Omron F150 User manual

Cat.No. Z126-E1-1A
F150
Visual Inspection System
Manual 3:
EXPERT MENU
OPERATION MANUAL

F150 Visual Inspection System
Expert Menu Operation Manual
Revised October 2000

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iv
Notice:
OMRON products are manufactured for use according to proper procedures
by a qualified operator 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.
Visual Aids
The following headings will help you locate different types of information.
Note Indicates information of particular interest for efficient and con-
venient operation of the product.
Indicates pages where additional information can be found.
1Indicates a procedure. The step numbers in the procedure
correspond to the numbers in any related illustrations.
OMRON, 1998
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted,
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. Never-
theless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for dam-
ages resulting from the use of the information contained in this publication.

TABLE OF CONTENTS
v
PRECAUTIONS ix. . . . . . . . . . . . . . . . . . . . .
1 Safety Precautions x. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions xi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1
The Expert Menu Mode 1. . . . . . . . . . . . . . .
1-1 Features 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Measurement Methods 4. . . . . . . . . . . . . . . . . . . . . . . .
1-3 Position Compensation 9. . . . . . . . . . . . . . . . . . . . . . . .
1-4 Overview of F150 Installation and Operation 12. . . . . .
1-5 Terminology 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6 Documentation Conventions 13. . . . . . . . . . . . . . . . . . .
SECTION 2
Basic Operations 15. . . . . . . . . . . . . . . . . . . . .
2-1 Starting and Quitting 16. . . . . . . . . . . . . . . . . . . . . . . . .
2-2 Menu Operations 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 Using Auto Menu Data 30. . . . . . . . . . . . . . . . . . . . . . .
SECTION 3
Operating Procedures 31. . . . . . . . . . . . . . . . .
3-1 Menu Tree 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 Adjusting Images 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3 Registering and Clearing Images 41. . . . . . . . . . . . . . . .
3-4 Position Compensation 44. . . . . . . . . . . . . . . . . . . . . . . .
3-5 Measurement Region Functions 67. . . . . . . . . . . . . . . . .
3-6 Settings Outputs 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7 Monitor Mode 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8 Run Mode 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9 Changing Scenes 116. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10 Displaying Memory Images 118. . . . . . . . . . . . . . . . . . . .
3-11 System Menu 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4
Terminal Blocks 133. . . . . . . . . . . . . . . . . . . . .
4-1 I/O Formats 134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2 Terminal Signal Operation and Timing 135. . . . . . . . . . .
4-3 Communications Settings 141. . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS
vi
SECTION 5
RS-232C Normal Settings 143. . . . . . . . . . . . .
5-1 Communications Settings 144. . . . . . . . . . . . . . . . . . . . . .
5-2 Command List 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 Input Format 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4 Input Commands 151. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5 Measurement Results Output Format 165. . . . . . . . . . . .
SECTION 6
RS-232C Host Link Settings 167. . . . . . . . . . .
6-1 Communications Settings 168. . . . . . . . . . . . . . . . . . . . . .
6-2 Sample Programming 175. . . . . . . . . . . . . . . . . . . . . . . . .
6-3 Command Tables 178. . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4 Host Link Commands 181. . . . . . . . . . . . . . . . . . . . . . . . .
6-5 Output Format 206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7
RS-232C Menu Operation Settings 209. . . . . .
SECTION 8
Troubleshooting 213. . . . . . . . . . . . . . . . . . . . .
Index 217. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History 223. . . . . . . . . . . . . . . . . . . . .

