Optical Character / Code Verification 6.220
Operating Manual
Rev A
Doc N°: OM_OCV_6_220_EN_A_ext.doc
Contents 1
General Instructions ..................................................................................................... 4
2
Description of Camera Hardware .................................................................................... 5 2.1 Camera Components ................................................................................................. 5 2.2 Camera Operation ..................................................................................................... 5 2.3 Connection-, Display- and Operating Elements ............................................................. 5
3
Connectivity ................................................................................................................ 6 3.1 Assignment for the System Plugs ................................................................................ 7
4
Type of Control ............................................................................................................ 8 4.1 Numbers and Types of Camera Control Windows (Smart Camera) .................................. 9 4.2 Numbers and Types of Sensor Control Windows (Smart Sensor) ..................................... 9
5
Operation of the Camera ............................................................................................. 10 5.1 Keys...................................................................................................................... 11 5.2 The Virtual Keyboard ............................................................................................... 12
6
Camera Start-Up (New Product) ................................................................................... 13 6.1 Teach-In – Control................................................................................................... 13 6.2 OCR / OCV - Control ................................................................................................ 14 6.3 CODE - Control ....................................................................................................... 15 6.4 Pixel - Control ........................................................................................................ 16 6.5 Pattern Check ......................................................................................................... 17 6.6 Instructions for Setting the Control Window ................................................................. 18 6.7 Instructions for Setting the Grey Threshold .................................................................. 19 6.8 OCV Window Colour Normal and Inverted .................................................................. 20 6.9 Track OCV/TIN/PIX Windows with Measurement Lines .................................................. 20 6.10 Track OCV/TIN/PIX or CODE Window with PATTERN CHECK Window ............................. 22 6.11 Color Inspection of the Pixel Window ......................................................................... 22 6.12 Control Mode of the Pixel Window ............................................................................. 22 6.13 Tolerances of the Pixel Window ................................................................................ 23 6.14 New Reference Code................................................................................................ 23 6.15 Production Mode..................................................................................................... 23 6.16 Menu Overview ....................................................................................................... 24
7
Product Management Menu ......................................................................................... 26 7.1 Change Product ...................................................................................................... 26
8
Font Menu ................................................................................................................ 27 8.1 Learn Character Group ............................................................................................. 27 8.2 Train Characters...................................................................................................... 27 8.3 Show Font .............................................................................................................. 28 8.4 Copying, Renaming, Deleting Font ............................................................................ 32 8.5 Correct Font Size ..................................................................................................... 32 8.6 Temporary Teaching Character ................................................................................. 32
9
Statistics Menu .......................................................................................................... 33
10 Service Menu ............................................................................................................ 34 10.1 Diagnosis .............................................................................................................. 34 10.2 System Parameters ................................................................................................. 35 10.3 User and Password Management .............................................................................. 45 11 Password, Zoom ....................................................................................................... 46
11.1 11.2
Change Password ................................................................................................... 46 Zoom In (Zoom Out) ............................................................................................... 46
12 Parameters of OCV / TIN Windows ................................................................................ 47 13 Parameter PATTERN CHECK Window ............................................................................. 54 14 Parameter Code Window ............................................................................................. 55 15 Barcode Quality Control Referring to ISO/IEC 15416 ......................................................... 61 15.1 Classification of a 1D Barcode .................................................................................. 61 15.2 Configuration of Quality Control................................................................................. 64 16 Pixel Window Parameters ............................................................................................ 65 17 Data Matrix Window Parameters ................................................................................... 67 18 Data Matrix Quality Control .......................................................................................... 72 18.1 Data Matrix Quality Control in Keeping with ISO/IEC 15415 .......................................... 72 18.2 Camera Calibration for Data Matrix Quality Control Reasons ......................................... 74 19 Code Aggregation ....................................................................................................... 76 20 Appendix .................................................................................................................. 78 20.1 Error Messages and Error Recovery ........................................................................... 78 20.2 Maintenance........................................................................................................... 79 20.3 Adjusting the Image Sharpness / Reading Distance ..................................................... 80 21 Specifications for OCR/OCV Control ............................................................................... 81 21.1 Font ...................................................................................................................... 81 21.2 Permissible Characters for OCR/OCV Control ............................................................... 82 22 Readable Code Types ................................................................................................. 84 23 Index ....................................................................................................................... 88
1 General Instructions Operator's Duty to Exercise Due Care The PCE OCV SMART CAMERA was designed and constructed in accordance with the stipulated harmonized standards and other technical specifications. It thereby conforms to state-of-the-art technology and enables an optimum degree of safety during operation. The safety of the system during everyday operation can, however, only is ensured if all the necessary, relevant measures are taken. Planning these measures and controlling their implementation is part of the system operator's responsibility for exercising due care. The operator must ensure that • The system is used in accordance with the stipulations, • The system is only operated in perfect, fully functional condition, • The Instruction Manual is always in a readable condition and is readily available, in full, where the machine is installed, • Only respectively qualified and authorized personnel operate and service the system, • This personnel is instructed on a regular basis in all the relevant aspects concerning work safety, and that they are familiar with the Instruction Manual and the safety instructions it contains, • All the system features relating to safety are carefully tested at regular intervals, • The higher the safety risks protected against by this device are, the more frequently regular inspections must be carried out. Basic Safety Measures For safe operation of the image processing system, the following points must be observed: • The camera must be mounted on a stable, mechanical, permanently fixed attachment. • During operation, the camera must be protected against the influence of external light. • The voltage supply system of the device is 24V DC and is supplied from an external voltage source. All the safety instructions necessary for this type of system design are to be observed. • The device may only be operated by persons trained on and authorized to use the device, who are familiar with the Instruction Manual and are able to operate the device accordingly. To ensure safe operation of the image processing system, repeated inspections are to be carried out on all the relevant safety parts, and particularly the above-mentioned points and Instruction Manual are to be observed. Requirements for the Operating Personnel The device is operated via user administration. This may only be operated by personnel specifically trained for the respective level. In this connection, please also read the section “Operating details and menu structure”. This Instruction Manual serves for enabling the user to install and operate the device. However, this Instruction Manual on no account replaces the installation and Customer Service performed by trained personnel! Transport, Installation and Start-up During transport it must be ensured that the device is packed and transported such that it is protected against moisture and impact. When installing the device in an industrial environment, this should typically be done where the adverse effects of dust, moisture, temperature and vibration are at their very lowest. Safe operation of the device can only be guaranteed if specially trained personnel have conducted the installation and start-up.
Note:
To avoid the danger of tripping, all the device connections (cables) are to be laid in such a way that nobody can trip over them! Intended Use
The PCE OCV SMART CAMERA is suitable for inspecting the readability of:
Identification number, lot number, proof of origin, expiry date and variable print on labels, cartons, films and other printed items.
The optical character reading monitors the most important errors of:
Stamp, hot stamp block, photo plate, thermal transfer, laser or inkjet printers, that render the print unreadable or result in incorrect recognition, for example: Reversed characters; blurred characters; worn characters; merged characters or missing character(s).
4
Typical applications for PCE optical character verification are on:
Brochures, labels, vignettes, cartons, tubes and tins.
Note: If the PCE optical character verification is not used correctly, reliable operation of the system cannot be guaranteed. The operator of the PCE image processing system is liable for any personal injury and damage to property caused by incorrect use, not the manufacturer.
2 Description of Camera Hardware 2.1
Camera Components
The Smart Camera consists of an intelligent camera with integrated signal processor and a software which is able to control different characteristics. Further the camera hardware contains memory, network interface, an optical component and illumination. The illumination can be integrated into the camera or mounted around the camera as external illumination.
2.2
Camera Operation
The camera is handled with a cable-bound network LAN (Local Area Network). A PC must be present in this LAN for the operation of the camera. With the Pharmacontrol PILOT PCE offers a suitable hardware and software, in order to operate the camera comfortably. Descriptive visualizations indicate the adjusting options on the touch display and ensure comfortable operation by means of large sized key top touch areas. The PC offers all the necessary functions to handle the camera. The screen shows e.g. buttons and a keyboard to send commands and characters. For mounting the camera and for calibrating the system, a live image can be displayed on the screen.
2.3
Connection-, Display- and Operating Elements
The following picture shows the back plate of the camera. The exact allocations are specified in the tables on the following pages.
LED indication for input
Optional External Illumination Plug
LED indication for output
Plug for additional in- and outputs
Main System Plug
LED indication for power supply Pushbutton
Plastic Mounting Plate
5
With the pushbutton in the camera’s rear panel a camera trigger can be released. Thus the camera starts a picture recording and evaluation. The LEDs in the rear panel indicate the input and output signals. They are arranged in lines. A LED flashes, if the appropriate signal applies.
Description
IN0 IN1 IN2 IN3 OUT0 OUT1 OUT2 OUT3
Function
Machine trigger Signal of the pushbutton Reset Signal, Printer Ready (option) Universal, function belongs to software settings Good Signal Camera Ready Signal Universal, function belongs to software settings Universal, function belongs to software settings
3 Connectivity The camera is connected to the connection box with screw clamps at the open cable end. In the minimum wiring the camera can be attached directly to the LAN interface of the PC. For the handling of several camera systems a LAN Switch is used. Beside the LAN interface a 24V voltage supply and the connection with the machine signals have to be ensured.
Touch Display
Power supply 230 V Machine signal
Power supply
Camera
and system signals
Filters, power supply, screw clamps etc.
Several camera systems optional Camera Camera
Power supply
Switch
and system signals
Camera
Standard wiring of the Smart Camera.
6
PC
LAN-I/Oextension
(small-) connection box
3.1
Assignment for the System Plugs
With the 8 pin system plug the camera is supplied with 24V and can be connected with an input and output signal to the machine. The camera establishes a connection to the network “LAN” (Local Area Network) with four leads. Further inputs and outputs are optional. They are available with a LAN I/O extension or an additional I/O cable. System cable Pin No. of the 8pin plug 1 2 3 4
Color
Description
white / blue blue brown white / brown
+24V GND In0 / Trigger Out0 / Good Result
5 6 7 8
white/orange orange white/green green
LAN LAN LAN LAN
I/O-Cable Pin No. of the 8pin plug 1
Color
Description
brown
2 3 4
yellow orange black
5 6 7 8
green red blue violet
External Illumination Connection Pin No. Color of the 4pin plug 1 2 green
In1 In2 In3 Out1 Out2 Out3 TxD RxD
Description
Function Power Supply +24V Supply GND Input 0 = Trigger Signal Output 0 = Good Result Signal Camera connected to PC (according to TIA 568 A) via 1:1 LAN cable RJ45 Pin 3 – TxDRJ45 Pin 6 – TxD+ RJ45 Pin 1 – RxDRJ45 Pin 2 – RxD+
Camera connected to Switch (according to TIA 568 B) via 1:1 LAN cable RJ45 Pin 1 – TxDRJ45 Pin 2 – TxD+ RJ45 Pin 3 – RxDRJ45 Pin 6 – RxD+
Function Input 1 = Pushbutton at camera’s rear panel Function according to software settings. Input 2 = Confirmation Signal Input 3 = Universal, function belongs to software settings Output 1 = Camera Ready Signal or belongs to software settings Output 2 = Universal, function belongs to software settings Output 3 = Universal, function belongs to software settings RS232: TxD of the camera RS232: RxD of the camera
Function
+24V
+24V supply for external illumination, delivered from the camera 3 brown Trigger Trigger signal for external illumination, delivered from the camera 4 white GND GND Various external illumination units can be connected to a camera via splitter.
7
4 Type of Control OCV mode (optical character reading) The individual characters are taught in one time by the operator/in samples. The sample will be deposited at the character set. When changing the batch the reference characters will be taught-in via keyboard. If the deviation of the character set compared to the reference code is too big, the print will be evaluated as “BAD”. Application: For bad print, because several samples of one character can be taught in. If there is a small gap or the gap is missing between the characters. OCR mode (optical character reading) As in the OCV mode, here reference character samples can be taught-in in one character set. . When changing the batch the reference characters will be taught-in via keyboard. During the production the actual character will be compared with all samples of the character set. The sample with the least deviation is then selected and compared to the reference code (reference code). Is the matching too small, the print will be evaluated as “bad”. The OCR mode is slower than the OCV mode. There must be spaces between the characters, otherwise they cannot be recognized as individual characters! Application: If the OCV mode is not sufficient for distinguishing between different characters (example: "O" vs."0" or "8" vs."B") If the content of a print job needs to be read and output. If the exact reference code is unknown but only characters from the taught-in character set are allowed. Note: OCV has a greater tolerance for poor quality print and is generally sufficient. Teach-In mode (optical character reading) The operator teaches in the reference character samples as a reference code. No allocation of samples to characters takes place. Application: Constant changes of font type and font sizes; characters must be separated clearly by a gap. Note: This mode should not be used if reference codes are specified by the PLM.
Pixel mode In a pixel window the sizes of the black and white areas are verified. The tolerances can be entered as absolute, or relative. Application: Presence control of objects or print.
Code mode With the set window, a barcode (1D code) is read and the code content is compared with the reference code. See the "Readable Code Types" chapter for the various possible code types. Application: Object control using code reading. Verification of the code quality (grading)
Data Matrix mode With this window, a data matrix code (2D code) can be read and compared with the reference code. See the "Readable Code Types" chapter for the various possible code types currently available. Application: Object control via data matrix code reading. Verification of the print quality of the data matrix code (grading)
Pattern Check The camera will search for a teached in pattern. The position of pattern and the deviation from reference will be measured. This control type can be used for positioning of OCV/OCR, PIXEL or CODE windows. Application: Presence control of correct print. Positioning tool for other control types
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4.1
Numbers and Types of Camera Control Windows (Smart Camera)
The following control types are available: Type Optical character (OCR, OCV, Teach In) window Pixel windows Barcode window Data matrix code window Pattern Check window
Name OCRn, OCVn, TINn PIXn CODEn DM PCn
Number n 20 20 5 2 4
The different control types for the camera can be freely combined. The results of the controls (checks) can be AND or OR linked and routed to different outputs. An AND link and OUT0 have been preset as a GOOD output.
