NEW Ultra High-Speed, Flexible Image Processing System XG-7000 Series Comprehensive Machine Vision System Intuitive, Quick, Flexible, High Performance and Fully Customisable XG - 7000 Series Ver.4.2 Solve all your application needs XG-7000 Series Arrival of the XG-7000 Series PROCESSING SPEED CV-5000 Series CV-3000 Series XG-7000 conventional models CV-5000 CV-3000 PC base CV-2100 CV-700 FUNCTION(Problem solving ability) 2003 High-speed general-purpose vision system incorporating twin processors and digital transfer camera is released. 2 2004 Upgrades in features and functionality with the introduction of 2 Megapixel cameras. 2005 to 2008 The CV-3000 and CV-5000 raise the bar for machine vision performance with 4 monochrome / colour camera connectivity, unmatched speed, and the industry's most user friendly programming interface. 2010 Providing a new approach to vision with customisation and simple operating methods that overcome all hurdles. This single system meets all your image processing needs with the simplicity of a stand-alone vision system but with the flexibility of a PC-based system. PC based image processing problems: Time consuming programming Programme verification Protection of intellectual property Optimisation based on tool processing time Stand alone system requirements: Easy to use programming User-friendly interface No compromise on inspection accuracy Increased compatibility with other control devices Operational requirements: Maintain the simplest operation possible Display inspection details in a manner that is easy to understand Modify settings as inspection requirements change Retention of as much NG data as possible The XG-7000 enables high problem solving ability in the shortest possible time. XG Performance Flexible hardware Powerful Inspection Toolset User friendly interface Intuitive programming flow Increasing speed, stability and quality to stay at the forefront of the vision market Simultaneous image capture from up to 4 cameras. 16 colour and monochrome camera options High speed (7x) 310K & 2 Megapixel High resolution 5 Megapixel Ultra small 12 mm HARDWARE CAMERAS VISION EDITOR page 06 page 08 page 10 Hardware VisionEditor Reliable and ultra high-speed hardware design Development of a complete vision solution 3+1 Processor Solid state hard drive Integrated lighting controller 5 Megapixel camera support 4 Cameras C Plug In ActiveX Control Flowchart creation Debugging Testing Customisation Utilities and Security Pre-Processing Utilities and security tools make the XG-7000 easy for anybody to work with. Optimising the image using advanced pre-processing functions Useful utilities for designers Security related functions FTP images direct to a network PC simulation and remote support Filters Image operation Calibration unit Colour processing UTILITIES & SECURITY ANALYSIS PREPROCESSING TOOL SET page 20 page 24 page 26 page 30 Analysis Tool Set New tools designed to assist with online performance tracking and reporting Abundant inspection algorithms, variables and calculations. Online OK/NG batch analysis Online re-testing and flowchart editing Image calibration Pattern search Calculation/Scripting Looping Branching Stain Trend edge Trend edge stain OCR 1D/2D code 5 HARDWARE All in One Controller with Parallel Processing Ensures High Performance with Greater Reliability than a PC FASTEST IN THE INDUSTRY “3 + 1” processor system: Ultra high-speed, parallel processing KEYENCE always strives to create the industry standard and best performance for ASIC/CPU based vision systems. Placing a heavy emphasis on the benefits of parallel processing and processor architecture has helped keep KEYENCE at the forefront of technology. In addition to the “A.C.E.II” (colour image processing engine), KEYENCE has achieved stable, high-speed processing by combining 2 DSPs (image processing and screen display) and a RISC-CPU for overall control and communication into one dedicated hardware package. [Comparison with conventional processing] Conventional XG-7000 Series DSP CPU Output Camera Camera Colour image processing engine CPU Output DSP Achieving faster processing speeds by sharing imaging processing tasks between multiple processors. Example of ultra high-speed processing Electric component surface inspection 3 ms Using a 7x high-speed 310,000-pixel colour camera with a 240 CCD line field of view to capture edge angle, this inspection using position correction, binary area and colour defect inspections takes only 3 ms ! Highly reliable fan-less/solid state drive (SSD) design Fans and conventional HDD’s have moving components that will eventually wear out. By not having moving components, long-term continuous reliable operation is possible. The XG-7000 Series has sophisticated heat dissipation technology allowing for a fan-less design even while putting heavy loads on processors running at ultra high speeds. In addition, this design is particle emission-free and therefore suitable for use in clean-room environments. Fan-less 6 Conventional HDD EXPANDABLE HARDWARE KEYENCE Continues to Develop Innovative Hardware Resulting in the World’s First Expandable Machine Vision Controller INDUSTRY FIRST Expandable Controller By connecting additional modules to the side of the controller, the optimum system can be setup as well as allowing future expansion when needed. CC-Link communication module INDUSTRY FIRST Main controller Camera expansion module Multi-camera, simultaneous acquisition The XG-7000 Series allows for the seamless use of up to 16 different camera models. Depending on the inspection required, the most suitable camera can be selected and combined with other cameras on the same controller. For instance camera 1 and 2 could be high speed monochrome cameras for simple part position, where as camera 3 could be a 5 million pixel colour camera for part quality inspection. Up to 4 cameras can be connected by adding the camera expansion module. The system runs all 4 cameras simultaneously*, (including the data-intensive 5 million-pixel colour camera). This controller flexibility also allows for easy upgrading and changes to be made based on changes in the inspection criteria. If another camera is needed, it can be specified based on the task required and easily added to the system. * Connection of 1 million-pixel or more cameras is limited to the XG-7501/7701 only, 5 million-pixel camera connection limited to the XG-7701 only [Multi-camera system] [Combination examples] Controller Expansion Unit Camera 1 Moulding flaw inspections, print inspections Select up to four cameras out of 16 models 2 million-pixel compact colour camera + side view unit Camera 2, 3 Coplanarity inspection 2 million-pixel monochrome compact cameras Camera input 2 + 2 WORLD’S FIRST When conducting inspections using several cameras simultaneously, the total system cost can be kept down by selecting the optimal camera for the required inspection. In the case above both colour and monochrome cameras are used. LED light control expansion unit Easily control dedicated lighting without any extra wiring Up to 4 lighting expansion modules can be connected to the main controller. Each single unit has 2 lighting connections (connector and terminal style) so that up to eight 12 or 24 VDC lights can be connected. Light settings Lighting can be easily controlled as part of the image processing flowchart by setting the lighting conditions in the light settings tab within the image capture unit. By using multiple image capture units with different lighting patterns or intensities within a single processing flowchart, multiple image capture and advanced light sequencing is made easy. In addition, as the light intensity value is a variable that can be referenced, dynamic changes can be made to a programme after an inspection has been processed. The ON/OFF status, strobing and intensity of 8 lights is possible in each image capture unit. Light control expansion module Controller Conventional methods require PLC control with large numbers of I/O. No I/O allocation, no wiring and no PLC programming is necessary 7 CAMER AS Wide Range of Cameras Covering Every Possible Need and Performance Criteria WIDEST RANGE Select the best camera for the application Whether the application calls for high quality inspection with a colour megapixel camera, fast processing inspection with a 7x highspeed camera, or mounting a compact camera in a tight space, the wide variety of XG-7000 Series cameras can provide the ideal solution. Type Model 5 million-pixel camera series 2 million-pixel camera series 1 million-pixel camera series 310,000 pixel camera series Specification CCD capture range (pixels) Image transfer time (ms) XG-H500M 11x high-speed monochrome 2432 × 2050 61.2 XG-H500C 11x high-speed colour 2432 × 2050 61.2 XG-H200M 7x high-speed monochrome 1600 × 1200 29.2 XG-H200C 7x high-speed colour 1600 × 1200 29.2 XG-200M Monochrome 1600 × 1200 59 XG-200C Colour 1600 × 1200 59 XG-S200M Ultra-compact monochrome 1600 × 1200 59 XG-S200C Ultra-compact colour 1600 × 1200 59 XG-H100M 7x high-speed monochrome 1000 × 1000 XG-H100C 7x high-speed colour 1000 × 1000 XG-H035M 7x high-speed monochrome 640 × 480 XG-H035C 7x high-speed colour 640 × 480 XG-035M Monochrome 640 × 480 XG-035C Colour 640 × 480 XG-S035M Ultra-compact monochrome 640 × 480 XG-S035C Ultra-compact colour 640 × 480 20.5 20.5 4.7 4.7 16.7 16.7 16.7 16.7 [Difference in defect detection ability based on number of pixels] Pattern break 8 310,000 pixels 2 million pixels 5 million pixels Lines are out of focus and cannot be detected. Broken pattern is out of focus and lacks the clarity for an accurate inspection. The image requires a smaller field of view. Details appear sharp and the break can be accurately detected. CONTROLLER OPER ATION Direct Flowchart Interaction and Manipulation Without PC Software NEW Controller Flowchart Editing Gives the User Complete Control The controller supports direct interaction with the image processing flowchart without a PC. Enabling editing, addition, movement and configuration of different vision units with the handheld console. With the easy to navigate GUI, the time taken to make adjustments is kept to a minimum. Overall flow chart display The full flowchart can be displayed on screen for a full view of the operation. Navigation on large scale flowcharts is quick, easy and stress free as the area needing to be viewed can be selected from the map with the display cursor. Unit operation & judgement display Unit direct view Each unit on the flowchart has an indicator to show whether it is being processed and its pass/fail status (OK/NG). This enables the current state of the image processing flow to be easily checked at a glance. The detailed results and settings of a unit can be verified simply by placing the cursor over the relevant unit on the flowchart. [Mark display] ● Unit processed, judgement - pass (OK) ● Unit processed, judgement - fail (NG) O Unit not processed Display unit results, show calculation terms, and the individual unit processing time Conditional branching The conditional branching used in an image processing flowchart can also be configured and displayed. Branches can be displayed in different colours and minimised to help with effective programming. Conventional model Conventional systems have a single flow structure. So a “jump to” command is required making navigation and understanding very hard. Image acquisition Search Condition branching Defect Area Dimension measurements Burr chip Output Real branching structure The XG-7000’s intuitive design shows the branches as physical divides allowing for easy understanding and navigation. Units can be simply inserted in the correct branch as required making setup changes quick and simple. 