Siemens SIMATIC VS120 User manual

SIMATIC Sensors Image processing systems Vision Sensor SIMATIC VS120
DOCUMENTATION
DOCUMENTATION
simatic sensors
SIMATIC VS120
Image Processing Systems
Operating Instructions Edition 02/2006

Introduction 1
Safety instructions 2
Description 3
Image processing 4
Network and system
integration 5
Installation 6
Connecting 7
Commissioning 8
Operation 9
Process interfacing over an
automation system (PLC,
PC)
10
Alarm, error and system
messages 11
Technical data 12
Dimension drawings 13
Scope of
delivery/Spares/Accessories 14
Service & Support 15
Directives and declarations 16
SIMATIC Sensors
Image processing systems
Vision Sensor SIMATIC VS120
Operating Instructions
Edition 02/2006
A5E00757507-01

Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended
by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and
assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Automation and Drives
Postfach 48 48
90437 NÜRNBERG
GERMANY
Order No.: A5E00757507-01
Edition 02/2006
Copyright © Siemens AG 2006.
Technical data subject to change

Vision Sensor SIMATIC VS120
Operating Instructions, Edition 02/2006, A5E00757507-01 iii
Table of contents
1 Introduction............................................................................................................................................. 1-1
2 Safety instructions .................................................................................................................................. 2-1
3 Description.............................................................................................................................................. 3-1
3.1 Product description .................................................................................................................... 3-1
3.2 Performance features ................................................................................................................ 3-2
3.3 Function ..................................................................................................................................... 3-3
3.4 System components .................................................................................................................. 3-4
3.5 System requirements ................................................................................................................. 3-5
3.6 Design of the SIMATIC VS120 processing unit......................................................................... 3-6
3.7 Design of the sensor head with LED ring flash.......................................................................... 3-8
4 Image processing ................................................................................................................................... 4-1
4.1 General information ................................................................................................................... 4-1
4.2 Shutter Speed and Brightness................................................................................................... 4-2
4.2.1 Different exposures and brightnesses ....................................................................................... 4-2
4.2.2 Disturbing contours caused by shine......................................................................................... 4-3
4.3 Generating models and detecting orientation............................................................................ 4-5
4.3.1 Setting for the Precision parameter ........................................................................................... 4-5
4.3.2 Measures for optimizing object recognition ...............................................................................4-6
4.4 Quality of the measured values ................................................................................................. 4-7
4.5 Geometric distortion................................................................................................................... 4-8
4.6 Main ROI and sub-ROI .............................................................................................................. 4-8
4.6.1 Example: Main ROI and 3 sub-ROIs .........................................................................................4-9
4.6.2 Example of the influence of sub-ROIs on the quality value..................................................... 4-10
4.7 Job parameter.......................................................................................................................... 4-13
4.8 Search parameter .................................................................................................................... 4-16
4.9 Model type parameter .............................................................................................................. 4-17
4.10 Model sets................................................................................................................................ 4-19
5 Network and system integration.............................................................................................................. 5-1
5.1 Overview .................................................................................................................................... 5-1
5.2 System configuration over digital I/O ......................................................................................... 5-2
5.3 PROFIBUS DP system configuration ........................................................................................ 5-3
5.4 PROFINET IO system configuration.......................................................................................... 5-4
5.5 System configuration with Ethernet or RS-232 over Com server .............................................. 5-5