4.2
Numbers and Types of Sensor Control Windows (Smart Sensor)
The following control types are available: Type Optical character (OCR, OCV, Teach In) window Pixel windows Barcode window Data matrix code window Pattern Check window
Name OCRn, OCVn, TINn PIXn CODEn DM PCn
Number n 4 4 2 1 4
The different control types for the sensor cannot be freely combined. The user must decide whether to use the sensor for pixel, optical character, barcode, or data matrix checking. Except for these restrictions, the sensor software functions just like the camera software. The results of the controls (checks) can be AND or OR linked and routed to different outputs. An AND link and OUT0 have been preset as a GOOD output. The sensor cannot be used for code quality verification (grading).
9
5 Operation of the Camera The PCE image processing system is operated using simple menu navigation on the display and with the integrated touch screen. The areas to be inspected are marked and verified using the window technique, operating instructions are displayed for the single products. The following illustration shows the main menu after choosing a camera and pressing “Menu” on the touch screen.
Menu selection Status Line
Note:
When the system is switched on, the production run – the actual control mode – is started. After choosing the camera and pressing “MENU”, one can quit the production run, and the main menu is then displayed.
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5.1
Keys
The following key assignments are valid in the menus: A menu item can be selected via touch screen. • A menu item will be selected upon release of a menu item. • Quit a sub-menu or cancel using the “Exit button”. Setting windows, frames and lines: The windows for the different types of control (OCV, OCR, Code,) will be configured on the touch screen via control symbols. The windows can be changed directly via touch screen (mouse). By pressing the center of the window this can be moved, by pressing on the side next to the window the size of the window can be changed.
Arrow keys
Mode
•
By choosing the center button the active mode can be switched.
•
In “scrolling” mode
the window can be shifted using the arrow keys
•
In “zoom in” mode
the window can be enlarged using the arrow keys.
•
In “zoom out” mode
•
The entry will be acknowledged using the
•
The entry will be cancelled using the
the window can be reduced using the arrow keys.
button.
button.
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5.2
The Virtual Keyboard
Alphanumeric characters (passwords, set texts, codes) will be entered via touch screen using the virtual keyboard. This will be displayed as soon as an entry has to be made.
•
• • • • •
12
characters.
Changes between capital and small letters as well as numbers and special
Confirms the entry of characters or completes the entry. Cancels the entry. Shifts the keyboard upwards,
. Shifts the keyboard downwards.
allows to freely position the keyboard let the keyboard disappear
6 Camera Start-Up (New Product) 6.1
Teach-In – Control
Product administration
New product
New product name: ... Live image Live image with trigger
Type of control Teach In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK Window with measuring arrows
Position reading window:
See also chapter: "Instructions for setting the control window" See chapter: "Instructions for setting the measuring lines"
Setting grey threshold: See also chapter: “Instructions for setting the grey threshold”
Window without measuring arrows
13
6.2
OCR / OCV - Control
Product administration
New product
New product name: ...
Live image Live image with trigger trigger
Type of control Teach-In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK
Entry of characters: 12345HN00G
Position reading window: Setting grey threshold:
Use existing font
See also chapter: "Instructions for setting the grey threshold"
See also chapter: "Instructions for setting the control window"
Setting grey threshold: See chapter: “Instructions for setting the grey threshold”
Create new Font
See also chapter: "Instructions for setting the control window" Window without measuring arrows
Window with measuring arrows
See chapter: "Instructions for setting the measuring lines"
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6.3
CODE - Control
Product administration
New product
New product name: ...
Live image Live image with trigger Type of control Teach-In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK
All barcodes automatic?
Determine information for code search
Position reading window:
See chapter: "Instructions for setting control window”
Set the size of the codes
Prior choice of code determination Pharmacode? Omnidirectional?
Chosen code type automatic? Barcode Pharmacode Code 39 Int 2/5 Code 128 Code 32 UPC_A Code 10 figures UPC_A Code 12 figures EAN 13 Codabar 2-Track Pharmacode GS1 DataBar (RSS) CC-A EAN 8
Static Omnidirectional
Set contrast:
See also chapter: “Instructions to set the contrast” Manual?
15
6.4
Pixel - Control
Product administration
New product
New product name: ...
Live image Live image with trigger
Type of control Teach-In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK
Entry of the tolerances See also chapter "Tolerances of the pixel windows"
Positioning of pixel-window:
See also chapter: "Instructions for setting the control window"
Selection of print control or presence control See also chapter "Control mode of the pixel windows"
Setting grey threshold:
Setting an additional control function
See also chapter: "Instructions for setting the grey threshold"
Window with measuring arrows
Inspection color bright or dark? See also chapter "Inspection color of pixel windows"
16
See also chapter: "Instructions for setting the measuring lines"
Window without measuring arrows
6.5
Pattern Check
Product administration
New product
New product name: ...
Live image Live image with trigger
Type of control Teach-In Control OCV Control OCR Control CODE Control PIXEL Control DATA MATRIX Control PATTERN CHECK
Teach-In reference pattern
Teach-In searching area
17
6.6
Instructions for Setting the Control Window
The described procedure is valid for all types of windows (verification types) of the camera. The control window is superimposed as a yellow frame. The position and size of the window can be changed. Detailed description of the keys on the touch screen can be found in section 5.1 “Keys”. The active mode is shown on the mode key between the arrow keys. • Shift window, • Enlarge window, • Reduce window. Shifting the window or changing the size is carried out either via touch screen (follow cursor) or using the four arrow keys which are also suitable for fine adjustment. Change the mode using the key between the arrow keys. Complete and save the procedure by pressing "ENTER" Editing multiple windows Existing windows can still be edited in position and size. The Editing Menu is accessible through the windows parameter tables. If multiple windows of the same type are existing, this Editing Menu will provide a multi edit mode. All at once The possible options in this mode are Individual and . The active option is marked green.
Individual: The currently selected window is shown yellow. This window is the one which is currently editable. Another window can be selected by pressing near its center. All at once: The last selected window is shown red. All changes in position or size which are done to this reference window will be also applied simultaneously to the other (yellow) windows. The reference window can be switched by selecting Individual mode, choosing your preferred window and switching back to All-at-once mode. Individual
18
All at once
6.7
Instructions for Setting the Grey Threshold
Separating the object from background is done using the grey threshold, which is set by operator as follows: After the control window has been set, the camera displays the binary image (black/white image).
Canceling input
Binary Image The black and white part of the binary image can be set changed by moving the slider up and down. The image will be updated as soon as the slider is no longer pressed. The histogram on the right shows the frequency scale of the grey scale values within the window. The threshold is set correctly if the characters are displayed in strong black. No black points should be visible in the background.
Slider
Histogram
Accept settings The inkjet filter is also used for adjusting the threshold values of an optical character control window, thus making it easy to check the effect
19
6.8
OCV Window Colour Normal and Inverted
If there is a combination of windows with dark font on light background and light font on dark background in the document, this action can be performed separately for each window in the OCR parameter table ('Parameters of OCV/TIN Windows'). If different settings in the OCR parameter table are used in a product, then for each new window the camera will ask whether dark font on light background or light font on dark background should be used.
X
Optical character window parameters Control
Window name: OCV0
Identifier GTIN
Font: tz1
Search area
165/205
57/46
>>Next>>
Search area
Threshold: 120
Colour: Black
Direction: L->R
Lines
Tilting: 0
Noise pixels 5
Distance: 0
In the production display a window with inverted font (light on dark background) is marked with a window name with inverted font (see image OCV1 below). If the reading direction is vice versa (from right to left / from bottom to top) the reference code will be displayed in an inverted font (see image 0A186A12.2011 below).
6.9
Track OCV/TIN/PIX Windows with Measurement Lines
In case the print position of the text characters differs between the printed labels, the window position should be tracked using measurement lines, Data Matrix-Code, Bar-Code or a Pattern position. If the Label has a code or a check pattern printed together with the text or pixel you have to control, try to use tracking via Data Matrix , Barcode or check pattern. On other cases the inquiry “Window with measuring lines?” has to be answered with “Yes”.
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Instructions for Setting the Measuring Lines: To keep operation expenditure small, two lines should be set only for the first window. All further windows are likewise corrected with these lines. Also in the pixel windows can be worked with measuring lines. In case e.g. the black printed area varies several millimeters to the left, right or up and down. First of all the measuring lines adjust the yellow control window to the correct position. Afterwards the content of the window is evaluated. It always has to be set to at least two lines. These can be active for only one window, several windows or for all windows. If necessary own measuring lines can be set for each window. That means each window can be adjusted individually with two lines. Regarding the OCV, OCR and Teach-In control the measuring lines can be set to automatic or manual. Please see also Section “Set measuring lines automatic”. One measuring line is necessary horizontally or vertically respectively. Scanning width
Scanning width
Capture range Capture range
Inside the capture ranges a changeover from bright / dark is searched across the scanning width. The line indicates the search direction here.
Setting the measuring line to the horizontal guiding position First, the measuring line is set to the horizontal guiding position. By operating the arrow keys you can choose between “Measuring line from the left” or “Measuring line from the right”. This is to be set as shown in the example: Correct:
Expiry 6 weeks after opening Subject to saleby pharmacists only
For greater clarity in the example, only one window is set around the first line. The line scans the second line from the right and guides the window back into position accordingly. The line is correctly positioned as no other additional print is found in the scanning area of the measuring line. Setting the measuring line to the vertical guiding position The line for the vertical guidance can scan downwards or upwards. In the example, the line is shown scanning upwards. Correct:
Expiry 6 weeks after opening Subject to saleby pharmacists only
The line is correctly positioned, as no other additional print is found in the scanning area of the measuring line.
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A grey threshold is also defined for each measuring line. The threshold is optimally set when the background is an even grey and the print is shown in black with sharp outlines. After setting each window and measuring line, except "Automatic", the grey threshold is inquired. In the normal case, with good contrasting conditions, the preset value can simply be taken over by pressing “Enter”. The grey threshold is set as described in the chapter “Instructions for Setting the Grey Threshold.”
6.10
Track OCV/TIN/PIX or CODE Window with PATTERN CHECK Window
Instead of measurement lines it is also possible to use a PATTERN CHECK window for positioning of other control windows. This tool is more flexible, because there are not so many restrictions. If you want to use this feature, please deny measurement lines during setting procedure of OCV/TIN/PIX windows. At the end of PATTERN CHECK adjustment, you will be asked, if all other active controls ((Data Matrix windows expected) should be tracked with this tool. If you select “Yes” all windows will be moved depending on reference pattern position.
„Exp“ = reference pattern; „PC0“ = Pattern Check window; “OCV0” = window, which will be moved;
6.11
Color Inspection of the Pixel Window
The following message is displayed, “Which pixels are to be counted?” The answering possibilities are “dark pixels” or “bright pixels”. Please select the answer that is suitable for your object. For example: “dark pixels” if you wish to inspect a dark print on a white background, or “bright pixel”, if you wish to inspect a white label on a brown bottle.
6.12
Control Mode of the Pixel Window
The following message is displayed “Reference value for the tolerances” with the choice of “Presence control” and “Print control”. “Presence control” (absolute measurement) For the “absolute measurement”, the black area e.g. is displayed as a measured pixel number. When the black area increases, the measured number of pixels increases, and vice versa. The plus tolerances and the minus tolerances are entered as a pixel number. Finally, in the production mode, the measuring value is similarly displayed as a pixel number. “Print control” (relative measurement) In the relative setting, the size of an area (reference area) is taught in and accepted as 100%. The following measurements can be smaller than 100% if, e.g. the printed area is missing, or greater than 100% if, e.g. there is too much print. The input of the plus and minus tolerance and the display of the measuring values is given as a percentage value.
22
6.13
Tolerances of the Pixel Window
After selecting and acknowledging with “Enter” the present measuring value is displayed in pixels or as 100%. The camera waits for the entry of the minimum tolerance. Following this, the maximum tolerance is entered. For the presence control: the minimum tolerance value should be less than the actual pixel value and the maximum tolerance value should be greater than the actual pixel value. For the print control: the minimum tolerance value should be entered less than 100% and the maximum tolerance value greater than 100%.
6.14
New Reference Code
The entering of new reference codes depends on the control windows which have been set before. Control window
New Reference Code
Teach-In
Reference character will be taught-in by the means of a GOOD-print
OCV
Reference character will be entered via the keyboard
OCR
Reference character will be entered via the keyboard
Code
Depends on the “Teach-in” parameter, see the “Parameters for the Barcode Window”. - Reference character will be entered via the keyboard - Index a./o. Parameter of the code will be taught-in by means of a GOOD code
Pixel
In case of control type "Print Control" the print reference will be taught-in by the means of a GOOD-object.
Data matrix
Depending on the parameter “Teach-in Code”, see “Parameter Data matrix window”. - Reference character will be entered via the keyboard - Index a./o. Parameter of the code will be taught-in by means of a GOOD code
Pattern Check
No action
Note:
If the camera is being operated with the PLM 4 software, reference codes will be transferred from the pilot to the camera at the start of production. The input reference codes are of secondary importance in this operating mode, nevertheless this function is useful in that CODE and data matrix windows detect important settings as the code is being taught-in.
6.15
Production Mode
After entering the reference code it is possible to change over to the production mode, and the camera is then ready for operation. If only PIXEL or PATTERN CHECK windows are used for inspection, one can change directly to the production mode after creating a new product. The camera is now ready for operation.
Note:
For safety reasons it is not possible with the “Default Product” to switch to production mode, as there are no set control windows. A warning message appears on the screen “No windows set”.
