cadbury mce720 training mar08
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MC-E720 Autosort
A Training Guide
for
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Why an Autosort ?
Camera
Inspection
Electronics
Software
Pneumatics
Autosort
Reject
Dark
Light
Small
Large
Misshapen
Accept
Improved Product
Added Value
Customer Satisfaction
Increased Margin
Automated
Processing/Packaging
Raw
Product
Natural Imperfections - specks, diseased...
Production Faults - burnt, uncoated...
Foreign Bodies - plastic, wood...
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MC-E720
Purpose built for whole formed products
Fitted to new or existing lines
Encoder for accurate measurement and
rejection
Product passes under a pair of red, infrared and
blue LEDs for colour check
Additional pair of red + infrared LEDs for
Heightcheck
Top camera only (250mm inspection width)
Control and electronics enclosures integral to
sorter
Separate pneumatic Reject station positioned tosuit
Acceptable product continues along belt to
packaging, reject blown by one or more nozzles
sideways
Customised accept and reject take-offs
Defects from 0.5mm in size
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General View of MC-E
PneumaticCabinet
Camera
Enclosure
Electronics
Cabinet
Main Isolator
Switch
on Electronics
cabinet
Beacon
Green OK
Red-AlarmTouchscreen
Inspection
area
Air reservoir
Power On
Lamp (on
both sides)
Password
Keyswitch
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Inspection Area
2 outer LED
bars for
Heightcheck
(red + infrared)
2 inner LED bars
for colour and size
check (red, infrared
& blue)
Heightcheck
adjustment
(detects under
height bars)
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Camera Enclosure
Camera Window
Mounting plate with
positional adjustments
Camera lens (50mm)
focus & aperture
adjustment
Signal Connector
(CameraLink)
Line Scan Camera
12V powerConnector
(Hirose)
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Camera Adjustments
Power Supply Lead
Focus adjust
Aperture adjust
Range adjust
Pan adjust
Roll adjust
Tilt adjust
Baseplate
Signal Lead
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Electronics Enclosure
Power Supply 24V
for I/O boards and
touchscreen
Camera Power
Supply 12V
Industrial PC
With Snapshot
PCI control card
HeightCheck LED
Switch 3 posn -
A, B, Both
Input boardHeightCheck LEDbars (outer pair)
Output board
Power socket
for servicing
Signal to Valve
Island
LED ITG Driver
Board
Power Supply 15V
for LED Driver board
Colour LED Switch2 posn - On/Off
Colour LED bars
(inner pair)
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Mechanical Enclosure
Air to
valves via
reservoir
(4 5 bar)
LED bars (inner pair
colour; outer pair
heightcheck
Valve Island
PCB
Pneumatics control;
isolator, regulator,
filter, drain
Signal to EjectorValves
Pressure Switch
(~3.5 bar)
Air inlet (~6 7 bar)
5V PSU forValve Island
24V PSU for
valves
Signal from
Snapshot to
Valve Island PCB
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Valves
Electrical
Connection
from Valve
IslandValve Body
Hood
support
frame
Air In from
reservoir
Nozzle jets
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Principle of Operation
Camera basedCCD Line scan up to 10,000 scans/sec (0.1ms exposure)
2048 pixels/camera
3 wavelength illumination (red, infrared, blue)
Optional Heightcheck illumination (red + infrared)
ElectronicImageProcessingSnapshot PCI card
Valve Island
RejectionPneumatic
Fast acting valves
Defect removed. Good product undisturbed
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Principle of Operation
Direction of travel
Overhead
Camera
Colour check
LED Lighting (2)
Inspection Module
over line, including
pneumatics
Air Ejector nozzles.
Rejects blown
sideways into bin
200mm
Belt Speed 200 500 mm/sec
(up to 9 bars/sec)
Control Cabinet with
PC touchscreen
1500mm minimum
Reject Bin Heightchack LED
Lighting (2)
Shaft Encoder to
synchronise camera
scans
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Principle of Operation - Width
02048
pixels
Camera
Resolution
= Inspection Width (mm)/ 2048
= x mm / pixel
1 camera 250mm I. W.
Res. = 250/2048 =
0.12mm/pixel
Belt Width
~200mm
Camera Inspection Width
250mm
~1700
pixel
~300
pixelActive pixel range
(user sets)
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Principle of Operation - Sequence
Top Camera
Valve Island PCB
Snapshot
Processing Card
PCI Card
Camera Enclosure
Electronics Cabinet
Reject station
Nozzles 25mm apart
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Host Software
Display
Screen
Product
Select(24 choices)
MC HostMain Menu
(8 choices)
Available from all displays:-
Position
Reports
Operator Display
Enable
Access
Product
Configuration
Reports Display
Product Selection
Event Log
System Logs
Enable Access
Disable Access
Profile Camera
Colour
Training
System
Configuration
*
*
*
* Password Protected
*
General Change
Password
Run/Stop
Alarms Valve SelfTest
Main Menu Status
CopyProduct
*
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Display Screen
Batch zone. Shows
thecount of defects
and total product countfor thecurrent batch.
