Rockwell international Allen-Bradley VIM 2803 User manual

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Important User Solid-state equipment has operational characteristics
Information differing from those of electromechanical equipment.
“Application Considerations for Solid-State Controls”
(Publication SGI-1.1) describes some important differences
be.tween solid-state equipment and hard wired
electromechanical devices. Because of this difference, and
also because of the wide variety of uses for solid-state
equipment, all persons responsible for applying this
equipment must satisfy themselves that each intended
application of this equipment is acceptable.
In no event will Allen-Bradley Company be responsible or
liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included
solely for illustrative purposes. Because of the many
variables and requirements associated with any particular
installation, Allen-Bradley Company cannot assume
responsibility or liability for actual use based on the
examples and diagrams.
No patent liability is assumed by Allen-Bradley Company
with respect to use of information, circuits, equipment, or -
software described in this manual.
Reproduction of the contents of this manual, in whole or in
part, without written permission of the Allen-Bradley
Company is prohibited.
6 1987 Allen-Bradley Company
$50.00

Table
of Contents
Chapter Title Page
1 Using this manual
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . _
What This Manual Contains . . . . . . . . . . . . . . . . . . _. .
Audience . ..___._._._........._................
Vocabulary . . . . . . . . .._.....................__._
Warnings and Cautions . . . . . . . . . . __. _. . . _. . . . . . .
Related Publications . __. . . . . . . __. __. _. . __. . . . . . .
Revision Information __. . . . . . . . . . . . . ___. . . _. . . . .
l-l
l-l
l-2
l-2
l-5
l-6
l-6
2 Introduction to the Vision Input Module (VIM)
Chapter Objectives .............................
What isthe Vision Input Module? ................
Functional Features ............................
HardwareFeatures .............................
Vision Input Module Hardware Description . . _____
The Vision Input Module (Cat.#2803-VIMl) . . __
Light Pen (Cat.#2801-N7) ....................
Camera (Cat.#2801-YB) ......................
Camera Cables ..............................
VIM Power Supply (Cat.#2801-Pl) .............
Video Monitor (Cat.#2801 -N6) ...............
Video Monitor Cables ........................
Applying the VIM Vision Tools ...................
Chapter Summary ..............................
2-l
2-l
2-2
2-3
2-7
2-7
2-8
2-10
2-10
2-10
2-11
2-13
2-13
2-17
3 VIM System Theory of Operation
Chapter Objectives .............................
The VIM Module Imaging Process ................
Characteristics of Images .....................
Gray Levels ....................................
Gray-scale Conversion .......................
The VIM Module Gray Scale ..................
Binarization of Gray-Level Images ................
Setting Image Thresholds ....................
Reading Image Thresholds ...................
Brightness Probe Lightness Compensation ........
The Probe Operation ........................
The Probe Reference Patch ...................
LineGauges ...................................
Blobs .......................................
Line Gauge Measurements ......................
Line Gauge Measurement Pairs ...............
3-l
3-l
3-l
3-3
3-3
3-4
3-4
3-6
3-7
3-7
3-7
3-7
3-9
3-10
3-10
3-l1