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6.16
Menu Overview
Main menu
Edit product
Production New reference code Change product Edit product Product management Font Batch record Service Change Password Zoom On Product Management
Live image Add control window Delete control window Set DM windows automatically Track windows Parameter OCV/TIN window Parameter CODE window Parameter PIXEL window Parameter DATA MATRIX window Parameter PATTERN CHECK window Switch on/off camera
New product Show product Rename product Copy product Delete product Font Learn character group Train characters Show font Copy font Rename font Delete font Correct font size Temporary teaching character Batch record Start batch record Show batch record Stop batch record Show faulty pictures Reset counters
Service Live image Diagnosis System parameters User administration
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Tolerances Change matching tolerance Change searching tolerance Change size tolerance Change threshold 1 Change threshold 2
Diagnose Level
Service
Live image Diagnosis System parameters User administration
System parameters Optical Settings I/O configuration Time Out Clock overflow Printer communication On/Off measurement line automatic Image transfer configuration Trigger edge Save counters Image geometry Image Shading Long names Configuration illumination Language Default text colour Reader Mode
Pattern Check: current value Binary picture OCR/OCV window Blank-out OCR/OCV window Show current character Matching accuracy OCR window Binary picture PIX window Show Data Matrix (Edge and Grid) Binary picture Data Matrix Current values PIX window Debugging Data Matrix searching (exp. mode) Debugging of character searching (exp. mode) Debugging of code reading (exp. mode) XML data on port 23 (exp. mode) GUI data on port 23 (exp. mode) Data Matrix: show quality parameter XML ACK on Port 23 GUI ACK on Port 23 Barcode: show quality parameter
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7 Product Management Menu New product To create a new product, please follow the section “Camera start-up (new product)”. The teach-in procedure is basically identical for all the camera inspection types (Teach-In, OCV, OCR, code, pixel and Data matrix): imagetaking, naming the product, and selecting the inspection type, setting windows and different parameters. This procedure is repeated for each control window required. Naming, copying and deleting the product Before a product is renamed, copied or deleted, the required product is selected from the product list. Then the product can be changed or deleted accordingly. Show product Here the entire data specific to the product is displayed. To print out the data, drag the slider on the right of the window down until the text line "Print data" at the end of the list appears, and then use the touchscreen to select it. By default you will be asked if you want to save it (as a PDF-file) or send it directly to a connected printer (via the PCs standard printing menu). The file will be saved by default to the PLM (resp. MscClient) installation folder on the PC. Printing and saving works only for PLM versions above 4.1. Change product Here all the products are stored and therefore a product changeover can be carried out very quickly. After addressing, a list is displayed of the products created until now. The required product can be selected. In this way, all the settings stored under this product are called up and active.
7.1
Change Product
Use the “Menu” button to navigate to the “Main Menu” and then activate the “Change product” submenu therein. This submenu contains the various options for changing an existing product. You will need to do this if the window position, window size, arrow position, arrow size, etc., are no longer correct. You can make the changes under the corresponding menu items. You will find a description of the parameters for each type of control or inspection further below in these instructions. Switching off the camera The camera can be switched off in the menu “Change product”. During the product run, the message “Camera is switched off” is displayed. The following signal conditions are possible for adaptation to the machine control: Camera ON Camera OFF Camera OFF
System Ready = High System Ready = Low System Ready = High
Note:
Good signal(s) as per the setting in the service Good signal(s) always = High Good signal(s) always = High
When the camera is switched off, it always sends a “GOOD signal” to the machine. Because no check is being performed, the light will not flash.
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8 Font Menu In this menu you can teach in several characters in one or several character sets. Up to 70 different characters can be applied per character set.
8.1
Learn Character Group
After selecting the menu item “Learn character group” in the sub-menu Character set, an image first has to be taken of a sample object. You are now requested to choose between “Live-image” and “Live-image with trigger”. Then the character set has to be selected in which the characters are to be saved. A teach-in window is inserted in the live-image. The position and size of the window can now be changed. The active mode is displayed in the lower status line. Depending on the mode, the window can be shifted, enlarged or reduced using the touch screen or the four arrow keys, as mentioned in chapter 5.1. • •
Changing the mode using key “Mode”; Acknowledge and terminate the procedure using the “ENTER” key.
With one teach-in window, a complete line can be taught in. The character(s) must lie completely inside this window. For character strings without a gap or for poor printing quality, the teach-in procedure should be carried out for each character separately. In this case, one should make sure that only this one character and no additional print is inside the teach-in window. After setting the window you are requested to enter the character (or characters) using the keyboard. For entering letters, press the Alpha key and for capital letters, additionally press the shift key. If the same characters are already available in the character set, a message is displayed asking you whether the characters are to be additionally taught in, or whether they should be overwritten. After all the characters have been taught in please change to the mode, "Train characters".
8.2
Train Characters
In this special mode a re-correction of the taught-in characters is carried out inside the reading window. For this reason the references for all the windows are first scanned. The trigger signal is required for starting. Using the training function, additional character samples are created. These are to reduce the “Pseudo rejection” in the production mode.
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8.3
Show Font
Here all the characters from one character set are displayed one row after the other. For inspecting the “Teach-in and training results”, the samples of a character shown as a group of 8 can be viewed.
Characters that cannot be read properly can be deleted. The quality of the samples is decisive for the system's readability exactness. One should make sure that the character samples are easily readable and can be distinguished well from the samples of other characters. • •
The black character contour should be shown without any discontinuation. The green zone describes the pixels that may be black or white during the evaluation. In other words, this is the tolerance zone.
For checking how good the separation of characters works, please see ConfusionList.
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1. Confusion List The Confusion List shows for each character the most similar character. Since there exists up to 8 different patterns for each character, the number of the most fitting pattern will also displayed.
The values in the last row show the amount of different modules and the matching tolerance (here for example “6”). In this confusion list, separation of all characters is guaranteed, because for all characters the amount of different modules is greater than matching tolerance. If this is not fulfilled, the matching tolerance for the regarding character can be decreased or the regarding pattern can be deleted.
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2. Tolerances
X
Character set tolerances Change matching tolerance Change searching tolerance Change size tolerance Change threshold 1 Change threshold 2
Change matching tolerance and searching tolerance The matching tolerance specifies the maximum permissible deviation between the actual character and the reference character. If the deviation is less than the matching tolerance, the character is recognized as “good”. --> Character marked green. The current character will be searched for as long as the deviation is smaller than the searching tolerance and larger than the matching tolerance. When the max. search time is exceeded (“! TO !” marking) or when the end of the window is reached, the search will be terminated and the control window marked red. Value small
Pass tolerance
Green
Search tolerance
Char. and window red.
Value large
Deviation
Only window frame red.
A character recognized as “Good” will be marked green. An incorrect character will be marked red. Matching tolerance is adjustable for each single character! Change size tolerance This factor determines how much the size of a taught-in sample may vary from the read character and still be recognized. The default value is 30%, which means that a taught-in sample and a read character may vary by as much as 30% and still be recognized as “Good”. This setting can be reduced to less than 10% in order to distinguish between characters that are only different in terms of size, e.g., whether zero = “0” or an “O” or whether an eight = “8” or a “B”. For such character sets we also recommend using OCR, because characters are no longer recognized with certainty if the size tolerance is under 5%.
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Change threshold 1 and threshold 2 Threshold 1 and threshold 2 define the black and white proportions of a character. Threshold 1 specifies a mean value and threshold 2 a deviation from this mean value. The graphic illustration of the values can be seen in “Display character set”. The gray background is above threshold 1+(1/2*threshold 2). In “Display character set “, the characters are displayed as follows: The green area lies within the tolerance specified by threshold 2. And the black area is below threshold 1-(1/2*threshold 2).
Threshold 1 dark
bright
Threshold 2 black
green
grey
black = core area of the character, green = black or white area, grey = background (white)
2. Delete sample By selecting the character and the respective sample number a sample can be deleted.
3. Delete character By selecting the character and selecting the "Delete character" menu item, it is possible to delete an entire character with all samples.
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8.4
Copying, Renaming, Deleting Font
The simple character set administration allows copying, renaming and deleting a character set. Caution! A complete character set can be deleted here. In the menu item “Display character set” individual characters can also be deleted.
8.5
Correct Font Size
For each taught-in character the width and height is saved. If now, e.g. the reading distance is considerably changed, or the same character set is to be created in another size, it is possible to correct the character size (height and width) in the menu “character set”. To change the character size, please proceed as follows: 1. 2. 3. 4. 5. 6.
Call up menu “Correct character set/character size”; Take picture with “Live-image” or “Live-image with trigger”; Select the required character set; Use window to completely frame a line with several characters; Setting grey threshold; Enter character sequence in the window;
Then the size for all the characters of the selected character set is corrected.
8.6
Temporary Teaching Character
The procedure of “Temporary teaching character” is the same as “Learn character group”. But in this menu the taught in character will be saved only until change of format. After teaching character please go to “show font” to check results.
Pattern 1 is marked “brown”, because this pattern was taught-in temporarily.
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9 Statistics Menu Starting, viewing and ending batch Within the statistics menu, a batch protocol can be started. A batch protocol is intended for documenting the production. All the relevant data, such as e.g. the order number, quantity, remarks, etc., can be entered in the batch protocol at the start of the batch. The first three lines, which are designated with "", are input one time and from then on will appear at each protocol start. The information in the first "" line (max. 45 characters in length) will also be displayed in the production run and in the main menu in the top margin of the screen. With this it is possible e.g. to differentiate faster the different batches. To print out the data, drag the slider on the right of the window down until the text line "Print data" at the end of the list appears, and then use the touchscreen to select it. By default you will be asked if you want to save it (as a PDF-file) or send it directly to a connected printer (via the PCs standard printing menu). The file will be saved by default to the PLM (resp. MscClient) installation folder on the PC. Printing and saving works only for PLM versions above 4.1.
Note:
To display the menu screen after changes a restart of the system is necessary.
Display error images Depending on the configuration, as many four error images that were generated during the previous production run will be displayed. Options Buttons: [Continue] Displays the next error image [Cancel] Ends the display [Accept] Accepts the error image as the current sample, so that it will be available for teaching in characters and other improvements.
Note:
The error images are lost once the system is switched off. In the Service menu one can select whether no error image, one error image or four error images are to be displayed. Delete counter The counters for good and bad readability are set to zero. The deletion of the counters is only active if no batch protocol has been started.
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10 Service Menu When calling up the menu item “Service” the password for access to the service settings is required. The PCE password on delivering the device is: "000". Select the menu item “Service” in the main menu if you wish to make any specific settings on the system.
Note: If you wish to make any alterations to the service settings please find a table available for documentation purposes in the section “Form for settings”.
10.1
Diagnosis
In order to be able to switch the different presentation functions of the system on and off, the diagnosis value is changed. The diagnosis value is thus also a helpful instrument for seeking errors. At present the following functions can be called up as diagnosis displays:
Diagnose Level
X
Pattern Check: current values Binary picture OCR/OCV window Blank-out OCR/OCV window Show current character Matching accuracy OCR window Binary picture PIX window Show Data Matrix (Edge and Grid) Binary picture Data Matrix Current value PIX window Debugging Data Matrix searching (exp. mode) Debugging of character searching (exp. mode) Debugging of code reading (exp. mode) XML data on port 23 GUI data on port 23 Data Matrix: show quality parameter XML ACK on Port 23 GUI Ack on Port 23 BarCode: show quality parameter
Note: Please observe that changes in the diagnosis level can increase the evaluation time of the camera. The “debugging” display functions cannot be used during machine up time. Data that is output via the serial interface to Port 23 (Ethernet, TCP/IP, Telnet-Port) can be received by a PC, e.g. with the PCE service program “JDATATRANS”, or can be visualized via a laptop and a suitable terminal program.
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10.2
System Parameters
Specific camera parameters that as a general rule only have to be changed when mounting the camera are set in the “System Parameters” submenu. Optical Setting Shutter The shutter value states the exposure duration of the image in µs. For high values, the image is brighter and for low values, darker. The exposure duration relates to the flash duration of the internal or external LEDs and the exposure duration of the image taken by the camera. High shutter speed may results in blurry pictures when fast moving samples have to be controlled. The shutter is adjusted via a slider that switches between high and low values when needed.
Shutter 30-1200 + X
30 0 -
OK
Shutter 800-10000 + X
210 0 -
The cameras come with the following preset values: Type Resolution [Pixel] 200 640x480 205 752x480 202 1024x768 201 640x480 203 1024x768 204 1550x1200 150 752x480 215 1600x1200 240 2048x2048
OK
Description Standard Standard-2 HiRes HiSpeed HiRes HiSpeed VeryHiRes HiSpeed Smart Sensor 2 2M Pixel 4M-Pixel
Shutter [µs] 150 150 300 150 300 300 150 300 300
Note: If your camera is equipped with a dimmable internal illumination always set dimmer values to maximum before adjusting the shutter values. For data matrix quality analysis, it is recommended that these values not be changed. The values may be different for cameras with external illumination, UV illumination, or for special requirements.
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Dimmer Some cameras might be equipped with a dimmer for the internal illumination. The shutter could only be adjusted in steps of 40 – 80 µs dependent form camera model used. Dimming the illumination allows a precise adjustment of image brightness for Print Quality inspection. If the camera does not support brightness adjustment via illumination, you will have to change the aperture instead. Focus & Autofocus Some cameras are equipped with a variable lens, adjusting the focus could be done manually via a slider after pressing the Focus button or automatically by using Autofocus. I/O configuration Good outputs and results-linking for windows groups Control windows can be organized into groups. Each control window must be in exactly one group. The first group is G0 in the basic setting for each window. The good output of a group determines which camera to output the result of the control window for this group. The good/bad results of the control window or window groups is given in the basic setting on the “good output” (OUT0) of the camera. There is, however, a further output (OUT2) of the camera available which can be used as a second good output. Within a group, the results of window control are linked to one another, and therefore give a group result. In the basic setting, the results are linked with AND If the results from several groups go through the same outlet, these group results are always connected together with AND. Linking logic:
AND - already bad reading from only one control window leads to a total 'bad' result. (“Bad wins”) OR - already a good reading from only one control window leads to a total 'good' result. (“Good wins”)
Group G1
Group G0 CODE0
PIX0
CODE1
(Good)
(Bad)
OR
AND
Good
Bad
Output OUT0 Bad
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PIX1
(Good)
(Bad)
The camera offers a “good signal”; it is high with a good reading (+24V) and low with a poor reading (0V). There are four variations of good signal behavior to choose from. •
Mode 0: For the setting “Good pulse after evaluation up until the next trigger” the good signal is high or low, depending on each evaluation after a trigger pulse. During the evaluation time, the good signal is low.
