Cognex In-Sight 1010 User manual

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Copyright, Trademarks, Patents
The software described in this document is furnished under license, and may be used or copied
only in accordance with the terms of such license and with the inclusion of the copyright notice
shown on this page. Neither the software, this document, nor any copies thereof may be
provided to or otherwise made available to anyone other than the licensee. Title to and
ownership of this software remains with Cognex Corporation or its licensor. Cognex
Corporation assumes no responsibility for the use or reliability of its software on equipment that
is not supplied by Cognex Corporation. Cognex Corporation makes no warranties, either
express or implied, regarding the described software, its merchantability, or its fitness for any
particular purpose.
The information in this document is subject to change without notice and should not be
construed as a commitment by Cognex Corporation. Cognex Corporation is not responsible for
any errors that may be present in either this document or the associated software.
Copyright © 2000-2001 Cognex Corporation.
All Rights Reserved.
This document may not be copied in whole or in part, nor transferred to any other media or
language, without the written permission of Cognex Corporation.
Cognex P/N 590-6372

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The hardware and portions of the software described in this document may be covered by one
or more of the following U.S. patents. Other U.S. and foreign patents are pending.
In-Sight Patents pending
Hardware 4,972,359; 5,526,050; 5,657,403; 5,793,899
Vision Tools 5,495,537; 5,548,326; 5,583,954; 5,602,937;
5,640,200; 5,717,785; 5,742,037; 5,751,853;
5,768,443; 5,796,868; 5,818,443; 5,825,483;
5,825,913; 5,845,007; 5,859,466; 5,872,870;
5,909,504
The following are registered trademarks of Cognex Corporation:
Cognex
Cognex, Vision for Industry
The following are trademarks of Cognex Corporation:
The Cognex logo
In-Sight
Other product and company names mentioned herein are the trademarks, or registered
trademarks, of their respective owners.

iv
CE Compliance Statement
CE Declaration of Conformity
Manufacturer Cognex Corporation
One Vision Drive
Natick, MA 01760 USA
Declares this CE-marked product
Product Number In-Sight 1000
Complies With 73/23/EEC Low Voltage Directive
89/336/EEC Electromagnetic Compatibility Directive
Compliance Standards EN 60950:1992
Electrical Safety
A1:1993, A2:1993, A3:1995
EN 55022
RF Emissions
Information Technology
EN 50082-1
EMC Immunity Standard
European Representative Cognex France
Immeuble le Patio
104 avenue Albert 1er
92563 Rueil Malmaison
France

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Table of Contents
Introduction.................................................................................................................. vii
In-Sight 1010 .......................................................................................................... vii
In-Sight 1010 Product Kit ....................................................................................... vii
For More Information............................................................................................. viii
Chapter 1: Setting Up Your In-Sight 1010....................................................................1
Connecting the In-Sight 1010...................................................................................1
Loading the Jobs from the CD .................................................................................1
Navigating the In-Sight Interface..............................................................................2
Loading your job.......................................................................................................3
Operator Display ......................................................................................................4
How do you know if the code is being read? ...................................................4
What are the 2D Setup Options? .....................................................................4
What are the Barcode Setup Options? ............................................................5
What are the General Setup Options?.............................................................5
Positioning your In-Sight 1010 .................................................................................5
Acquiring a Working Image ......................................................................................6
Working with the In-Sight 1010 ................................................................................6
Saving your job.........................................................................................................7
Automatically Load Your Job on Startup..................................................................7
Communications.......................................................................................................7
Digital Input ......................................................................................................8
Digital Outputs .................................................................................................8
Connecting to a PLC........................................................................................8
Connecting to a Relay......................................................................................9
Serial Output ....................................................................................................9
Reporting the Code Over the Network.............................................................9
Chapter 2: 2D Setup – Using the 2D Model ...............................................................10
Chapter 3: Image Filtering ...........................................................................................13
2D Code Filtering ...................................................................................................14
Barcode Filtering ....................................................................................................15
Appendix A: Lens Selection Chart .............................................................................16
Appendix B: Lighting Guide........................................................................................17
Appendix C: 2D Code Tutorial ....................................................................................18
Introduction.............................................................................................................18
Adjusting the lighting ..............................................................................................19
Training A Model ....................................................................................................20
Applying Image Filtering.........................................................................................22
Appendix D: Troubleshooting.....................................................................................24

