Banner PresencePLUS Pro User manual

Printed in USA 04/02 P/N 68369 rev. B
68369 (ppp quickstart guide) 5/7/02 11:50 AM Page 1

Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
page 2
Introducing PresencePLUS Pro
PresencePLUS Pro is an easy-to-use camera system with
advanced visual inspection capabilities. With limited knowledge
of vision systems, a user can quickly and accurately set up
PresencePLUS Pro for an inspection that evaluates product on a
production line.
Inspection parameters are set up using a remote personal
computer (PC). A digital camera captures images and the sensor
software analyzes those images, using one or more vision tools,
to pass or fail the product. The PC is not required for running
inspections after the inspection files have been stored in the
controller’s memory.
Start
Hook Up the Hardware
Install the Software and
Establish Communications
Acquire an Image of the Part
Being Inspected
Choose Vision Tools to
Find the Flaw or Feature
Add a Test Tool To Set Up
Pass/Fail Criteria
Teach Good Examples
Run
Finish
Quick Start Overview
This guide is designed to
provide – even to those new
to vision sensing – the
information needed to use
this system. It provides an
overview of the sensor and
illustrates how to easily set
up the PresencePLUS Pro to
inspect a product. The flow
chart at right provides an
overview for the system
setup.
TIPS
TIPS
For more detailed
instructions, both
the Installation
Manual and the
Operator’s Guide
are on the
PresencePLUS Pro
installation CD.
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Banner Engineering Corp. • Minneapolis, MN U.S.A.
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components/
connections
components/
connections
Error
Model PPCTL
Controller
Fail
Pass
Power
Ready
Trigger
CHASSIS GND
20
10-30V dc
dc COMMON
TRIGGER IN
STROBE OUT
TX
RTS
RX
CTS
I/O 1
I/O 2
I/O 3
I/O 4
I/O 5
PRODUCT SEL0
19
PRODUCT SEL1
18
PRODUCT SEL2
17
PRODUCT SEL3
16
PRODUCT CHANGE
15
I/O 6
14131210 11090807060504030201
Model PPCAM
Camera
Camera
Ethernet PC Serial
Video
TIPS
TIPS
The trigger device
can be any
10-30V dc
photoelectric
sensor, or a
device with a
similar output.
10-30V dc
dc COMMON
TRIGGER IN
STROBE OUT
TX
RTS
RX
CTS
I/O 1
I/O 2
I/O3
I/O4
I/O 5
PROD
UC
15
I/O 6
14
1312
10 11 09
08
07
06050403
0201
+V –V
Trigger
Device
Additional Connections
(Pins 4 - 20)
Pin 1 Pin 2 Pin 3
step 1
step 1
step 2
step 2
step 3
step 3
Cable Connections
1.Thread the c-mount lens onto the camera
(PPCAM).
2.Connect the camera cable (PPC..) to the
camera (PPCAM) and controller (PPCTL).
3.Connect the controller to a Windows®PC
using either an ethernet cable or a serial
cable (DB9D..).Use crossover ethernet
cable (STPX..) for a direct connection,
and a straight ethernet cable (STP..) for
network connection.
4.Optional: Connect an NTSC video monitor
using a BNC cable.
Electrical Connections
Connect the following to the controller’s
terminal block
•+V to Pin 1 (10-30V dc)
•–V to Pin 2 (dc common)
•Trigger device to Pin 3 (Trigger In)
•Additional connections (Pin 4 - Pin 20)
Lighting
Install the dedicated light source, according
to the instructions included with the light
source.
PPCAM
Camera
to
PC
to
Monitor
to PC (Crossover)
or Network (Straight)
STPX..
Ethernet
Connection
PPC..
Camera
Cable
Video
Connection
(Optional)
DB9D..
Serial
Connection
PPCTL
Controller
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page 4
system
configuration
system
configuration
Error
Model PPCTL
Controller
Fail
Pass
Power
Ready
Trigger
CHASSISGND
20
10-30Vdc
dcCOMMON
TRIGGERIN
STROBEOUT
TX
RTS
RX
CTS
I/O1
I/O2
I/O3
I/O4
I/O5
PRODUCTSEL 0
19
PRODUCTSEL1
18
PRODUCTSEL 2
17
PRODUCTSEL 3
16
PRODUCTCHANGE
15
I/O6
1413
12
10 11
090807
0605
040302
01
Camera
Ethernet PC Serial
Video
PPCTL
Default IP Address
192.168.0.1
Typical IP Address:
192.168.0.2
step 4
step 4
PC Configuration
1. To use ethernet communication,
configure the IP address of your
computer.