9 DEVELOPMENT PROCESS 1 Intuitive Operation Anyone can Use and Visual Design for Everyone to Understand Easily achieve what you want, without the stress Integrated image processing development software “XG VisionEditor” Simulation Flowchart construction User interface design During application testing and solving, simulations and debugging can be quickly conducted at any time, allowing for efficient design. Testing/Debugging Seamless development, enabling fast and powerful yet efficient application solutions The “XG VisionEditor” is specialised PC software that can conduct everything from the construction of image processing solutions and the creation of user interfaces to debugging and simulations all at once. The PC software does not use programming language, and instead all operations are conducted in an easy to understand GUI environment. Here drag-and-drop dominates, enabling complex processing to be easily developed in minimal time. Due to the incorporation of debugging tools that simultaneously discover errors (both static and dynamic) that occur during development, man-hours dedicated to debugging have been dramatically reduced. The overall time between construction and deployment have been substantially reduced. By focusing on the optimisation of the tools required for providing a solution (the core of image processing inspections) KEYENCE has given the opportunity for significant improvements in machine vision development efficiency. Flowchart view By dragging-and-dropping processing units from the parts list into this section, you can easily construct an image processing flowchart. Debugging is easy as errors are highlighted and the usage of variables can be easily seen. Simulation tool bar Simulations can be run from images taken from a connected controller, held on a PC or across a network. Options for continuos programme operation, step by step or a single iteration are possible too. Vision window In addition to displaying captured images and setting up GUI, you can confirm in real-time the processing results of filters or inspections tools Unit results 10 Resource display Parts list Shows the resources used in different areas of the controller from the settings made. Lists everything all the way from inspection tools such as edge detection and pattern matching, to control processing such as condition branching timers and loops. By dragging-and-dropping items from this list to the flowchart, the image processing flowchart can be easily constructed. All aspects of result and measurement data from units and variables can be viewed here. The unit results section is also equipped with a watch view allowing the display of only the variables or measurement values you wish to see. Helping allow for easy confirmation and analysis of results. In the unit results you can also conduct editing of the variables making dialling in and changes very easy. DEVELOPMENT PROCESS 1 Easy construction of the image processing flowchart through the click of a mouse The basic structure is created through the intuitive Windows based drag-anddrop method. The desired items are simply dragged from the list on the right onto the flowchart to create the structure. The processing units themselves can also be picked up and moved around the flowchart as desired. You can even drag-and-drop a variable from the list straight into the unit parameter. Typing is also an option, and input is made easy with auto-complete functionality. Possible options are shown as the string is built up helping to ensure the right information is entered without errors. From the variable list drag-and-drop the variables straight into the setting box Drag and drop processing units Freely move units around Easily understand the effects of changes The XG-7000 Series allows you to confirm current/initial settings against any changes ranging from image preprocessing combinations, variable values, through to measurement result differences from parameter changes. By being able to confirm the effect of changes and easily test options quickly, optimal settings can be reached in minimal time. As soon as the preprocessing filter has been selected, you can immediately see the results Each variable result according to setting changes can also be understood in realtime via the unit result list. Stress free large scale editing INDUSTRY FIRST Divided & magnified displays The flowchart display can be divided and each divide can be magnified as desired. Enabling overviews and specific areas to be viewed at the same time for easy navigation. Displays the flow section at an observable magnification Grouping function The grouping function allows for efficient flowchart creation and management. Multiple units can be grouped, named, colour coordinated and minimised when not required. By managing the units by gathering them into meaningful groupings, even the processing of large-scale flows becomes easier to understand. This function also allows you to copy each individual group and paste these groups into a separate flowchart just like sub-routines. Freely set the group name and colour On-line real time image editing The XG VisionEditor software can communicate directly in real-time with any connected controller and camera. Parameter adjustment, simulations and images are automatically transferred, enabling quick programme construction and testing. 11 DEVELOPMENT PROCESS 2 High-End Power and Flexibility Equivalent to PC Based Systems Variable processing A wide range of variables are able to be defined, including image, positional, linear, scalar and array based. Variables are not limited to a single programme and can be set for local, system or global use. The re-writing and initialisation of each variable can be individually set depending on its intended operation. By using the variable setting utilities, even such tasks as the batch substitution of an allocated variable name or searching for a specific variable is made easy. Variable comment function Each variable can be assigned comments, indispensable to debugging and programme review. So as the flowchart becomes large and complicated, variable selection becomes simple. Comments displayed when the cursor hovers over the variable Variable setting screen Control processing The XG-7000 Series provides control processing including conditional branching and looping essential to programme flexibility and customisation. This allows for flexible image processing enabling switching and processing based on changing conditions. Timing controls such as processing delays or waiting on terminal/operator interaction are also available. As the vision flowchart can be created to interact with different machine and control processes so the XG-7000 Series can easily become an embedded part of the overall machine and system Control processing definitions Branch - Join Loop Loop End Break Timing control definitions Pause Timer Timer setup Terminal I/O Delay Variable Delay Wait dialogue WIDEST RANGE Based on input value branch flowchart accordingly (up to 64 points) Repeat unit operation until end or break condition Stop loop Break loop and exit Pause for a specified time User specified timer Pause until specified user time finishes Pause until changes in specified I/O occur Pause according to the results from selected variable compared with a selected reference value Pause until changes made by an operator Flexible calculation & script based processing Calculations are also essential in customisation and the XG-7000 Series allows for over 100 different functions and commands to be used. Calculations and script can be quickly created by dragging and dropping in functions from the parts list. Direct typing, cut, copy and paste are also supported, along with an auto-complete function to help minimise input errors. Script based design is also possible making complex calculations easy to break out and understand. NEW Up to 5000 characters per single calculation Automatic call out error checking function WIDEST RANGE Automatic and interactive command processing Commands like programme switching, image capture, reset, start/stop operation log, and so on, typically require external control. However such commands can now be automated and made an integral part of the image processing flowchart. The command set is of such a power that the controller can be made to control itself. Machine functionality at higher levels than the image processing alone is also possible with the in-built commands. For instance changing to a different displayed image, zooming in on a defect based on an inspection result or saving image data for a certain part failure are all possible, as are many things due to the wide range of commands available. KEYENCE has also provided the ability to create custom commands which allow the user to combine specified built-in commands into a single command making macro based simple operation possible. Examples of built-in commands System control (73 types) Common commands include: programme switching, image save, trigger input enable/disable, mode switching (run/stop), reset, write variables, clear history data, export history data, image capture, start/stop operation log User interaction (22 types) Common commands include: open/close dialogue boxes, image switching, image zoom, image scroll, change password, switch user accounts Command list 12 DEVELOPMENT PROCESS 2 The user-defined “C-Language Unit” can be freely integrated into the processing flow Source code constructed by the user in C can be integrated into the XG-7000 process flow. The essential sections of image processing, communication output settings and the creation of displays are developed efficiently and without complex programming, allowing for concentration of resources toward the development of core processing sections. The source code can be compiled with a single click, and can be debugged during simulation by coordinating with the C-language development environment. PC based Device selection Compatibility verification Image processing Algorithm development Image capture/lighting Condition settings Communication/control Programme construction Trustworthy and ultra high-speed hardware that can be used immediately XG-7000 Efficient design without complex programming Image processing Algorithm development Image processing Programme design Debugging Creation of display/utilities Development environment that encompasses communication, GUI creation and operation Established debugging/simulation environments Concentrate time and effort on the development of core sections Examples of C-language Unit uses Pixel-unit access to the image data • Unique filter development • Unique algorithm development • Appropriation of company assets Calculations, scripting and variable processing • Condense large calculations into one unit of operation • Process large more complex calculations • Increase the processing speed of large computational calculations The compilers for the PC