•
Mode1: For the setting “Latch mode” the good signal remains low after a poor evaluation, even if other trigger pulses and possible good readings follow. For resetting a poor reading, the quit key therefore has to be pressed. The quit key is located on the terminal, or separately on the machine. During the evaluation time the good output remains at high.
•
Mode 2: For the setting “Good pulse after evaluation up until expiry of the defined time” the output is set after the evaluation time up until the expiry of a settable time. In the case of a negative reading result the output remains at low. The GOOD pulse length can be set between 5 and 100 ms.
•
Mode 3: not supported at the present time.
Caution:
In order for the camera to be able to recognize the negative trigger edge, the white quit lead has to be connected to the brown trigger lead. •
Mode 4: not supported at the present time.
•
Mode 5: not supported at the present time.
•
Mode 6: For the setting “like configuration ' 2 ', only with additional RESULT-READY signal on exit ' OUT3” the output is set after the evaluation time up until the expiry of a settable time. In the case of a negative reading result the output remains at low. The GOOD pulse length can be set between 5 and 100 ms. In addition the output ' OUT3 ' is set on High. This means that starting from this time a good signal can be measured. Thus 2 identical signals come at the same time during a positive reading.
•
Mode 7: For the setting “like configuration ’6’, but good signal and the next trigger can be overlapping” if the output is set after the evaluation time up until the expiry of a settable time. In the case of a negative reading result the output remains at low. The GOOD pulse length can be set between 5 and 100 ms. In addition the output ' OUT3 ' is set on High. This means that starting from this time a good signal can be measured. Thus 2 identical signals come at the same time during a positive reading. In addition, it is possible that the good signal and the next trigger are overlapping, without any problems.
•
Mode 8: In this mode there will be a delayed emission of a GOOD impulse at a precisely defined time after the trigger. The mode has been programmed for applications in which a good signal confirms the position and content of a code at a precise time. The delay interval and the pulse length are adjustable. A second trigger before the possible output will be ignored.
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The following diagram clearly shows the different signal samples. Signal overview of the trigger and good signal. Trigger signal from the machine: 24V 0V
Result (Mode 0): 24V 0V
Evaluation time
Good reading
Evaluation time
Evaluation time
"Good pulse after evaluation“ Error
Good reading
Result (Mode 1): Evaluation time 24V
"Latch-mode" 0V
Good reading
Error
Good reading
Quit
Result (Mode 2): 24V
Length can be set between 5100ms Evaluation time
Evaluation time
0V Good reading
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Error
Evaluation time
"Good pulse with def. length after evaluation.“
Good reading
Trigger signal from the machine: 24V 0V
Result (Mode 3):
24V
Evaluation time
Length can be set between 5100ms
Evaluation time
Evaluation time
"Good pulse with def. length after neg. edge, one cycle later.“
0V Good reading
Good reading
Error
Good reading
Result (Mode 4): Evaluation time 24V
Evaluation time
Evaluation time
“Good pulse one cycle later with pos. trigger edge up until the next pos. edge”
0V Good reading
Good reading
Error
Good reading
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Trigger signal from the machine:
24V 0V
Result (Modes 6&7): OUT0 – Good Signal
Evaluation time
"Good pulse with def. length and DataValid on OUT3."
Evaluation time
24V Error 0V OUT3 – Data Valid
Good Reading
Length can be set between 5-100ms
24V 0V
Result: (Mode 8) OUT0 – Good Signal
Delay time 20-2000ms
Delay time
24V 0V
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Good Reading
Error
False code The universal camera output OUT2 can as an option also be used for a display of a false code. This additional signal is High (24V) if the code agrees with the reference, or is not legible. If the code is legible, however, and has false contents, the signal is Low (0V). OUT2 can in this mode be used together with OUT0 in order to discover sub-mixes. When using this function, all DataMatrix, Barcodes and OCR controls are checked. Furthermore, OUT2 can no longer be used as a good output. A “false code” error (OUT2->Low) occurs in the following cases: DM
Code
OCR
If at least one DM code has a legible contents which deviates from the reference code.
If at least one barcode code has a legible contents which deviates from the reference code.
If at least one OCR window reads a string in which at least one character does not match the reference character, but a different character from the character set or if the character set does not match.
OR
OR
DataValid- / “Data ready” signal See good output configuration, modes 6 & 7. Control output OUT3 Using the option “Control output OUT3,” one can choose depending upon format whether the output OUT3 is switched with 0V or 24V. At this output, for example, an additional illumination can be switched on. So that the choice of a specific format in which this output is set to 24V, the external illumination is switched on.
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Time Out With the “Time out” time value set, the maximum evaluation time of the camera is limited. The value is given in milliseconds [ms]. A typical product with a data matrix window and three OCV windows requires less than 100 ms on a standard camera. These times could vary through bad print quality, grading, switched on diagnosis functions, or high image quality image transfer setting. Clock overflow The camera offers a function for detecting when the machine is running too fast. If the camera is triggered within the evaluation time, then the error message “Machine over clocked” is shown on the display. This can be deleted by pressing any key. The speed of the machine must be reduced. The function can be switched on and off.
Caution:
If for example the trigger signal bounces it is recommended switching off the over clocking protection. Printer communication (option) This function configures a client that could transfer reference values from a printer into an OCV window, barcode window or into a data matrix window. An additional program (ocrclt.000) is required to use this function. On/Off measurement line automatic When this menu item is active, the measuring lines for position guiding are automatically set when setting a new product. After selecting “automatic” a grey offset (basic setting 15%) can be set for the measuring lines. Finally you are requested to enter the maximum permissible position tolerance in the reading direction (basic setting 50). Image transfer configuration Here you can modify the quality of the transferred images or turn off image transfer. Depending on the value used for image quality, the transfer is activated or deactivated; the screen will be updated accordingly in the production mode. Image transfer is turned on (activated) and set to a quality of '2' by default, which means that with a resolution of 640 x 480, only every other pixel in X and only every other pixel in Y will be transferred. The evaluation time could increase to 30 ms if every pixel were transferred.
Caution:
If image transfer is deactivated, in the production mode nothing in the image will be updated, including counters. Internally, however, the recorded image will be analyzed and all signals will be emitted as usual. It is possible to call up the main menu at any time with “MENU”. In this case image transfer is always activated! Trigger edge With this option there can be adjusted whether the camera takes a picture after the rising trigger shoulder from 0V to 24V, or after the falling shoulder from 24V on 0V. The rising shoulder is set by default. Save counters If this option is active and a High signal is applying at input IN3, the counters (ALL and GOOD) are stored in the file “_counter.110 “in the Flash. This option prevents that with a sudden power loss the counters of the camera are lost. The supply voltage of the camera has to be buffered longer than 100 ms. In the frame buffer the message appears “!Power fail! Counters are saved!”.
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Image geometry The geometry of the recorded image can be adjusted to the presentation and processing. A typical application is the correction of an upside-down image. Possible options are: ‚turn image by 180 degree’, ‚mirror image horizontally’, ‚mirror image vertically’ and ‚normal image’. Image Shading If the camera image has an unevenly or inhomogeneous brightness distribution, we talk about image shading. This shading can for example be caused by the illumination or the camera optics. For these cases the camera has a correction function to compensate the shading. For using this shading correction the camera has to be calibrated once. Calibration The camera switches to the Live Image view. You need to place a plane, white surface into the cameras field of view in the same distance as the product, which the camera will inspect. It will be used as a reference for defining the appearance of the shading. Before calibration:
Calibrating (full correction range):
The range of the correction is adjustable while calibrating. For a low range value, only pixels with a strong deviation will be corrected, for a high value, also pixels with a small deviation will be corrected. A higher range value will cause a more homogenous image but also increases the calculation time. Correction On/Off The correction data is global but the correction can be activated or deactivated for each product. In this menu the shading correction can be turned on or off for the current product. This menu will show a live image preview, to see the effect of the correction and also the time consumption of the processing. View Shading Template This menu displays the correction template/image for diagnosis purposes.
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Long names Due to the restrictions of the data system the names of a product are limited to 8 characters. If this function is activated 16 long product names with up to 16 characters are possible. These long names are stored in the product files itself. This results in a loss of transparency. Copying a product from one camera to another or making partial restores of a camera will lead to inconsistencies in the management of product names. Configuring illumination It is possible to switch between internal, external and internal, and external lighting here. The setting is stored under the current format name. This function is only available for certain types of cameras! Language The language of the user interface can be changed here. The corresponding language files must be installed on the camera. In some cases the currently existing language files are only available upon request. German =ocr_de.222, Italian = ocr_it.222, Hungarian = ocr_hu.222, Polish = ocr_pl.222 English = ocr_en.222,
English = ocr_en.222, Spanish = ocr_es.222, Dutch = ocr_nl.222, Portuguese = ocr_pt.222, Swedish = ocr_sv.222,
French = ocr_fr.222, Danish = ocr_da.222, Norwegian = ocr_no.222 Slovenian = ocr_sl.222, Turkish = ocr_tr.222,
Preferred font color Here you can pre-select the preferred font color for OCR, OCV, or Teach-In windows and for teaching in fonts. Depending on the setting, “dark font on light background” or “light font on dark background” will be the default for creating a window or teaching in a character set. The camera analyzes the set reading fields and queries again if there is an obvious deviation from the preset text color. If “both” is specified as the preferred font color, the camera will then query the desired font color for each new font window. Reader Mode Standard: Camera is waiting for the trigger signal on input 0. With rising or falling edge (adjustable) a picture will be taken. After that the camera starts with evaluating the image. When finished, the good signal will be set. Auto-Read: When gate signal on input 1 is high, camera grabs a picture and evaluate the image. This will be repeated till end of gate signal or positive reading result. Aggregation Please see Chapter “Code Aggregation”. Aggregation (partial rejection) Please see Chapter “Code Aggregation”.
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10.3
User and Password Management
The default password for all the menu levels is “000”. This can be freely configured in the “User management” or under “Changing the password”. The password “000” allows “Administrator rights”. By default, the password is requested on the menu levels: • “Change product”, • “Product Management”, • "Character set" • “Service”, • “Change password” requested.
Note:
The pilot software will handle user management if the camera is being used with Version 4 or more recent versions thereof. User management Several users with user names, passwords and different rights can be set up. These settings are made in the “User management menu”. In the basic setting, the user is “admin” with password “000”. The selection of the menu levels for which a password is requested, can be set in the user “admin”. By pressing the key “admin” twice the settings “Change password”, “Define password”, “Minimum password length” and “Logout time”. Under “define password”, the required password levels can be defined. A password is required for the levels marked red. The levels marked blue can be reached without password. The following password levels/rights can be assigned: • “A Product new, delete or rename”, • “B Delete or rename character set”, • “C Start or end batch protocol”, • “D Reference code”, • “E Change product”, • “F Product management” or ‘Edit product’, • “G Change character set”, • “H Service”, • “I Switch on/off camera”, • “J Temporary characters”, If a new user is created, a blank window will be opened via clicking twice, here the desired user name and password have to be entered. Subsequently the requested right ort he requested rights are assigned to the user. If clicking twice on the entry of an existing user, the menu “User management” appears with the items “Change user profile”, “Delete user” and “Switch password invalid” When a user registers for the first time he has to change his password. The administrator can block or delete users. Changing the password Here for example, the password “000” can be changed if “Administrator” only (default) is created as user. If several users are created, all the created users can change their password. When changing the password, first the user name, then the new password must be entered twice.
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11 Password, Zoom 11.1
Change Password
In the “Change password” menu item, the user can change his/her actual password on the camera.
11.2
Zoom In (Zoom Out)
In the “Zoom in” menu item, the camera display mode can be changed to Zoom in order to highlight details for teaching in fonts or creating products. After the Zoom function is selected, the software expects the user to select the center of the zone that he/she wishes to have enlarged. Only a magnification by a factor of two is possible at the present time. Please only use the view in the Zoom mode for teaching in the product or for error searches. With continuous operation in the zoom mode, there is a risk of mix-ups with the actual image size occurring.
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12 Parameters of OCV / TIN Windows With an OCV Control window, plain texts can be checked in the TIN (Teach In), OCV (Optical Character Verification), and OCR (Optical Character Recognition) modes. Texts can be read horizontally or vertically, and also forwards or backwards; this is governed by the orientation of the control window and also the setting of the reading direction.
Parameters of TIN, OCV, OCR Windows
X
Control
Window name: OCV0
Alias GTIN
Font tz1
Search area
165/205
57/46
>>Next>>
Searching area
Threshold: 120
Color: Black
Direction: L->R
Lines
Tilting: 0
Noise pixel: 5
Distance: 0
Character
Min. Size: 5
Max. Size: 100
Check Quantity: Off
Special characters
Gap: -2
Wildcard: 5
Control “ . „ a. „ – „ 0/3
Filter
Ink-Jet: 0
Reflection: 0
Brightness corr. OFF
Filter
Delete border pix: 0
Noise reduction: OFF
----
Reference code
Compare: ---
Dynamic OFF
from Data Matrix: ---
Control Window name The name of the window currently being processed is shown here. When you select a window, a menu will open in which you can select the TIN (Teach In), OCV (Optical Character Verification), and OCR (Optical Character Recognition) modes for that window.
Note:
Before changing to production, a teach-in window will analyze the text portions and create a character set with the name #auto for them. The sample is not allocated alphabetically; hence these windows cannot be used with version 4 of the pilot software, which sends reference values to the camera. Alias It is possible to give a window an additional name. This identifier is used by older versions of the pilot software to assign reference values. The “reference code from data matrix” option also uses these additional identifiers. Font Here you can makes subsequent changes to the character set for a control window.