2. Install the PresencePLUS Pro software
a. Insert the Installation CD
b. Click Install PresencePLUS Pro PC Software
a. Right mouse-
click on Network
Neighborhood
and select
Properties
b. Open the TCP/IP Properties
under the Protocols tab c. Change the IP address to
192.168.0.2 and subnet
mask to 255.255.255.0
Write down the existing address of your PC before changing it: _ _ _ • _ _ _ • _ _ _ • _ _ _
To change the IP address of your PC, do the following:
(The following screen captures are from Windows NT; other Windows versions vary.)
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system
startup
system
startup
step 6
step 6
Launching Software
1. Start the PresencePLUS Pro program by clicking
Start > Program Files > PresencePLUS Pro.
2. At start-up, PresencePLUS Pro will try to communicate with the camera.
•If communication with the camera is successful, the application will launch and
display the Setup or Run screen.
•If the current communication port is not available, the application will prompt you
to select a different port. Click OK to access the communications window.
To Change the Communication Port
•Ethernet connection:
a. choose IP Address
b. type: 192.168.0.1 in the space provided
c. click OK
•Serial connection:
Choose serial. Refer to the on-line
Instruction Manual (p/n 68367) for detailed
instructions on serial port configuration.
3. If using an optional NTSC video monitor, verify that the monitor is displaying an
image.
4. When the software launches, create an inspection, configure the discrete I/O, and
begin running inspections.
NOTE: Initially, all discrete I/O are configured as inputs. Go to the System window to
change the discrete I/O. For detailed configuration information, refer to the
Instruction Manual (P/N 68367).
TIPS
TIPS
DO NOT
click Modify
Camera IP
Address when
trying to establish
communications.
Modify
works only after
communications
have been
established.
step 5
step 5
Starting the PresencePLUS Pro
1. Power up the hardware and verify that
the Error light turns OFF (during
power-up, all the controller LEDs
will come ON for 15-20
seconds).
2. Verify that the LED on the
camera is ON and has started
to flash.
Error
Model PPCTL
Controller
Fail
Pass
Power
Ready
Trigger
CHASSIS GND
20
10-30V dc
dc COMMON
TRIGGER IN
STROBE OUT
TX
RTS
RX
CTS
I/O 1
I/O 2
I/O 3
I/O 4
I/O 5
PRODUCT SEL 0
19
PRODUCT SEL1
18
PRODUCT SEL 2
17
PRODUCT SEL 3
16
PRODUCT CHANGE
15
I/O 6
14131210 11090807060504030201
Green LED
Red LED
Red LED
Green LED
Green LED
Green LED
Flashing
Green LED
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Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
page 6
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
Banner Engineering Corp. • Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: [phone]
creating
inspections
Inspection Work Flow
step 7
step 7
Software Setup
Use the Main Menu toolbar to navigate the PresencePLUS Pro options. Proceeding from left to
right, the buttons in the Menu toolbar step through the process of creating an inspection file.
Set up the camera, lens, and lighting, to acquire a reference image.
a. Set up the camera lens and lighting.
b. Choose Trigger option Continuous for a live image.
c. Click Auto Exposure to adjust the brightness.
d. Focus the lens on the camera by turning the lens until the Focus
Number is maximized.
e. When you have the desired image, click Next to proceed to the Tools
screen, this will acquire the reference image.
Add tools to the inspection. Build the tools from scratch or add tools from
a previous inspection file saved on the PC or controller. To add a vision
tool, click the Tool button. To remove a tool, click the “X” in the lower left-
hand corner of the screen.
a. Add Location Tool(s) to find the target to adjust the following Regions
of Interest (ROI) for transitional and rotational changes.
b. Add Vision Tool(s) to inspect the part.
c. Add Measure Tool(s) to create distance measurements from points
found.
d. Add Test Tool(s) to set the Pass/Fail criteria. (The Vision and Measure
Tools are inputs to the Test Tool.)
e. Click Quick Teach to automatically set all the selected parameters in the
Test Tool and proceed to the Run screen, or click Next to proceed to
the Teach screen, to teach a sample set of good products.
