Atlas Copco Unity Manual
Unity
Die Check Camera
Issue 7
Original instructions for operation
and maintenance of die check camera.
Patents granted and pending.
Copyright © 2022 Atlas Copco IAS
Intellectual property of
Atlas Copco Industrial Assembly Solutions
part of Atlas Copco Group.
All rights reserved.
No part of this publication may be reproduced,
distributed, or transmitted without the express
written permission of the publisher, except in the
case of work instruction documents.
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Unity Die Check Camera, Issue 7
Contents
1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. 1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. 2 Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. 3 Intended Use of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. 4 Retention of Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. 5 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. 1 Die Check Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. 2 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. 3 Operation and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Installation and Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. 1 Packaging & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. 2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. 3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. 4 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. 5 Powering on Die Check Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. 6 Camera Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. 7 Die Check Camera Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5. 8 Communications Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5. 9 Imager External Trigger Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5. 10 Inspection Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5. 11 Mode Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6. 1 Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6. 2 Menu Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6. 3 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Unity Die Check Camera, Issue 7
Contents
7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7. 1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8. 1 Performance / Specication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8. 2 Services Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8. 3 Associated Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Unity Die Check Camera, Issue 7
1 Equipment
This book contains original instructions for following part numbers:
4222 624 855 Camera with Light Ring
E4523 HMI & Basic Bracket
4222 624 860 Gripper Arm
4222 624 861 Floor Stand
4222 624 863 Bracket for HMI
The Die Check Camera assembly comprises:
Camera with integrated ring light
HMI (Human-Machine Interface)
Interconnecting Cables
Camer Mounting Kit (specic to layout)
Bracketry (specic to layout)
Patents granted and pending.
Whilst every eort is made to ensure all information is correct, Atlas Copco IAS cannot be held
liable for misprints or inaccuracies.
Atlas Copco IAS also reserves the right to change the specications of any product to improve its
function without prior notice.
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Unity Die Check Camera, Issue 7
2 Introduction
2. 1 Scope
This manual will guide the user during set-up, operation and maintenance of the Henrob Self
Pierce Riveting (SPR) equipment. An overview of assembly component parts is provided. System
requirements are detailed in this manual as well as instructions which reference safety and
installation factors of the equipment functionality.
Application of the equipment provided, including the accessories and documentation, is restricted
to use by duly authorised personnel.
All reassembly tasks shall be conducted with due reference to the appropriate manufacturing and
assembly drawings, paying particular attention to fastener torque values and the application of
consumables such as lubricants, sealants and thread-locking compounds.
The illustrations and procedures contained within this document are correct at the date of issue.
2. 2 Intended Use of the Equipment
Atlas Copco IAS warrants the supplied equipment to be correct and t for purpose as described,
declared and agreed in the quotation/sales order or supervening contract.
Atlas Copco IAS accepts no liability for damages arising in whole or in part from:
Non-observance of the supplied instructions.
Any use outside of the declared operating envelope.
Use for a purpose other than the original design intent.
Connection to electrical and pneumatic supplies which do not conform to the
specied ratings of the equipment.
Undeclared use in adverse environmental conditions.
Lack of due care and/or maintenance of the equipment.
Damage arising from external inuences, such as re, ood etc.
Use by unauthorised or untrained personnel.
Arbitrary dismantling and reassembly or unauthorised technical modications.
Use of incorrect rivets or unlicensed replacement parts.
Use of incorrect or unlicensed software.
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Unity Die Check Camera, Issue 7
2. 3 Intended Use of this Manual
This manual is intended to be used by trained operators of the equipment and Atlas Copco IAS
personnel when operating or maintaining the Self Pierce Riveting (SPR) equipment described.
The information contained within this manual is provided as a guide for the intended use of the
Henrob Self Pierce Riveting (SPR) equipment only. The information contained within this manual
does not pertain to any other equipment or its usage.
All users of the Henrob Self Pierce Riveting (SPR) equipment must read and understand the
information contained in this manual.
The safety warnings, cautions and notes should be adhered to at all times when carrying out any
of the procedures in this manual.
2. 4 Retention of Rights
Atlas Copco IAS retains the right to withdraw or change the information within this document, at
any time, without prior notication.
Atlas Copco IAS retains the rights to patents and patents pending, at all times, for this equipment.
2. 5 Warnings, Cautions and Notes
Warnings, cautions and notes appear throughout this document, at the point at which they are
relevant.
WARNING
This Warning symbol identies a potential hazard which may cause
fatal or serious injury to operating and maintenance personnel.
CAUTION
Cautions are intended to prevent possible damage to the component
parts of the equipment.
NOTE
Notes provide important/supporting information. A note is inserted to
aid personnel when working on the equipment.
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Unity Die Check Camera, Issue 7
3 Safety
It is important that the following safety precautions are observed:
Only trained and authorised operators shall use this equipment. Contact Atlas
Copco IAS or an approved engineer for help if you are in any doubt of your
ability to operate or maintain the equipment.