2 Table of Contents
-
Chapter Title
3 (cont.) Edge Measurements . . . . . . . . . . . . . . . . . . . . . . . .
Center Measurements . . . . . , . . . . . . . . . . . . . . . . .
Width Measurements
Count BlackWhite Pixels’ ’ : : : : : : 11: : : : : 1:: 1: : :
Count Number of Blobs . . . . . . . , . . . . . . . . . . . . . . . . .
Count Number of Edges . . . . _. . . . __. . . . . __. . . . __
Using Line Gauge Filters . . . . . . . . . . . . . . . . . . . . . . . .
X/Y Float Gauges . . . . . . . . . . . __. . . . . __, . . . _. . . . . _
Window Measurements . . . . _. . . . . . . _. . . . . _. . . . .
Setting Windows . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counting Pixels . . . . _. . . . _. . . . . . . _. . . . . _. . . . .
PLCCommunications Overview . . . . . . . . . . . . . . . . . .
Discrete Bit Communications . . . . . . . . . _. . . . . __
Block Transfer Communications . . . . . . . . . _. . . .
Chapter Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12
3-15
3-17
3-19
3-20
3-21
3-22
3-24
3-24
3-24
3-25
3-26
3-26
3-26
3-27
4 Staging for Vision Applications
ChapterObjectives .............................
Forming the Image .............................
Focus ......................................
Image Contrast .............................
The importance of Illumination .................
Different Types of Illumination ..................
Methods of Illumination ........................
Direct Illumination ..........................
Indirect Illumination ........................
Lens Selection and Adjustment ..................
How a Lens Works ..........................
Selecting the Lens for Your Application ..........
Using the Lens Selection Table ..................
Lens Selection if FOV is Known ...............
Lens Selection if Accuracy is Known ...........
Lens and Camera Set-up ........................
Object Positioning .............................
Still Objects ................................
Moving Objects .............................
4-l
4-l -
4-l
4-2
4-2
4-4
4-5
4-5
4-6
4-7
4-7
4-10
4-12
4-12
4-12
4-12
4-14
4-14
4-14
5 Installation and Integration
ChapterObjectives . . . . . . . . . . . . . . . . . . . . . .._.....
Integration of VIM Components . . . . _. . . . . _. . . . . _
Requirements for Installation Into an
Existing PLC 1771 I/O Rack . . . . . . . . . . _. . . _.
5-l
5-l
5-l

Table of Contents 3
Chapter Tit/e
5 (cont.) Requirements for Installation Into a
1771 Standalone I/ORack ....................
I/O Rack Installation .........................
Power Supply Installation ....................
VIM Module Installation .....................
CameraComponent Installation ..............
Light Pen installation ........................
Video Monitor Installation ...................
Strobe Light Connection .....................
Swingarm .....................................
Swingarm Connections ......................
Swingarm Installation .......................
Grounding Considerations ...................
Indicator Lights (LED’s) .........................
Integrating aVIM System With Your Process ......
Defining Your Interface Requirements ........
The Discrete Data Interfaces ....................
Swingarm Field Wiring Discrete
Datalnterface ..........................
Discrete Bit Communications to the PLC .......
BlockTransfers ................................
Configuration Blocks ........................
ResultsBlock ...............................
Addressing the Discrete Bits
From a PLC Program .....................
PLC Control of the VIM System ..................
Bit Manipulation ............................
Bit Manipulation Example 1: .................
Bit Manipulation Example 2: .................
PLC Block Transfer Interface .....................
BlockLength ...............................
Typical Inspection Handshake Sequence .......
Inspection Cycletime ........................
Displaying the Results Block ..................
Results Block Format ........................
Block Transfer Numbering Systems ............
Push-button Triggering .........................
“Single Shot” Push Button ...................
“Continuous” Push Button ...................
Page
5-2
5-2
5-2
5-2
5-5
S-10
S-10
5-11
5-11
5-11
5-13
5-14
5-15
5-16
5-16
5-18
5-18
5-18
S-20
S-20
5-21
5-22
5-22
5-22
5-23
5-24
5-24
5-25
5-27
5-28
S-30
5-31
5-32
5-35
5-35
5-36
6 htroduction to the User interface
Chapterobjectives ............................. 6-l
The Icon Interface .............................. 6-l
How the Icon system works .................. 6-2
Commonly Used Icons .......................... 6-3