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List of Figures
Figure 1-1. In-Sight 1010 Setup Wizard .......................................................................1
Figure 1-2. In-Sight 1010 GUI Interface........................................................................4
Figure 1-3. 2D Data Matrix Code (16 X 16 Code Format)............................................6
Figure 2-1. 2D Code Created Using Dot-Peen Technology .......................................10
Figure 2-2. ModelDMCode Property Sheet ................................................................12
Figure 3-1. Improving Images Using Filters................................................................13
Figure C-1. Dot-peen 2D Code...................................................................................18
Figure C-2. Filtered Image of 2D Code.......................................................................19
Figure C-3. Training a Model Region..........................................................................20
Figure C-4. ModelDMCode Property Sheet................................................................21
Figure C-5. 2D Code (Numbering Added) ..................................................................21
Figure C-6. NeighborFilter property sheet ..................................................................22
Figure C-7. Filtered Image of 2D Code.......................................................................23
List of Tables
Table 1-1. Input Device Actions ....................................................................................2
Table 1-2. Job Descriptions ..........................................................................................3
Table 1-3. Breakout Cable Wiring and Connector Pinouts...........................................8
Table 2-1. 2D Setup Procedures ................................................................................11
Table 3-1. 2D Code Image Filtering Procedures ........................................................14
Table 3-2. Barcode Image Filtering Procedures .........................................................15
Table A-1. Lens Selection Chart.................................................................................16
Table B-1: Lighting Guide ...........................................................................................17
Table D-1. Troubleshooting Guide..............................................................................24

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Introduction
In-Sight 1010
The compact, stand-alone In-Sight 1010 vision sensor reads 2D matrix codes and 1D bar
codes, and communicates the information to local and remote locations. Advanced recognition
algorithms provide reliable reading of codes that have been poorly formed, degraded, or vary in
position or orientation from part to part. The processing power available also means codes can
be read at rates of 30 reads per second.
The operator interface makes using this powerful software extremely easy. The user also has
the flexibility to access In-Sight’s spreadsheet environment, if more advanced functionality is
required.
The system’s interfaces include digital, serial, and Ethernet communications. The networking
capability allows the system to share real-time information with other In-Sight units as well as
other third party devices and host computers within the plant and beyond.
This manual is designed to assist the user in the process of:
•Mounting the In-Sight 1010 and acquiring an image.
•Using the operator interface in order to read the required codes.
•Supply the interfacing information enabling the In-Sight 1010 to communicate to the
necessary external devices.
In-Sight 1010 Product Kit
The standard items you will receive for your first In-Sight 1010 (Starter kit) are:
•Camera with Integrated Processor.
•CD-ROM containing code reading jobs and Setup Wizard.
•CAT5 cable for connecting the 1010 to an Ethernet network.
•Crossover cable for connecting the 1010 directly to a PC or an In-Sight 3000.
•Power cable.
•24Vdc power adapter.
•Seven foot power adapter cable - 7’.
•RJ-45 serial cable.
•Getting Started with In-Sight 1010 manual.

viii
For More Information
Other resources available to help you learn about the In-Sight vision sensor and its
spreadsheet interface include:
•The following documents describe how to connect the vision processor and other
components. They also contain specifications, mechanical drawings, and other hardware
details:
Installing the In-Sight 1000
Cognex P/N 590-6346 (English)
Cognex 590-6346F (French)
Cognex 590-6346J (Japanese)
•In-Sight Guide and Reference, an HTML Help file provided on the In-Sight CD-ROM.
•The In-Sight Online Support Center at
http://www.cognex.com/insight/support/support.asp.