NOTE: If you want to keep parameters in a test tool, skip Teach and go
directly to Run.
1.
2.
creating
inspections
TIPS
TIPS
Before creating an
inspection file, set
up the electrical
configuration of
the external
trigger. (Click
System button,
select Trigger tab.)
Required
Required
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Tool Options
Location Tools
Pattern
Find
Translation and
rotation
Locates the target by searching for a taught pattern
and compensates for translation and ±10° of rotation.
Locate Translation and
rotation
Finds the edge of the part and compensates for
translation and rotation.
Vision Tools
Average
Gray
Scale
Determines
presence, absence,
color sensitivity
Determines the average gray-scale value in the Region
of Interest (ROI).
Blob Counts and
measures areas
Detects groups of connected light or dark pixels within
ROI; designates them as “Blobs”. After Blobs are
found, they can be counted, sized and located.
Edge Counts and
locates edges
Detects and counts transitions between bright and
dark pixels. The total number of edges can be counted
and the position of each edge can be found.
Object
Locates and counts
objects, determines
midpoints and
measures widths
Detects the edges of dark and bright objects,
locates their midpoints, counts dark and bright objects
and measures the widths of each dark and bright
object.
Pattern
Count
Find one or more
patterns Locates and counts a taught pattern.
Measure Measures between
points
Measures distance between two prescribed points.
These points can be either edges or centroid locations.
Test Logic
input/output
Evaluates results of selected vision and analysis tools
to determine whether an inspection passes or fails. It
also performs logical operations and activates outputs.
Analysis Tools
creating
inspections
creating
inspections
Tool Name Function Description
This screen automatically configures the parameters
chosen in the tools screen.
a. Choose the sample size
b. Click Start
c. Trigger the controller with the external trigger device
d. Click Stop
e. Click Next to proceed to Run
Before entering Run, save the inspection file to one of the
12 memory locations on the controller.
3. TIPS
TIPS
• Each
inspection
must contain
at least one
Vision tool and
one Test tool.
• Save a backup
copy of your
inspection to
the host PC.
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running
inspections
running
inspections
Viewing Results
Display Options
Next Pass Display only the next passing inspection.
Next Fail Display only the next failing inspection.
Next Continuously display inspections.
None Don’t display any inspections.
Click +to
expand and –
to contract
category
Click on
Tool name
to show
the ROI
Passing
Tool
Failing
Tool
Product
Select
#3 (Pin 16)
Product
Select
#2 (Pin 17)
Product
Select
#1 (Pin 18)
Product
Select
#0 (Pin 19)
Inspection
#
OFF OFF OFF ON 1
OFF OFF ON OFF 2
OFF OFF ON ON 3
OFF ON OFF OFF 4
OFF ON OFF ON 5
OFF ON ON OFF 6
OFF ON ON ON 7
ON OFF OFF OFF 8
ON OFF OFF ON 9
ON OFF ON OFF 10
ON OFF ON ON 11
ON ON OFF OFF 12
Select an inspection to run, and view the results of the inspection.
To select an inspection, (in the Select tab) enable Software Override and
select the inspection file from the list of stored inspections on the camera.
Alternate method: Use Hardware Input to select an inspection via discrete
inputs to the controller.
The following table shows which inputs to activate to select an inspection.
4.
To begin inspecting, click the Start button in the Run screen.
TIPS
TIPS
When using the
Hardware input,
pulse the Product
Change input to
initiate an
inspection change.
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page 9
system
configuration
system
configuration
step 8
step 8
System Setup
Use the System Setup screen to change discrete I/O, the communication port, the product
change/select inputs, the strobe output (for external lighting control), the trigger input, and
to view diagnostic information.
Save inspections on the controller or PC.
Provides help files and PDFs of the Installation Manual (p/n 68368)
and the full-length Operator’s Guide (p/n 68367).
Input/Output Configuration Tab
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Maintenance
Maintenance tasks include keeping the hardware free of dust and
dirt and updating the PresencePLUS Pro software as new
versions become available.
Cleaning the Camera and Controller
Regularly remove any accumulated dust or dirt from the camera
and controller using a soft cloth. If needed, slightly dampen the
cloth with a weak solution of neutral detergent. Avoid getting dirt
on the camera’s imager (the area behind the lens). If the imager
is dirty, use anti-static compressed air to blow off the dust.
