Omron F160-2 - 2 User manual

Cat. No. Z171-E1-01A
F160-2
Vision Sensor
Manual 2:
CONVERSATIONAL
MENU
OPERATION MANUAL
Covers.fm Page ix Monday, July 26, 2004 11:27 AM

READ AND UNDERSTAND THIS DOCUMENT
Please read and understand this document before using the products. Please consult your OMRON
representative if you have any questions or comments.
WARRANTY
OMRON’s exclusive warranty is that the products are free from defects in materials and workmanship for
a period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING
NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE
PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS
DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR
INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL
DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE
PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR
STRICT LIABILITY.
In no event shall responsibility of OMRON for any act exceed the individual price of the product on which
liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS
REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE PRODUCTS
WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO
CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to
the combination of products in the customer’s application or use of the product.
At the customer’s request, OMRON will provide applicable third party certification documents identifying
ratings and limitations of use that apply to the products. This information by itself is not sufficient for a
complete determination of the suitability of the products in combination with the end product, machine,
system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not
intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the
uses listed may be suitable for the products:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this document.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
equipment, amusement machines, vehicles, safety equipment, and installations subject to separate
industry or government regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.

NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND INSTALLED
FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PERFORMANCE DATA
Performance data given in this document is provided as a guide for the user in determining suitability and
does not constitute a warranty. It may represent the result of OMRON’s test conditions, and the users
must correlate it to actual application requirements. Actual performance is subject to the OMRON
Warranty and Limitations of Liability.
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other
reasons.
It is our practice to change model numbers when published ratings or features are changed, or when
significant construction changes are made. However, some specifications of the product may be
changed without any notice. When in doubt, special model numbers may be assigned to fix or establish
key specifications for your application on your request. Please consult with your OMRON representative
at any time to confirm actual specifications of purchased products.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when
tolerances are shown.
ERRORS AND OMISSIONS
The information in this document has been carefully checked and is believed to be accurate; however, no
responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user’s programming of a programmable product, or any
consequence thereof.
COPYRIGHT AND COPY PERMISSION
This document shall not be copied for sales or promotions without permission.
This document is protected by copyright and is intended solely for use in conjunction with the product.
Please notify us before copying or reproducing this document in any manner, for any other purpose. If
copying or transmitting this document to another, please copy or transmit it in its entirety.

F160-2 Vision Sensor
Manual 2: Conversational Menu Operation Manual
Revised July 2004

iv

v
Notice:
OMRON products are manufactured for use according to proper procedures by a qualified opera-
tor and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always
heed the information provided with them. Failure to heed precautions can result in injury to people
or damage to property.
!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
!Caution Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it
refers to an OMRON product, regardless of whether or not it appears in the proper name of the
product.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types
of information.
Note Indicates information of particular interest for efficient and convenient opera-
tion of the product.
1,2,3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc.
Precaution Indicates information required to take full advantage of the functions and per-
formance of the product. Incorrect application methods may result in the loss
of damage or damage to the product. Read and follow all precautionary infor-
mation.
CHECK Indicates points that are important in using product functions or in application
procedures.
TwoCamera Indicates information required when using a 2-camera system.
SeeAlso Indicates where to find related information.
HELP Indicates information helpful in operation, such as the definition of terms.
OMRON, 2003
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or trans-
mitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise,
without the prior written permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover,
because OMRON is constantly striving to improve its high-quality products, the information contained
in this manual is subject to change without notice. Every precaution has been taken in the preparation
of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is
any liability assumed for damages resulting from the use of the information contained in this publica-
tion.


vii
TABLE OF CONTENTS
SECTION 1
Features of Conversational Menus . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Vision Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 Inspection Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-3 Advantages of Conversational Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-4 Useful Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-5 Operational Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 2
Basic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-1 Starting the F160 and Displaying Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-2 Menu Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-3 Understanding Setting Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2-4 Saving Settings and Exiting the F160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 3
Designing Inspections for Specific Applications . . . . . . . . . . . 47
3-1 Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3-2 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3-3 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3-4 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3-5 Chips and Burs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3-6 Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SECTION 4
Application Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4-1 Changing and Clearing Inspection Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 66
4-2 Changing Scenes and Scene Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4-3 Backing Up Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4-4 Checking Image Density Distribution: Line Brightness . . . . . . . . . . . . . . . . . . 88
4-5 Checking I/O Status with External Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4-6 Memory Card Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
SECTION 5
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5-1 Entering System Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5-2 Camera Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5-3 Screen Display and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5-4 Customizing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5-5 Setting Conditions for Saving Measurement Images . . . . . . . . . . . . . . . . . . . 112
5-6 Using BUSY Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