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Search area: You can change the position and size of the control window by selecting a parameter. The values shown here define the coordinates of the control window in which the OCR process is being performed. >>Next>> You can switch between the different windows by clicking this field. Only windows created beforehand will be displayed. Search area: Threshold The grey value threshold for the OCR is shown in this window. You can change the setting here. Details can be found in the “Instructions for Setting the Grey Value Threshold” section Colour You can use this function to adjust the color of the print relative to the background: Black stands for "dark font on light background", White stands for "light font on dark background". The default for creating an OCV window is black, but it will change if there are only white windows or if there is a combination of black and white windows. Direction Here you can adjust the reading direction relative to the screen layout. Possible settings: L->R: Left to right R->L: Right to left U->D: Up to down D->U: Down to Up Lines: Tilting The text line being checked may be tilted horizontally or vertically by the number of degrees specified here
Text tilted vertically by +12 degrees Tilting Text tilted horizontally by -10 degrees
A maximum tilting up to +/-44 degrees is possible. The basic setting is 0 degrees. The greater the permissible tilting, the longer the analysis time may last. This setting is valid for all TIN, OCV, or OCR windows
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Noise pixels The maximum number of pixels that can be contained in an empty line is defined here.
Example: Parts of the barcode are located above (and within) the text line. The black pixels of the barcode will interfere with the empty line needed for searching. The “Max. Empty Line Pixels” has been set to 30 in the example (the basic setting is 5).
Note:
For some parameters an input in pixels is expected. A size expressed in millimeters can be converted to pixels if the camera resolution and the image size are known. For the standard camera, the resolution in X is 640 pixels and the image size in X is 40 mm. A character with a width of 2.5 mm would thus have a width of 2.5/40*640 = 40 pixels. This setting is valid for all TIN, OCV, or OCR windows Distance: The minimum number of pixel lines for the empty space between two lines is entered here.
Line spacing =1
Line spacing = 5
If characters consisting of several non-connected parts (e. g., Ü, Ä, À, ´B....) are being checked, the line spacing must be set to a value greater than the largest gap within the character so that all parts will be combined into one character. This setting is valid for all TIN, OCV, or OCR windows
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Character: Min. Size: The minimum character size masks dots. Any dots < the size of the set pixel number will be masked. It is thus possible to eliminate disruptive dots in the background. This setting is valid for all TIN, OCV, or OCR windows Max. Size: Here you can specify the maximum character width for character recognition. The value corresponds to the pixel width of a character. For example, if a character is wider than this value, a green frame will be drawn around that character in “Teach-in reference code” (in Batch change).
Note: This value plays an important role in character recognition in the OCR, Teach-in, or character set teach-in modes. The setting is valid for all TIN, OCV, or OCR windows.
Check quantity If the character number check is activated, an error message will be generated if additional characters are detected in the reading window in front of or after the reference characters. This setting is valid for all TIN, OCV, or OCR windows Special characters Gap Here you can specify the size (in pixels) of the gap between two characters. If there is no gap, please enter a negative value for the gap size. In this case, the next character will still be searched for within the previous character. This setting is valid for all TIN, OCV, or OCR windows Wildcard
for example the quality is not adequate for an OCV/OCR control, characters can simply be checked for presence. To do so, the operator enters a star (*) in the reference code for the character in question.
ABCDEFG1234 This setting is valid for all TIN, OCV, or OCR windows
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Control “ . “ and “ – “ Distinguishing “.” (periods) from “–“ (hyphens) If you want the camera to do a very precise period and hyphen check, in this menu you can set two parameters: the limit value and the tolerance. The first pixel value indicates a limit value for the black surface, e.g., 150 means that each character smaller than 150 pixels will be evaluated as a period or a hyphen. The length of the period or hyphen is then measured with the accuracy specified in the “Tolerance” setting. For example, the “Tolerance” can be +/-3 pixels. The size of the tolerance value can be used to distinguish between periods and hyphens.
8A5W The length of characters with an area of, e.g. more than 150 pixels = “threshold value”, is not measured.
Characters with less than, e.g. 150 pixels are verified in their length using the “tolerance” value.
This setting is valid for all TIN, OCV, or OCR windows Filter: Inkjet The inkjet filter must be used for inkjet printing or for similar printing results. The filter function enlarges individual dots so that undesired white spaces between the dots are filled in. Setting the value of the filter size to zero (Filter size = 0) will turn off the filter. A different type of filter will be used if the filter is set to a value > 16. This filter closes gaps without changing the size of the dots overall. Inkjet Filter 0 1 2 3 - 15 16 17 18 19
Meaning Off Pixels increase by 1 pixel in X and Y Pixels increase by 2 pixel in X and Y Pixels increase by 3 – 15 pixels in X and Y Closes gaps of 5 pixels in X and Y Closes gaps of 7 pixels in X and Y Closes gaps of 12 pixels in X and 5 pixels in Y Closes gaps of 14 pixels in X and 5 pixels in Y
Note: Character sets should always be taught in with each inkjet filter. In other words, if the filter is changed, then a character set needs to be taught in again. The inkjet filter is also used for adjusting the threshold values of a control window, thus making it easy to check the effect This filter is used for all TIN, OCV, or OCR windows
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Reflection You can adjust the reflection filter to reduce disruptive reflections (such as those on aluminum blisters). The value is specified as a %. Excessively bright areas in the window will thus be darkened. This filter is used for all TIN, OCV, or OCR windows Brightness correction With the "Brightness correction" filter you can make the background more evenly colored. The filter should be turned on if the brightness of the background is not uniform. Areas that are too dark will be made brighter. This setting is valid for all TIN, OCV, or OCR windows Filter: Delete border pix This filter deletes black pixels projecting from the outside into the edge area of an OCV field; the parameter defines how large the interruptions may be. This function is especially useful for optical character fields with disruptions in the edge areas. Such disruptions interfere with tilting recognition. Noise reduction This filter is suppressing noisy background when switched on. Reference code: Compare The camera normally always performs a comparison between target and reference values in OCR windows. If the camera only reads window content, however, the result of the reading can be obtained from the statistics report in the VDMAXML log. In this case the target/reference comparison for OCR windows can be turned off. This setting is valid for all OCR windows
Caution:
If this function is active, there will be no comparison between the read characters and the reference code. The camera works for character reading and display. Dynamic The “Dynamic reference code” setting should only be turned on when checking sequential number series. A listing or counting of the code is thus possible. The setting can be turned ON or OFF individually for each OCV window, OCV0-OCV3, or code window. It is thus possible to check dynamic and static print simultaneously. The dynamic counter is not increased until after the first GOOD reading.
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From Data Matrix:
This function is designed for stand-alone systems in which pilot software does not specify dynamic reference values. A data matrix code reading is used as a source for OCV reference codes. The content in the data matrix code must be in GS1 format. The content is allocated via the identifiers of the windows. Identifier DMx : DMX OCVx : GTIN OCVx : LOT OCVx EXP OCVx : PROD OCVx : SER
Function DM window as source of data in GS1 format OCV window as target, GTIN data OCV window as target, BATCH (LOT) data OCV window as target, expiration date OCV window as target, manufacturer date OCV window as target, serial number
A wizard will help with the selection once the function has been activated:
Example of an application:
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13 Parameter PATTERN CHECK Window Within the search region, a previously learned pattern will be searched. The position with the lowest deviation between located and learned pattern will be marked. This tool can be used also for positioning of other control windows.
Parameter Pattern Check
X
Control
PC0
Pattern
Show
Change
53x46
Search Region
Change
50/50
400x199
Congruency
0%
---
---
Group
0
---
---
Control Window name The name of the window currently being processed is shown here. Show only! > Select next or previous control window. Pattern Show Displays the learned pattern; Change Learn the reference pattern. Window can be moved only inside of the search region. Maximum size of reference pattern is 200 Pixel x 200 Pixel. Search region Change Learn the search region. Moving of search window limited by pattern window. Congruency Is a tolerance which indicates how well the learned pattern must match the found pattern. 0% means: Search for the best match, matching value is minor. 100% means: Only if learned pattern and found pattern are absolutely identical, the result is good; Group This is the number of the group which this control window belongs to. Show only! For modifying this setting see chapter “System Parameters/ I/O configuration”.
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14 Parameter Code Window Barcodes can be checked with one window for code control (barcodes, pharmacodes, batch codes). Barcodes can be read in horizontal or vertical directions, or omnidirectionally. This is controlled with the value for code size as well as the geometry of the control window.
X
Parameters of BARCODE Windows Window Name
CODE0
----
>>NEXT>>
Search Area
250/190/100/75
----
Omnidirectional:On
Code Type
Pharmacode
QZone:0
---
Pharmacode
binary
L->R
---
Threshold / Color
#AUTO#
#AUTO#
---
Size
#AUTO#
Attempts:1
---
Finder
0
0/0
---
Filter
Delete:0
Connect:4
Noise reduction: Off
Contrast
0
Attempts:1
---
Learn
All Barcodes
‘11’
----
Quality check
OFF
11111111
Code Syntax: CTRLC ON
Scans Min. / Steps
1
2
---
Compare / Dyn.Code
ON
OFF
---
Search area PX, PY, DX, DY By choosing this parameter, the control window's size and position can be changed. The values displayed here describe the coordinates of the control window in which the barcode will be searched for. Omnidirectional ON/OFF If “Omnidirectional” is switched on, the camera is able to read a barcode on any rotated position. Some additional parameters as Threshold, Color and Size will appear in this mode. Please switch on only when necessary, because Omnidirectional reading isn’t possible in some cases. QZone, checking the quiet zone A test can be allowed for the minimum width of the quiet zone on the left and right border of the code window. If the quiet zone is too small, the code will be indicated as invalid; the standards for most codes indicate a quiet zone of at least 10x the width of the smallest module; if the code is tested for adherence to these values, a '10' is to be entered. If a '0' is entered as a value, no test is undertaken. For quality control of a printed barcode, this function is recommended to be used together with the function “minimum number of positive scans,” and to set a minimum number of code height/4. Scans with false quiet zones are marked in the reading window; red lines indicate a disrupted quiet zone, blue lines an error-free range.
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Checking the quiet zones is only possible at this time with static codes, for omnidirectional code reading, the QZone displays a value which is added to the length of the codes, and makes it possible to have a quiet zone for the reliable reading of codes. The default value is 10, and means that the code found has been lengthened by 10 pixels. Code Type The type of barcode is set under code type. This can also be later changed for a code window. The currently legible code types are found at “general” in Appendix “smart camera code types”. The code type can be analyzed by specifying the reference codes, and is then entered into the product. Code Type dependent settings: Pharmacode For pharma codes, the decoding of the reference codes can have additional decimals or binary settings. Binary (Pharmacode): 1=thin bar, 2=thick bar; Trinary (2-track -Pharmacode): 0=bar below, 1=bar above, 2=bar above and below; Decimal: Decimal value; PDF417 A PDF417 Code has some special properties as the Number of Rows and Lines and the Level for Error Correction (ECC). Those can be manually defined (but they can also be automatically detected) Furthermore the camera has an ECC Mode option which can be turned off to prevent the camera from using the Error Correction Data inside the code. If the Decoding is turned off completely, the camera will only count the readable Code words and return this as the number of positive scans. L->R / R-> L ; U->D / D->U - Direction If a Pharmacode, a two-track Pharmacode or a PDF417 is chosen as a code type, the reading direction can be set here. Threshold [for omnidirectional reading] The gray value threshold is shown in this window for omnidirectional reading to find the barcode. The value can be taught. If the value is at #AUTO#, then the camera tries to automatically determine this value, and then enters the value found into the product. Colour [for omnidirect. reading] Here a setting is made which searches for a code which is black on white or white on black. Size [for omnidirect. reading] The size and print color of the code can be set in this window, with omnidirectional code reading, it constructs an important value to find the code within the control window. If the value is at #AUTO#, then the camera tries to automatically determine this value, and then enters the value found into the product.
Note:
With omnidirectional reading of pharmacodes, the code size must necessarily be taught.
Attempts (1,3,5,7) [for omnidirectional reading] The number of tries to search for the barcode with omnidirectional code reading can be set here; if the code is not found in the first attempt, then the code search will be repeated with changed threshold values and filter settings. Finder [for omnidirectional Reading and pharma code] Additional information must be configured to find the pharmacode with omnidirectional code reading, because pharma codes possess identifiers for the start or end, such additional information is needed in order to determine the reading direction of the pharmacode.
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In addition, the size of the codes must be learned:
Then the range can be established in which the additional information is searched for:
The size of the search area and the number values found are entered as parameters in the product. Filter: Delete points, Connect points [for omnidirectional. reading] These parameters are important to find the barcodes with omnidirectional code reading, with codes with large gaps, a large filter value is needed with “connect points,” small codes with small distances to disrupting objects need a smaller filter value. The behavior of the filters can be analyzed with the diagnostic function. [Menu]->|Service|->|Diagnostic|->|Data Matrix: Display binary image|check.
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Filter: Noise Reduction This filter is suppressing noisy background when switched on.
Improves the image quality in colored background.
Can be used for smoothing of holes in bars. Should not be used, if structures are extremely fine. Contrast The contrast value is related to the contrast between the code and the background. A small value is set for low (“poor”) contrast, a larger value accordingly for a high contrast. The value range is from 1 to 255. Undesired contrast in the background can be grayed out, or the sensitivity increased with the contrast value. The contrast can also be automatically taught if the respective option is chosen to set or change the code window. Contrast: Attempts (1,3,5,7) Camera is trying to read the code with up to 7 different contrast settings. This can be useful, when illumination or contrast conditions are inconstant during production. Learn: Code 39, Int2/5, Code 128…… These are the predefined code types, which will be used for automatic code learning. Learn: ‘11’ Here one can choose whether contrast and reference codes are automatically taught, or should be set manually. Manual [X] Reference code [_] Reference code [X] Reference code [_] Reference code [X] Reference code [_] Reference code [X] Reference code
[_] Contrast [X] Contrast [X] Contrast [_] Contrast [_] Contrast [X] Contrast [X] Contrast
The setting determines which parameters can be learned automatically with the “new reference code” function.