Table of contents
Vision Sensor SIMATIC VS120
iv Operating Instructions, Edition 02/2006, A5E00757507-01
6 Installation .............................................................................................................................................. 6-1
6.1 Installing the SIMATIC VS120 processing unit .......................................................................... 6-1
6.2 Installing the sensor head with LED ring flash........................................................................... 6-1
7 Connecting ............................................................................................................................................. 7-1
7.1 Guidelines on installation and avoiding electrical interference .................................................. 7-1
7.2 Guidelines on installation when using PROFIBUS DP or PROFINET IO.................................. 7-1
7.3 Connecting components ............................................................................................................ 7-2
8 Commissioning ....................................................................................................................................... 8-1
8.1 Prerequisites .............................................................................................................................. 8-1
8.2 Overview of the steps in commissioning.................................................................................... 8-2
8.3 Turn on the VS120 processing unit............................................................................................ 8-3
8.4 Establish an Ethernet connection between the processing unit and PG / PC........................... 8-5
8.4.1 Select the connection variant..................................................................................................... 8-5
8.4.1.1 Connection variants ................................................................................................................... 8-5
8.4.1.2 Operating the VS120 processing unit as a DHCP server.......................................................... 8-6
8.4.1.3 Connecting the VS120 processing unit manually ...................................................................... 8-7
8.4.1.4 Integrating the VS120 processing unit as a DHCP client in a network...................................... 8-9
8.4.1.5 Integrating the VS120 processing unit as a device in a PROFINET IO network..................... 8-10
8.4.2 Check whether a proxy server is being used........................................................................... 8-12
8.4.3 Change the proxy configuration of your Internet Explorer ....................................................... 8-13
8.4.4 Check the connection............................................................................................................... 8-14
8.5 Start setup support over the Internet Explorer......................................................................... 8-15
8.6 Adjust the sensor head using setup support............................................................................ 8-17
9 Operation................................................................................................................................................ 9-1
9.1 Overview .................................................................................................................................... 9-1
9.2 Working with the processing unit ............................................................................................... 9-1
9.2.1 Introduction ................................................................................................................................ 9-1
9.2.2 Adjust ......................................................................................................................................... 9-2
9.2.3 Connect...................................................................................................................................... 9-2
9.2.4 RUN............................................................................................................................................ 9-9
9.2.5 Options..................................................................................................................................... 9-15
9.2.6 Maintain.................................................................................................................................... 9-18
9.3 Working with setup support...................................................................................................... 9-19
9.3.1 Introduction .............................................................................................................................. 9-19
9.3.2 Adjust Sensor........................................................................................................................... 9-24
9.3.3 Connections ............................................................................................................................. 9-25
9.3.4 Train ......................................................................................................................................... 9-27
9.3.5 Processing................................................................................................................................ 9-33
9.3.6 Options..................................................................................................................................... 9-37
9.3.7 Information ............................................................................................................................... 9-43
9.3.8 Maintain.................................................................................................................................... 9-49
9.3.9 Stop.......................................................................................................................................... 9-51
10 Process interfacing over an automation system (PLC, PC) .................................................................. 10-1
10.1 Integrating the PROFIBUS DP slave SIMATIC VS120 in HW Config ..................................... 10-1
10.2 Integrating the PROFINET IO device SIMATIC VS120 in HW Config..................................... 10-4
10.3 Control over the "DI/DO" I/O interface ..................................................................................... 10-7

Table of contents
Vision Sensor SIMATIC VS120
Operating Instructions, Edition 02/2006, A5E00757507-01 v
10.4 Control over PROFIBUS DP and PROFINET IO................................................................... 10-10
10.4.1 Principle of data transfer over PROFIBUS DP and PROFINET IO ....................................... 10-10
10.4.2 Assignments for PROFIBUS DP / PROFINET IO-relevant interfaces for the
processing unit....................................................................................................................... 10-11
10.4.2.1 Control byte............................................................................................................................ 10-11
10.4.2.2 Status byte ............................................................................................................................. 10-12
10.4.2.3 User data interface "Send" VS120 processing unit >>> automation system......................... 10-12
10.4.2.4 User data interface "Receive" automation system >>> VS120 processing unit.................... 10-14
10.4.3 Programming data fragmentation .......................................................................................... 10-14
10.5 Function block FB1 ................................................................................................................ 10-16
10.5.1 Job ......................................................................................................................................... 10-16
10.5.2 Parameter .............................................................................................................................. 10-17
10.5.3 Operator control ..................................................................................................................... 10-19
10.5.4 Error information .................................................................................................................... 10-20
10.6 Sample programs................................................................................................................... 10-21
10.6.1 Example 1: Program for interfacing the SIMATIC VS120 processing unit with a
SIMATIC controller using FB1 ............................................................................................... 10-21
10.6.2 Example 2: Program for archiving diagnostic information on a PC/PG................................. 10-23
11 Alarm, error and system messages ...................................................................................................... 11-1
11.1 Overview .................................................................................................................................. 11-1
11.2 Error messages and error handling ......................................................................................... 11-1
11.3 Diagnostics based on the "BF" LED ...................................................................................... 11-10
11.4 Slave diagnostics or /O device diagnostics ........................................................................... 11-11
12 Technical data ...................................................................................................................................... 12-1
12.1 General technical specifications .............................................................................................. 12-1
12.2 Technical specifications of SIMATIC VS120 ........................................................................... 12-5
12.3 Port assignment of the processing unit.................................................................................... 12-8
13 Dimension drawings ............................................................................................................................. 13-1
13.1 SIMATIC VS120 processing unit ............................................................................................. 13-1
13.2 SIMATIC VS120 sensor head.................................................................................................. 13-2
13.3 SIMATIC VS120 lighting unit ................................................................................................... 13-3
14 Scope of delivery/Spares/Accessories.................................................................................................. 14-1
14.1 Components............................................................................................................................. 14-1
14.2 Full packages........................................................................................................................... 14-2
14.3 Accessories.............................................................................................................................. 14-4
14.4 C-mount lens and inspection window size............................................................................... 14-5
15 Service & Support................................................................................................................................. 15-1
15.1 A&D Mall / Interactive Catalog (CA01) .................................................................................... 15-1
15.2 Service and support ................................................................................................................. 15-1
16 Directives and declarations................................................................................................................... 16-1
Glossary ..................................................................................................................................... Glossary-1
Index................................................................................................................................................ Index-1