viii
TABLE OF CONTENTS
5-7 Selecting Items to be Shown in Overall Judgements. . . . . . . . . . . . . . . . . . . . 117
5-8 Setting Startup Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5-9 Setting the Calendar Date and Time (Date/Time) . . . . . . . . . . . . . . . . . . . . . . 119
5-10 Checking System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5-11 Changing to Expert Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
SECTION 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6-2 FAQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Appendices
A Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
B Training Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

ix
About this Manual:
This manual describes operating procedures for the F160 Vision Sensor using the Conver-
sational Menus and it includes the sections described below. The Conversational Menus
enable easily setting inspections by responding to quires provided on the screen.
This is one of four manuals used to operate the F160. Refer to the following table for the
contents of each manual.
Please read the above manuals carefully and be sure you understand the information pro-
vided before attempting to install or operate the F160.
Section 1 Features of Conversational Menus describes the features of the Conversa-
tional Menus and the types of inspections that are possible.
Section 2 Basic Operations describes the basic operations of the Conversational Menus.
Section 3 Designing Inspections for Specific Applications describes the six inspection
methods not described in 2-3 Understanding Setting Operations. The other inspection
method, presence inspections, are explained in 2-3 Understanding Setting Operations.
Section 4 Application Settings describes how to change, delete, and save inspection set-
tings and how to use various functions with Conversational Menus
Section 5 System Settings describes how to set conditions related to the system environ-
ment. Refer to the Communications Reference Manual for information on communications
specifications.
Section 6 Troubleshooting provides information on troubleshooting and a list of frequently
asked questions.
Manual Contents Cat. No.
1: Setup Manual Provides information on system hardware and installa-
tion. Be sure to read this manual first.
Z170
2: Conversational
Menu Operation
Manual
Describes operation of the F160 using the Conversa-
tional Menus. The Conversational Menus enable the sim-
plest operation based on registered images of
acceptable and unacceptable products.
Z171
3: Expert Menu
Operation Manual
Describes operation of the F160 using the Expert Menus.
The Expert Menu enable application of all F160 capabili-
ties, including setting region images and criteria.
Z173
4: Communications
Reference Man-
ual
Describes the communications settings and communica-
tions protocol used to transfer data through the parallel
interface or serial interface.
Z172
!WARNING Failure to read and understand the information provided in this manual may result in per-
sonal injury or death, damage to the product, or product failure. Please read each section in
its entirety and be sure you understand the information provided in the section and related
sections before attempting any of the procedures or operations given.


1
SECTION 1
Features of Conversational Menus
This section describes the features of the Conversational Menus and the types of inspections that are possible.
1-1 Vision Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 Inspection Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-3 Advantages of Conversational Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-4 Useful Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-5 Operational Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2
Vision Sensors Section 1-1
1-1 Vision Sensors
Vision Sensors work in place of the human eye to perform inspections by pro-
cessing images using cameras. The visual inspections can be automated and
complicated inspections can be performed accurately at high speeds.
The OMRON F160 Vision Sensor helps create production lines with a highly
efficient inspection system, which is important to meet current demands for
small-lot, variable-product production, produce greater added-value, and
improve product quality.
Using the F160 yields a high return on investments by ensuring the following
benefits:
• Repetitive work is reduced.
• More complicated, more precise inspections are possible.
• Inspection data management is easier (CIM, GMP, ISO9000).
• Working hours can be shortened.
• Less 3-D work (difficult, dirty, dangerous) is required.
• Work can be performed by less experienced staff.

3
Inspection Types Section 1-2
1-2 Inspection Types
Presence
Presence inspections detect whether a component, mark, hole, etc., is at a
specified position on the workpiece.
SeeAlso Refer to page 28.
Inspecting for the Presence of a Medical Tablet
• Inspections for labels.
• Inspections for electronic parts on PCBs.
• Inspections for soldering on PCBs.
Conformity
Conformity inspections check whether or not the workpiece matches a regis-
tered product image.
SeeAlso Refer to page 48.
Inspecting for Package Conformity
• Model checks based on grading marks.
• IC model checks based on number of leads.
• Model checks based on shape.

4
Inspection Types Section 1-2
Orientation
Orientation inspections detect the orientation of the workpiece to see if it is
facing correctly.
SeeAlso Refer to page 50.
Checking Label Orientation
• Checks for IC orientation and front/back positioning.
Position
Position inspections find the position of a specified mark, hole, or other feature
and determine whether or not it is within the correct range.
SeeAlso Refer to page 52.
Inspecting for Label Displacement
• Checks for printing displacement.
• Checks for registration marks on liquid crystal.
• Position checks for PCBs.
• Position checks for screw holes.