and XG controller enviroments maximise the ease of use by using DSP native commands rather than scripts or an intermediary language. Insert the C Plug In Unit into the flow in order to reflect the independent algorithm Compile the source code constructed using C-language with the touch of a single button 13 NEW Independent image capture Capture images out of sync based on physical machine processes and device interaction The XG-7000 Series is capable of “Independent Image Capture” so that it captures images during the flow of operation rather than at the beginning of the sequence. Images can be captured in sync with device movements and with no dependence on the current image processing being conducted. Conventional systems have to wait for the return of a programme to the beginning of its cycle for a new image to be obtained. The “Independent Image Capture” function independently captures images, and should the XG-7000 be currently processing another image it will be buffered. Up to 1013 images can be stored in the buffer helping enable a zero image processing delay period to maintain a high throughput during processing. PC simulations can also be efficiently conducted with the XG software suite by directly saving the individual camera images to individual folders. Conventional Images that have been buffered are processed in the order they were received in the camera buffer area. Background image capture Camera 1 Camera 2 Camera 3 Camera 1 During first time processing Camera 2 Camera 3 During first time processing Even if the next target arrives during processing, the image is captured and progress continues The next image capture cannot take place until processing is complete, progress is stopped Example: Non-synchronous image capture for high speed pick & place processing Conventional model As it is possible to send a trigger input from the machine to the XG-7000 controller in sequence with the index and transfer operation so the cycle time can be dramatically improved. Independent image capture The operation timing has to be synchronised by lengthening the stop time of the index, or two separate controllers needed to be used. There is no need to stop the index cycle as the single controller can capture both images with no waiting period. Unsurpassed multi-image capture Optimisation of a single inspection cycle. Conventional systems rely on the completion of the process before acquiring the next image In conventional image processing, one inspection cycle consists of “image capture -> inspection -> output”. If multiple inspection is required on the same target but under different lighting conditions, this cycle would have to be repeated multiple times. However in the XG-7000 Series a secondary image capture can be performed straight away (after the first and before any processing starts), the lost time associated with the additional unnecessary trigger inputs, and outputs can be eliminated. Conventional Image capture Image processing Output Image capture Image processing Output Multi image capture 2 cycles of control processing are required Example: Defect inspection with multiple lighting Using the XG multi image capture capability allows the detection of defects and quality control that is not possible with conventional image processing. Image capture Image processing Output 1 cycle everything is done Halation elimination due to multiple image capture Using multiple light sources and the image calculation function means the perfect image can be obtained in one cycle, even if different lighting combinations need to be put together. In a conventional system 3 or more cycles would need to be performed to get all of the images severely impacting on the machines cycle time. Even then the system may not be able to process the images and inspection correctly. Composite image via image calculation function Multiple image capture increasing light intensity 14 Image capture Resultant image used for inspection with no over or under exposure. DEVELOPMENT PROCESS 2 Custom Image Enhancement Filters Custom image filters ranging in size from 3 x 3 to 21 x 21 can be designed where the processing kernel can be freely defined. In addition to convolution, expand and shrink can also be chosen as the main processing method to support all your custom filter needs. Expanded raw image Post-processed image [21 x 21 shrink filter use example] Solar battery electrode pattern break [21 x 21 custom filter setting screen] Image Operations Create an optimal image aligned with the inspection The image operation breaks from the tradition of a PC-based library and has included various image calculation processes including mathematical (addition, subtraction, multiplication, division), logical operations, bit calculations, rotating/parallel translations, zoom, trapezoidal correction and pixel number conversion. With the immediate confirmation of resultant images, the image calculation function is more user-friendly than a PC-based library. Furthermore, by storing images to image variables before and after processing, different processes can be conducted on images independently and combined at later stages. Example of Image Calculation: Defect Detection on a Chip Defect: reject part Stain: acceptable Coaxial vertical illumination NOT calculation (invert) Only the defect section is highlighted Min calculation (dark-side prioritised) Low angle lighting FIRST IN ITS CLASS Different defects appear on the image when using both coaxial vertical illumination and low-angle lighting. However, the stain does not appear when using low-angle lighting. By utilising this difference, the chip only can be highlighted by reversing the image light with the coaxial light and then using the Min calculation between the images so the lowest greyscale value of the two is the result. The region where the stain is completely black in one image remains black while the area where the chip exists in both remains highlighted. Automatic Region Formation [Processed Image Region] The binary white or black areas can be used as a custom inspection region. • The inspection region can change dynamically without missing any defects. • Automatic adjustments at the binary level support changes in brightness. • Complex region settings are created based on the binary settings. • The Blob filter can be used to remove noise outside the target region. Including the printed section in the region Example of automatic region formation: IC stain inspection While the print changes from package to package, stains can be detected on the package and around the printed text. Abnormalities on the leads can be detected at the same time by including the leads in the image inspection region. So even if the shape changes, the correct region can still be processed. All areas outside the printed section considered the inspection region Detecting the region outside the printed section 15 USER INTERFACE Operator Friendly Customised GUI can be Easily Created the Click of a Mouse Using Drag and Drop Screen Editor Easy creation of the controller display screen and operating interface A unique display screen configured to your needs and desires can be easily created by dragging, dropping and re-sizing different components from the parts list. By being able to use and configure many components such as BMP images, graphics, text, measurement value and camera images the screen can be designed with the operator in mind. Up to 100 different screens can be created per programme for full customisation to any process. Screens and components can be easily displayed and switched between, not only via external inputs, but also based on image processing results or settings. INDUSTRY FIRST Settings for dialogues or display items can be easily found and navigated to with the tree-view hierarchal screen browser. Screen positioning is completed by dragging-anddropping required components, such as camera images and display components, from the parts list. NEW The layered display view helps allow for easy intuitive design of the screen overlays, components and dialogues that would have been typically complex to achieve. INDUSTRY FIRST Dialogue creation function Create and customise operator menus and interfaces for easy operation For user interaction with the image processing of the XG-7000, up to 900 unique custom dialogues can be created per programme. Dialogues can be linked to create cascading menus or choices based on a user input. Dialogues can also be tied into the timing and operation of the image processing flowchart so that they appear when necessary for a user action and input to be taken. Dialogues and menus can also be configured and displayed based on the user account logged into the system. Dialogue parts list Cascading and overlaying menu design Dialogue components These are the fundamental parts for the creation of a dialogue. Drag and drop from the list the components that suit your needs for your custom dialogue. Built-in dialogue Frequently used operations, such as statistics, image archive and library registration. Have already been prepared to be incorporated right away. User account based dialogues By changing the display/non-display parameter for each dialogue menu based on user accounts, different menus and levels of operation can be created for administrators and operators. 16 Detailed dialogue display and interaction settings Detailed settings for each dialogue are possible, including parameters for position, when to display/remove on screen as well as handheld console button interaction. USER INTERFACE ActiveX Control Fully customisable PC interfacing The XG-7000 controller can be incorporated and become an integral part of a machine through the use of the ActiveX control. A PC interface can be designed that not only interacts with the XG-7000 system, but also other aspects of the machine and its operation. In addition to being able to create a PC control interface, measurement data, result information, historical data and file management are also possible through the Active X control. Multiple connections can also easily be established and configured for bringing together multiple controllers or machines. All this allows for the collective management of multiple systems into one interface and the development of a full production management system. This is an example of a PC interface bringing together camera images and operational buttons for the XG-7000 vision system as well as other machine functions required for wafer alignment and process control within the semi-conductor industry. The operator only needs to use one interface for both vision and machine control. • ActiveX is a registered trademark of Microsoft Corporation, U.S.A. Machine control and structure with ActiveX Server Full machine control can be developed through a single interface that is displayed on the PC. All devices are connected and controlled via the PC. ActiveX makes it possible to bring all these elements together into one interface. PC for device control User Interface PC Display Integration of XG-7000 image processing components and other device controls XG-7000 Series Additional Devices (E.g. XY stage, robot etc) User Interface Remote data logging and monitoring software “XG Vision Terminal” The XG Vision Terminal software enables the remote monitoring, logging and support of any XG-7000 controller