vii
About this Manual:
This manual describes the operation of the F150 Visual Inspection System using the Ex-
pert Menu and includes the sections described below. This is one of three manuals used
to operate the F150. Refer to the following table for the contents of each manual.
Manual Contents Cat. No.
1:Setup
Manual Provides information on system hardware and installation. Be sure to read this manual first. Z124-E1-1
2:Auto Menu
Operation
Manual
Describes operation of the F150 using the Auto
Menu. The Auto Menu enables the simplest
operation for OK/NG outputs based on registered
images of acceptable and unacceptable products.
Z125-E1-1
3:Expert
Menu
Operation
Manual
Describes operation of the F150 using the Expert
Menu. The Expert Menu enables application of all
F150 capabilities, including setting region images
and criteria, and outputting OK/NG terminal
signals or RS-232C measurement values.
Z126-E1-1
Please read the above manuals carefully and be sure you understand the information
provided before attempting to install and operate the F150.
Section 1 The Expert Menu outlines the features of the Expert Menu. This section also
describes the overall flow of F150 application and basic operations, and the conventions
used in this manual.
Section 2 Introduction describes the overall flow of F150 application and basic opera-
tions. It also describes the conventions used in this manual.
Section 3 Operating Procedures describes operating the F150 using the Expert Menu
mode.
Section 4 Terminal Block describes the communications settings and I/O formats for
communications with external devices via the terminal blocks.
Section 5 RS-232C Communications Settings (Normal) describes the communica-
tions settings for the RS-232C port when communications are in Normal mode.
Section 6RS-232C Communications Settings (Host Link)describes the communica-
tions settings for the RS-232C port when communications are in Host link mode.
Section 7RS-232C Communications Settings (Menu Operation) describes the com-
munications settings for the RS-232C port when communications are in Menu operation
mode.
Section 8 Troubleshooting lists the errors that may occur, along with their probable
causes and remedies
WARNING Failure to read and understand the information provided in
this manual may result in personal 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.
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ix
PRECAUTIONS
This section provides general precautions for using the F150 Visual Inspection System.
The information contained in this section is important for the safe and reliable ap-
plication of the F150 Visual Inspection System. You must read this section and under-
stand the information contained before attempting to set up or operate a F150 Visual
Inspection System.
1 Safety Precautions x. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions xi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1PRECAUTIONS
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1 Safety Precautions
WARNING Cover the terminal blocks with the Terminal Block
Protection Covers. Uncovered terminal blocks
can result in electric shock.
WARNING Use DC power supplies with safe extra
low-voltage circuits on the secondary side for the
main F150 power supply and power supplies for
the terminal blocks. Excessively high voltages
can result in electric shock.
Caution Do not touch fluorescent or halogen lights while
the power is ON or immediately after the power is
turned OFF. These lights generate heat and can
cause burns.
Caution Do not use the F150 in environments with flam-
mable or explosive gases.
Caution Install the F150 away from high-voltage equip-
ment or motors to ensure safety during operation
and maintenance.
Caution Use the power supply cables and crimp terminals
of specified sizes.
Caution Use at the power supply voltages specified in this
manual.
Caution Be sure to securely tighten the screws when
mounting F150 components.
Caution Do not dismantle, repair or modify any F150 com-
ponents.
Caution Dispose of F150 components as industrial waste.

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2PRECAUTIONS
xi
Caution To prevent damage from static electricity, use a
wrist strap or another device for preventing elec-
trostatic charges when touching terminals or con-
nector signal lines.
Caution Do not turn OFF the power while a message is be-
ing displayed indicating that processing is being
performed. Data in memory will be destroyed,
and the F150 may not operate correctly the next
time it is started.
2 General Precautions
The user must operate the product according to the performance
specifications described in the operation manuals.
Before using the product under conditions which are not de-
scribed in the manual or applying the product to nuclear control
systems, railroad systems, aviation systems, vehicles, combus-
tion systems, medical equipment, amusement machines, safety
equipment, and other systems, machines, and equipment that
may have a serious influence on lives and property if used im-
properly, consult your OMRON representative.
Make sure that the ratings and performance characteristics of
the product are sufficient for the systems, machines, and equip-
ment, and be sure to provide the systems, machines, and equip-
ment with double safety mechanisms.

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SECTION 1
The Expert Menu Mode
This section outlines the features of the Expert Menu mode and will tell you what can be
achieved using it. The Expert Menu mode enables using all the capabilities of the F150.
This section also describes the overall flow of F150 application and basic operations, and
the conventions used in this manual.
1-1 Features 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 Measurement Methods 4. . . . . . . . . . . . . . . . . . . . . . . . .
1-2-1 Density Searches 4. . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-2 Binary Center of Gravity and Area 6. . . . . . . . . . . .
1-2-3 Binary Axis Angle 7. . . . . . . . . . . . . . . . . . . . . . . . .
1-3 Position Compensation 9. . . . . . . . . . . . . . . . . . . . . . . . .
1-3-1 Density Searches 9. . . . . . . . . . . . . . . . . . . . . . . . . .
1-3-2 Binary Center of Gravity and Area 10. . . . . . . . . . . .
1-3-3 Binary Axis Angle 10. . . . . . . . . . . . . . . . . . . . . . . . .
1-3-4 Rotational Position Compensation 11. . . . . . . . . . . . .
1-4 Overview of F150 Installation and Operation 12. . . . . . .
1-5 Terminology 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6 Documentation Conventions 13. . . . . . . . . . . . . . . . . . . .