Table of contents
Vision Sensor SIMATIC VS120
vi Operating Instructions, Edition 02/2006, A5E00757507-01

Vision Sensor SIMATIC VS120
Operating Instructions, Edition 02/2006, A5E00757507-01 1-1
Introduction 1
Purpose of the manual
This manual contains all the information you require to install, commission and work with the
SIMATIC VS120 Vision Sensor System.
It is intended both for persons configuring and installing automated plants with image
processing systems and for service and maintenance technicians.
Scope of this manual
The manual is valid for all supplied versions of the SIMATIC VS120 Vision Sensor system
and the processing unit with order number (MLFB) 6GF1 018-2AA10.

Introduction
Vision Sensor SIMATIC VS120
1-2 Operating Instructions, Edition 02/2006, A5E00757507-01

Vision Sensor SIMATIC VS120
Operating Instructions, Edition 02/2006, A5E00757507-01 2-1
Safety instructions 2
Caution
Please observe the safety instructions on the back of the cover sheet of this documentation.
You should not make any expansions to your device unless you have read the relevant
safety instructions.
This device meets the relevant safety requirements in compliance with IEC, VDE, and EN. If
you have questions about the validity of the installation in the planned environment, please
contact your service representative.
Repairs
Only authorized personnel are permitted to repair the device.
Warning
Unauthorized opening of and improper repairs to the device may result in substantial
damage to equipment or risk of personal injury to the user.
System expansion
Only install system expansions intended for this device. If you install other upgrades, you
may damage the system or violate the safety requirements and regulations for radio
frequency interference suppression. Contact your technical support team or where you
purchased your device to find out which system expansion devices may safely be installed.
Caution
If you install or exchange system expansions and damage your device, the warranty
becomes void.

Safety instructions
Vision Sensor SIMATIC VS120
2-2 Operating Instructions, Edition 02/2006, A5E00757507-01

Vision Sensor SIMATIC VS120
Operating Instructions, Edition 02/2006, A5E00757507-01 3-1
Description 3
3.1 3.1 Product description
The SIMATIC VS120 Vision Sensor is used for the optical detection and testing of objects
with lighting from above. The SIMATIC VS120 Vision Sensor checks whether or not the
correct object is being tested, whether or not it is damaged and the position of the object.
The SIMATIC VS120 Vision Sensor returns the following recognition values during object
recognition:
• x coordinate
• y coordinate
• Angle
• Quality rating of the specimen, number of detected parts
This object recognition data is transferred to processing units in automation systems. The
data is processed in the processing units of the automation systems.
The SIMATIC VS120 Vision Sensor is suitable for:
• Recognition of parts in sorting tasks
• Determining the position for Pick & Place applications
• Checking the presence and position of objects in production
• Checking position in feed systems, for example with oscillating conveyors, workpiece
holder, conveyor belts, circulating systems, grasper units and robots.
• Quality control of specimens

Description
3.2 Performance features
Vision Sensor SIMATIC VS120
3-2 Operating Instructions, Edition 02/2006, A5E00757507-01
3.2 3.2 Performance features
• Overhead lighting head with LED ring flash
• Object recognition with object search and object test
• Commissioning using adjustment support on the PG / PC with installed Internet Explorer
• Up to 20 objects tested per second
• Up to 64 specimens can be stored
• Two digital outputs are available for sorting the specimens: OK, N_OK
• Fully Web-based user interface
• Extensive operator control and monitoring functions even in the processing mode
• Wide-ranging diagnostics and logging functions: Error image memory and event logging
• Firmware update using operator interface of the Web browser
• Control via Digital I/O, PROFIBUS DP and PROFINET IO
• Result output via:
– PROFIBUS DP
– PROFINET IO
– RS-232 port of an RS-232 Ethernet converter
– TCP/IP connection of the PC / PG