connected to a PC via a standard network. Maintenance labour-hours, down-time and business trips can be significantly reduced as problems can be resolved remotely with the transfer of setting files and image data. File transfer Ethernet Office PC Main functions Management of multiple controllers connected via a LAN Remote desktop function Enables the verification and remote operation of a connected controller, without extra data being sent and interfering with controller processing. Logging function Enables the display, logging of measurement results and storage of image data to a PC folder from an inspection with any connected controller. This function also supports the accumulation output buffer of the controller to ensure complete data collection. File acquisition function Enables the transferring of setting data files and image data files between the XG-7000 controller and a PC. 17 DEBUGGING Automatic Error Checking and Easy Debugging — The Secret to Development Efficiency Seamless simulation and debugging Highly efficient programme development The XG suite of software gives the opportunity for simulations, whether it is for image processing flow, GUI construction or I/O and control to be run at any point during development. Having this capability at any time means debugging can be performed whenever desired, helping maintain development efficiency all the way to deployment. XG software brings together all the components from development to implementation Flow construction UI construction Seamless debug & simulations Control communications INDUSTRY FIRST Error checking function Instantly see and go to the source of an error This function enables you to check for the presence of errors within the inspection settings simply by pushing the check button. This automatically creates a list for any errors found and reports back on the error type and their location. In units that have calculations, functions and expressions definitive information is not only displayed on the type of error, but also the row and location of the error. INDUSTRY FIRST Checks down to exactly what row and column the error has occurred Automatic logging function Trace dynamic errors Errors that occur under specific conditions are relatively difficult to find. In the XG VisionEditor software, all processing results and errors from simulations, are displayed in a continual log format. Debugging and error checking can be quickly performed as dynamic errors can be easily found, checked and resolved. Dynamic errors, such as those that occur when variables occur outside the reference range, are also included in the display. INDUSTRY FIRST Variable reference list indicator Quickly see and locate where variables are used The XG VisionEditor software also incorporates a variable reference list that allows the quick verification of exactly which variables are being used, and where. In addition to the unit ID being shown next to the variable, the unit can be made to flash in the flow view by simply clicking on the variable. This makes it very easy to see all the locations where a variable is referenced and used. By selecting a variable, all reference destination units on the flow view will flash. Variable list INDUSTRY FIRST NEW Flowchart break function Step by step debugging Multiple break points (pauses) can be used anywhere on the flowchart. These cause the running programme to pause during simulation. When a break point is reached all processes, including variables can be checked for efficient debugging. This debugging function can also be enhanced by using multiple break points so a step by step running process can be setup. 18 Each unit can be independently processed and stepped through. By pushing the re-open button when a breakpoint is reached the image processing flow will continue to run until the next break point is reached. By using the step button only the current unit will be processed. DEBUGGING Unit result and variable information list Quickly understand unit and variable operation All units used in the flowchart and associated variables can be viewed and confirmed in a tree based list view. This is beneficial for seeing and confirming all the results and data that is being processed. Sorting and filtering is also possible so only the desired unit result data and variables are shown. To allow for easy setting, click on any unit or variable. The properties open and parameters can be changed directly then and there. SUBSTANTIAL FUNCTION STRENGTHENING Full PC simulator function Supporting up to 50,000 images The inspection settings developed in the XG VisionEditor can be automatically run directly in the XG Vision Simulator from the VisionEditor software. Up to 50,000 images can be used and processed to mimic on a PC the exact operation of the XG-7000 controller. The simulator displays the configured GUI along with dialogues and supports output data (CSV format) while allowing for simulated I/O control and external input. Measurement results, variables and I/O can be all shown at the same time. GUI used during operation displayed complete with dialogue menus. Statistical analysis function INDUSTRY FIRST Obtain optimal settings in minimal time Easily troubleshoot I/O and signal processing Any measurement data or variable value can be displayed as a trend graph or histogram. In the trend graphs, up to 4 graphs of any value type can be simultaneously displayed. Optimal settings can be easily configured by lining up different graphs for multiple results based on changes in the processing conditions. The result data includes information on yield rates as well as standard statistical data (such as max., min., average, SD and 6σ values). Trace log function The trace log function is a great tool to help with processing and I/O troubleshooting. Giving integrators and developers the capability for checking and monitoring the sequencing of units being processed, I/O signals and commands. The results display can be split and the processing time for each unit along with other information can be easily displayed. The trace log can also be saved and be used at a later date as a reference guide. Up to 4 trend lines displayed simultaneously Trend graph Histogram 19 UTILITIES AND SECURITY Additional Utilities and Security Tools Make the XG-7000 Easy for Anybody to Work with Useful utilities for designers PC Image Settings With a thumbnail filmstrip view, captured images can be easily managed inside the XG VisionEditor software. The collection of live images from a connected controller or the image archive with historical measurement data can be done with the couple of clicks of the mouse. Windows Clipboard output for setting details and flowchart Detailed settings and the image processing flowchart can be copied into the Windows Clipboard with a single click. Having parameters formatted to be used with Excel means information can be easily saved for later reference or the creation of a settings manual and other documentation. NEW Clipboard output items · Excel is a registered trademark of Microsoft Corporation, U.S.A. Multiple region distribution and alignment Repeat, partial copy and paste Setting up multiple inspection regions that need to be equal distance from each other can be a mundane, time consuming task. The multiple region distribution function allows for quick distribution of multiple unit inspection regions in a circle, arc or straight line. Normal copy and paste functionality is enhanced with the repeat and partial paste option. Repeat paste allows for multiple units to be constructed all at once with one operation, saving countless repetitive operations. Partial paste allows for user selected parameters to be pasted across multiple units, which becomes very useful when one modified setting needs to be applied to many units. An example of using multiple edge position regions equidistant from each other to check teeth and overall circumference of a cog. You can select any item you wish to paste to another unit. I/O monitor for smooth integration An I/O monitor, RS-232C monitor, EtherNet/IP memory monitor, PROFINET memory monitor, PLC-link memory monitor, CC-Link memory monitor, and Ethernet monitor have been loaded on to the XG controller and are extremely beneficial in the verification of communication and I/O terminal wiring, ensuring smooth verification during the startup process. Simple multi-controller setup with removable SD card Multiple and replacement controllers can be easily setup with the external SD card. Settings files can be easily copied across and a controller is ready to go in a matter of minutes. Confirmation of historical inspection results during operation NG images and measurement results saved to the controller can be easily verified on the controller screen without any influence on processing during operation. I/O monitor 20 RS-232C monitor UTILITIES AND SECURITY Security related functions User account and grouping management Group locking Up to 100 different user accounts with individual passwords can be registered. At the same time there are also 5 user groups that user accounts can be allocated to. For each group different ranges of permissions and access levels can be set including editing, menu operation, and screen displays. Different interfaces, dialogues and button control can also be customised based on the needs of different operators, technicians, QA staff and administrators. The XG VisionEditor allows for password locking according to the group. After locking, the group settings cannot be viewed on the controller, so it is possible to prevent incorrect operations due to the operator’s unnecessary change in the settings and leakage of image processing know-how. XG VisionEditor Controller Without group locking Available operations can be limited such as that only the measurement range adjustment is available for the operator privilege (the administrator’s menu is greyed out.). With group locking Password lock setting via the XG VisionEditor The password is required to unlock the group. By switching the account (with a password), the privilege is changed to the administrator’s and the menu that only the administrator can operate is displayed. Operation log Controller password lock setting The operation log when used keeps and stores a date & time stamped log of all the button presses and settings changed by a user. This information can then be accessed as a CSV file for machine process security and management. A password lock can be placed in order to prevent operator errors by ensuring that inspection units (from within the flow constructed in XG VisionEditor) cannot be edited through the controller. • Changing parameters • S witching product type numbers • O pening dialogues • D eleting/adding units, etc. CSV file Setting file XG unit Controller ID -> IHGFEDCBA Controller ID -> ABCDEFGHI LOCK! LOCK! CUSTOM MACHINE MANUFACTURING The KEYENCE XG-7000 Series allows for OEM customisation to enable full incorporation into a custom machine Customising the startup screen Display of a BMP image such as a company logo or machine model is possible upon startup Camera logos The KEYENCE logo and model numbers used on the camera body are all stickers and can be removed as required. Blank handheld console For on-machine changes with the handheld console a blank version (OP-84236) is available for customisation. 