colour check

    LED Lighting (2)

    Inspection Module

    over line, including

    pneumatics

    Air Ejector nozzles.

    Rejects blown

    sideways into bin

    200mm

    Belt Speed 200 500 mm/sec

    (up to 9 bars/sec)

    Control Cabinet with

    PC touchscreen

    1500mm minimum

    Reject Bin Heightchack LED

    Lighting (2)

    Shaft Encoder to

    synchronise camera

    scans

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    Principle of Operation - Width

    02048

    pixels

    Camera

    Resolution

    = Inspection Width (mm)/ 2048

    = x mm / pixel

    1 camera 250mm I. W.

    Res. = 250/2048 =

    0.12mm/pixel

    Belt Width

    ~200mm

    Camera Inspection Width

    250mm

    ~1700

    pixel

    ~300

    pixelActive pixel range

    (user sets)

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    Principle of Operation - Sequence

    Top Camera

    Valve Island PCB

    Snapshot

    Processing Card

    PCI Card

    Camera Enclosure

    Electronics Cabinet

    Reject station

    Nozzles 25mm apart

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    Host Software

    Display

    Screen

    Product

    Select(24 choices)

    MC HostMain Menu

    (8 choices)

    Available from all displays:-

    Position

    Reports

    Operator Display

    Enable

    Access

    Product

    Configuration

    Reports Display

    Product Selection

    Event Log

    System Logs

    Enable Access

    Disable Access

    Profile Camera

    Colour

    Training

    System

    Configuration

    *

    *

    *

    * Password Protected

    *

    General Change

    Password

    Run/Stop

    Alarms Valve SelfTest

    Main Menu Status

    CopyProduct

    *

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    Display Screen

    Batch zone. Shows

    thecount of defects

    and total product countfor thecurrent batch.

    Reject Distributionzone. Shows the

    distribution ofeach typeof reject as a percentage

    of the total rejects in thebatch.

    Run Time. Thecurrent total of time

    during which the sortersaw product in this

    batch.

    Stop Time. Thecurrent total of time

    during which the sortersaw no product in this

    batch.

    Reject Rate zone.(Reject rate = defects

    per minute).Displaysthe rejects for the

    previous minute as apercentage of the user-

    defined Alarm Level foreachcamera. Shown as

    a green within AlarmLevel and red ifexceeds

    Alarm Level.

    Main Menu button.Press to return to the

    main menu.

    Current productrunning

    Status button.DisplaysAlarm screen.When yellow

    an alarm condition exists.

    Run/Stop button.Press to

    start, to stop sorting.

    Current Time (fromPCs own clock).

    Defect Count shows

    totals foreach defect

    type for thecurrent

    batch.

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    Red indicates Fault

    (alarm) condition.Will

    remain red until

    acknowledged andcondition has cleared.

    Host Mode indicates

    Run or Stop as and

    buttons are pushed.

    System Inhibit

    indicates when

    the sorter is

    inhibited e.g. a

    Run switchhas

    been set to 0, or

    Stop button

    depressed, or in a

    Camera Set-upscreen

    External Mode

    indicates Run or

    Stop. Set byexternal Run switch

    or byexternal

    switch from a PLCetc.

    Air Pressure indicates air

    supply pressure is below thatof sensor setting in blastbar.

    Check supply is turned on and

    at required pressure.

    Reject Rate is illuminated if

    rejects/min exceed Alarm

    Level. Checkcorrect product

    selected or product being

    sorted is not unusually

    contaminated.If 2 top cameras

    used then shown as separate

    rates for A & B.

    System Errorcaused by fault

    in communication betweencomputer and system.If this

    occurs frequently, call an

    approved service technician.

    Press Acknowledge

    Alarm to show a yellow

    box against the fault

    condition. Once the alarmhas been acknowledged it

    will clear automaticallywhen the alarm conditionhas been rectified. N.B.If

    all devices areeither OK

    or already acknowledged

    then this button is

    inactive.

    Press to return

    to the original

    screen.Will be

    yellow if alarmcondition(s)

    exist, grey once

    all clear.

    Temperature Electronics

    Enclosure not used.

    Green OK shows that

    device status is

    functioning normally.

    Acknowledged shows

    that an alarm condition

    still exists but has been

    acknowledged by the

    user.

    Valve PSU indicates status of

    the power supply to the valves.

    Temperature Valve

    Enclosure - not used

    Alarm/Status Screen

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    System Configuration

    Profile

    Position

    HeightCheck

    System

    Configuration

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    Camera Profile Screen

    Exclusivecheck boxes.

    Raw Profile:- Press toobserve thecurrent signalwhich should be a smilecurvewhich no largespikes.Corrected Profile:- Press

    to observe previouslystored profile. Shouldappear as horizontal line if

    current and stored profilessimilar.

    Virtual oscilloscope.Shows thecameraprofile in graphical

    form.Horizontal axis is the2048 pixels across thecamera scan i.e.widthacross inspectionbelt/chute.

    Vertical axis is thesignal strength from 0(dark) to 255 (bright).

    On multi-camera sorters,use drop down list toselect the requiredcamera to check or adjust.

    Select Profile tab tocheckcamerareference signal.

    Current CursorPosition on the virtualoscilloscope is shown

    to assist in locatingposition on sightbar.

    Press to store thecurrent profile intomemory, to be used as

    the new referenceshade level.

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    Camera Profile - White

    0

    Dark

    255

    Light

    Raw Profile looking onto white profile bar Corrected Profile looking onto white profile bar

    0

    Dark

    255

    Light

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    Camera Position

    A Camera

    B Focus

    C Delivery Chute

    D Target Bar

    E RangeF Roll

    G Tilt

    H Pan

    A

    B

    D

    C

    F

    E

    G

    H

    D

    E

    C

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    Camera Position Screen

    Display ofcamera position errors. Adjust to obtain valuesbetween 2, with the 4 rectangles changing from red to greenat an acceptable value of 10. (Values of 2999 mean cameracannot see target correctly).

