StreamCap Inspection System

application manual ver. 1.0

1.

Introduction
This manual contains information about using the inspection system for StreamCap closures deployed at several manufacturer sites. These systems are based on ProInspect, a configurable vision system. ProInspect was tailored for this inspection task by developing a specific configuration or inspection recipe. This document it focuses on topics that are specific to the inspection of Stream Cap closures. For a more general description of ProInspect please refer to its user manual.

2. 3.

System configuration Inspected Items

Images
Two images of the caps are taken from the same camera with two different lighting configurations.

A back lit image is used to inspect the inner part of the lid. A front lit image with side view mirrors is used to inspect the frame and to check the assembly of the caps.

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application manual ver. 1.0

Checked Items Front Lit View

The following table depicts the controls carried out for the front lit image. Item StreamCap Description general inspection of the front lit view. Any relevant difference relative to a reference model is detected. Black spots, flashes, missing material fall into this category. In addition this ispection tools provides the position of the cap to other inspection tools. Results Score: indicates the amount of conformity of the pattern relative to its reference model (0..1) Position (x, y, ). Defect number: number of detected defect regions. Defects size: size of the larger defect Left Search, Right search The position of the cap is searched within each mirror view. The results are used as fixtures for inspecting te side views. Results Score. Position (x, y).

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application manual ver. 1.0

Lid-frame distances L1, L2 (left) R1, R2 (right)

A distance measured between two edges as depicted by the following figure:

Such distances are an indication of a correct assembly of the cap. these measurements are carried out separately for left and right views. Results Contrast. Size Position (x, y). Frame A distance measured between two edges as depicted by the Tamper evidence following figure: band distance L3, L4 (left) R3, R4 (right)

Such distances are an indication of a correct assembly of the cap. note: these measurements are carried out separately for left and right view. Results Contrast. Size Position (x, y).

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application manual ver. 1.0

Frame edge points E1, E2.

A pair of edge points used as a fixture for inspecting protruding blades.

Results Contrast. Position (x, y). Protruding blades Cutter blades must not protrude from the frame. The inspected region (depicted in the figure) must be free of any material.

Results are returned only if defects are detected. Results Contrast. Position (x, y).

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application manual ver. 1.0

Back Lit View

The following table depicts the controls carried out for the front lit image. Item Lid Description An inspection and search tool that locates the position of the Lid. The result is used by further inspection tools. Results Score Position (x, y, ). Finn conformity (A1, A2, A3, A4) The conformity of each fin is checked by comparing it to a reference model. Results Score Position (x, y, ).

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StreamCap Inspection System

application manual ver. 1.0

4.

Inspection settings
In order to make it easier to adjust inspection parameters a comprehensive dialog is provided. Such dialog was specially developed for this installation and thus is not described in the product manuals. The Settings button allows accessing this dialog.

Frame inspection settings

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StreamCap Inspection System

application manual ver. 1.0

Frame Inspection Item Description Score Limit A limit from 0 to 1 for the conformity score of the part provided by the system. The conformity score is a result of the comparison of the part to its model used for locating the part. A higher value indicates better conformity. Part location fails (and the part is rejected) if the score is inferior to this limit. hint: if part location fails (the search region is indicated in red) try to decrease this value. Intensity Sensitiveness It is an index from 1 to 10 that influences the sensitivity of the system to the intensity / strength of defects. 10 is the maximum sensitivity. note: The actual sensitiveness is determined also by the conformity of the parts trained as statistical sample. The system automatically becomes less sensitive in regions were larger deviations were detected. hint 1: if normal variations of the cap lluminance (gray levels) are detected as defects try to decrease the Intensity index. hint 2: if tollerable part variations are detected as defects try to redo the statistical sample. Area Sensitiveness It is an index from 1 to 10 that influences the sensitivity of the system to the area of defects. 10 is the maximum sensitivity hint: if the system detects defects that are too small try decrease the Area index.

