ipf electronic opti-check Guide

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Content
1Welcome......................................................................................................................................................7
2Imprint.........................................................................................................................................................8
3Safety instructions.....................................................................................................................................9
4Correct Use...............................................................................................................................................12
5Mode of operation....................................................................................................................................13
6Installation and initial set-up...................................................................................................................15
6.1 Mechanical set-up ...............................................................................................................................15
6.2 IP protection ratings.............................................................................................................................17
6.3 Electrical installation............................................................................................................................18
6.4 Wiring...................................................................................................................................................19
6.4.1 Notes on using an incremental encoder .......................................................................................20
6.5 Software installation ............................................................................................................................22
6.6 Initial set-up of the Ethernet interface on your computer ....................................................................24
6.7 Notes on using gateways in a network................................................................................................26
6.8 Important network terms......................................................................................................................26
6.9 LED panel (device dependant)............................................................................................................28
6.10 LED panel (devices with integrated Industrial Ethernet) .....................................................................29
7Overview of the Application Suite..........................................................................................................30
7.1 Operating modes of the device ...........................................................................................................31
7.2 Help, info and support .........................................................................................................................32
8Image display options .............................................................................................................................33
8.1 Images from PC...................................................................................................................................34
8.2 Defect images......................................................................................................................................35
8.3 Loading, saving and recording images................................................................................................36
8.4 Job features.........................................................................................................................................38
9Creating a job ...........................................................................................................................................39
9.1 Adjusting the image (image focus)......................................................................................................39
9.1.1 Adjusting the image (additional parameters) ................................................................................40
9.1.2 Coordinates (device dependant)...................................................................................................45
9.1.3 Focus ............................................................................................................................................47
9.1.4 White balance (device dependant) ...............................................................................................48
9.2 Checking features................................................................................................................................49
9.3 Configuring interfaces..........................................................................................................................55
9.3.1 Occupancy of digital I/Os..............................................................................................................55
9.3.2 Timing digital I/Os .........................................................................................................................59
9.3.3 Output process interface (device dependant)...............................................................................62
9.3.4 Input process interface (device dependant)..................................................................................66
9.3.5 Web interface................................................................................................................................69
9.4 Device activation .................................................................................................................................70
9.4.1 Statistics / Details..........................................................................................................................71
10 Device menu.............................................................................................................................................72
10.1 Connect to device................................................................................................................................73
10.2 Device settings... .................................................................................................................................78

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10.2.1 Device name.................................................................................................................................79
10.2.2 Access rights (device dependant).................................................................................................80
10.2.2.1 Application Suite .....................................................................................................................80
10.2.2.2 Web interface..........................................................................................................................81
10.2.3 Customizing web interface............................................................................................................82
10.2.3.1 Functions.................................................................................................................................82
10.2.3.2 Design.....................................................................................................................................85
10.2.4 Digital I/Os.....................................................................................................................................86
10.2.5 Alarm signal ..................................................................................................................................88
10.2.6 IP address / network .....................................................................................................................89
10.2.7 Process interface (device dependant) ..........................................................................................90
10.2.8 FTP ...............................................................................................................................................93
10.2.9 Job management ..........................................................................................................................95
10.2.10 Job selection / Teach.....................................................................................................................97
10.2.11 Illumination controller (device dependant)....................................................................................98
10.2.12 Firmware update.........................................................................................................................101
10.3 Backup...............................................................................................................................................103
10.3.1 Backup - using the PC... .............................................................................................................104
10.3.2 Backup –using the FTP server...................................................................................................105
10.3.3 Backup –restoring from the PC..................................................................................................106
10.3.4 Backup - restoring from the FTP server......................................................................................108
10.4 Digital I/O Assistant ...........................................................................................................................109
10.5 Process interface assistant (device dependant) ............................................................................... 111
10.6 Operating mode display.....................................................................................................................113
11 Job menu ................................................................................................................................................114
11.1 Create new job ..................................................................................................................................115
11.2 Load job from PC...............................................................................................................................116
11.3 Load job from device.........................................................................................................................117
11.4 Save job to PC...................................................................................................................................118
11.5 Save to the device.............................................................................................................................119
11.6 Test job..............................................................................................................................................120
11.6.1 Test Protocol –Overview............................................................................................................123
11.6.2 Test Protocol –Statistic...............................................................................................................124
11.7 Result and user display.....................................................................................................................125
12 Feature checks.......................................................................................................................................126
12.1 Part location.......................................................................................................................................127
12.1.1 Part location on contours ............................................................................................................127
12.1.2 Part location on edges ................................................................................................................130
12.1.3 Part location on circle..................................................................................................................132
12.1.4 Part location on text line..............................................................................................................134
12.2 Geometry...........................................................................................................................................136
12.2.1 Distance ......................................................................................................................................136
12.2.2 Circle...........................................................................................................................................139
12.2.3 Angle...........................................................................................................................................142
12.2.4 Count edges................................................................................................................................145
12.2.5 Point position...............................................................................................................................148
12.2.6 Edge characteristics....................................................................................................................150
12.3 Feature comparison...........................................................................................................................156
12.3.1 Count contour points...................................................................................................................156
12.3.2 Contour comparison....................................................................................................................158
12.3.3 Colour identification ....................................................................................................................161