Reject Distributionzone. Shows the
distribution ofeach typeof reject as a percentage
of the total rejects in thebatch.
Run Time. Thecurrent total of time
during which the sortersaw product in this
batch.
Stop Time. Thecurrent total of time
during which the sortersaw no product in this
batch.
Reject Rate zone.(Reject rate = defects
per minute).Displaysthe rejects for the
previous minute as apercentage of the user-
defined Alarm Level foreachcamera. Shown as
a green within AlarmLevel and red ifexceeds
Alarm Level.
Main Menu button.Press to return to the
main menu.
Current productrunning
Status button.DisplaysAlarm screen.When yellow
an alarm condition exists.
Run/Stop button.Press to
start, to stop sorting.
Current Time (fromPCs own clock).
Defect Count shows
totals foreach defect
type for thecurrent
batch.
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Red indicates Fault
(alarm) condition.Will
remain red until
acknowledged andcondition has cleared.
Host Mode indicates
Run or Stop as and
buttons are pushed.
System Inhibit
indicates when
the sorter is
inhibited e.g. a
Run switchhas
been set to 0, or
Stop button
depressed, or in a
Camera Set-upscreen
External Mode
indicates Run or
Stop. Set byexternal Run switch
or byexternal
switch from a PLCetc.
Air Pressure indicates air
supply pressure is below thatof sensor setting in blastbar.
Check supply is turned on and
at required pressure.
Reject Rate is illuminated if
rejects/min exceed Alarm
Level. Checkcorrect product
selected or product being
sorted is not unusually
contaminated.If 2 top cameras
used then shown as separate
rates for A & B.
System Errorcaused by fault
in communication betweencomputer and system.If this
occurs frequently, call an
approved service technician.
Press Acknowledge
Alarm to show a yellow
box against the fault
condition. Once the alarmhas been acknowledged it
will clear automaticallywhen the alarm conditionhas been rectified. N.B.If
all devices areeither OK
or already acknowledged
then this button is
inactive.
Press to return
to the original
screen.Will be
yellow if alarmcondition(s)
exist, grey once
all clear.
Temperature Electronics
Enclosure not used.
Green OK shows that
device status is
functioning normally.
Acknowledged shows
that an alarm condition
still exists but has been
acknowledged by the
user.
Valve PSU indicates status of
the power supply to the valves.
Temperature Valve
Enclosure - not used
Alarm/Status Screen
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System Configuration
Profile
Position
HeightCheck
System
Configuration
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Camera Profile Screen
Exclusivecheck boxes.
Raw Profile:- Press toobserve thecurrent signalwhich should be a smilecurvewhich no largespikes.Corrected Profile:- Press
to observe previouslystored profile. Shouldappear as horizontal line if
current and stored profilessimilar.
Virtual oscilloscope.Shows thecameraprofile in graphical
form.Horizontal axis is the2048 pixels across thecamera scan i.e.widthacross inspectionbelt/chute.
Vertical axis is thesignal strength from 0(dark) to 255 (bright).
On multi-camera sorters,use drop down list toselect the requiredcamera to check or adjust.
Select Profile tab tocheckcamerareference signal.
Current CursorPosition on the virtualoscilloscope is shown
to assist in locatingposition on sightbar.
Press to store thecurrent profile intomemory, to be used as
the new referenceshade level.
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Camera Profile - White
0
Dark
255
Light
Raw Profile looking onto white profile bar Corrected Profile looking onto white profile bar
0
Dark
255
Light
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Camera Position
A Camera
B Focus
C Delivery Chute
D Target Bar
E RangeF Roll
G Tilt
H Pan
A
B
D
C
F
E
G
H
D
E
C
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Camera Position Screen
Display ofcamera position errors. Adjust to obtain valuesbetween 2, with the 4 rectangles changing from red to greenat an acceptable value of 10. (Values of 2999 mean cameracannot see target correctly).
Select Position tab tocheckcameraalignment.
Reminder to insertPosition Target Barinto camera view tocheck/adjustcamera position.
Virtual oscilloscope.Shows thecameraprofile in graphicalform.Horizontal axis is the2048 pixels across thecamera scan i.e.widthacross inspection
belt/chute.
Vertical axis is theshade signal strengthfrom 0 (dark) to 255(brightest).
On multi-camerasorters, use dropdown list to selectthe requiredcamera to check oradjust.