58
Note:
Because reference codes are for the most part sent from the pilot, the camera in normal operation can be easily used manually with Teach-in set to manual. Print quality (ISO15416) Here, the Quality Control of the Barcode reading can be activated and configured. The quality analysis corresponds to ISO15416. Print quality (ISO15416)
C Off / A / B / C / D / F
11111111 Quality Parameters
Note:
The correct code analysis depends on an accurate adjustment of the camera; the aperture of the camera must be configured accurately by means of calibration cards. Any later changes such as illumination, distance, focal length or contamination change the reliability of the quality analysis. Quality check / Grading
The grading classes ABCDF correspond to the proposals of the ISO15416. Class ‚F’ is classified as no longer readable. At this point the minimum quality class that has to be reached by a barcode, to be evaluated as a “Good Product”, can be set. Quality Parameters
Configuration of possible parameters for the classification of a code is made here. All seven parameters must be set for an analysis according to ISO15416. Code Syntax CTRLC ON (default): Camera will read and transfer all control character. CTRLC OFF: When “CTRLC OFF” is set, a control character like value 102 (“]C1”) will be hidden in the current code. GS1: If “GS1” is set, then a code must start with a decimal value 102, which during decoding will be converted to the character sequence “]C1”. This setting helps distinguish a GS1-compliant code from a code that is merely similarly decoded.
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Scans, minimum numbers of positive scans This inputs how many scans must be positive so that the code can be assessed as GOOD. Image from production run: Barcode with 27 positive scans. Minimum number is 6.
With CC-A-Code, the minimum number of positive scans is given for how many rows of stacked code must be present at a minimum. Image from production run: CC-A-Code with two columns and 6 rows. The minimum number of positive scans is six. Scan Steps (distance of the individual readings) Code reading by the camera is carried out similar to a laser scanner. Individual rows of the code are read. The reading frequency of the codes can be set using the parameter “scan distance.” The adjustable step width is 1-10 rows. As a default here, '2' is set; for very small codes, one can set '1,' for large codes, greater values can be set in order to save calculating time. Reference - Actual Comparison The way the reference/actual comparison is performed is defined here. The possibilities are as follows: 0 1 2
= Good signal for a positive reference/actual comparison = Machine stops for an incorrect code 1) = NO positive reference/actual comparison
The reference/actual comparison is adjusted for each defined code window. 1)
If the Function 1 is activated and if the code is incorrect, the active signal of the camera will be reset and the message “Wrong Code” will be displayed.
Dynamic Reference Code In order to check a continuous barcode, the reference code of the camera must be changed too. With the “Dynamic reference code” setting, the camera can adjust the reference code. For doing so, various settings can be input in the camera menu item “New Reference Code”:
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Correction =
Pre-specification of the next reference characters (reference codes). The first code for which the check is to start must be entered.
New Format =
Specify a new counting system: Input unchanging characters, next counter reading, minimum counter reading, maximum counter reading, counting direction (up, down) for counters and interval for counters.
15 Barcode Quality Control Referring to ISO/IEC 15416 The bar coding technology is based on the recognition of samples, which are encoded in bars and gaps with different widths. The translation of numbers and characters into bars and gaps is defined for every code type in its on guideline. If a barcode shall fulfill its purpose, it has to be decodable reliably at the place, where it will be used. The standard ISO/IEC 156416 is a basis for the classification of the quality of 1D codes, related to specific demands on the reading process. The print quality control with a PCE Smart Camera can only be an approximation to the standard, because the control conditions of the standard are adjusted for an Offline-Inspection, the PCE SMC instead is an InlineInspection system. Various adverse conditions for inline inspection (e.g., position tolerances, aberrant lighting, limited analysis time, etc.) may result in a difference of one grading class between inline inspection and offline inspection. The viewing direction of the camera as well as any additional lighting can also affect the grading results!
15.1
Classification of a 1D Barcode
The classification of the quality of a barcode divides into the classes A (best) to F (worst).
Quality
Good
Bad
Numeric
4
3
2
1
0
Letter
A
B
C
D
F
Note: Class E will not be used for classification!
The class of a 1D barcode is determined from the classes of 10 different lines inside the code. This means, that every one of these lines will be evaluated. If a line has been decoded successfully, afterwards its quality will be checked by the usage of a number of parameters. The quality class of the line arises from the class of the worst rated parameter. If, for example, 5 parameters are rated A, but 1 is only rated C, the result class of this line will be C. The total class of the barcode is the average value over the 10 result classes from the 10 analyzed lines.
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Parameters of Classification In the following the parameters, which have to be checked in order to fulfill ISO/IEC 15416, are described. Image 2 shows a grey value profile or reflection profile of one line of the code, shown in image 1. In this profile some of the parameters, which have to be analyzed, are shown.
Image 1: Original barcode image
250
Quiet zone min. Adjacencycontrast
225
Quiet zone
max. Grey Defect
Gaps
200 175 150 125 100
Global Threshold
75 50 25 min. Grey
0
Bars
Image 2: Grey value profile for one line through the barcode
Decode [DEC] The classification of a Barcode Scanline can only be done, if the decoding was possible with the reference decoding algorithm. This means that the code data has to be readable and the checksum (if applicable) has to be correct. Also the Quiet Zone will be checked.
Note:
If decoding of the barcode is possible, but the quality analysis claims a bad Decode-parameter, this suggests a Quiet Zone which is too small. If Omnidirectional Reading is deactivated: Make sure that the Control Window is set big enough to contain the whole Code and its Quiet Zone. If Omnidirectional Reading is activated: Increase the parameter QZone in the CODE-Window parameter table step-by-step if required Make sure, there are no other graphics/texts on the product inside of the codes Quiet Zone.
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Symbol Contrast [SC] The Symbol Contrast indicates the maximum difference of reflection in the barcode. Through the whole Barcode including its Quiet Zone the minimum and maximum reflection values are searched. Adjacency Contrast [ECmin] The Adjacency Contrast or Edge Contrast is the reflection difference between 2 adjacent elements. Every bar or gap is an element. The minimum of these contrast values which are found in the barcode will set this parameter. This value is checked to make sure that a good contrast is not only available between the maximum and minimum brightness of the code, but also between every bar and gap Modulation [MOD] The Modulation is the ration from the Adjacency Contrast to the Symbol Contrast. An Adjacency Contrast near the Symbol Contrast means that the Contrast is constant and will result in a better Modulation value. Minimal Reflection [Rmin] The Minimal Reflection is the lowest reflection value in the whole barcode. According to ISO/IEC 15416, it may not be greater than the half of the maximum Reflection. This parameter shall make sure, that there is enough difference between the brightness of bars and gaps. Defects [Def] Defects are irregularities within spaces and bars. If there are interfering elements in the spaces or scratches in the bars, the code indicates defects at these places. Defects are identified in the whole barcode including its Quiet Zone. Decodability [V] The decodability of a barcode is an indicator of its printing accuracy in relation to the dimensions specified by its standard decoding algorithm. It is calculated on basis of different reference decoding algorithms depending on the code type. "Dimensions" refers to the widths of the elements and their relationship to one another. Inconsistent widths of bars and gaps in the barcode will result in a lower Decodability. This Parameter uses different calculations for 2-width-codes (Interleaved 2/5, Code39) and multi-width-codes (Code128, EAN13).
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15.2
Configuration of Quality Control
Calibration of the camera for barcode quality control reasons For barcode quality control reasons the camera must be calibrated in advance. An adequate calibration is essential for the correct evaluation of the quality. Please refer to the instructions in chapter 17.2 „Kalibrieren der Kamera zum Zweck der Datamatrix Qualitätskontrolle“. Maybe you will have to create a new temporary product with a data matrix control window, in order to perform the calibration. Usage of the Barcode Quality Control A Minimum-Quality-Class has to be chosen. If the printing of a barcode does not achieve this Minimum-QualityClass, it will be rated as a Bad-Product. For example, if the class B was chosen, the printing of a code has to receive class A or B, to be rated as a Good-Product. Furthermore, single parameters can be specifically excluded from the print quality analysis. The quality control can be activated in the parameter table for CODE windows (see chapter 12 “Parameter code window). It is recommended to use the omni-directional reading with the quality control if possible, to improve the code finding and the reliability of the quality analysis.
Note:
The print quality control is currently only available for barcodes of the type Code128.
In production, the result of the quality analysis of the present barcode will be shown inside the CODE-Window.
Structure of the result view: Grade: C (2.2) (MOD) Grade: Grading-Class (numerical Class) (worst average Parameter) Additional display of parameters: The parameter view shows the average quality of all line readings for each parameter. See chapter 10 „Service-Menü“ (p. 34). Note: By activating the view, the cameras calculation time possibly increases.
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16 Pixel Window Parameters By using a pixel window, sizes of the black and white areas will be measured. In this way, the presence of a label or printing can be verified very easily, for example: For one control window two limit values always have to be set, the upper and the lower tolerance value. If the camera is in the production run, and the actual measuring value lies within the two tolerances, the object is then assessed as “good”. Below and above the tolerance values the object is “bad”. If the camera works with large tolerances, the system controls the presence. If the plus and minus tolerance is kept small the camera is able to carry out measurements. The operator can choose whether the tolerance values are to relate to a black or white area. In addition, the operator can decide whether the measuring values and tolerances are to be absolute or relative. The inspection principle “Area measurement” is the same for both measurements. During the pixel inspection, the first window is given the name “Pix0”. This is displayed in the top left corner of the window. The other pixel windows are given the names “Pix1”, “Pix2”, etc. Up to twelve different pixel windows can be set and thus up to twelve different features can be verified on an object. When the first window has been set, press the Enter button to save the settings. “Presence control” (absolute measurement) For the “absolute measurement”, the black area e.g. is displayed as a measured pixel number. If the area to be inspected is enlarged, the number of pixels is then greater. If the size of the black area is reduced, the number of pixels measured is smaller. The plus tolerances and the minus tolerances are entered as a pixel number; the display for the actual value is shown in the production mode as a pixel number. The measurement of an area does not depend on the size of the control window. Examples:
Pixel number =1000 (reference value)
Pixel number =500
Pixel number =2000
“Print control” (relative measurement) For the “relative” setting, the size of an area (reference area) is taught in and set as 100%. The following measurements can be smaller than 100% if, e.g. the printed area is missing, or greater than 100% if, e.g. there is too much print. The input of the plus and minus tolerance and the display of the measuring values is given as a percentage value. Examples:
Measuring value =100% (reference value) Measuring value =50%
Measuring value =200%
Note:
The pixel windows are to be set as described in the section “Camera start-up” with OCV windows.
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Changing an existing product with pixel windows If for example, after a change in format, the window position is no longer correct or only the tolerances have to be changed, this can be changed quickly and easily in the parameter table. Using the main menu you can call up the sub-menu, “Change product” > “Parameters PIXEL window”. A table appears there with all the pixel inspection parameters. Here the size and position of each window can be changed, the grey threshold aligned or the tolerances modified. Parameter table Windows PX, PY, DX, DY The parameters Px, Py, Dx and Dy give the coordinates of the control window. The size and position of the window can thereby be documented and, if necessary, reproduced. If the black cursor is positioned on one of the values and the Enter key is pressed, the yellow control window appears in the following step for processing. The size and position can be changed using the line keys. Grey threshold The contrast value “Grey threshold” should be set for each window such that the object appears black and the background is shown in white without any black points. If the inspection is inverted, the background should be an even black and the object an even white. Object color Here it is possible to choose whether the tolerances are to relate to the white or black areas. Minimum, maximum tolerance For one control window two limit values always have to be set, the upper and the lower tolerance value. For the absolute measurement, the entry is given as a pixel number and for the relative measurement as a percentage value. (see absolute, relative measurement above). Mode The relative or absolute measurement can be selected as the mode. The absolute measurement is called “presence control” (mode0) and the relative measurement, “Print control”. • The absolute measurement supplies the pixel number. (Mode 0) • The relative measurement supplies a percentage value in respect to the teach-in object. (Mode 1) Contrast Here a filter can be activated for improving the contrast. This is beneficial for poorly contrasting images, or images that are illuminated unevenly. Pixels supplying contrast values that are smaller than the settable minimum value, are set to the background (background = black, if object color = “bright pixels” is activated; background = white, if object color = “dark pixels” is activated). The evaluation time is longer if the contrast filter is switched o. Send result Here, the output of the reading result via the interface RS232 can be switched on and off.
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17 Data Matrix Window Parameters In a DM window a Data matrix code (ECC200) or a EAN Data matrix is inspected. The code content is read by the camera and compared with the reference code. If they agree, the “good” signal is given. The quadratic code can be read in any position (omni directional), i.e. the code can be turned at any angle within 360°. Currently there is no omni directional reading at rectangular code possible, but only in the orientations of 0, 90, 180 and 270° with a tipping up to 30°. The camera can also send the read content of the code on the serial interface without a comparison. With “Main menu” > “Change product” > “Parameter Data matrix window” any necessary setting can be made by the operator. Further information about Data matrix Code sizes with preset content can be found in the appendix
"Size/Data Comparison Chart".
X
Parameter Data Matrix CODE Control
DM0
ON
Calibration
>>NEXT>>
Searching area
180
74
364
351
Code size/Module number
136x135 px²
14x14 mod²
---
---
MultiCode(Amount/Int./Tol.)