Chapter 1: Setting up Your In-Sight 1010
1
Chapter 1: Setting Up Your In-Sight 1010
This document is a guide to setting up your In-Sight 1010 system to read barcodes and 2D
matrix codes.
Connecting the In-Sight 1010
Refer to Installing the In-Sight 1000, which is included with your In-Sight 1010 system on the In-
Sight CD-ROM. This explains how to connect the system directly to your PC, an In-Sight 3000,
or an Ethernet network. Once you have completed the system installation described in Installing
the In-Sight 1000, proceed to the next section, Loading the Jobs from the CD.
Loading the Jobs from the CD
1. Place the In-Sight 1010 CD-ROM in your PC’s CD-ROM drive.
2. The In-Sight 1010 Setup Wizard should start automatically, see Figure 1-1.
3. If the Setup Wizard does not start automatically, click on the Windows Start button and
select Run, then enter [x]:\IS-1010.exe, where [x] is the drive letter of your CD-ROM
drive.
Figure 1-1. In-Sight 1010 Setup Wizard
4. Follow the directions provided by the Wizard. When it finishes, reboot your In-Sight 1010.

Getting Started with In-Sight 1010
2
Navigating the In-Sight Interface
Instructions for input are primarily for the PC keyboard only; Table 1-1 details the alternative
controls for the mouse and control pad.
Table 1-1. Input Device Actions
PC Keyboard Mouse Action In-Sight 3000
Control Pad Functionality
Arrow keys Left-click and drag
The cursor keys are used for moving around
menu options and defining image regions.
Enter Left-click or double
left-click
Used in the same way as ‘Enter’ on a regular
keyboard.
F2 n/a
Allows the user to zoom in to a region of the
image.
F3
Right-click with
pointer over cell
focus
Selects the different modes when defining
regions on the image.
Esc
Right-click with
pointer not over cell
focus
System menu selection. Also acts as an
escape out of any menu.

Chapter 1: Setting up Your In-Sight 1010
3
Loading your job
1. Log on to your In-Sight 1010 with the PC Host software.
2. Select Esc to access the System Menu.
3. Select Save & Load (ensure the Online box is unchecked).
4. Select the appropriate job (see Table 1-2 for a description of the various jobs).
5. Select Load.
Table 1-2. Job Descriptions
Job name Description
2Dcode One 2D code
Barcode One barcode
2DcodeX2 Two 2D codes
BarcodeX2 Two barcodes
2Dcode_ Barcode One 2D code and one barcode
BarcodeX2_2D Two barcodes and one 2D code
2DX2_Barcode Two 2D codes and one barcode
Tutorial A tutorial job that provides an example of how to configure the In-Sight 1010 for
reading dot-peened 2D codes. Refer to Appendix C of this document.
Welcome Welcome job that explains how to load a code reading job

Getting Started with In-Sight 1010
4
Operator Display
The operator display consists of an image acquired by the camera, the In-Sight 1010 GUI
interface (see Figure 1-2), and setup options.
Figure 1-2. In-Sight 1010 GUI Interface
How do you know if the code is being read?
•The alphanumeric code will be displayed in green.
•A 2D matrix will have a green square around the matrix. (Barcodes have no graphics).
•A 2D matrix will display a grade of A through F. Click on this cell for more detailed
verification data.
What are the 2D Setup Options?
•Search window: Highlight the cell containing the structure and press F2 to
define the search window around the 2D code. The region need not be tightly constrained
around the 2D code; in general you should be able to leave the region at its default
setting of the full screen.

Chapter 1: Setting up Your In-Sight 1010
5
•Configure advanced settings: Highlight the cell containing the structure and
press Enter to open the ReadDMCode property sheet. Refer to the ReadDMCode topic
in the In-Sight Guide and Reference for more information.
•The 2D Model function can be selected by enabling the checkbox Train a Model? (see
Chapter 2: 2D Setup – Using the 2D Model for further instructions).
•Image filtering can be selected by enabling the checkbox Apply Filtering? (see Chapter
3: Image Filtering for further instructions).
What are the Barcode Setup Options?
•Search window: Highlight the cell containing the structure and press F2 to
define the search window around the barcode. It is recommended that this region be
sized as closely as possible around the barcode, while still allowing sufficient room for
variations in the position of the barcode within the image.
•Select the barcode type: Highlight the cell containing the structure and press
Enter to open the ReadBarcode property sheet. Refer to the ReadBarcode topic in the In-
Sight Guide and Reference for more information.
•Image filtering can be selected by enabling the checkbox Apply Filtering? (see Chapter
3: Image Filtering for further instructions).
What are the General Setup Options?
•The cell on the top left of the operator display (containing the structure) contains
the required parameters to acquire images. Refer to the AcquireImage topic in the In-
Sight Guide and Reference for more information.
•The Communications wizard allows selection of digital, serial, and network options. See
the Communications section below.
•The Help cell offers a list of on-line help topics.
•The screen graphics can be turned on and off using the Graphics checkbox via the
spreadsheet.
Positioning your In-Sight 1010
•Position the camera at a suitable height to view your code(s). Refer to Appendix A: Lens
Selection Chart to aid in the selection of a lens, spacers (if required), and the lens to
object distance. As a rough guide, aim for a field of view (in the vertical axis of the
camera) approximately double the width of the code(s) to be read.