Description
3.3 Function
Vision Sensor SIMATIC VS120
Operating Instructions, Edition 02/2006, A5E00757507-01 3-3
3.3 3.3 Function
Testing correctness of individual characteristics of the specimen
64 models are available for the recognition of specimens. The SIMATIC VS120 checks
whether or not the individual characteristics of the specimens have the same shape as the in
the trained model.
When specifying the recognition and evaluation areas, avoid shiny surfaces on specimens.
Principle of edge recognition
To recognize image patterns, edges are used. These edges from the images are the
transitions from light to dark or vice versa. A model is created from the sum of the edges
extracted in the image and their arrangement.
Recognition and localization of parts
The SIMATIC VS120 scans specimens and determines the coordinates including the roll
angle and passes them to the control system such as S7, for example, via PROFIBUS DP.
Testing the completeness of a model
The SIMATIC VS120 also checks specimens for completeness. Deviations from the trained
model are detected and the quality values of the evaluation are displayed.
Sorting functions for models and model sets
Depending on the importance of the application, 15 model sets with 64 different models can
be assembled and saved for processing. The models are sorted according to the application
with a controller for processing with the SIMATIC VS120.

Description
3.4 System components
Vision Sensor SIMATIC VS120
3-4 Operating Instructions, Edition 02/2006, A5E00757507-01
3.4 3.4 System components
SIMATIC VS120 Vision Sensor full package comprising:
• Sensor
• Processing unit
• Lighting
• Cable
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Description
3.5 System requirements
Vision Sensor SIMATIC VS120
Operating Instructions, Edition 02/2006, A5E00757507-01 3-5
3.5 3.5 System requirements
You require the following hardware and software components for the SIMATIC VS120 Vision
Sensor system:
Hardware
• SIMATIC VS120 processing unit
• Sensor head with CCD sensor chip for detection of the object
• LED ring flash for SIMATIC VS with degree of protection IP65 (not included in every full
package), for optimum illumination of the object
• Cables:
– Power supply cable
– Lighting cable
– Sensor cable
– DI / DO cable
• Documentation package
– Operating Instructions (compact)
– Documentation CD
You also require the following:
• 24 V DC, 2 A power supply; (20.4...28.8 V DC, safety extra low voltage, SELV).
• PC / PG with the following configuration:
– At least 500 MHz clock frequency
– Graphics card with at least 65536 colors and a resolution of at least 1024 x 768 pixels
– Ethernet port with up to 100 Mbps (protocol: TCP/IP)
• Crossover RJ-45 Ethernet cable for connecting the processing unit and the PC / PG
Software
• Microsoft Windows XP Professional SP1 operating system with Internet Explorer 6.0 as of
SP1
• Microsoft Java VM or Sun Java VM version J2SE 1.4.2_06 or J2SE 5.0 (you will find
more detailed information on the Internet at the following address
http//:www.java.sun.com/J2SE)

Description
3.6 Design of the SIMATIC VS120 processing unit
Vision Sensor SIMATIC VS120
3-6 Operating Instructions, Edition 02/2006, A5E00757507-01
3.6 3.6 Design of the SIMATIC VS120 processing unit
VS120 processing unit (MLFB 6GF1 018-
2AA10)
Item
No.
Meaning
(1) Status LEDs
(2) LCD display
(3) Keypad
(4) Housing consisting of hood and base
   

(5) Interfaces
Status LEDs LEDs Color Meaning
SF Red General fault
POWER Green Power supply is turned on
TRAINED Green Selected model has been trained
READY Green • off = device startup or SIMATIC VS120 in Stop
• on = SIMATIC VS120 in Run
OK Green Result good: Model was recognized
- Green -
N_OK Yellow Result bad: Object was not recognized
BF Red Bus fault on PROFIBUS DP or PROFINET IO

Description
3.6 Design of the SIMATIC VS120 processing unit
Vision Sensor SIMATIC VS120
Operating Instructions, Edition 02/2006, A5E00757507-01 3-7
LCD display and keypad Item
No.
Designation Meaning
(1) LCD
display
Displays menu commands (lines 1 to 3) and the keys
that are currently available (line 4)
 
(2) Keypad Navigation from menu to menu and within the menus
Interfaces Item
No.
Meaning
(1) Supply voltage 24 V DC, circular M12 connector
(2) Functional ground with M5 screw-type connector
(3) Lighting unit, circular M12 connector
(4) Sensor head, HD D-sub connector, 26-pin
(5) I/O, D-sub connector, 15-pin
(6) PROFIBUS DP, D-sub connector, 9-pin
    
(7) Ethernet / PROFINET IO; RJ-45 plug

Description
3.7 Design of the sensor head with LED ring flash
Vision Sensor SIMATIC VS120
3-8 Operating Instructions, Edition 02/2006, A5E00757507-01
3.7 3.7 Design of the sensor head with LED ring flash
Sensor head with LED ring flash Item
No.
Meaning
(1) Circular connector M12
(2) Sensor head
(3) LED ring flash (not supplied with all full packages)
(4) Lens, permanently installed and non-adjustable (fixed focus version)