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12.3.4 Brightness...................................................................................................................................166
12.3.5 Contrast.......................................................................................................................................168
12.3.6 Areasize......................................................................................................................................170
12.3.7 Area size (colour)........................................................................................................................173
12.3.8 Colour positioning .......................................................................................................................178
12.3.9 Count areas.................................................................................................................................183
12.3.10 Count areas (colour) ...................................................................................................................186
12.3.11 Pattern comparison.....................................................................................................................191
12.3.12 Pattern comparison (older version).............................................................................................194
12.3.13 Pattern comparison (colour)........................................................................................................196
12.4 Identification ......................................................................................................................................199
12.4.1 Barcode.......................................................................................................................................199
12.4.2 Barcode (colour)..........................................................................................................................203
12.4.3 Matrix code..................................................................................................................................207
12.4.4 Matrix code (colour) ....................................................................................................................211
12.4.5 Text..............................................................................................................................................216
12.4.6 Text (colour) ................................................................................................................................221
12.4.7 Appendix: Quality characteristics for barcodes and matrix codes..............................................226
13 Digital interfaces ....................................................................................................................................228
13.1 Explanation of terms from the timing diagram...................................................................................228
13.2 Timing when an external trigger is used............................................................................................229
13.3 Timing for continuous image acquisition ...........................................................................................230
13.4 External Teach...................................................................................................................................231
13.5 Job switching.....................................................................................................................................232
13.6 Job selection via digital inputs...........................................................................................................233
13.6.1 Binary job selection.....................................................................................................................234
13.6.2 Bit serial job selection .................................................................................................................235
13.7 Alarm signal.......................................................................................................................................237
14 Web interface..........................................................................................................................................238
14.1 Supported browsers ..........................................................................................................................239
14.2 Connecting to the web interface........................................................................................................240
14.2.1 Connection to one device ...........................................................................................................240
14.2.2 Connection to multiple devices...................................................................................................242
14.3 Device specific functions...................................................................................................................244
14.4 Job specific functions ........................................................................................................................246
14.4.1 Image acquisition........................................................................................................................248
14.4.2 Part location................................................................................................................................248
14.4.3 Geometry ....................................................................................................................................249
14.4.4 Feature comparison....................................................................................................................249
14.4.5 Identification................................................................................................................................251
14.5 Functions selectable via the address bar..........................................................................................253
14.5.1 Language selection.....................................................................................................................253
14.5.2 Scaling down the transferred image ...........................................................................................253
14.5.3 Live image...................................................................................................................................254
14.5.4 Defect images.............................................................................................................................255
14.5.5 Static images...............................................................................................................................256
14.5.6 Setting the display screen...........................................................................................................258
15 Communication via the process interface (device dependant) ........................................................259
15.1 Process interface via TCP/UDP (device dependant) ........................................................................259
15.1.1 Configuration of the Ethernet interface.......................................................................................259