    Select Position tab tocheckcameraalignment.

    Reminder to insertPosition Target Barinto camera view tocheck/adjustcamera position.

    Virtual oscilloscope.Shows thecameraprofile in graphicalform.Horizontal axis is the2048 pixels across thecamera scan i.e.widthacross inspection

    belt/chute.

    Vertical axis is theshade signal strengthfrom 0 (dark) to 255(brightest).

    On multi-camerasorters, use dropdown list to selectthe requiredcamera to check oradjust.

    Position screen alwaysuses Corrected Profileonly (not RawProfile).

    Adjust focus toobtain minimumpossible value.

    (Value of 888means cameracannot see targetclearly).

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    Underheight sections of bar distort Heightcheck light out ofcamera view

    HeightCheck lineone LED bar on

    at a time

    Camera Scan Line

    Product Flow

    HeightCheck Calibration

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    HeightCheck Calibration Screen

    Bothheight LED bars on togethergives double the signal.

    Select Profile tab tocheckHeightCheck.

    Virtual oscilloscope.Shows thecameraprofile in graphicalform.

    Foreachheight LED

    bar theHeightCheckcalibration bar profilecan be seen with darkpeaks. Check both aresimilar intensity.

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    Product Configuration

    Colour (good and defect colour categories)

    Size (length/width/area/shape/height)

    Autosort determines if defective product by:-

    Product

    Configuration

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    Colour Training Capture

    Save to keep a capturedimage on file

    Captured imagethumbnail

    Capture Status

    Red armed,Green captured image

    Capture Threshold Setto triggercapture (seebelow)

    Capture Press to armcamera

    Open previously savedcaptured image

    OK to go toColour Training

    screen

    Capture Threshold blue setto trigger on bars but not belt

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    Colour Training Screen - Good

    Keypad button tochangecategorytitle and psuedocolour

    Categories ofproduct/defect with title,psuedo colour and colourspace value

    Update button.If anychanges are madethis will becoloured.Press to implementnew parameters. Alsoto reset last objectreadings

    InspectionParameters can beindividually set foreachcamera.

    Captured imagewith slider to selectpart to view

    Training imagefrom selection ofcaptured image

    Magnifier to zoomin/out part of imageusing +/- buttons

    Slider to adjustHeightCheck

    threshold value

    Filter to ignore specksof defect colour.Value 0 (off) to 8

    (max)

    Trained imagewithpsuedo colours forproduct /defects

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    Colour Training Screen - Defect

    Categories ofproduct/defect with title,psuedo colour and colourspace value

    Defect shown as pinkarea from definedcolour spaceCaptured image

    with slider to selectpart to view

    Training imagefrom selection ofcaptured image

    Slider to adjustHeightCheck

    threshold value

    Trained imagewithpsuedo colours forproduct /defects

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    CorrectHeight barUnderHeight bar

    HeightCheck line

    Camera Scan Line

    Excess height area causes Heightcheckline to go out ofcamera view (darker)

    Normal Heightcheck lineappears in camera view

    Product Flow

    HeightCheck Low Bars

    HeightCheckThreshold linedetermines how muchof bar is underheight

    Heightcheck SignalBelt

    Choc Bar

    Underheight

    BeltBelt0

    255

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    HeightCheck Threshold

    Height On/Off togglebutton

    Captured image ofproduct bar

    Training imagefrom selection ofcaptured image

    Slider to adjustHeightCheck

    threshold value

    Trained image;yellow

    showing product ofcorrect height, redshowing productbelow required height

    - set by

    HeightCh

    eckThreshold

    Actual HeightCheckthreshold value (0-255)

    Height colourselection button

    Correct Bar

    HeightCheck image

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    General Screen

    Duration is timeforwhich rejectvalve is blowing atdefect

    Update button.If anychanges are madethis will becoloured.Press to implementnew parameters. Alsoto reset last objectreadings

    HeightCheck Limitand actual value.Percentage ofproduct allowedunder set height.

    Filters are limitsbelowwhichproduct not counted

    Delay sets timefrom seeing defectto when rejectvalve opens

    Total product andReject Counts forcurrent batch

    Actual reported -Length, Max/MinWidth, Product Areaand Defect ColourArea

    Reject Rate Alarm

    is defects /minabovewhich alarmactivated

    Alignment Limitand actual value.Degrees of productalignment fromviewing line

    Parameter Max andMin Limit Values setby user

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    Rejection Control

    By default only one valve fires,By default only one valve fires,

    but if product more than 35mm,but if product more than 35mm,

    both will fire to remove defectboth will fire to remove defect

    DelayDelay - Time between determining a

    defect and opening of ejector valve

    No.1 (farthest from sorter)

    DurationDuration - Time for which

    valve(s) are open

    Valve OffsetValve Offset - Not used

    35mm

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    Advanced Camera Settings

    Update if anychanges made

    Re-Synch if profiletrace sawtoothed orstarts after 0 pixel

    Camera ScanSpeed 10kHz

    First and Last Pixeldefines edge blindareas

    Fixed ExposureUncheck no encoder,Checked encodersynchronises camerascanning

    Camera Offset andGain (Max 10)

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    Advanced Scaling Factors

    Valve Pitch is distance betweenthe two nozzles

    Length Calibration Camerascans per metre travel. (Lengthis always in direction of travel).

    Width is pixels per mm acrossbelt (i.e. Longest dimension ofbar) always 1/1000 of Length

    Length/Width Scaling Factoris ratio of the length to thewidthand determines actual widthreported

    Min Object Distance