1-1SectionFeatures
2
1-1 Features
The F150 features supported by the Expert Menu mode are de-
scribed below.
Three Measurement Methods →p 4
Any of the following measurement methods can be used.
Density Searches
The position of the measurement object is determined and the
image is compared with registered measurement conditions to
determine if the object is acceptable or unacceptable.
Binary Center of Gravity and Area
The size and position of the measurement object are determined
based on the overall image density and the image is compared
with the registered measurement conditions to determine if the
object is acceptable or unacceptable.
Binary Axis Angle
In addition to the binary center of gravity and area, the angle of
the measurement object is also determined and the image is
compared with the registered measurement conditions to deter-
mine if the object is acceptable or unacceptable.
Position Displacement Compensation →p 9
Position displacement compensation can be used to correct the
position of the measurement object based on density searches,
the binary center of gravity and area, or the binary axis angle.
Sample Image Registration →p 41
Acceptable and unacceptable images can be registered as sam-
ple images. Measurements on these sample images can be
used to set measurement conditions. Any images registered in
the Auto Menu can also be used as sample images.
Shutter Speed →p 33
The shutter speed can be selected to suit the speed of move-
ment of the measurement object. Adjustment of the shutter
speed can also be adjusted depending on the level of illumina-
tion of the measurement object.
Filtering →p 34
The camera image can be adjusted to allow easier measure-
ment of objects. The edges of the measurement object can be
enhanced, and noise can be reduced.
Background Suppression →p35
The background can be excluded from the measurement by set-
ting it to a specific density.

1-1SectionFeatures
3
Calibration →p 37
The measurement value can be converted to actual dimensions
(e.g., cm or mm) and output to an external device.
Scene Changes →p 116
Scenes are used to set up for different measurement objects or
measurement conditions. The F150 can thus be automatically
switched between different applications merely by changing the
scene. Up to 16 scenes be set.
Terminal Block →pp 85, 133
The F150 can communicate with PLCs and other external de-
vices via the terminal block. Calculations can be performed on
measurement results, or math functions can be used to calculate
the distance between two regions or the maximum measure-
ment results. Evaluation criteria can then be set for the results to
output OK/NG judgements via the terminal block. (Numeric re-
sults cannot be output via the terminal block.)
RS-232C Port →pp 96, 143, 167
The F150 can communicate with computers, PLCs, and other
external devices via the RS-232C port. Calculations can be per-
formed on measurement results, or math functions can be used
to calculate the distance between two regions or the maximum
measurement results. Evaluation criteria can then be set for the
results to output OK/NG judgements along with the numeric
measurement results.
One of the following three communications methods can be cho-
sen.
•Normal, for communications with a computer or other external
device.
•Host Link, for communications with an OMRON PLC.
•Menu Operation, for menu operation from a computer.

1-2SectionMeasurement Methods
4
Output Data The following data can be output via the terminal block and
RS-232C port.
Output device Measurement
results Judgements (OK/NG)
Terminal block No Yes
RS-232C Normal Yes No
RS-232C Host Link Yes Yes
Menu operation Yes No
Measurement Images →p 128
Up to 23 measurement images are stored in memory for easy
confirmation of past images to see what problems have oc-
curred.
The images in memory are cleared when power is turned OFF or
the scene is changed. These images, however, can be backed
up to a computer.
1-2 Measurement Methods
The F150 provides three measurement methods: Density
searches, the binary center of gravity and area, and the binary
axis angle. The measurement method can be set separately for
each of the 16 measurement regions.
1-2-1 Density Searches
Density searches are used when inspecting specific objects.
The density image taken by the camera is utilized without modifi-
cation to measure the object using a registered measurement
pattern called a model. The position of the object (X, Y) and the
degree of conformity (i.e., the “correlation”) with the model can
be calculated.