Getting Started with In-Sight 1010
6
Acquiring a Working Image
•Mount the lighting chosen for the application. A range of LED lights (rings, domes, etc.)
are available from Cognex. The appropriate choice of lighting can be critical for
demanding applications (see Appendix B: Lighting Guide).
•Adjust the aperture ring on the lens to control the image intensity. If you cannot make the
image bright enough use a brighter light or increase the exposure time. The 1 ms default
exposure should be appropriate for most applications. If the images are blurred in very
fast applications, then lower this value.
•Adjust the focus ring of the lens to sharpen the image of your code. If this is not possible,
adjust the height of the camera or the amount of extension spacers.
Working with the In-Sight 1010
The In-Sight 1010 is designed to work ‘straight from the box’ for the majority of applications.
After you load the appropriate job and set up the camera/optics, place your code underneath
the system.
Bottom Left Corner
Figure 1-3. 2D Data Matrix Code (16 X 16 Code Format)
If the system reports ‘No Read’ for 2D codes, try using the 2D Model function (Chapter 2: 2D
Setup – Using the 2D Model). If the code is still not being read try the image filtering option
(Chapter 3: Image Filtering).
NOTE: In-Sight only reads AIM standard Data Matrix ECC 200 symbols.

Chapter 1: Setting up Your In-Sight 1010
7
Saving your job
To save your job use the following steps:
WARNING: When saving a job, the selected file will be overwritten. Instead of
overwriting the job, you may want to save it with a new file name.
1. Select Esc to access the System Menu.
2. Ensure the Online box is unchecked.
3. Select Save & Load.
4. Select the appropriate job (see Table 1-2 for a description of the various jobs), or click
New if you will be entering a new file name.
5. Select Save.
Automatically Load Your Job on Startup
1. Select Esc to access the System Menu.
2. Ensure the Online box is unchecked.
3. Select Settings.
4. Select Startup.
5. Select the job to automatically load on startup from the drop-down list.
6. Ensure the Online box is checked.
Communications
A combination of digital, serial, and network communications can be used to interface with the
In-Sight 1010. These interfaces can be configured using the Communications wizard box in the
operator display.

Getting Started with In-Sight 1010
8
Serial and digital signals are provided on the breakout cable (see Table 1-3). An optional
Breakout Module is available to assist in the task of wiring these signals.
Table 1-3. Breakout Cable Wiring and Connector Pinouts
Pin Signal Breakout Cable
Wire Color
Breakout Module
Terminals In-Sight 1010 Functionality
1 +24 VDC White-Green 1,2,3,4,6,8,10 Power supply to the In-Sight 1010.
2 Trigger + Green 12
Trigger to start read.
0V/24V signal from the proximity
sensor or PLC.
3 Trigger - White-Orange 13 0V common with the proximity
sensor or PLC.
4 Output 0 Blue 11 Pass/Fail status signal.
5 Output 1 White-Blue 9
Job Completed signal. On receipt
of this signal, read the Pass/Fail
status signal.
6 Serial Receive Orange 5 No functionality.
7 Serial Transmit White-Brown 7 The code read is transmitted via
this pin.
8 Ground Brown 14,15,16 0V supply to the In-Sight 1010.
Digital Input
When the In-Sight 1010 is in ‘Trigger’ mode, a code read is started on receipt of a 24V signal,
typically from a proximity sensor or PLC.
Digital Outputs
The In-Sight 1010 can send a Job Completed output pulse of 20ms that activates when the
code has been read.
Also, the In-Sight 1010 can be configured to compare the code read to an expected string and
report a Pass/Fail signal based on the result of that match. On receipt of the Job Completed
signal, read the Pass/Fail status signal.
Connecting to a PLC
Connect a 2k resistor between the output signal and 24V.
•Pass - 0V.
•Fail - 24V.
The active state of the Job Completed output pulse is 0V.