4 Table of Contents
Chapter Title -
Page
6 (cont.) Removing Icon Strips and Displaying Analog
Images .....................................
Changing the Run-Time Display .................
The Menu Branching Map ......................
Main Software Branches ........................
The Menu Branching Diagram ................
Points to Remember When Using the
Menus and Icons ............................
Chapter Summary ..............................
6-5
6-5
6-6
6-7
6-7
6-7
6-8
7 User interface Reference Section
Chapter Objectives .............................
The Sign-on Banner ............................
MainMenuTasks ..............................
TheMainMenu ................................
The Brightness Branch ..........................
Brightness Branch Tasks ........................
The Brightness Main Menu ......................
The Probe Move Menu .........................
The Probe Hi/Lo Range Menu ...................
The Threshold Adjust Menu .....................
The Line Gauge Menu Branch ...................
The Line Gauge Tasks ...........................
The Line Gauge Main Menu .....................
The ETC Line Gauge Menu ......................
The Line Movement Menu ......................
The Line Size Menu ............................
The Line Hi/Lo Range Menu .....................
The Window Branch ............................
The Window Tasks .............................
The Window Main Menu .......................
The ETCWindow Menu .........................
The Window Move Menu .......................
The Window Size Menu ........................
Window Sizing Characteristics ................
The Window Hi/Lo Range Menu .................
7-l
7-l
7-2
7-3
7-7
7-8
7-9 -
7-13
7-15
7-19
7-23
7-24
7-25
7-31
7-37
7-39
7-41
7-45
7-46
7-47
7-51
7-53
7-55
7-55
7-57
Appendix A Menu Branching Diagram
Appendix B Results Block Format

Table of Contents 5
FigurelTable Title Page
List of Figures
2.1
2.2
2.3
2.4
2.5
The Vision Input Module (VIM) . . . . . . . . . . . . . _. _. _.
The VIM Module Installed in a 1771 I/O Rack . . . . . . .
The VIM Module Installed in a Standalone
Rack Configuration . . . . . . . . . . . . . . . . . . . . . . .
VIM Module I/O Paths . . . . . . . . . . . . . _. . ___. _______
Easy Installation of Swingarm
Field Terminations . . . . . . . . . . . . . _. . . . . _. ___
LightPen . . . . . . . . ..__.._.....................___
Front Panel Features
CameraandLens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Video Monitor . . . . . . . . . _. . . . . . . . . . . . . . . . . . _. _. . .
Video Monitor Connections . . . . . . . . . . . . . . . . . _. . . _
The VIM Module, Peripherals, and Cables . _. _. __. . _
Hole Presence Verification Using a Circular
Window Image of a Properly
Punched Hole _____. . . . . . . . . . . . . . . . __. _. __. _.
Hole Presence Verification Using a Circular
Window Image of an Improperly
Punched Hole . . . . . _. . . . . . . . . . . . . . . . . . . _. . . . .
Line Gauge Check for Proper
Label Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stripped Wire ImageShowing Line Gauge
Placement . . . . . . .._.__....................__.
2-l
2-4
2-5
2-6
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2-7
2-8
2-9
2-10
2-11
2-11
2-12
2-14
2.13
2-14
2.14
2.15 2-15
2-16
3.1
3.2 Pixels Arranged in Rows and Columns ............. Image Scanning Pattern and Image
Coordinates .................................
Four Grays Converted to Digital Values ............
Gray-level (Analog) Image .......................
Binarized Image With a
LowThreshold ...............................
Binarized Image With a
High Threshold ..............................
The Probe as Seen in the Video Monitor
DuringSetup ................................
The Probe Reference Patch Seen in the
Live Video Image ............................
Pixels and Corresponding Digital Values ...........
Black and White “Blobs” .........................
Line Gauge Function One Measuring the
Left/top Edge of the Largest Blob ..............
Line Gauge Function Four Measuring the
Left/top Edge and Width of the Leftflop Blob ...
Edges for a Black Blob ...........................
Line Gauge Function Two - Measuring the Center
of the Largest Blob ...........................
Line Gauge Function Five - Measuring the Center
of the Left/top Blob ..........................
3-l
3.3
3.4
3.5
3-2
3-3
3-4
3-5
3.6 3-6
3.7 3-8
3.8
3.9
3.10
3.11
3-8
3-9
3-10
3-12
3.12
3.13
3.14
3.15
3-13
3-13
3-15
3-15