Position screen alwaysuses Corrected Profileonly (not RawProfile).
Adjust focus toobtain minimumpossible value.
(Value of 888means cameracannot see targetclearly).
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Underheight sections of bar distort Heightcheck light out ofcamera view
HeightCheck lineone LED bar on
at a time
Camera Scan Line
Product Flow
HeightCheck Calibration
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HeightCheck Calibration Screen
Bothheight LED bars on togethergives double the signal.
Select Profile tab tocheckHeightCheck.
Virtual oscilloscope.Shows thecameraprofile in graphicalform.
Foreachheight LED
bar theHeightCheckcalibration bar profilecan be seen with darkpeaks. Check both aresimilar intensity.
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Product Configuration
Colour (good and defect colour categories)
Size (length/width/area/shape/height)
Autosort determines if defective product by:-
Product
Configuration
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Colour Training Capture
Save to keep a capturedimage on file
Captured imagethumbnail
Capture Status
Red armed,Green captured image
Capture Threshold Setto triggercapture (seebelow)
Capture Press to armcamera
Open previously savedcaptured image
OK to go toColour Training
screen
Capture Threshold blue setto trigger on bars but not belt
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Colour Training Screen - Good
Keypad button tochangecategorytitle and psuedocolour
Categories ofproduct/defect with title,psuedo colour and colourspace value
Update button.If anychanges are madethis will becoloured.Press to implementnew parameters. Alsoto reset last objectreadings
InspectionParameters can beindividually set foreachcamera.
Captured imagewith slider to selectpart to view
Training imagefrom selection ofcaptured image
Magnifier to zoomin/out part of imageusing +/- buttons
Slider to adjustHeightCheck
threshold value
Filter to ignore specksof defect colour.Value 0 (off) to 8
(max)
Trained imagewithpsuedo colours forproduct /defects
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Colour Training Screen - Defect
Categories ofproduct/defect with title,psuedo colour and colourspace value
Defect shown as pinkarea from definedcolour spaceCaptured image
with slider to selectpart to view
Training imagefrom selection ofcaptured image
Slider to adjustHeightCheck
threshold value
Trained imagewithpsuedo colours forproduct /defects
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CorrectHeight barUnderHeight bar
HeightCheck line
Camera Scan Line
Excess height area causes Heightcheckline to go out ofcamera view (darker)
Normal Heightcheck lineappears in camera view
Product Flow
HeightCheck Low Bars
HeightCheckThreshold linedetermines how muchof bar is underheight
Heightcheck SignalBelt
Choc Bar
Underheight
BeltBelt0
255
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HeightCheck Threshold
Height On/Off togglebutton
Captured image ofproduct bar
Training imagefrom selection ofcaptured image
Slider to adjustHeightCheck
threshold value
Trained image;yellow
showing product ofcorrect height, redshowing productbelow required height
- set by
HeightCh
eckThreshold
Actual HeightCheckthreshold value (0-255)
Height colourselection button
Correct Bar
HeightCheck image
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General Screen
Duration is timeforwhich rejectvalve is blowing atdefect
Update button.If anychanges are madethis will becoloured.Press to implementnew parameters. Alsoto reset last objectreadings
HeightCheck Limitand actual value.Percentage ofproduct allowedunder set height.
Filters are limitsbelowwhichproduct not counted
Delay sets timefrom seeing defectto when rejectvalve opens
Total product andReject Counts forcurrent batch
Actual reported -Length, Max/MinWidth, Product Areaand Defect ColourArea
Reject Rate Alarm
is defects /minabovewhich alarmactivated
Alignment Limitand actual value.Degrees of productalignment fromviewing line
Parameter Max andMin Limit Values setby user
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Rejection Control
By default only one valve fires,By default only one valve fires,
but if product more than 35mm,but if product more than 35mm,
both will fire to remove defectboth will fire to remove defect
DelayDelay - Time between determining a
defect and opening of ejector valve
No.1 (farthest from sorter)
DurationDuration - Time for which
valve(s) are open
Valve OffsetValve Offset - Not used
35mm
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Advanced Camera Settings
Update if anychanges made
Re-Synch if profiletrace sawtoothed orstarts after 0 pixel
Camera ScanSpeed 10kHz
First and Last Pixeldefines edge blindareas
Fixed ExposureUncheck no encoder,Checked encodersynchronises camerascanning
Camera Offset andGain (Max 10)
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Advanced Scaling Factors
Valve Pitch is distance betweenthe two nozzles
Length Calibration Camerascans per metre travel. (Lengthis always in direction of travel).
Width is pixels per mm acrossbelt (i.e. Longest dimension ofbar) always 1/1000 of Length
Length/Width Scaling Factoris ratio of the length to thewidthand determines actual widthreported
Min Object Distance
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