Chapter 1: Setting up Your In-Sight 1010
9
Connecting to a Relay
Connect the outputs to one side of the relay coil. Connect the other end of the coil to 24V.
•Pass – Coil Activated.
•Fail – Coil De-activated.
The active state of the Job Completed output pulse is ‘coil activated’.
Serial Output
The code read by the In-Sight 1010 is transmitted on the system’s RS232 serial port. The
default port settings are:
•Baud rate 9600.
•8 data bits.
•1 stop bit.
•No parity.
•No Handshaking.
When reading one code the output stream will be:
<ASCII data><CR>
When reading two codes the output stream will be:
<code1 ASCII data><delimiter>< code2 ASCII data<CR>
The delimiter is a comma (,) by default; this can be changed using the Communications wizard.
Reporting the Code Over the Network
The code read can also be transmitted over the network to a specific device. The name of the
device receiving the code and the communication channel number needs to be specified.
These settings (and more detailed help) are found in the Communications wizard.

Getting Started with In-Sight 1010
10
Chapter 2: 2D Setup – Using the 2D Model
Codes that are poorly printed or degraded may not be read using the default In-Sight 1010
configuration. A typical example of such a code is a direct-marked part using dot-peen
technology, as shown in Figure 2-1. If, when you load your job, No Read is constantly or
intermittently displayed, follow the instructions in Table 2-1.
Figure 2-1. 2D Code Created Using Dot-Peen Technology

Chapter 2: 2D Setup – Using the 2D Model
11
Table 2-1. 2D Setup Procedures
Instruction Notes
1. Highlight the cell containing the Train a
Model? Checkbox. Press Enter to check the
box.
This enables the 2D Model function. A message
box is displayed with additional instructions.
2. Highlight the cell containing the
structure to the right of the checkbox. This cell contains the 2D Model function.
3. Press F2. Activates the graphics mode for defining the four
corners of the 2D matrix.
4. Press F3 twice. Selects the top left-hand corner of the square
graphic.
5. Use the cursor keys to position the cross in
the center of the top left-hand corner cell of
the 2D matrix.
NOTE: The bottom left-hand corner of an ECC200
2D matrix is always the apex of the ‘L’ location
feature.
6. Press F3 to select the bottom left corner. Right-click on the mouse.
7. Use the cursor keys to position the cross at
the apex of the ‘L’ locator on the 2D matrix.
See Figure 1-3 for an example of a 2D matrix
code.
8. Position the last two corners. Use F3 and the cursor keys as in the two previous
steps.
9. Press Enter to finish. Double left-click on the mouse.
10. Press Enter on the cell.
This will open the ModelDMCode property sheet
(See Figure 2-2. Also see the In-Sight Guide and
Reference for more help on the ModelDMCode).
11. Select the code format.
This is the number of cells (black and white) along
the two sides opposite the ‘L’ sides. Figure 1-3
shows a 16 column x 16 row code.
12. Select the color of the code. For example, a black code on a white
background.
13. Select OK to accept the settings. If the settings have worked, the read result will
now be displayed.
For further assistance see Appendix C: 2D Code Tutorial.

Getting Started with In-Sight 1010
12
Figure 2-2. ModelDMCode Property Sheet
If the rotation of the 2D matrix varies, a fixture (Row, Column, Theta) can be specified in the
ReadDMCode property sheet (see the In-Sight Guide and Reference for more help on the
ReadDMCode property sheet). The property sheet is accessed from the cell to the
right of the Grade cell in the operator interface. Note that the speed of the read rate will be
slower as the angle parameter is made larger.