21 STOR AGE AND COMMUNICATION A Multitude of Protocols and Storage Options Create the Complete Inspection System Save only the desired images for analysis and simulation The image output buffer enables images to be streamed to a variety of external devices (such as an FTP server) making it easy to test and analyse with the simulator software and statistical functions of the XG-7000 Series. Being able to define how and what images are stored and where significantly helps with the separation, analysis and retesting of failed inspections. Using the simulator and statistical tools together makes the correction and the optimisation of settings very easy. [Setting optimisation using the XG-7000 Series] Required items for setting optimisation Image Storage Statistical Analysis Simulation Image Storage y Save a large volume of images y Specify locations based on conditions Simulation y Work with the XG-7000 Series controller environment for testing on a PC y Re-test and simulate results with stored images Statistical Analysis y Superior analysis and understanding of processed items y Automatic generation of statistical results including maximum, minimum, yield and standard deviation. Setting adjustments IMPROVED FUNCTIONS Image output buffer (ensuring complete image output) The external image output function (SD card, PC application, FTP servers etc.) works with the same image bank as used for image capture. As the inspection and output result only occur after the image is saved, the image is always available for output allocation. Even if the output transfer process is backed up due to uncontrollable protocol demands, the image output has its own dedicated buffer. This ensures all images are accounted for and output (within the buffer capacity), even if delayed. SD card PC application FTP servers All images are stored in the buffer. FTP images direct to a network or HDD drive NEW Images can not only be saved directly to the SD card used in the controller but also transferred directly to NAS* (Network Attached Storage) through a LAN connection. Long-term image storage can also be conducted by connecting an easily sourced large capacity (10GB, 100GB, 1TB etc) external HDD. In addition, by using the image output buffering option, continuous NG images will not be lost. * NAS refers to a storage device that is designed for use on networks and contains file server software. Unlike USB based external drives that can be only connected point to point and need to be configured, a NAS device becomes immediately part of the network when it is connected, making it available for all other devices to use. Thus simplifying data browsing and file sharing. HUB Output image XG-7000 Controllers STRONGER NEW ABILITIES Output image Use as a simulation image HDD PC Multiple PC Software simulations can be easily managed and run from the images transferred by FTP. By defining a folder the XG-7000 controller can directly output the images to the correct location on the PC for the individual simulator to reference. PC simulation and remote support via a PC and mouse Interact directly with the XG-7000 GUI via your PC and mouse. Existing settings can be tested and simulated with saved images via the PC simulator. Furthermore, the XG Vision Terminal software offers remote connectivity and data logging capability NEW Fully interact with the system with a mouse Process up to 50000 images with Simulator+ 22 STOR AGE AND COMMUNICATION Save only the desired images for analysis and simulation Supports PLC link connection between PLCs from various manufacturers and exchanges results and commands via the data memory just by selecting the connection destination manufacturer/device. As standard, the main unit is equipped with I/O, RS-232C, Ethernet, USB, and SD card slots. Furthermore, it is also possible to check communication with the communication monitor. This achieves significant reductions in cost, time, and effort. PLC PC SD card Switching hub FTP server function-installed network supporting HDD PLC Ethernet/RS-232C PLC link Handheld console button allocation The buttons on the handheld controller can be freely allocated. Even detailed settings, such as options when buttons are pushed simultaneously, can also be set. A blank handheld controller (OP-84236) is also available for independent naming of buttons. Analogue RGB monitor output SVGA output XGA output User group function menu access The function menu is the heart of conducting and managing the flowchart and operations directly on the XG-7000 Series controller. Operator error can be prevented by enabling the display/or non-display of different options depending on the access needed for the 5 user groups. EtherNet/IP support To enable easy integration into many existing facilities across many industries the XG-7000 Series fully supports EtherNet/IP communication. Connectivity can be established with any PLC supporting EtherNet/IP via a standard LAN network. NEW PROFINET compatible PROFINET is an open industrial Ethernet standard that has been equipped with high flexibility and high speed for automation control in a variety of industries and it has been included as part of the communication functions for the XG-7000 Series. If a compatible device is present, it is possible to communicate via the LAN port on the main unit regardless of vendor. INDUSTRY FIRST CC-Link unit (Supports ver.1.10 and 2.00) Smooth easy PLC connectivity Remote device communication is possible by connecting a CC-Link device (such as a PLC) and the CA-NCL10E (connected to the side of the main controller). Smooth and easy integration of the XG-7000 into the PLC is possible with simple wiring, connectivity and setting through the PLC link function. To PC CC-Link unit * The CC-Link is a registered trademark of the Mitsubishi Electric Corporation. 23 ANALYSIS New Tools Designed to Assist with Online Performance Tracking and Reporting NEW Online OK/NG batch analysis While the system is processing parts online, the batch results from a series of images (taken from the main memory, a SD card or the FTP server) can be displayed. This allows for the easy confirmation of changes in settings without affecting inspection performance. In addition to the batch testing, Master OK (pass) and NG (fail) images can also be used for comparison purposes. The batch analysis function makes it very easy for a user to fully understand a systems performance at any time without having to collect data or take the system offline. OK (pass) and NG (fail) results can be separated in the statistical analysis display OK Master Image Batch Analysis Settings can be adjusted directly by selecting the inspection number. NG Master Image A summary of the batch test results are displayed on screen, and images from the image strip can be compared to pre-saved OK and NG master images. This single view easily enables users to confirm results from adjusted settings. Image Strip (Controller Buffer, FTP server, SD Card etc) Conventional performance analysis Batch Testing When initially dialling in a system or making modifications to existing settings, it becomes very easy to loose sight of the original requirements of the inspection. OK images become NG and vice versa and it becomes harder and harder to meet the desired standard. By retesting images against master images, it is easy to confirm whether there are any changes in the inspection standards compared to the initial standard. If changes have occurred having master OK and NG images to work with makes it simple to compare and adjust settings without affecting the original intent of the inspection. Initial setup Settings changed Additional changes Comparing against an OK standard Compared to Comparing against a NG standard “!” indicates the effect of altered parameters when compared to the standard. NEW Reduction in risks when changing settings Inspection Images NG Master Images OK Master Images Quantification of inspection standards Reduction in labour-hours and downtime Customised screens and interfaces The XG-7000 Series supports the creation of custom screens directly on the controller. A fully customised screen can be easily created to display a wide range of results, images or graphics as required. Multiple intuitive screens can be designed for different views of the image processing results Judgement results and measurement values can be freely set and made to change colour based on unit judgement results Freely size and position displays of captured, registered or archived images Easy to use menu for adding, editing, deleting and moving multiple screen elements Automatic zoom function for highlighting points or defects detected in an inspection Logo display for company customisation 24 ANALYSIS NEW Online re-testing and flowchart editing The Retest function of the XG-7000 Series allows images stored from inspections to be selected, retested, and edits to be made while the controller still fully processes other inspections online. This allows the user to make programme adjustments in order to optimise the settings without effecting the current inspection process or causing any downtime on the machine. Inspection processing carries on as normal in the background NG occurs during operation Easy image selection From the image strip a thumbnail version of the image can be selected. Additional images can be loaded from saved locations and identification is easy through the OK/NG colour coding. All the Retest feature settings are available from the same menu allowing for easy setup and use. Retesting begins by selecting an image. Retest settings Retest By simply picking the image from the image strip, retesting is performed. From the results and information generated by the retest adjustments can be made accordingly. Batch retesting can also be performed for a deeper understanding of the process and changes that need to be made. Edit Flowchart Programme Changes can be made to the units in the flowchart based on the retest image and results to optimise the settings. Confirm settings and avoid mistakes Adjustments reflected Retesting is complete with no effect on the controller In Retest mode, the image strip can be accessed from any screen. This means you can seamlessly switch between current and retest images while changing parameters to ensure settings can be reliably confirmed for correct operation. 