1-2SectionMeasurement Methods
5
The part of the input image that most corresponds to the model is
found.
Model
Search
The extent of conformity with the model is shown as the correla-
tion value. The OK/NG judgement is determined by comparing
the correlation value and the position with an evaluation criteria.
OK if the correlation value is
within the specified range.
OK if the position is with-
in the specified range.
Application Methods. →p 67

1-2SectionMeasurement Methods
6
1-2-2 Binary Center of Gravity and Area
Density images with 256 gradations are read by the Camera.
Binary processing involves separating these density images into
black pixels (picture elements) (0) and white pixels (1). The F150
uses the white pixels to measure the object.
•The size (i.e., area) of the measurement object can be calcu-
lated by counting the number of white pixels.
•The position (i.e., center of gravity) of the measurement object
can be calculated from the position of the white pixels.
The center gravity is calculated by taking the white pixels
and treating them like a piece of thick paper of uniform thick-
ness. The center of gravity is the point at which the piece of
paper would balance when placed on a sharp point. For ex-
ample, the center of gravity for a circular object would be the
center of the circle. The center of gravity of a rectangular ob-
ject would the intersection of lines drawn from diagonally
opposing corners. The center of gravity is used to calculate
the position of the object.
The area and center of gravity of the white pixels in the measure-
ment region can be calculated.
Center of gravity
Measurement region

1-2SectionMeasurement Methods
7
The measurement results are compared to evaluation criteria,
and the object is judged as OK or NG.
OK if the center of gravity is
within the specified range.
OK if the area is within the
specified range.
Application Methods. →p 72
1-2-3 Binary Axis Angle
Binary processing is performed on the density image, the same
as for binary center of gravity and area calculations, but the in-
clination of the measurement object, called the axis angle, is also
be calculated.
Note The axis angle is the angle along the major axis of the ellipse
when the white pixels are graphically converted to an ellipse with
the same center of gravity and moment around the axis as the
white pixels. In simple terms, an ellipse is drawn that approxi-
mates the white pixels. It shows the inclination of the object.
More processing time is required to calculate the axis angle. Use
the binary center of gravity and area measurement method un-
less alignment of the axis angle is required.

1-2SectionMeasurement Methods
8
The area, center of gravity, and axis angle are calculated for the
white pixels in the measurement region.
Axis angle
Center of gravity
Measurement region
The measurement results are compared to evaluation criteria,
and the object is evaluated as OK or NG.
OK if the axis angle is
within the specified range.
OK if the center of gravity is
within the specified range.
OK if the area is within the
specified range.
Application Methods. →p 78

1-3SectionPosition Compensation
9
1-3 Position Compensation
If the measurement object is inclined or displaced, the positional
relationship between the image read by the camera and the
measurement region can be corrected by using the position dis-
placement compensation function. This function is useful when
the position and orientation of the measurement object are not
fixed.
The position of the measurement object is compared to a refer-
ence position, the amount of displacement is calculated, and the
image is scrolled by the detected amount of displacement before
measurements are performed.
There are three methods of position compensation, i.e., com-
pensation based on a density search, on the binary center of
gravity and area, or on the binary axis angle. These three meth-
ods use the same basic processes as the three measurement
methods outlined above.
1-3-1 Density Searches
The area of the image that most highly correlates with the model
is found, and the amount of displacement is calculated by
comparing the actual position of the measurement object and the
reference position.
Reference position
(registered model position)
Input image
Application Methods. →p 47

1-3SectionPosition Compensation
10
1-3-2 Binary Center of Gravity and Area
The center of gravity is calculated for the white pixels, and the
deviation from the reference position is calculated.
Reference position
Input image
Application Methods. →p 51
1-3-3 Binary Axis Angle
The center of gravity and the axis angle are calculated, and the
deviation from the reference position is calculated.
Reference position
Input image
Application methods →p 57

1-3SectionPosition Compensation
11
1-3-4 Rotational Position Compensation
In addition to binary axis angle, the angle between two models is
used for rotational position compensation. The angle where two
lines joining two models meet is used. This angle has a range of
360°, with the X axis at 0°, and the Y axis in positive direction
from the X axis.
•When the density search method is used, the center of two
models is joined.
•When the binary center of gravity and area method is used, the
center of gravity of the white pixels for each model is joined.
The angle can be calculated using a density search measure-
ment for model 0 and a binary center of gravity and area mea-
surement for model 1.
Reference position
(relative angle)
Model 1
Model 0
Reference position (X, Y)
Application methods →p 74