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15.1.2 Protocol structure –Ethernet......................................................................................................260
15.2 Process interface via RS485 (device dependant).............................................................................260
15.2.1 Configuration of the RS485 interface..........................................................................................260
15.2.2 Protocol structure –RS485.........................................................................................................261
15.3 General Information...........................................................................................................................264
15.3.1 General description of data formats............................................................................................264
15.3.1.1 Integer...................................................................................................................................264
15.3.1.2 Float ......................................................................................................................................264
15.3.1.3 Text........................................................................................................................................264
15.3.1.4 Composite data type: Integer point .......................................................................................265
15.3.1.5 Composite data type: Float point ..........................................................................................265
15.3.1.6 Composite data type: List......................................................................................................266
15.3.2 Numeric values in commands.....................................................................................................266
15.3.3 Conversion Table Decimal ↔ Hexadecimal ↔ Character ..........................................................267
15.3.4 Receipt timeout...........................................................................................................................268
15.3.5 Response delay ..........................................................................................................................269
15.4 Available commands for TCP / UDP / RS485 ...................................................................................270
15.4.1 CS command –reset statistics ...................................................................................................270
15.4.2 Command GB –access device backup......................................................................................271
15.4.3 GD command –retrieve last result .............................................................................................272
15.4.4 Command GF –retrieve individual files from the device............................................................275
15.4.5 GI command –access an image (only via Ethernet)..................................................................276
15.4.6 GM command –access information about the device................................................................277
15.4.7 GP command –access the current configuration of the SP command......................................278
15.4.8 GS command –request status ...................................................................................................279
15.4.9 SJ command –change to a different job ....................................................................................281
15.4.10 SM command –change operating mode....................................................................................282
15.4.11 SP command –set parameters for the feature checks...............................................................284
15.4.12 TE command –use next image for external teach .....................................................................287
15.4.13 TR command –request image acquisition and response datagram ..........................................289
15.4.14 TI command - trigger immediately ..............................................................................................290
15.4.15 TD command –request image acquisition and transfer data.....................................................291
15.4.16 UD command –transfer backup data (only for Ethernet)...........................................................292
15.4.17 UJ command –transfer a new job..............................................................................................294
15.4.18 VB command –restart device.....................................................................................................295
15.5 Process interface via Industrial Ethernet (device dependant)...........................................................296
15.5.1 Mode of operation.......................................................................................................................296
15.5.2 Data.............................................................................................................................................297
15.5.2.1 Cyclical data..........................................................................................................................297
15.5.2.2 Group: Control and status.....................................................................................................298
15.5.2.3 Group: Result data................................................................................................................302
15.5.2.4 Group: Parameters................................................................................................................303
15.5.2.5 Group: Trigger data...............................................................................................................304
15.5.2.6 Handshake............................................................................................................................305
15.5.2.6.1 Simple handshake.........................................................................................................305
15.5.2.6.2 Handshake with acknowledgement...............................................................................306
15.5.2.6.3 Data elements for handshake .......................................................................................307
15.5.3 PROFINET..................................................................................................................................309
15.5.3.1 LEDs on the Vision Sensor ...................................................................................................309
15.5.3.2 Cabling..................................................................................................................................309
15.5.3.3 Planning in the PLC ..............................................................................................................310
15.5.3.4 Vision Sensor alarm..............................................................................................................311

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15.5.3.5 Depiction of the data elements on the PROFINET module ..................................................312
15.5.3.5.1 Module: Control and status ...........................................................................................312
15.5.3.5.2 Module: Result data ......................................................................................................313
15.5.3.5.3 Module: Parameters......................................................................................................313
15.5.3.5.4 Module: Trigger data .....................................................................................................314
15.5.3.5.5 Example.........................................................................................................................315
16 Cleaning..................................................................................................................................................319
17 Technical data.........................................................................................................................................320
17.1 Overview of feature checks...............................................................................................................320
17.2 Overview Features ............................................................................................................................321
17.3 Technical drawing
(except OC53962x/OC53972x/OC53982x/OC539F2x/OC539G2x / OC539H2x) ............................322
17.4 Technical drawing
(OC53962x/OC53972x/OC53982x/OC539F2x/OC539G2x/OC539H2x only) ..................................323
17.5 Technical drawing (OC5394V0 only).................................................................................................324
17.6 Temperature measurement point ......................................................................................................325
17.7 Fastening bracket, 90 degree (VS mounting adapter) ......................................................................326
17.8 Fastening bracket, 90 degree............................................................................................................327
17.9 Fastening bracket, straight................................................................................................................328
17.10 Technical data....................................................................................................................................329
17.11 Electrical Connection (View on Device) ............................................................................................331
17.12 Power Cable M12 / 12-pin.................................................................................................................332

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1 Welcome
Welcome to the Help Guide.
Please read these operating instructions carefully and observe the safety instructions!
Target group:
These operating instructions are intended for users that want to perform feature checks with the Vision
Sensor.

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2 Imprint
ipf electronic gmbh
Kalver Straße 25-27
58515 Lüdenscheid
Tel: 02351 / 9365-65
E-Mail: [email protected]
Version 2.8.2-K11
10/2017 Issue
All rights reserved. Reproduction of this document in whole or in part is only permitted with previous written
consent from ipf electronic GmbH.
Revisions in the course of technical progress and possible errors reserved.