25 IMAGE OPTIMISATION Create the Optimal Image for Processing in Real Time Based on the Raw Camera Image PR E PRO C E S SI NG F I LT E R S Highlight and Improve features that previously could not be seen. Remove features and aspects of an image for stable inspection. The XG-7000 Series includes 21 types of preprocessing image enhancement filters that can dramatically improve the raw camera image based on changes that are caused from differences in the target or the targets environment. In using these original KEYENCE filters correctly, an optimal image for processing can be created resulting in an improvement in inspection stability and performance. This can help reduce misdetection and inspection errors and give a high level of confidence to using machine vision. Shading correction (Real time) Shading correction is a real time filter that evens out any large random shadows or glare on a target surface. Leaving behind smaller defined points which are often associated to being flaws or defects. As this is a grey scale processing filter, it dynamically changes the processed image based on the input image rather than being based on a fixed binary setting level. This ensures consistency with target variation and changes in the raw image. Surface quality on a metal roller Stain detection on the bottom of a can After preprocessing Original image Shading correction can be used to extract just bright, dark or both bright and dark defects depending on the nature of the surface and image needing to be created. Original image After preprocessing By cancelling out the hot-spots caused by changes in the target surface a uniform background with the strain present can be created. Defect detection on connector housing Glass panel alignment Original image Original image After preprocessing The rough background causing uneven illumination is cancelled, yet the defect remains. After preprocessing The structural shadows are cancelled leaving the defect clearly visible. Blur filter (Bidirectional smoothing) With this image enhancement filter, any fine background patterns or image noise can be blended into the background and removed. This filter can be used numerous times to get the desired level of blending as well as in individual directions to keep a distinct aspect to one dimension of the image. Foreign particle detection on a striped pattern Original image After preprocessing By eliminating the striped texture to the target, the foreign particles can be detected. 26 Counting individual parts in packaging Original image After preprocessing The filter is applied to the image in one axis resulting in the packaging being removed and leaving the parts to be perfectly visible. IMAGE OPTIMISATION INDUSTRY FIRST Blob filter Blob filtering of certain grouped image elements based on attributes (surface area, shape size etc), enables only the desired areas to be processed. Width measurement of a welded section Measuring the width of a weld after cancelling shadows, dents and removing spatter and excess from the weld section. Original image Before preprocessing After preprocessing Contrast conversion The contrast conversion filter helps enhance contrast by emphasising or reducing ranges of grey scale without causing shadows or overexposure. This helps increase edge strength, unify levels of grey or reduce noise on an image. Defining PCB components and connections By increasing the difference between the board and mounted components the areas for inspection are easily highlighted. Original image After preprocessing Preserve intensity (Illumination compensation) The Preserve Intensity filter automatically corrects for any intensity changes in the image due to light deterioration or external lighting fluctuations. The level of intensity in the captured image is compared to a pre-determined standard on a reference image and the difference is applied before processing. Screw position inspection Original image (normal light intensity) Binary image Original image (lowered light intensity) Binary image No preserve intensity Binary image With preserve intensity For each inspection unit, you can combine filters creating optimal images for an inspection. Multiple processing On-screen effects and results A total of 21 types of preprocessing filters can be set and each filter can be processed up to 13 times per unit. For each unit, filters can be combined together in the optimal combination for that single inspection. Preprocessing results are displayed in real-time on the screen. Making it quick and easy to see and set the optimal combination in the minimal time. Filter order and sequencing The preprocessing sequence can be easily changed by moving filters up and down the list. 27 I M AGE C A L C U L AT ION F U NC T ION Create a single image from multiple images through a host of advanced image combining functions The XG-7000 Series has a multitude of image calculation functions, including mathematical (addition, subtraction, multiplication, division), logical operations, bit calculations, rotating/parallel translations, zoom, trapezoidal correction and pixel number conversion. Being able to combine multiple images into one resolves a number of issues that have made some conventional inspections difficult. Image calculation example 1: Multi-lighting and image composition Optimal lighting can differ for different types of flaws (projections/depressions) and stains (shade intensity) on the same target. Two image captures and two different lighting techniques are used for individual defect inspection of the target. Then combination of the two images and defects can be put together to be processed and displayed together. Nut stain/flaw inspection Stain: Dome lighting Conventionally As the two defect inspections have to be separated due to the need for different lighting, so the total number of defects, total defect size or overall target pass / fail can not be easily determined for a single target. NOT to reverse the image Flaws: Low angled lighting Image calculation Max image composition (higher intensity priority) Combining the stain/flaw images into a single image Judgements can now be conducted to the same standard as inspections previously implemented visually, including the area judgement of total stains or flaw. Image calculation example 2: Changing light intensity and image composition Targets can often have different types of defects requiring different lighting methods for stable detection eg (scratches / burrs and surface stains). The flexibility of the XG-7000 means multiple lighting patterns can be cycled through and tools applied ensuring correct inspection of the part. At the same time the image operation function enables composite images to be created so all the detected defects can be shown on screen and processed at once per inspection Aluminium cast hole inspection Average image composition Stable detection of defects using preprocessing filters and the stain inspection tool. Acquisition of a uniform image without the dark or bright defects being lost. Capturing multiple images with a variable shutter speed NEW C A L I BR AT ION F U NC T ION Image calibration including tilt, and lens distortion correction The XG-7000 removes conventional image processing problems caused by camera mounting angle and lens distortion. The camera can be calibrated precisely, orientated about its axis and have its origin offset from its location for true measurement, scaling and position processing. Calibration unit with the multi-sized calibration sheets The calibration unit can correct both lens distortion and perspective distortion at the same time. A correction by using more than one pattern with different intervals is available along with that using only a standard calibration pattern. It is possible to precisely correct an entire screen even in the wide field of view with the large perspective distortion. Simultaneous correction of lens distortion and perspective distortion Original image 28 Calibrated image Lens distortion correction The calibration function also corrects for lens distortion. A uniform image can be acquired on the entire screen, allowing for accurate dimensional measurements, positioning and part inspection to be achieved. Width measurement of a solar battery cell Resolves the problem of differing measurement results at the centre and edges of the image area due to lens distortion. Original image Calibrated image IMAGE OPTIMISATION C OL OU R PRO C E S SI NG Optimal colour processing for stable inspections using the new colour extraction engine “A.C.E.II” The XG-7000 Series is equipped with a new colour extraction engine. The A.C.E.II is based on the HSB colour model (closest colour model to the human sensory system) to attain high colour extraction performance that stabilises previously unstable colour processing schemes. The XG-7000 Series also features “fine colour processing” to extract full colour information exactly the way the camera captures it. This technology significantly broadens the range of colour processing applications previously accomplished by machine vision systems. Colour to grey processing Colour to Grey processing can optimise the shade gradation using hue, saturation, and brightness. This makes it possible to convert images with low contrast into images with defined shade differences. Unlike conventional full colour processing, which picks up all tone changes and makes distinction difficult, colour shade processing can optimise the shade difference between a user-specified colour and the background. Extraction of copper foil on printed circuit boards Standard colour processing… Original image Conventional processing captures all tone changes, rendering any distinction of the copper foil and its surrounding components impossible. Shade differential display If using colour shade processing Colour to Grey display Shade differential display A.C.E. II selects the copper colour and blackens the area around it A.C.E.II accurately extracts only the copper foil portions. KEYENCE’s original colour shade processing Standard colour shade processing KEYENCE colour to grey processing This process converts all colours to a certain level of grey. Making similar or close colours hard to differentiate between, as well as not accounting for saturation and brightness levels and potential changes. Hue (H) Saturation (S) Unlike conventional colour extraction where Brightness (B) small colour changes are hard to distinguish and saturation & brightness are not accounted for, the KEYENCE colour extraction works with all three aspects. As Hue, Saturation & Brightness are all adjustable, small changes in colour or shade can be adjusted for and reliable stable processing is ensured. The edge required for detection Fine colour processing Fine colour processing directly processes full colour information exactly as the colour camera captures it. This is ideal for detecting stains on sheets, films and non-woven cloths where the stain can appear in any colour with respect to the background. No setup is required for colour extraction, allowing users to complete the inspection with one simple operation. Foreign particle detection on a non-woven cloth Original image Shade differential stable detection of all colours. Even if the background is darkened… Reliably extracts all colours. Even in targets with varying lighting conditions Detects only the defect Overcoming the weaknesses of full colour processing Intensity cancellation function (glare removal) The newly added intensity cancellation function solves a common problem of detecting all the changes when using full colour processing on colour images. This function delivers stable detection performance by ignoring glare and lighting variations on the target background, and detecting only the area where hue and saturation differences exist. 