Right view measurements A, B, D1, D2, S1, Contrast threshold: the minimum contrast level at which the S2 system detects an edge. The contrast is measured ad difference in gray levels. hint: if the system does not detect the desired edges try decrease the contrast threshold. Size tolerance: positive and negative tolerances relative to the nominal value. D3 T1, T2 Size tolerance: positive and negative tolerances relative to the nominal value. Contrast threshold: the minimum contrast level at which the system detects an edge. The contrast is measured ad difference in gray levels. hint: if the system does not detect the desired edges try decrease the contrast threshold.

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StreamCap Inspection System

application manual ver. 1.0

Camera settings
Some camera parameters such as exposure time, brightness and contrast can be set and saved in a recipe. In orde to access these settings select Camera Settings from the Images menu. hints increase the exposure time up to 0.5 ms maximum if the image is too dark. decrease the exposure time down to 0.1 ms minimum if the image is too bright.

Lid inspection settings

A control can be enable in the advanced setting dialogs. For each control you have the following settings. Name Inspection Lid Control settings Intensity: tells the system how to be sensitive to lighter or darker defects. 10 is a high sensitivity, 1 is a low sensitivity Dimension: tells the system how to be sensitive to a smaller or larger defects. 10 is for detect small defects, 1 is for detect only larger defects Contrast threshold: tell the system how strong must be the break you are searching for

E1, E2

Here are some hints to use these controls and their settings

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StreamCap Inspection System Name Valid values Inspection Lid Sensitivity: 1..10 Dimension: 1..10

application manual ver. 1.0 Value Sensitivity: 5-6 If the system finds false defects decrease the sensitivity If the system finds few defects increase the sensitivity Dimension: 5-6 If the system finds too many small defects decrease the area index If the system does not find defects increase the area index Contrast threshold: 20. If the system does not find the break decrease the threshold If the system find false break increase the threshold

E1, E2

Contrast threshold: 0..255

Camera settings
You can set the camera exposure time and contrast using the Camera Settings in the Images menu. These setting can be different on every recipe. If the image become dark: Increase the contrast and the brightness increase the exposure time (no more than 0.5 ms) If the image is too bright: decrease the contrast and the brightness decrease the exposure time (no less than 0.1 ms)

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application manual ver. 1.0

5.

Train of a New SlimCap

This section tells you how to set up new recipe if your part changes. The changes could involve: different colors different SlimCap caps change in the mold This operation can be done only stopping the inspection.

Train
1. Press the Train button 2. acquire a new image with the right sample, pressing the Acquire button 3. move the trackers to adjust the inspection areas 4. when finished, press again the Train button 5. check with a Test

Sampling
Remember that a new train will destroy the statistical sampling. You need to resample the system. To resample the system you can: 1. Press the Sample button in Setup mode, one view per time 2. Press the Sample button in Run mode, once

Save
After the training and sampling you must save your work with the menu File > Save Now the system is ready with the new settings. Press the Start button to go to automatic inspection.

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5.1

Area Settings
This section suggests you how to set up the areas of inspections Name Inspection Frame, Inspection Lid D1, D2, S1, S2, A, B T1, T2 E1, E2 Suggested position Centre the area on the cap, making it a little bigger than the corner Place it centred on part you want to measure Place it centred on edge you want to find Place it just after the lid

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5.2

Calibration
To measure in units (mm) the system must be calibrated. Usually you do not have to calibrate the system. You have to calibrate the system if: The camera are moved The mirrors are moved The following picture show the calibration dialog

To calibrate the system you should: 1. measure the dimension you want to calibrate with a real calliper, to have the measure in units 2. acquire a new image with the right sample, pressing the Acquire button 3. select the measure and open the calibration dialog, using the Vision\Calibration\Measurement Calibration menu 4. Get the new vision data pressing the Test button; This will update the row columns 5. Insert the real measure in the measure column 6. click on the scale column: this will update the calibration scale 7. press the Exit button to finish

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StreamCap Inspection System

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6.

Support contacts
e-mail: support@univision.it phone +39 0362 326799

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