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3 Safety instructions
Explanations of safety instructions
NOTE
Gives helpful notes on operation or other general recommendations.
ATTENTION!
Indicates a possibly dangerous situation. If this is not avoided,
slight or minor injury could result or the device may be damaged.
WARNING!
Indicates an immediate imminent danger. If this is not avoided, death or serious injury
may occur.
General notes / Safety instructions for the Vision Sensor
NOTE
There is a scratch-resistant foil on the glass cover of the tube for devices with
interchangeable lenses. Remove the foil before carrying out inspection tasks.
NOTE
For optimum electrical noise immunity, the use of shielded cables is recommended. The
appropriate cables can be obtained from the manufacturer.
NOTE
Networking problems can occur for a number of different reasons, such as power saving
modes on portable computers, defective cables or other defective components, or
incorrect settings on the PC. Should an error occur, contact a technician to locate the
source of the problem.

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NOTE
Characters allowed in file names and job names:
0123456789ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz
ÀÁÂÃÄÅÈÉÊËÌÍÎÏ
àáâãäåèéêëìíîï
ÐÑÒÓÔÕÖÙÚÛÜÝß
ðñòóôõöùúûüýÿÇ,
¦!#$%&'+-÷×±,.
¡@_`()[]{}«»~
ATTENTION!
Connection, installation and initial set-up may only be carried out by specialized
personnel.
Protect optical areas from moisture and dirt.
ATTENTION!
The IP protection class is only valid if all connectors are connected as described in the
technical documentation and, for devices with protection class IP 69K, if the sealing screw
on the lens setting opening is correctly screwed in.
ATTENTION!
Disconnection of power to the unit during booting can result in damaged files.
Never disconnect the power supply during booting. Booting is finished when intermittent
blinking of the PASS / FAIL –LED or blinking of the POWER LED has stopped.
ATTENTION!
The device may become warm during operation. High temperatures may damage the
device. Ensure that any heat generated is dispersed by installing it with the rear to a good
heat conductor (metal). The housing temperature must not exceed 50°C.
Direct mounting on a solid metal object without using a retaining bracket is required when
operated in the limit zone (e.g. full load on the flash controller and utilisation of the
maximum operating temperature)!
For devices with integrated Industrial Ethernet only:
These devices are equipped with an internal temperature monitor for built-in protection.
There may be a warning message or emergency shutdown if the device is operated
outside its specified range.

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ATTENTION!
Incorrect supply voltage will destroy the device!
Pin 1: Power (+18…30 VDC)
Pin 2: Ground
ATTENTION!
The device can become damaged by strong radiation or electrical fields.
For this reason, never place the device near strong radiation sources or strong electrical
fields. These can occur in close proximity to lasers, for example.
ATTENTION!
The Vision Sensor is a class A device (DIN EN 55022:2011). It can cause radio
interference in residential environments. Should this happen, you must take reasonable
measures to eliminate the interference.
WARNING!
The device emits bright, pulsed light (Risk group 1, low risk, EN 62471:2008).
Bright, pulsed light can cause damage to the eyes and seizures.
Never look directly into the pulsed light from the LEDs!
For devices with infra-red illumination
NOTE
The device uses LED illumination of the risk group RG 0 (exempt group, no risk) as per
IEC/EN 62471.
The radiation of the LEDs does not pose a hazard to the human eye if the device is used
for its intended purpose.
Even so, do not look directly into the light source –there is a danger of dazzle and
irritation. Mount the device so that it is not possible to look directly into the light source.

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4 Correct Use
Depending on the device, the Vision Sensors in combination with the Application Suite software are used to
monitor and verify:
Completeness
Presence
Position
Correct position
Barcode and matrix code
Numbers and characters
Colour features
e.g. for objects passing the Vision Sensor on conveyor belts.
You can find an overview as to which Vision Sensors check which features under: Technical Data (Overview
of feature checks).
NOTE
The colour devices are suitable for tasks such as sorting objects by colour. They are not
suitable for measuring colours or determining colour deviations (ΔE).
NOTE
These devices are not suitable for use in the food sector as per EN 1672-2.
ATTENTION!
Only use the devices for its intended purpose! The guarantee becomes void in the case of
any application not described in the technical documentation!