While every eort has been made to ensure this equipment is safe a
comprehensive assessment is not possible before the equipment is installed
and commissioned in its ultimate environment. It is therefore incumbent on the
end user of this equipment to conduct a nal risk assessment of the equipment
when installed and to implement any additional preventative measures.
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Unity Die Check Camera, Issue 7
4 Overview
An automated vision system for non-contact detection of broken Henrob self pierce riveting dies.
The system is intended to detect gross die failures where a signicant section of the die has broken
away from the main body. It is not capable of detecting subtle variations in die condition such as
low level contamination or surface defects.
NOTE
Each separate riveting tool requires a corresponding dedicated broken
die detection system.
The Die Check Camera can be either robot mounted, for presentation to dies on xed/pedestal
riveting tools, or static stand mounted for dies on robot mounted riveting tools to be presented to
the vision system.
The ring light aids when the die is presented at an angle. The ring light diuses ambient shadows
that can result in incorrect results.
Die Check Camera with Ring Light to be
used with HMI and relevent mounting kit.
Part number : 4222 624 855
Gripper Arm Assembly for mountung
camera when used with Pedestal tool.
Part number : 4222 624 860
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Unity Die Check Camera, Issue 7
Floor Stand for mounting camera when
used with Robotic tool.
Part number : 4222 624 861
HMI & Bracket (Basic) to be used for
communication with camera.
Part number : E4523
Bracket for mounting HMI to metal
surfaces.
Part number : 4222 624 863
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Unity Die Check Camera, Issue 7
4. 1 Die Check Camera
3 42
1
1 - Power I/O connector
2 - Ethernet connector
3 - USB connector
4 - Remote display connector
4. 2 Basic Operation
The Die Check Camera is used to monitor the condition and integrity of the upsetting die currently
installed onto the tool. After being ‘taught’ the correct condition of a die the Die Check Camera
will analyse the die image when requested. The inspection and monitoring process is automatic.
4. 3 Operation and Use
Due to variations in dies and in installation and operating environment conditions, each system
must be individually taught after initial commissioning and periodically during use, such as when a
new die is installed. This is carried out manually at the die check camera HMI.
A threshold gure (%) is established and set, based on experience, with reference to the image
for a “good die” enabling the system to output either a “pass” or a “fail” signal each time a die
inspection is performed. The determination of the threshold gure, which will vary from system to
system, is the responsibility of the user.
An adaptor cable is available enabling connection of a USB memory stick to the die check camera;
this facilitates the storage and back up of multiple application parameters.
In use, the system runs automatically with triggering of the camera to capture and analyse an
image initiated by the Robot or Cell PLC, once it is in position. This signal is passed through the
Henrob control cabinet using the existing eld bus cable between the robot controller and the
Henrob control cabinet. The pass and fail signals from the camera will also be passed through the
Henrob control cabinet back to the robot.
NOTE
The die breakage detection capability, repeatability of detection and
“pass/fail criteria” are application and environment dependent and
are to be set by the end-user, based on operating conditions and
experience.
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Unity Die Check Camera, Issue 7
5 Installation and Set-up
5. 1 Packaging & Storage
Henrob riveting equipment is packed suitable for short term storage. In storage it should
be protected from dust, moisture & excessive temperature (i.e. store at +5°C to +40°C, non-
condensing).
Once the equipment is unpacked it should be suitably protected from damage.
NOTE
Please check for and report to Henrob any damage to the equipment
found on receipt or after unpacking at your premises.
5. 2 Location
5. 2. 1 Clean Environment
Do not install the equipment in locations likely to be aected by dust, spray, uids, weld spatter or
other contaminants. If an unclean operating environment cannot be avoided,increased cleaning
frequency will be necessary and it is recommended that a removable protective cover is considered
for the camera lens as a countermeasure.
5. 3 Mounting
The Camera is mounted onto a specic bracket depending on the application (die checking on
robot or pedestal tools).
5. 3. 1 Vibration
Ensure that the Camera does not suer vibration from nearby processes at the time of use. If
necessary, review the design of mounting structures including consideration of isolation features
to achieve this. In particular, take care to ensure that oor-transmitted vibration from large
machinery, such as presses, does not result in small movements of the camera. If the image is
blurred, the detection capability is impaired.
5. 3. 2 Orientation
It is recommended to avoid installing the camera with the lens facing upwards, in an unprotected
condition. This will reduce the risk of both accumulation of dirt on the lens and loss of
performance from spurious changes in overhead lighting conditions. If the camera is robot
mounted then its orientation should be considered when the robot is in it’s parked/wait position.
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Unity Die Check Camera, Issue 7
5. 4 Positioning
The Camera can be mounted either to a static location (such as to a magazine lling plate stand)
or robot mounted.