#1
100%
300%
---
Ori/Col
#AUTO#
Black
---
---
GW threshold
Search: 102
Code: 102
Attempts:1
---
Code Syntax/Code to RS232
CTRLC ON
OFF
---
---
Dot-Code
OFF
---
---
---
Max. Distortion/Grid
0°
Grid: 20%
---
---
Print quality
ON
C,40%
11111110
Minimum
Learn Code/Compare
4:’1111’
ON
---
---
Filter: Erase/Dilat
0
3
---
---
Dynamic Code
OFF
---
---
---
OCV Reference
OFF
---
---
---
Calibrate This function starts code reading of a Data Matrix Code in the presented search area. It will help you adjusting the camera for Data Matrix print quality inspection. Searching area The search area stipulates the position and size of the control window using four coordinates. Code size The code size provides the camera with information telling it how large the code is printed, or seen by the camera. This is given using two size coordinates. Module number The number of modules states the number of modules the code consists of, e.g. 14x14 modules. At present, the camera can inspect quadratic codes from 10x10 to 144x144 and rectangular codes with 8x18, 8x32, 12x26, 12x36, 16x36 and 16x48 modules. Using the “Auto” function, the camera can automatically determine the number of modules and read the code.
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MultiCode - Code Amount Sets the number of codes inside of the DM window. This way multiple Codes can be found and read in one single DM window. All codes will be evaluated separately. Only if the adjusted number of codes was found and every code was evaluated positively, the DM window will state a good reading. Please note that there is only one reference code per DM window so that all Codes inside must have the same content if the Comparison is set to ON. MultiCode - Search Intensity If the camera is finding other objects inside of the window (which have the appearance of the searched DM Code), it may not find the real DM Code Objects. In this case the Search Intensity can be increased. The system will then try to find and read additional objects, under which the DM Codes should be. A higher value will increase calculation time. MultiCode - Match Tolerance If the DM codes inside of the window have high deviations in their shape, this value may be increased to find them. If the camera instead is trying to decode other objects which are no DM Codes but have a slightly similar shape, this value may be reduced, to ignore those objects. A smaller value will reduce calculation time. (Use this when working with multiple Attempts.) Ori / Col The Orientation parameter (Ori) stands for the position of the L-finder in the code. Different positions or “Auto” can be preset for the camera. The Color parameter (Col) states whether the code has been printed in black or white, i.e. black on a white background or white on a black background. GW threshold The grey value or contrast threshold appears in the list with three parameters. Grey value 1 “Search” defines the contrast for finding the code and for distinguishing it from any other additional print and the background. Grey value 2 “Code” is used for code reading. By using the adjustment “Attempts” a multiple evaluation can be set. The quantity of trials can be chosen between 1, 3 and 7. The standard adjustment is 3. Code to RS232 (option) If this function is activated, the camera sends the code content via the RS232, for example, to a PC.
Code Syntax CTRLC ON (default): Camera will read and transfer all control character. CTRLC OFF: When “CTRLC OFF” is set, a control character like value 232 (“]d2”) will be hidden in the current code. GS1: If “GS1” is set, then a code must start with a decimal value 232, which during decoding will be converted to the character sequence “]d2”. This setting helps distinguish a GS1-compliant code from a code that is merely similarly decoded. PPN: If “PPN” is set, then a code must start with a decimal value 237, which during decoding will be converted to the character sequence “[)>06”. This setting helps distinguish a PPN compliant code from a code that is merely similarly decoded.
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Dot-Code Printing a data matrix code with an inkjet printer results in the creation of round or circular modules. An ideal printed module, however, should be square. The camera has various filter functions so that such codes can also be read accurately. In the software, the user can specify whether a dot (module) = a gap is printed. Or whether a module smaller or larger than a gap is printed. With this function, several dots per module are used for analysis. Max. Distortion / Grid In order for the code reading to be less sensitive to printing errors, a setting can be allowed that permits the code to be read with a trapeze-shaped deformation. The value given by the grid parameter determines the deviation of a module from the ideal place in the grid. Print quality Quality control of the Data matrix reading can be activated and configured. The quality analysis corresponds to ISO15415.
Print quality
ON/OFF
Grading L-Finder
Quality Parameters
Search for quality
ON
C,30%
11111110
Minimal
Grading
The grading classes ABCDF correspond to the proposals of the ISO15415, class ‚F’ is classified as no longer readable. L-Finder Damage
L-Finder Damage is an additional parameter that only evaluates the modules in "L". The percentage value refers to individual modules in the “L-finder” and sets the maximum number of pixels in a module that might be missing. Quality Parameters
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Configuration of possible parameters for the classification of a code is made here. The seven first parameters must be set for an analysis according to ISO15415.
Search for quality
Classification of the code quality depends on the internal settings during the reading. During the setting ‚Minimal’ the reading will be accepted with the first readable and valid quality. During the setting ‘Maximal’ the parameters will be varied until a result with the utmost quality is reached. For pure control reasons the timesaving function ‚Minimal’ is sufficient. For quality classifications (e.g. during configuration) the function ‚Maximal’ is recommended.
Note:
The correct code analysis depends on an accurate adjustment of the camera; the aperture of the camera must be configured accurately by means of calibration cards. Any later changes such as illumination, distance, focal length or contamination change the reliability of the quality analysis. Teach-in code The following parameters can be set manually by the operator or determined automatically by the camera: threshold value (grey), code size (print size), reference code and number of modules. The selection is made using a table. 0 1 2 3 4
[_] Threshold [X] Threshold [X] Threshold [X] Threshold [X] Threshold
[_] Size [X] Size [X] Size [X] Size [X] Size
[_] Reference code [_] Reference code [X] Reference code [_] Reference code [X] Reference code
[_] No. modules [_] No. modules [_] No. modules [X] No. modules [X] No. modules
Comparison As standard the camera offers the good signal of the machine control. It can then be shown whether the correct code or no code has been read. With the comparison setting, the camera can also indicate when an “incorrect” code has been read. For this purpose the “camera ready” signal (SR) is either set or not set.
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Filter: If for example there are disruptive ink splashes in the background of the code, the “Erase” filter function can be used. The “Dilat” filter function is helpful if the code is printed with large gaps. The standard value is “3”, but it can be lowered to 2 or 1 if interferences in the vicinity of the data matrix code are causing code recognition problems. For codes with small modules, large gaps, and defective finders, increasing the value may help. This can be checked with the “Diagnostics: Data Matrix Binary Image” function. Dynamic Code Here you can activate a counter for the reference code, which will count up or count down with each trigger. The counter can be configured as follows: - “dynamic reference code” ON /OFF - “start counting with first proper reading”: The counter only starts after the first proper reading. Example:
ABCDEF012009056 - left start digit of the counter (first digit is 0): 6 - number of counting digits: 9 - Increment and counting direction: -1
Dynamic Code
ON
ON
6\9\1
---
In this example the reference code after the next trigger would look as following:
ABCDEF012009055
Note:
In operation with the pilot software, the latter will usually specify the reference codes. Dynamic reference codes may not be used in this operating mode.
OCV Reference These parameters define a function which enables an adjustable portion of the read data matrix code to be used as the reference code of an OCV/OCR window. A wizard will ask for the necessary values one after the other and thus simplify input: -
First it will ask which the OCV/OCR window to use as the target for the operation. Then it will ask for the start position in the Data Matrix reference code (There is a '0' position) Then it will input the number of characters to transfer Lastly, it will ask for the position in the target. (There is a '0' position and the target must have at least enough reference characters to accommodate the beginning of the transferred characters.
Example: The text “Total---” was input as the reference code for OCV0. The setting in the parameter table looks like this:
OCV Reference
OCV0
6\7\5
---
---
A calibration card with the text “Pharmacontrol Electronic GmbH” appears in front of the camera. Reading in the production mode results in the following reference code in the OCV0 window: „Total control“
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18 Data Matrix Quality Control 18.1
Data Matrix Quality Control in Keeping with ISO/IEC 15415
To determine the code quality, 8 parameters are measured and the measurement results are assigned to classes ranging from A to F.
Good
Quality
Bad
Numeric
4
3
2
1
0
Letter
A
B
C
D
F
The 8 parameters are: 1. Decode Code is legible or code is illegible. Result is A or F. 2. Symbol Contrast Difference between light and dark modules examined over the entire code. 3. Modulation Difference between light and dark modules relative to the individual code words. 4. Fixed Pattern Damage Damage in the search sample, frequency sample, and in the quiet zone. 5. Axial Nonuniformity Differences in the length of the X-axis relative to the Y-axis. 6. Grid Nonuniformity The greatest deviation of the actual position of the modules relative to the ideal position. 7. Unused error correction Number of blocks not used for error correction
The worst parameter determines the quality rating of the code.
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dy dx
8. ’L’-Finder Damage This parameter is not part of the ISO norm. It was established for detection of typical Ink Jet faults.
The value gives the percentage of pixels that may be missing in an individual Module on the L-Finder.
Note:
The ISO/IEC 15415 standard covers offline inspection. At the present time there is no corresponding standard that covers inline inspection. Various adverse conditions for inline inspection (e.g., position tolerances, aberrant lighting, limited analysis time, etc.) may result in a difference of one grading class between inline inspection and offline inspection. Should a code rated as “D” by the offline verifier be rated as “poor” inline, the grading threshold must therefore be set to “B” in the Smart Camera menu (also see the “ Data Matrix Inspection Type” chapter). Laser labeling by removing color: Because the measured contrast is strongly dependent on the interplay of the varnish used with the lighting employed, it is possible that uniform results may not be achieved with different verifiers. The viewing direction of the camera as well as any additional lighting can also affect the grading results!
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18.2
Camera Calibration for Data Matrix Quality Control Reasons
For data matrix quality control reasons the camera must be adjusted strictly according to the instructions by means of a calibration card. A suitable calibration card can be ordered from PCE. Adequate calibration is essential for the correct evaluation of the quality. It is recommended that calibration should be checked every 3 months. Furthermore, if components (camera or illumination) are replaced or if the reading distance of the camera is changed, recalibration will be essential. In case the amount of DM codes evaluated as faulty during the production exceeds extensively, the calibration should be checked.
Note: For all formats, it is important to use the same shutter value! For black ink-jet-print on white cartons, the following settings are recommended. Camera type - Standard; - High-Speed; - High Res; - High Res/High Speed; -Ultra-high Res/High Speed;
Shutter [microseconds] 150 300
Each calibration card is gauged at PCE. The ML (mean light) value is indicated on the card. Steps: 1.) Please select [menu] ->
[service] -> [system parameter] -> [shutter speed] for checking the right shutter value.
2.) You can adjust the ML (mean light)-value when you select the function ‚Calibration’ The function can be found under [Menu] -> |change product| -> |parameter data matrix| -> Calibration
X
Parameter Data Matrix CODE Control
DM0
ON
Calibrate
>>CONTINUE>>
In this mode, the camera initially tries to recognize the data matrix code and then continuously displays the read values for ML as well as the quality parameters for the data matrix reading.
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3.) Position the data matrix code on the calibration card in front of the camera, at the correct reading distance. Press [next] button for teaching-in the data matrix code. If there are no hits during setup, please check the parameter settings explained in chapter 15. The data matrix code should now be read continuously and the graphic evaluation of the quality analysis displayed. The following graphic should be displayed on the screen of the PLM PC:
The displayed ML value must correspond to the value on the calibration card (+/-5). Please make sure that the measurements are made in exactly the same area of the image where you want to read the production code. 4.) Adjustment of illumination If the ML value varies, the illumination of the camera must be adjusted. In order to do so, open the M18x1 screw blocking access to the objective and turn the aperture ring from the outside with a suitable tool, e.g. a small pointed screwdriver, making sure not to alter the focus of the objective. Make sure that you don’t change the focus of the lens.
Aperture
Lens
Connection
Focus Do not terminate the 'Calibration' function until you have successfully completed the process.
Note: Some cameras might have an adjustable internal illumination. If the software detects the presence of an adjustable illumination, it will display a slider for manual adjustment of image brightness. Please do not try any brightness adjustment on the aperture of your camera.
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19 Code Aggregation The Aggregation Mode is an optional mode for Smart Cameras which are for example integrated into a Case Packer System. The Aggregation can be activated in the Parameter Table of a Barcode or DM Code window. When activated, the mode will be applied to all Barcode and DM Code windows of the current product. For the function of aggregation, the camera needs two signals from the machine or PLC: • Primary Gate on Input1 • Secondary Gate on Input2 The Primary Gate Signal must be high during the aggregation cycle and point out the end of this cycle with its falling flank. If applicable, the Secondary Gate must point out the end of a subset of codes from the current cycle. After each aggregation cycle the camera will send all aggregated codes to the PLM. The maximum amount of codes for one aggregation cycle (e.g. one packing case) is 500.
Operating Modes The code aggregation can be activated in two different modes (the appropriate mode is depending on the type of the machine): • Aggregation In this basic mode all code reading results (no matter if positive or negative) will be submitted to the PLM, this means unreadable codes will also be sent as part of the aggregation data in form of an error message (prefixed with “#ERR”). In this operating mode, the Secondary Gate signal should be coupled [ ] with the Primary Gate signal physically.
Trigger & Analysis
Good
Bad
Good
Good
Aggregate
Aggregate
Aggregate
Aggregate
Secondary Gate
Primary Gate Submit
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• Aggregation (partial rejection) If the aggregation system e.g. has a rejection system for a series of products (a layer or a row), a PLC may use the cameras result output to reject a series if at least one code of it was unreadable. As the Codes from this series then should not be part of the aggregated data, the camera has this operating mode in which it will discard these codes (all codes of a series with at least one bad reading). A series of codes is defined by the Secondary Gate. Trigger & Analysis
Good
Bad
Good
Good
Aggregate
Aggregate
Secondary Gate Ignore Primary Gate Submit
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20 Appendix 20.1
Error Messages and Error Recovery Error message
System fails to start: System cannot be operated using the mini keyboard: System cannot be operated from the PC: System fails to take a photo: The photo is blurred: Good characters are mistaken for errors: Characters in the character set are not readable:
Incorrect readings in the production run for the optical character verification:
Incorrect readings at high speed: “No window set!” “Characters not found in the memory!” “No teach-in for character!” Please teach-in the character set first!” Please take photo first!” Reference code is not permissible!” Too many different characters!” “For dynamic reference code, teach-in compulsory for all digits!” „!! Password is incorrect!!” “Passwords are not identical” „! Character set memory is empty!” „! Character set memory is full!” “Incorrect number of characters! Characters found:” “Error when loading the device data” “The default settings are used” “ < > “ „!!!! Flash memory is full!!!!” „!!!! Error Flash memory!!!! “Data could not be stored.” “Error when loading the product! < > “ “Error when initializing the main FDC < >.”