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5 Mode of operation
In contrast with conventional photoelectric sensors, this sensor operates with digital images and is capable of
conducting several feature checks with parameters set by the software.
The strength of the device lies in the detection of contours. With the procedure, differences in brightness can
be optimally tolerated, as contours are usually independent of the absolute brightness (e.g. variations in
illumination).
Because a test object can normally be definitively described by its relevant contours, the device provides
powerful tools to check their presence, position, completeness or colour. The high quality of the method
ensures that a reliable result is always achieved even with a rapid sequence of objects.
The diagram shows the schematic mode of operation with the corresponding parts of the sensor.
Here, each inspection task ("job") is divided into several feature checks. Each feature check executes one
task and returns an associated pass/fail result or the associated measured values. For this purpose, a field of
view must be defined that is either circular, an arc, rectangular or polygonal. The contours can be given via
search arrows for geometrical feature checks.
Then you can link the results from the feature checks into one result and output it via a digital interface. With
the device, the stored jobs can be selected via external switching inputs.

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The device operates in two operating modes:
Activated
Configuration
In activated mode, the inspection task is conducted. The device operates autonomously in this mode and
can communicate directly with a PLC. The device receives all commands such as trigger or job number from
the external control system and mainly returns a pass or fail result. In activated mode you can also use the
Application Suite to monitor your inspection tasks.
In the Configuration mode you can configure and set the parameters for the jobs and features to be checked.
This is conducted using the Application Suite.
Because a high-quality digital image provides many means of visual inspection, the parameters of the jobs
have to be set according to the inspection task and the application. For this purpose, the Application Suite
provides a pre-configured input mask for each feature to be checked, which supports the determination of
the optimum settings.

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6 Installation and initial set-up
6.1 Mechanical set-up
You can operate the device in any position.
Attach the device to the M4 screws provided for this purpose.
Align the device sothat the image centre indicated below points directly at the object to be inspected.
The device should be installed so that it vibrates as little as possible during operation to avoid negative
influences on the image quality (blurred images).
Install the device so that there are no obstacles between the sensor and the object that could block the view
or cause reflections. Ensure that the device is protected as well as possible against dust.
Devices and its built-in lens can inspect fixed areas at fixed distances.
NOTE
The field of view and minimum module size for devices with interchangeable lenses
depends on the lens installed.

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Refer to the diagrams below for the maximum fields of view and minimum module size:
6) Working distances > 400 mm possible

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6.2 IP protection ratings
The devices continue working in an industrial environment to meet the requirements of various protection
ratings.
IP protection ratings
IP 67 (all devices)
Sealed against dust, protection against short-term submersion
IP 69K (only stainless
steel)
Sealed against dust, protection against jets of water. Although you should avoid
cleaning with a pressure washer.
ATTENTION!
The respective IP protection class is only valid if all connectors are connected as
described in the technical documentation and, for devices with protection class IP 69K, if
the sealing screw on the lens setting opening is correctly screwed in.
The electrical hose connections on the device must be tightened with a torque of 0.4 Nm.
The tube on devices with replaceable lens must be screwed without a gap as depicted in the figure below in
order to achieve the stated protection rating.

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6.3 Electrical installation
For initial set-up, you will require:
the Vision Sensor,
Installation CD for the Application Suite,
a M12-connecting cable (not supplied)
an Ethernet cable (not supplied)
a normal PC with Ethernet interface (not supplied).
NOTE
For optimum electrical noise immunity, the use of shielded cables is recommended.
ATTENTION!
The IP protection class is only valid if all connectors are connected as described in the
technical documentation and, for devices with protection class IP 69K, if the sealing screw
on the lens setting opening is correctly screwed in.
ATTENTION!
When connecting the power, ensure that all cables are connected correctly according to
their colour codes!
You will find the voltages necessary, the pin assignment and the corresponding electrical
power under Technical Data.
Screw the 12-pin power cable with M12 plug onto the power supply connection on the device.
NOTE
After installing the software, you can check the correct assignment of the digital
connections in the menu: Device → Digital I/O-Assistant.

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6.4 Wiring
Input
Encoder
Output

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6.4.1 Notes on using an incremental encoder
You have two options for operating the device with an encoder:
NOTE
After installation, the inputs must be defined in the software using:
Device → Device settings → Digital I/Os / Inputs tab
.
1-channel operation (CH-A)In this mode, every rising edge of the signal corresponds to one
pulse for the timing control of the device.
It is not possible to detect the travel direction of the belt.
The maximum frequency of 500 kHz should not be exceeded for reliable operation.
Pin assignment of
the power cable
Connect the encoder CH-A to pin 11 (IN 5; grey-pink).