Cleaning the Camera Lens
Regularly remove dust, dirt, or fingerprints from the lens. Use
anti-static compressed air to blow off dust. If necessary, use a
lens cloth and lens cleaner or window cleaner to wipe off
remaining debris. Do not use any other chemicals for cleaning.
Updating PresencePLUS Pro Software
The current version of PresencePLUS Pro software is available
for download from the Banner website:
www.bannerengineering.com
system
maintenance
system
maintenance
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Problem Cause/Solution
•Power light is not ON.
•Interface cannot connect to controller.
•No image on monitor.
Controller is not getting enough power.
1. Check the connection to the power supply.
2. Verify that the power supply is 10-30V dc with 1.5 amps.
3. Verify that the terminal block is plugged firmly into the
controller.
•No image on PC or monitor.
•Camera indicator LED is OFF.
•The software seems to be working
correctly, but the image is missing.
Camera is not connected to the controller.
1. Reconnect the camera cable at the camera and the controller.
2. Power down, then power up.
•Error message, “Failed to capture a
full resolution image on the camera.”
•Image is frozen on PC and monitor.
•Camera indicator LED is ON, but not
flashing
Camera lost the connection to the controller.
1. Reconnect the camera cable at the camera and the controller.
2. Power down, then power up.
•Image is frozen on PC, but image on
monitor properly updates.
•Error message, “Unable to
communicate with the camera.”
•Indicator lights on controller’s RJ-45
port are OFF.
Ethernet connection is lost.
1. Reconnect the ethernet cable.
2. Check the cable for breaks, power down, then power up.
3. Replace the cable.
system
troubleshooting
system
troubleshooting
Troubleshooting
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system
specifications
system
specifications
Model Number PPCTL
Part Number 62937
Mechanical
Construction: Steel with black zinc plating
Dimensions: 158 x 127 x 30.9 mm (6.22" x 5.0" x 1.22")
Weight: approx. 0.55 kg (1.2 lbs)
Environmental Rating: IEC IP20; NEMA 1
Operating Temperature: 0° to +50° C (+32° to +122° F)
Maximum Relative Humidity: 90%, non-condensing
Display Options PC and NTSC video (9 m [30'] max. cable length)
Discrete I/O
1 Trigger IN (pin 3)
1 Strobe OUT (pin 4)
6 Programmable I/O (pins 9 - 14)
1 Product Change (pin 15)
4 Product Select (pins 16 - 19)
Output Rating
150 mA (each)
ON-State Saturation Voltage: < 1V at 150 mA max. NPN
> V+ - 2 volts
OFF-State Leakage Current: <100 microamps NPN or PNP
Memory Stores up to 12 inspection files
Power Voltage: 10-30V dc
Current: 1.5 amps max.
Controller
Communication 1 RJ-45 Ethernet port for running PresencePLUS Pro software
1 RS232 port for running PresencePLUS Pro software
Output
Configuration NPN or PNP software selectable
Load
–
+
10-30V dc
NPN Hookup
Load
+
–
10-30V dc
PNP Hookup
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system
specifications
system
specifications
Camera
Model Number PPCAM
Part Number 62568
Mechanical
Construction: Black anodized aluminum
Dimensions: 32 x 30 x 78.2 mm (1.26" x 1.18" x 3.08")
Weight: approx. 0.09 kg (0.2 lbs)
Environmental Rating: IEC IP20; NEMA 1
Operating Temperature: 0° to +50° C (+32° to +122° F)
Maximum Relative Humidity: 90%, non-condensing
Acquisition
Frames per Second: 30 max.
Image Size: 640 x 480 pixels
Levels of Gray Scale: 256
Imager 4.8 x 3.6 mm, 6 mm diagonal (1/3" CCD)
Pixel Size: 7.4 x 7.4 microns
Interface LVDS
Max. Cable
Length 7 m (23')
Exposure Time 0.01 ms to 3600 ms
Lens Mount C-mount
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page 14
installation
notes
installation
notes
68369 (ppp quickstart guide) 5/7/02 11:50 AM Page 14

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page 15
installation
notes
installation
notes
68369 (ppp quickstart guide) 5/7/02 11:50 AM Page 15

Banner Engineering Corp.,
9714 Tenth Ave. No.
Minneapolis, MN 55441
Phone: [phone]
www.bannerengineering.com
Email: [email protected]
68369 (ppp quickstart guide) 5/7/02 11:50 AM Page 16