5
Inspection Types Section 1-2
Dimensions
Dimension inspections check the relationship between two specified points
and determine whether or not the distance between the two points is within the
correct range.
SeeAlso Refer to page 57.
Checking Bolt Length
• Dimension checks for molded products, such as connectors.
• Inspections for pin pitch of capacitors.
Chips and Burs
Chip and bur inspections check for chips and burrs on the profile and circum-
ference of workpieces.
SeeAlso Refer to page 62.
Inspecting for Chips and Burrs on O Rings
• Inspections for chips and burs on plastic molded parts.

6
Inspection Types Section 1-2
Surfaces
Surface inspections check for defects and impurities within a specified range.
SeeAlso Refer to page 63.
Checking for Marks on Sheets
• Checks for pin holes
• Checks for bubbles on liquid crystal panels.
• Checks for cracks in cast items.
• Checks for impurities in liquids.

7
Advantages of Conversational Menus Section 1-3
1-3 Advantages of Conversational Menus
Operating guidance is given on the monitor screen and settings can be made
easily by entering information as requested - just as though you are having a
conversation with the F160. Try the Conversational Menus if using a Visual
Sensor for the first time or if you want to set the inspection conditions simply.
Presence Inspection
Determines if a component, mark,
hole, etc. is at a set position
on the workpiece.
Help Screen Example
0.Scn 0 =SET= Region
Select the type of
inspection.
(Up to 32 regions)
S+ENT:Help S+←→:Switch display
Conform
Position
Chip/Bur
Back
Presence
Orient'n
Dimens'n
Surface
Start
Ref image
>>Region
Position
End
The F160 tells your what the
next procedure is.
Guides operation
Go to the Help Screen if you are unsure
Displays settings sequence
You can grasp what stage you
are at as you proceed.
The F160 has comprehensive Help Screens that give greater
understanding of and hints for settings operations.

8
Useful Features Section 1-4
1-4 Useful Features
The F160 provides the following features to enable more accurate and faster
inspections. Refer to the reference pages for details and operating proce-
dures.
Adjust Lighting Areas and Brightness from the F160
This function is supported only when Intelligent Lighting is connected.
SeeAlso Refer to page 25.
Save Up to 35 NG Images
Past NG results can be checked on the screen. Once the power is turned OFF,
however, the saved images will be cleared. The saved images can be backed
up to a computer.
SeeAlso Refer to page 112.
Change Measurement Setups Smoothly
If the scene function is used, 32 sets of inspection conditions can be set. If the
scene group function is used, the setting capacity can be expanded up to
1,024 scenes. The measurement setup can be changed easily for different
types of measurement objects simply by changing the scene.
SeeAlso Refer to page 71.
Input Measurement Triggers and Output Judgement Results via a Parallel Interface
SeeAlso Refer to the Communications Reference Manual.
Back Up Settings on a Computer or Memory Card
SeeAlso Refer to page 78.
Manipulate F160 Menus from a Computer
SeeAlso Refer to the Communications Reference Manual.
NG

9
Operational Flow Section 1-5
1-5 Operational Flow
Preparations
Turn ON the power supply.
The inspection object will appear on the monitor.
SeeAlso Refer to page 12 for information on starting the F160 and displaying images.
Set Detection Conditions
CHECK To learn about the basic operational flow from setting inspection conditions to
measurement, refer to page 21.
1,2,3... 1. Enter Set Mode. (Refer to Starting Conversational Menus on page 21.)
2. Register the reference image. (Refer to Registering Reference Images on
page 22.)
3. Set the detection conditions for presence inspection. (Refer to Selecting
and Setting Inspection Types on page 28.)
4. Compensate for workpiece position displacement. (Refer to Inconsistent
Workpiece Positions on page 31.)
5. Select the measurement method that suits the inspection target.
SeeAlso Refer to page 48 for information on conformity inspections.
Refer to page 50 for information on orientation inspections.
Refer to page 52 for information on position inspections.
Refer to page 57 for information on dimension inspections.
Refer to page 62 for information on chip and bur inspections.
Refer to page 63 for information on surface inspections.
Confirm Settings and Execute Measurement
1,2,3... 1. Perform tests and make fine adjustments to measurement conditions. (Re-
fer to Entering Monitor Mode and Testing on page 35.)
2. Start measurement. (Refer to Entering Run Mode and Starting Inspections
on page 43.)
Error Messages
When an error message has been displayed on the screen, refer to Trouble-
shooting on page 124.
Troubleshooting
If you think that there may be a malfunction, refer to FAQ on page 126 or refer
to the Setup Manual.
Changing, Adding, and Deleting Settings
Change, add, or delete the inspection position referring to Changing and
Clearing Inspection Conditions on page 66.
Saving Settings
• Save the inspection conditions. (Refer to Saving Settings and Exiting the
F160 on page 44.)
• Back up the image and system scene data. (Refer to Backing Up Data on
page 78.)
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