Error recovery Switch system off and on again. Check connection leads. LAN connection OK? Switch system off and on again. Has the IP address been configured correctly? Has the correct port on the PC been selected? Network hardware hub, switch and cabling correct? Firewall in PC active? Check the trigger signal. Check the distance between the camera and the object. Check character set, if necessary, conduct new character teach-in. Avoid reflections, new character teach-in. Control window or measuring lines wrongly positioned. Reset window. Brightness of background is not even. Reduce reflections. Protect against any external light. Check references entered. Train characters. Reduce machine clock speed. Check whether trigger signal bounces. One window has to be set. Teach-in character. Teach-in character. Teach-in character. Take live photo. Change reference code. Enter correct number of characters. Teach-in the characters 0, 1, 2, 3, 4, 5, 6, 7, 8 and 9. Enter correct password. The second new password must agree with the first. In the OCV mode the characters must be taught in first. No more characters can be taught in. To teach-in new characters, old characters first have to be deleted. The number of characters entered does not agree with the number of taught-in characters. Enter correct number of characters or repeat the procedure. No data is available in the camera. Error message only occurs when switching on for the first time. Flash memory is full, delete characters not required. Memory is full or an error has occurred. Repeat memory procedure or delete old characters. Repeat loading, or product is not available. Error message cannot be influenced.
If the error cannot be remedied in this way, please call the Customer Service.
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20.2
Maintenance
The device has been specially designed for industrial requirements. As a result, reliable operation is guaranteed under the normal conditions existing in production plants, provided that trained personnel have installed the device. For perfect operation, it is necessary to clean the glass plate of the camera housing at regular intervals. For cleaning, only use the cleaning cloths and agents intended specially for this purpose.
Note:
The device itself has no mechanical wearing parts and therefore requires no maintenance.
Technical Specifications The following specifications apply to type 200 size 1 cameras. For other camera types, please see the corresponding specification sheets. Housing: Voltage: Image processing: Inputs / outputs:
Interface: Illumination: Lens: Distance between object - housing: Head inclination angle:
Aluminum (LxBxH) 103 x 55 x 55 mm, IP 54 (protected against dust and splash water); 24 V DC / approx. 300mA Digital signal processor for image evaluation; 4 Outputs 24 V DC, electrically isolated, Short-circuit proof, protection against ext. voltage up to 30V 4 inputs 24 V DC, electrically isolated (max. 30V), Response threshold: High ca. 14V, Low ca. 3V; LAN; white LEDs in flash operation; 12 mm focal length f = ~80 mm; 0 degrees (vertical);
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20.3
Adjusting the Image Sharpness / Reading Distance
The following means can be used to check whether the image sharpness as displayed by the PLM or the SC Client corresponds to the expected image quality or whether the image sharpness needs readjusting after setting the desired reading distance. 1.
2. 3. 4.
Increase the size of the displayed details either by turning on the “Zoom” mode in the “Main Menu” or by switching image quality to “1” in “Config. image transfer” in the “System parameters” menu. Then switch the camera to the “Live image” mode. Now adjust the distance between the object and the camera until the image displayed on the pilot screen becomes as sharp as possible. Change the quality of image transfer back to the pre-set value of “2” or turn off the Zoom mode. Setting the quality of image transfer too high can increase the processing time during production to more than 30 ms.
Standard cameras have a reading distance of 80 mm; as a general rule the reading distances are set during the installation of the system. You will have to adjust the image sharpness yourself if you need different reading distances for smaller letters or larger labels.
Note:
Some cameras might have an adjustable lens, if the software detects the presence of an adjustable lens, it will display the buttons Focus and Autofocus on the menu for ‘Optical Settings’. Please make all the adjustments by software using the Focus or Autofocus function. 1. Increase the size of the displayed details either by turning on the “Zoom” mode in the “Main Menu” or by switching image quality to “1” in “Config. image transfer” in the “System parameters” menu. 2. Then switch the camera to the “Live image” mode. 3. Now adjust the distance between the object and the camera until the image displayed on the pilot screen is the size that you want. 4. Loosen the M18x1 screw, which closes the opening to the objective, and turn the ring for the focal distance from the outside using a suitable tool such as a small pointed screwdriver until you see a clear, sharp image on the screen. Make sure that you did not accidentally change the f-stop.
Aperture Connection
Lens
Focal length 5. Change the quality of image transfer back to the pre-set value of “2” or turn off the Zoom mode. Setting the quality of image transfer too high can increase the processing time during production to more than 30 ms.
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21 Specifications for OCR/OCV Control 21.1
Font
Font type In principle the camera can check almost any font type. But because the characters in certain fonts can be hard to distinguish, we recommend using OCR-A (ISO 1073-1) or OCR-B (ISO 1073-2) font. Character spacing There should be a space of at least one line width perpendicular to the reading direction between characters. Font size The smallest possible font size depends on the size set for the field of view and on the camera resolution. Cameras are set to a minimum font size of 2 mm by default. Font color The camera can check either light font on a dark background or dark font on a light background. The contrast between the characters and the background should be as high as possible. Black font on a white background is ideal, whereas yellow font on a white background, for example, is problematic. The contrast can also be enhanced by using application-specific lighting. The character background should be uniform. Printing technique Stamp, hot stamp, block, thermal transfer, laser, and also inkjet and UV print can be read. A special UV light source is required for UV ink. For laser and inkjet print, there are filters in the software for connecting the individual dots.
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21.2
Permissible Characters for OCR/OCV Control
Unicode 0020 0021 0022 0023 0024 0025 0026 0027 0028 0029 002A 002B 002C 002D 002E 002F 0030 0031 0032 0033 0034 0035 0036 0037 0038 0039 003A 003B 003C 003D 003E 003F 0040 0041 0042
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Character SPACE (not checked) ! (not valid) " # $ % & ' ( ) * (not checked)
+ , . / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? (not valid) @ A B
Unicode 0043 0044 0045 0046 0047 0048 0049 004A 004B 004C 004D 004E 004F 0050 0051 0052 0053 0054 0055 0056 0057 0058 0059 005A 005B 005C 005D 005E 005F 0060 0061 0062 0063 0064
Character C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ ` a b c d
Unicode 0065 0066 0067 0068 0069 006A 006B 006C 006D 006E 006F 0070 0071 0072 0073 0074 0075 0076 0077 0078 0079 007A 007B 007C 007D 007E
Character e f g h i j k l m n o p q r s t u v w x y z { | } ~
00a3 00c4 00d6 00dc 00df 00e4 00f6 00fc
£ Ä Ö Ü ß ä ö ü €
20ac
Cyrillic character: Unicode 0401 0410 0411 0412 0413 0414 0415 0416 0417 0418 0419 041A 041B 041C 041D 041E 041F 0420 0421 0422 0423 0424 0425 0426 0427 0428 0429 042A 042B 042C 042D 042E 042F 0430 0431
Character Ё А Б В Г Д Е Ж З И Й К Л М Н О П Р С Т У Ф Х Ц Ч Ш Щ Ъ Ы Ь Э Ю Я а б
Unicode 0432 0433 0434 0435 0436 0437 0438 0439 043A 043B 043C 043D 043E 043F 0440 0441 0442 0443 0444 0445 0446 0447 0448 0449 044A 044B 044C 044D 044E 044F 0451
Character в г д е ж з и Й к л м н о п р с т у ф х Ц ч ш щ ъ ы ь э ю я ё
Note: The characters listed above can be teached-in or entered as reference characters respectively. The ability to differentiate the characters from each other depends amongst others on the font type and the features of the respective characters. “SPACE”(u0020) can be entered as reference character, however it will not be checked. “*” (u002A) is used as replacement character. “!”(u0021) and “?”(u003F) are used as control characters.
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22 Readable Code Types
Pharmacode
2-Track Pharmacode
Code-39
Code-32
Interleaved 2 of 5
Code128
GS1-128 (EAN.UCC 128)
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UPC_A
EAN-13
EAN-8
Codabar
Data Matrix (ECC 200)
GS1 Data Matrix EAN Data Matrix
PPN Code Data Matrix
GS1-DataBar (before RSS14)
GS1-DataBar Truncated
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GS1-DataBar Stacked
GS1-DataBar Limited
EAN.UCC Composite (CCA)
PDF417 (ECC Level 0 – 6) Compact PDF417 (truncated) (ECC Level 0 – 6) GS1-DataBar has been named as RSS14 before. EAN.UCC Composite (CCA-Code) does apply only in connection with GS1-DataBar. In this case a control window has to be set for both codes.
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87
23 Index A
G
Accept error images .......................................... 33 Adjusting image sharpness ................................ 81 Alias................................................................ 48 Applications for optical character verification.......... 5 Assignment for the System Plugs .......................... 7 Autofocus......................................................... 36
Black on white ................................................. 49 Brightness compensation .................................. 53 Brightness correction......................................... 53
Gap................................................................. 51 General Instructions ............................................ 4 Geometry ......................................................... 44 Good outputs ................................................... 37 Good signal ..................................................... 38 Grading ............................................... 60, 70, 73 Grey .................................................... 19, 67, 69 Grey threshold measuring arrows ....................... 19 Grey threshold windows .................................... 19 Grid................................................................. 69 GS1-Test.......................................................... 69
C
H
Calibrate ........................................ 68, 75, 82, 83 Change character set ........................................ 48 Change Product ................................................ 26 Character ......................................................... 27 Check quantity ................................................. 51 Clock overflow .................................................. 43 Code ..................................................... 8, 71, 85 Code Type ....................................................... 57 Code types ....................................................... 57 Code-Control .................................................... 56 Colour Inverted ................................................. 20 Configure ......................................................... 26 Connection ........................................................ 5 Connectivity ....................................................... 6 Contrast ........................................................... 59
Hardware ........................................................... 5
B
D Data ................................................................ 68 Data Matrix Mode ............................................... 8 Delete counter .................................................. 33 Diagnosis ........................................................ 34 Diagnosis value ............................................... 34 Dimmer ........................................................... 36 Direction .......................................................... 49 Display error images ......................................... 33 Disruptive pixels’ .............................................. 50 Distinguishing periods and hyphens ................... 52 Dot-code.......................................................... 69 Dynamic .......................................................... 71
E Empty line pixels .............................................. 50 Error messages ................................................ 79 Error recovery ................................................... 79 External Illumination ........................................... 7
F Filter .......................................................... 58, 71 Finder .............................................................. 57 Focus .............................................................. 36 Font ................................................................ 48 Fonts ............................................................... 27
I I/O configuration ............................................... 37 I/O-Cable ........................................................... 7 Identifier........................................................... 48 Image transfer quality ........................................ 43 Ink-Jet-Filter ..................................................... 52 Installation and start-up....................................... 4 Intended use ...................................................... 4 Interspaces ...................................................... 51 Inverse ...................................................... 67, 69 Inverse Filter ..................................................... 49 ISO15415 ................................................. 60, 70
K Key assignments .............................................. 11
L Language ........................................................ 45 Learn character group ....................................... 27 Lines tilting ...................................................... 49 Link................................................................. 37
M Maintenance .................................................... 80 Maximum character size ................................... 51 Menu Overview ................................................. 24 Menu selection ................................................. 10 Minimum character size .................................... 51 Mirror .............................................................. 44 Module ...................................................... 68, 69
N Noise pixels ..................................................... 50 Noise Reduction ......................................... 53, 59 Number ........................................................... 51
O OCR .................................................................. 8 OCR-Parameter ................................................ 48 OCV ............................................................ 8, 72 OCV-Parameter ................................................. 48
88
omnidirectional ................................................. 57 Operation ......................................................... 10 Optical Character Verification .............................. 48 Optical Character Verification Service ................... 48 Optical Settings ................................................. 35
P Pass- and search tolerance ................................ 30 Passwords ....................................................... 46 Pixel ...................................................... 8, 22, 66 Place holder ..................................................... 51 Position ........................................................... 49 Product administration ....................................... 26
Start-Up ................................................ 13, 14, 15 Statistics .......................................................... 33 switch off ......................................................... 26 Switching off the camera .................................... 26 System cable ...................................................... 7 System parameters ............................................ 35
T
Quiet zone ........................................................ 56 QZone .............................................................. 56
Teach-In Mode .................................................... 8 Technical Specifications ..................................... 80 Tilting .............................................................. 49 Time Out .......................................................... 43 TIN-Parameter................................................... 48 Train characters ................................................ 27 Transport ............................................................ 4 Turn ................................................................. 44 Type .............................................................. 8, 9
R
U
Reading direction .............................................. 49 Reference ......................................................... 23 Reflection ......................................................... 53 Reflection correction .......................................... 53
User ................................................................. 46 User administration ........................................... 46
Q
S Safety measures.................................................. 4 Save counters ................................................... 43 Service Menu .................................................... 34 Setting ............................................................. 21 Setting control window ....................................... 18 Show character set ............................................ 28 Show Font ........................................................ 28 Shutter ............................................................. 35 Size ................................................................. 49 Size tolerance ................................................... 30
V Valid ................................................................ 84 Virtual Keyboard................................................ 12
W White on black.................................................. 49 Wildcard .......................................................... 51 Window name OCR ..................................... 48, 55
Z Zoom ............................................................... 47
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Author: Pharmacontrol Electronic GmbH No part of this documentation shall be re-produced, transmitted, assigned, recorded in a data processing system or translated into another language in any form without prior written consent.
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