6 Table of Contents
Figure/Table Title
3.16
3.17
3.18
3.19
Center for a Black Blob . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Gauge Function Three Measuring the
Width of the Largest Blob . . . _. . . . . . . . . . . . . . _. .
Line Gauge Function Five Measuring the Width
of the Left/top Blob . . . . . . . _. . . . _. . . . . . , . . . . . .
Width of a Black Blob . . . . . . . . . _. . . . . . . . . . . . . . . . .
4.1
4.2
4.3
4.4
4.5
4.6
Specular and Diffuse Reflection . . . . . . . . . . . .
Example of Diffuse Backlighting . . . . . . . . . . . .
Examples of Indirect Illumination . . . . _. . . . . .
Relationship of the Focal Length of a Lens to
Standoff Distance Given a Constant Field
ofView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control of Light Collection Using the F-stop
oftheLens . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AspectRatio . . . . . . . . . . . . . . . . . . . . . . . . . . . .._
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
Installation of Keying Bands .....................
Configuration Plug Settings ......................
Installation of the VIM Module ...................
Camera Configurations ..........................
VIM Front Panel Features ........................
Camera I/O Locations ............................
VIM Power Supply ..............................
12lnchMonitor .................................
Swingarm - Field Wiring Terminals ___. . __. . ___. . __
Installation of the Swingarm .....................
Swingarm Latch Connection .....................
Instruction Addressing Terminology ..............
Instruction Addressing Example ..................
PLC Bit Manipulation Menu Used
to Force Control Bits ..........................
Rapid Firing of the VIM Under PLC Control .........
Free-Running Timer .............................
VIM Module Handshake Cycle ....................
Inspection Cycle Times ...........................
Results Block Display in Binary Format .............
Results Block Display in Hexadecimal Format .......
Binary Numbering ..............................
BCD Word Format ...............................
“Single Shot” Push-button Circuit ................
“Continuous” Push-button Circuit ................
6.1
6.2
6.3
6.4
6.5
6.6
“Picking” an Icon Using the Light Pen ...........
The Main Menu Shown asa Typical Icon Menu . . _
Brightness Main Menu Access Icon ..............
Window Main Menu Access Icon ................
Strobe Enabled Icon ...........................
Strobe Disabled Icon ..........................
. . . . 4-3
. . . . 4-5
. . . . 4-6
. . . .
. . . .
. .
-
Page
3-16
3-17
3-17
3-18
4-8
4-9
4-11
5-3
5-4
5-5
5-6 _
5-7
5-8
5-9
5-10
5-12
5-13
5-14
5-21
5-22
5-23
5-24
5-26
5-28
5-30
5-31
5-32
5-33
5-34
5-35
5-36
6-l
6-2
6-2
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6-3
6-3

Table of Contents 7
Figure/Table Tit/e
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
Page
“0K”lcon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
ETC(etcetera)lcon ._..._........................ 6-4
ETC Icon as Seen on the Line Gauge Main Menu . . . . 6-4
ETC Icon as Seen on the ETC Line Gauge
Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
The Window Move Menu Arrow Icons Used
to Move Window Position . . . . . . . . . . . . . . . . . . . . 6-4
The Window Size Menu Arrow Icons Used
to Change Window Size . . . . . . . . . . . . . _________ 6-5
The Three Main Branches of the VIM Menu . . . . . . . _ 6-6
Menu Branching Diagram . . . . . . . _. _. __. _. . _. . . . . 6-9
l.A List of Tables
VIM Module User’s Manual Organization . . . . . . . . . . l-l
4.A Lens Selection Table . . . . . . . . . . . . . . . . . . . . . . . . . _. . _ 4-l 3
5.A
5.B
5.c
5.D
5.E
Discrete Bits Description Decisions . . . . . . . . . . . . . . . . 5-19
Results Block 1 of 1
(Block Length of 59 Words) . . . . . . . . . . . . . . . . . . . 5-37
Configuration Block 1 of 3
(Block Length of 30 Words) . . . . . . . . . . . . . . . ___. 5-41
Configuration Block 2 of 3
(Block Length of 62 Words) . . . . . . . . . . . . . _. ____ 5-43
Configuration Block 3 of 3
(Block Length of 63 Words) . . . . . . . . . . . . . . . . . . . 5-45