5. 4. 1 Robot Mounted Tools
For robot mounted tools the camera will be mounted to the die detection stand and positioned in
one of two ways;
PERPENDICULAR
Where the nose-to-die gap allows, the robot will present the die under the camera for inspection.
Depending on the resulting “PASS” or “FAIL”. The robot will continue normal operation or if the
results from a die check is a FAIL then it is the responsibility of the user to take the appropriate
action. It is recommended that the robot moves to a specic position that enables easy inspection
of the die.
ANGULAR TO THE DIE
Where the nose-to-die gap restricts access (nose-to-die gap <107mm), the camera is positioned
angularly at 25° to allow the robot to present the die for inspection operation or if the results
from a die check is a FAIL then it is the responsibility of the user to take the appropriate action. It is
recommended that the robot moves to a specic position that enables easy inspection of the die.
Perpendicular
Inspection
38mm Approx.
92mm
4.5 - 5.5mm
25°
Angular
Inspection
Die Die
Ring Light
Die Detection
Image Sensor
Die Detection
Image Sensor
5. 4. 2 Robot Positioning - Presentation of Die
The die must be positioned at the focus of the camera and at the optimum point
of illumination from the light source.
To assist in robot programming, re-setting after a tool exchange or after a
crash, it is recommended that the desired die/camera presentation position is
identied by a xed pointer/tooling.
Repeatability of positioning: In direction of viewing ±0.5mm. Laterally ±1.0mm
Stationary condition: The die and the camera must not be moving at the point
the image capture takes place. It is recommended that a “settling time” of 1.0s is
allowed after robot movements before the camera is triggered.
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Unity Die Check Camera, Issue 7
Minimum nose-die gap
to allow camera to be
used directly in line.
Camera focus is
manually adjusted but
cannot cope with
camera being closer to
die due to loss of
image clarity and risk
of light flooding.
Nose
of
rivet
setter
I
Camera mounted to
bracket type 1 - this
enables attachment
to fixed structure or
robot end -effector
Nose
of
rivet
setter
Camera mounted to
bracket - this
enables attachment to
fixed structure or robot
end - effector.
Minimum nose-die gap to
allow camera to be used
directly in line.
Camera focus is manually
adjusted but cannot cope
with camera being closer
to die due to loss of image
clarity and risk of light
flooding.
92mm
Die
NOSE-DIE GAP > 92mm: IN-LINE INSPECTION
Positional
repeatability
+/- 0.5mm
(axial direction).
Positional
repeatability
+/- 1.0mm
(lateral direction).
~38mm
NOSE-DIE GAP < 92mm: ANGLED INSPECTION IS NECESSARY
For tools with small
nose-die gaps the
camera must be located
to the side.
In the case od angled
inspection, the camera
focus range means that it
may be positioned so that
the die is up to 300mm from
the lense. However it is
recommended to minimise
this distance.
If bracket type 2 is used, the
actual distance of
separation lense to die is
approximately 100mm.
Both camera and light
ring are mounted to
bracket type 2.
Nose
of
rivet
setter
Die
<92mm
Lorem ipsum
Where die inspection cannot be achieved at the default 25° due to the possibility of a collision,
a further 5° can be set on the robot for the inspection position, thus giving a total angle of up to
30°.
An adjustment of up to 5mm of the lateral position of the die is also acceptable both with or
without the additional 5° robot adjustment.
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Unity Die Check Camera, Issue 7
NOTE
The 5° and 5mm adjustments are made to the robot and NOT the
camera or bracket.
Die post & setter
Centre line
Move the gun
over 5mm
then rotate 5°
as shown
Light source
Centre line
Robot Positioning Die Presentation
5. 4. 3 Pedestal Tools
For pedestal tools the camera is mounted to the robot and connected via Ethernet.
CAUTION
Cables are not robot rated. For applications where the camera system is
robot mounted and the cable is articulated, it is recommended that the
robot loom supplier integrates a suitable cable into the robot loom.
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Unity Die Check Camera, Issue 7
5. 5 Powering on Die Check Camera
The rst time the camera powers up, it starts in Demo Mode. Demo Mode uses stored images and
inspection parameters that demonstrate how the camera is set up without having to congure
focus and lighting etc. In this mode, you can learn how to make adjustments while observing how
the adjustments aect the camera results.
To exit Demo Mode, go to Main Menu >
System > Mode and select Live from the
drop-down list. When you exit Demo Mode,
the camera restarts into its normal operating
mode with default settings. The camera now
requires teaching.
5. 6 Camera Adjustment
The following sections describe how the various controls work.
1 5 2 4
6 3
1 - Lens
2 - Focusing Window
3 - Locking Clip
4 - Locking Screw
5 - Filter Cap (not tted)
6 - Filter (not tted)
NOTE
The tool should be fully installed and operational before teaching the
Camera.