29 DEFECT INSPECTION TOOLS Fast and Easy Implementation of Complex Vision Algorithms with KEYENCE’s Original Toolset S TA I N I NSPE C T ION TO OL A wide array of setting parameters and strong visualisation tools makes this the industry standard in surface defect inspection. The stain inspection tool finds defects such as stains and flaws by comparing the intensity of a user defined pixel grouping to that of its surroundings. For stable reliable inspections, stains can be grouped and filtered based on size, shape and contrast level. In addition the contrast view enables real time visualisation on the performance of the tool to a user both during run and setup modes. Helping enable easy setup whilst maintaining consistent performance allowing for quick and easy on machine tuning. Foreign particle detection on the inside of a container Conventional binary processing would not be able to detect the foreign particles as there is very little contrast between the particles and the dark portions of the container. However, the stain inspection mode can compare the differences with the surroundings, allowing reliable detection of only the foreign particles. Foreign particle Original image Binary image Stain inspection mode (stability screen) Contrast view display Using the colours blue, light blue, green, yellow and red, the contrast view display assigns a colour to defects according to the intensity difference between them and the surrounding area. The contrast view display updates in real time so you are able to see the defect position and intensity differences, allowing visual and intuitive confirmation of the differences between the defect you want to detect in comparison with the background or noise. Bad mark detection on PCBs (Contrast view) Original image The contrast view can be used not only during setup, but also during operation. Leading to practical uses including the highlighting of potential areas of false detection and the verification of the current settings. Contrast view display Stain The area with an intensity difference is coloured from blue to red. The relationship between contrast view colours and the stain level (guideline) Stain level 0 Colour Blue 64 128 192 255 Light blue Green Yellow Red Dent detection on a metal shaft surface There is a greater stain level for the dents and scratches (green & red) than the background INDUSTRY FIRST Visually adjusting the optimal parameters whilst using the contrast view display Stable detection during processing Grouping filter Various group filter settings are also available for the stain tool to enable processing and sorting of stains and defects. Filters include basic fill and area based functions as well as degree of circularity, major axes length, aspect ratios and axis ratios. Such settings support the filtering of defects for more efficient pass/fail and sorting applications based on defect size and shape. 30 Crack detection of a tablet (before grouping filter) Crack detection of a tablet (after grouping filter) The stain tool also picks out the granules and other changes that are of a similar stain level. Filtering of defects down to long thin cracks only using area and axis ratio. DEFECT INSPECTION TOOLS T R E N D E D GE S TA I N I NSPE C T ION TO OL Optimised multi-point profile inspection for burr/chip applications This tool extracts the profile from the edge of a target and uses it to recognise slight differences such as burrs and chips. In addition to simple geometric shapes such as circles and straight lines the tool can also be used on complex contours such as ovals, and continually adjusting free form curves. Loose Cable Winding Inspection Even if the standard target shape changes from target to target during a process the free curve will still map the normal profile of the target. At the same time lots of individual edge points are detected ensuring the projection is recognised. Extensive parameter settings support various defects Due to the wide range of parameters, it is possible to filter out defects based on inspection criteria. Optimal settings can be chosen based on aspects such as +/defects (burrs/chips), defect level, width and area. Burr to be detected Defect segment width = Edge points of target — = Normalised profile — = Detection threshold Moderate protrusions are OK FIRST IN ITS CLASS Defect level Defect area + Side of profile (burr) - Side of the profile (chip) PRO C E S SE D I M AGE R EGION F U NC T ION Map the inspection region to the ever changing target image or setup complex fixed inspection regions The XG gives a wide range of image inspection region options. Simple (rectangle, circles, arcs etc) and complex shapes (multi-node, multi-region) can be easily drawn on the image. Additionally, a region can be designated and mapped to the binary boundaries of an image for ever changing target shape and size inspections. The vision inspection region can adjust for geometric shapes like circles and straight lines or more complex contours such as ovals or free-from curves. Stain detection on a plastic mould Automatic inspection region adjustment on complex shapes based on their binary image. Enabling stable detection on any target even without position adjustment. [Image differentiation processing filters] Subtraction Real-time image extraction Produces the difference from two images by subtracting the input image from the master (registered image). Lead frame chip inspection Registered image (good part) Input image (defect) As this filter processes in real time on the acquired image only, so part movement doesn’t affect the image used for defect inspection. The filter extracts the small areas of change (such as stains and defects) in the image, where as the larger and uniform areas (such as the edge lines and background) are removed. Leaving a stable image for stain detection. Foreign particle inspection inside a cup Differential image As a true subtraction is performed even complex targets with defects can be easily processed as the difference is left over on a uniform background. Original image After preprocessing As part position is not always repeatable so stable defect detection is still possible as the edge line, border and background are removed from the initial raw acquired image. 31 POSITION AND DIMENSION INSPECTION SOLUTIONS High-Speed, High-Accuracy, High-Stability FASTEST IN THE INDUSTRY Sh a p eTr a x II Precise, even under bad conditions. Then searches with high-speed. ShapeTrax II finds position information of targets based on their profile shape. The high speed algorithm also accounts and eliminates changes in target conditions for accurate (to 0.025 pixels) stable detection. A stable search can still be conducted regardless of target changes such as chips, overlapping areas, contrast changes and even size changes. Alignment and registration marks that can easily be affected or largely distorted during a process can also be quickly processed and recognised. Glass panel alignment markings ShapeTrax II TM precisely finds the object even under bad conditions such as these. With both low contrast and defects present, there is complex noise found in the background. Registered image Defective profile Blurred profile Inverted appearance T R E N D E D GE F U NC T ION Measure profiles within a single designated area The Trend Edge tool detects edges at user-specified pitches within the inspection region and outputs all data for each detected point, in addition to the maximum, minimum and average values. Previously, this required multiple inspection regions and calculation settings, but now the same inspection can be completed by configuring a single trend edge inspection tool. The multiple edge points obtained can also be used to draw approximated best fit lines and circles for further processing. [Detection principle] The Trend Edge tool cascades from one segment to the next scanning for an edge based on the segment shift width. As edges are detected so the width (trend edge width tool) and position (trend edge position tool) for each segment is calculated. Condenser profile measurement Multiple measurements and identification of narrow or wide points across a single target are easily possible with one single tool. Each segment edge position can be clearly identified for easy confirmation Primary target identification Easy definitive settings are possible with the edge waveform that can be displayed per segment. Segment movement direction Linear processing Detecting the position of glass substrate edges Detected peak Segment width The trend edge tool can map a virtual straight line from all of the edge positions along a substrates edge. With the ability to filter and ignore abnormal points the virtual straight line can be used for accurate position, angle, reference and geometric data. Detected bottom Movement volume Direction of edge detection Abnormal data is cancelled Circular/Arc processing Detecting PCB hole centres Trend edge can calculate the centre position and diameter of a circle by detecting multiple edge points around a curve, using this data to project a best fit circle. Abnormal edge positions can be filtered and ignored before drawing the virtual circle to allow for reliable measurements. Edge tools In addition to the powerful trend edge tools, basic edge tools can be used as well for inspection and positional referencing. These edge tools include edge position, edge width, edge pitch, edge gap, edge angle, and edge pairs. Edge inspection tools Edge position Edge width Centre pitch Gap pitch Edge angle Edge Pairs 32 Finds the absolute position of multiple detected edges Finds the width between multiple detected edges Finds the centre pitch between multiple edges Finds the gap pitch between multiple edges Finds the angle between two edges Finds the width between multiple edges after pairing edges based on detecting criteria POSITION AND DIMENSION INSPECTION SOLUTIONS 1D / 2D A N D O C R F U NC T IONS NEW OCR tools 1D & 2D code reader Various inspections, such as inspections of the external appearance and dimensions, can be performed simultaneously with the reading of 1D and 2D codes printed on the target or with the inspection of the quality of the printed 2D codes. By removing the need for both conventional 1D & 2D code readers and a camera for image processing, space and money can be saved with the use of this tool. Stable and powerful OCR is easily possible with the OCR toolset on the XG-7000. User defined characters can be imported into a fully customisable library along with standard fonts. Flexible tuning and setup is also made possible with a variety of methods for character extraction and detection. 