CAUTION
The Tool requires manoeuvring to the die check position. This may
require a robot programmer.
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Unity Die Check Camera, Issue 7
5. 6. 1 Die Alignment
Check the die position relative to the Camera. Centralise the die to the camera Focusing Window
and position the die at a distance of ~38mm from the camera.
NOTE
For the camera to be perpendicular to the die a minimum Nose-to-Die
gap of 107mm is required. If the perpendicular position cannot be
achieved then the angular position will be required.
Providing the camera has been powered on, the die should now be
visible on the camera HMI.
Main Menu > Imager > Strobe > Internal
The Internal Strobe setting congures the operation of the integrated ring light. Setting options
are Always ON, Always OFF, or Exposure Based.
The external ring light is also always on, but this ring lights settings are not congured from the
camera menu.
Angular Setup Imager - Strobe Internal OFF
External OFF
Perpendicular Setup Inager - Strobe Internal ON
External OFF
5. 6. 2 Exposure
Main Menu > Imager > Exposure
Exposure is the amount of time the sensor allows light to energize the imager. Increase or
decrease the exposure time by moving the slider. This allows more or less light to energise the
imager, which brightens or darkens the image.
5. 6. 3 Gain
Main Menu > Imager > Gain
Gain is an electronic boost to the image signal. Altering gain by using the ‘-’ and ‘+’ keys or moving
the slider to the right increases image brightness without increasing exposure time.
NOTE
Gain brightens both the light pixels and dark pixels and may reduce the
image quality.
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Unity Die Check Camera, Issue 7
5. 6. 4 Auto-Exposure
Main Menu > Imager > Auto Exposure
Auto-exposure optimises the exposure time and gain for the current lighting conditions.
Select the Main Menu button.
Select the Imager button.
Select the Auto Exposure button.
NOTE
A warning prompt will be presented. Select the Continue button to
begin the auto exposure routine.
After the auto-exposure routine has completed it may be necessary to
ne tune the exposure.
5. 6. 5 Focus
Focus of the camera is adjusted with the Focusing Window (2).
Using a 1/16” (inch) hex key, loosen the locking screw (4), then adjust focus of the camera by
adjusting (rotating) the focusing window (2).
5. 6. 6 Discreet I/O
Main Menu > System > Discrete I/O > Output (#)
The Discreet I/O sets the output signal to
either latched or pulsed. By default it is
latched.
Output 1, 2, and 3 are setup separately to
improve exibility and simplicity.
Output can be congured for Inspection Pass, Inspection Fail, Sensor Pass, Sensor Fail, Sort Pattern
#1, Missed Trigger or System Error.
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Unity Die Check Camera, Issue 7
A Missed Trigger condition occurs when a trigger is received while sensor is busy
inspecting the pervious image. This output signal will be set to active state. This
signal will be reset upon resetting the ‘History’ on the statistics page.
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.
Output 1.
Should be set to Inspection Pass
Signal
Should be set to Pulsed and 500 milliseconds
Output 2.
Should be set to Inspection Fail
Signal
Should be set to Pulsed and 500 milliseconds
5. 7 Die Check Camera Teaching
CAUTION
Before teaching the die detection camera it is important to ensure the
Tool (and die) are moved to the correct check position and that the
camera is correctly set and focused.
Step 1: Select the top bar (by default titled ‘Inspection1’) to access the inspection screen.
NOTE
The sensor type used for die detection is always Match type.
Select the top bar again, this time to
access the sensor screen (by default titled
‘Match1’). The Match Menu will then
be displayed. The sensor is the software
parameters that inspect the die features.
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Unity Die Check Camera, Issue 7
Step 2: Select ROI Type.
The Region of Interest (ROI) is the user-dened area on the screen that the sensor will analyse. The
ROI Type can be rectangular, elliptical, or circular. ROI can be as large as the entire Field of View
(FOV).
Step 3: From the menu at the bottom of the ROI Type screen, select the ROI Type ‘Circle’.
Step 4: Press the dotted line to enable editing it. Move the dotted line to surround the
whole die, overlapping slightly to oer the best teaching of the die.
Step 5: Press the Teach button. Once this die is taught it will be used as the principle for all
further die inspections.
CAUTION
Ensure the taught die is new and the correct die for the application.
Step 6: Select the top bar again to access the Match Menu.
Step 7: Select Percent Match.
The Percent Match setting adjusts for how closely the inspected die matches the reference
(taught) die. The Percent Match scale is from 0 to 100 where 0 is the most tolerant and 100 is the
least tolerant.
Step 8: Adjust using the ‘+’ and ‘-’ buttons or move the slider to the left or to the right.
Step 9: Set the initial Percent Match gure to 90. This is to be adjusted based on operating
experience and the nal environment of the Tool.
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