1D code 2D code Recognition and processing of special characters Stable extraction and processing of characters in an arc Associate multiple inspections with product type based on identification. DataMatrix QR code VA R I A BL E S Freely share parameters, results and values throughout the whole vision programme Variables can be used as a means to change parameters, process results or store numerical values. This gives the XG-7000 Series the ultimate in flexibility for internal processing and interacting with menus and external devices. Such a degree of flexibility enables the system to be fully designed and used as desired without restrictions. Storing the ‘stain level’ parameter of the stain unit as the variable #stain_level #stain_level Shared settings between multiple units… Changes via menus… Locations where a variable is referenced are highlighted in blue Branching and processing control… Variables can be assigned to almost any parameter and can be freely shared or changed within the flow or through external control. Result processing and on-screen display… WIDEST RANGE C A L C U L AT IONS Powerful script based calculation functionality Over 100 functions are available for use in the calculation unit of the XG-7000 Series. Essential for processing and customisation, calculations can be used to perform a variety of tasks including variable definition, geometric processing, mathematical equations, scripting and logic based functions. Calculation units also support copy and paste, comment entry and error checking functions for full flexibility. Multiple calculation input Multiple equations can be specified in one calculation unit for script like processing. Up to 5000 characters per calculation unit NEW With a large amount of space to enter calculations, scripts and comments, any function should be possible to process. Copy and paste support Quick, easy creation and replication Desired area highlighted Error checking function In the event that calculations are mis-entered the error checking function can display the error and location making corrections quick and easy. Error display 33 INTERFACE FIRST IN THE INDUSTRY Camera port Removable mass storage capability Quick easy connection of any camera with quick disconnect camera cables. Max length up to 51 m. First in the industry to support the SDHC standard*, allowing information to be saved to removable mass storage SD cards up to 4 GB. Two SD slots are available as a standard giving total storage capacity to 8GB. All files including setting files, configuration data and measurement result data can be stored and read at high speeds. Camera expansion module Connect the XG-E700 camera expansion module when 3 or 4 cameras are needing to be used * Reading SDHC (high capacity SD cards) with a PC requires a dedicated card reader (commercially available). Camera expansion unit XG-E700 USB 2.0 port The USB connection allows for easy 1-2-1 PC connectivity for the transfer of settings, image and measurement based data. RS-232C communication Basic RS-232C or pre-configured settings (based on standard PLC manufacture parameters) via the PLC link function. Giving direction communication to PLC data memories without additional ladder programming. PC PLC LED lighting and CC link expansion modules Connect the light expansion module (CA-DC21E) and the CC-Link communication module (CA-NCL10E). FIRST IN THE INDUSTRY Ethernet (TCP/IP, EtherNet/IP, PROFINET) communication (PLC Link / FTP / Remote Connectivity) The 1 Gbps Ethernet port can be used as an EtherNet/IP, PROFINET or PLC link connection, ensuring easy connectivity and control among various PLC's without the need for complex ladder logic. The same port can be used for the connection of FTP server and NAS devices, as well as enabling remote management of multiple controllers via a single PC on a LAN. Light control expansion module CA-DC21E CC-Link module CA-NCL10E PC ❚ System configuration Sensors and others SD card Handheld controller RGB Monitor Camera 4 PLC CA-DC21E I/O terminals CA-NCL10E XG-7701 LED lighting XG-E700 Camera 3 Camera 2 PC Camera 1 Supports network HDD PC PC PLC USB 2.0 34 RS-232C Ethernet PRODUCT LINEUP ❚ Controllers 5,000,000-pixel camera supporting high-speed, high-capacity controller 2,000,000-pixel camera supporting high-speed controller XG-7701(P) XG-7501(P) 310,000-pixel camera dedicated controller Camera expansion module LED light control expansion module XG-7001(P) XG-E700 CA-DC21E CC-Link module Handheld controller CA-NCL10E OP-84231 OP-84236 (Blank) Image processing system integration software XG-H7NE1 Windows 2000 Professional Windows XP Home Edition/ Professional Windows Vista Home Basic/ Home Premium/ Business/Ultimate/ Enterprise Windows 7 Home Premium/ Professional/ Ultimate/Enterprise ❚ 5 megapixel cameras ❚ 2 megapixel cameras 11x high-speed colour camera 7x high-speed colour camera Colour camera Ultra-compact colour camera XG-H500C XG-H200C XG-200C XG-S200C 11x high-speed monochrome camera 7x high-speed monochrome camera Monochrome camera Ultra-compact monochrome camera XG-H500M XG-H200M XG-200M XG-S200M ❚ 1 megapixel cameras ❚ 310,000 pixel cameras 7x high-speed colour camera 7x high-speed colour camera Colour camera Ultra-compact colour camera XG-H100C XG-H035C XG-035C XG-S035C 7x high-speed monochrome camera 7x high-speed monochrome camera Monochrome camera Ultra-compact monochrome camera XG-H100M XG-H035M XG-035M XG-S035M ❚ Parallel I/O & Data Output Cables ❚ Camera Cables Camera cables Type L-type connector Standard-speed camera cable Standard high flex robot cable High-speed camera cable High-speed high flex robot cable Cable length Connector shape 1m 3m 5m Straight L-type CA-CN1 — CA-CN3 CA-CN3L CA-CN5 CA-CN5L Straight — CA-CN3R CA-CN5R Straight L-type — — CA-CH3 CA-CH3L CA-CH5 CA-CH5L Extension cable CA-CN10 CA-CN17* — CA-CN10L CA-CN17L* — CA-CN7RE CA-CN10R CA-CN17R* (7 m) CA-CH10 — — CA-CH10L — — Straight — CA-CH3R CA-CH5R CA-CH10R 10 m 17 m — — * Cables cannot be used with 2 Mega and 5 Mega pixel cameras. Parallel I/O cable OP-51657 (3 m) USB cable OP-66844 (2 m) RS-232C communication cable OP-26487 (2.5 m) ❚ Extension Cables Camera cables may be extended up to 51 m or 30 m. The maximum extension length varies according to the camera model. The dedicated extension cable is necessary in order to connect a repeater to a camera or a repeater to a repeater. Amplifier for extension cables CA-CNX10U (for standard cameras) CA-CHX10U (for high-speed cameras) 1Gbps Ethernet cable OP-66843 (3 m) RS-232C cable conversion connector OP-26486: 9 pins OP-26485: 25 pins Extension cables (camera to amplifier) Type Standard-speed camera cable Standard high flex robot cable Standard L-type cable High-speed camera cable High-speed high flex robot cable 3m Cable length 10 m 17 m CA-CN3X CA-CN10X CA-CN17X CA-CN3RX CA-CN10RX CA-CN17RX CA-CN3LX CA-CN10LX CA-CN17LX CA-CH3X CA-CH10X — — CA-CH10RX — ❚ LED Lighting Cables Y split cable CA-D1W (1 m) Connector to terminal OP-84457 (1 m) Standard cable CA-D2 (2 m) CA-D5 (5 m) High flex robot cable CA-D3R (3 m) CA-D5R (5 m) CA-D10R (10 m) CA-D17R (17 m) Cables must be used with deditcated amplifier. ❚ Accessories Monitor cable OP-66842 (3 m) OP-87055 (10 m) Industrial SD card CA-SD4G: 4GB (SDHC) CA-SD1G: 1GB OP-87133: 512MB 35 SPECIFICATIONS (SOFTWARE) Model XG-H7NE1 (XG VisionEditor) Unit configuration Image Input Common specifications Area Maximum 1000 units per programme (depending on internal memory capacity). Supports the simultaneous capture of up to 4 cameras. Supports multiple combinations, repeat capturing and background capturing. Supports HDR image capture Image acquisition (with or without background image capture). Supports delayed trigger functionality for correct image acquisition. Configuration of lighting (via the CA-DC21E) for image acquisition. Also supports parameter variable referencing. Shapes include: rectangle, rotating rectangle, circle, oval, ring arc, polygon (up to 12 sides), composite area (32 regions, including masks), processed (binary) Processing regions image region. Also supports parameter variable referencing. Filters: expand, shrink, average, median, edge enhancement, edge extraction X, edge extraction Y, Sobel, Prewitt, Roberts, Laplacian, binary, subtraction, preserve intensity, contrast conversion, real-time differential, real-time shade correction, average value correction, centre value correction, shading correction, high-speed shading correction, blur (softening), custom (3x3 or 5x5), custom (advance) (maximum 21x21 convolution, expansion, shrink), blob, Processing: Pre-processing filters Multiple processing of the same filter (up to 9 times) (for binary, subtraction, preserve intensity, contrast conversion, real-time differential, real-time shade correction, blur (softening), blob filter processing is once only), filter combination (13 stacks) (for binary, subtraction and blob can only be used once). Also supports parameter variable referencing. Colour extraction function Colour to binary conversion, colour shade processing, fine colour (stain mode only), RGB average (Colour correlates with HSB colour space). Also supports (valid for colour cameras only) variable parameter referencing. Scaling Ability to turn ON or OFF scaling coefficients for the X,Y and length measurements for each camera. Also supports parameter variable referencing. Selectable Execution Selection of whether to allow unit processing on controller or XG VisionEditor only. Also supports parameter variable referencing. Area Blob Count the number of white or black pixels in a region. 360 degree rotation and recognition of up to 99 patterns. Support for up to 4 mask regions, origin and reference point adjustment. Processing based on post image operation variables or registered (saved) images. Search measurements of up to 2000 detectable edge spaces. Supports 360 degree rotation and 50% to 200% scale changes. Supports the mask area setting of up to 4 locations including pattern area, and detection offset variable reference. Enables the use of multiple diagrams as mask areas. Supports references from postcalculation image variables of recorded images. Simultaneous position measurements of up to 3600 points in a linear or radial (circle, arc) direction. Average, maximum, minimum position, angle (when using circumference and arcs) measurements in a single region divided up into a maximum of 5000 segments. Best fit line and circle processing (using least square method) including abnormal point removal. Centre of gravity position, major axis inclination (180 degrees/360 degrees conversion) measurements of up to 9999 blobs. Edge Width Measurement of the distance between two edges (outer, inner, or specified). Edge Pitch Up to 1800 Edge Pitch / Centre Pitch (calculated from two edges) measurements from detected edge points. Edge Angle Measurement of the angle based on the straight line connecting two detected edge points. Edge Pairs Up to 3600 Edge Pitch / Centre Pitch measurements (based on pairs of edges) detected by 2 separate scans. Trend Edge Width Average, maximum, minimum width measurements between two edges (outer, inner) in a single region divided up into a maximum of 5000 segments. Centre of gravity, major axis inclination (180 degrees/360 degrees conversion), area, ferret diameter, circumference length, circularity, major axis parallel circumscribed rectangle, major axis length of the equivalent ellipse, minor axis length, major axis/minor axis comparison of up to 9999 groups of pixels. Detects flaw/stains through segment average intensity comparison within the defined region. Supports differential stain detection through the subtraction filter. Through the grouping function processing and filtering of up to 99 individual stains/defects. Supports the use of fine colour detection for colour based stain detection. Supports differential colour representative contrast display. Detects the location of variations in shape (projections or depressions) against a standard model line (straight line, circle, oval and free curve) derived from the normal target profile as defects. Measures pixel intensity value, and can be used as a reference for the preserve intensity filter. Pattern Search ShapeTrax2 Positional Edge Position Trend Edge Position Vision toolset Blob Stain Inspection and measurement Trend Edge Stain Intensity Colour inspection (valid for colour cameras only) Position Adjustment Alphanumeric and user defined symbol optical recognition of a maximum of 40 characters (20 per 2 lines) based on a pre-registered library of automatic and fixed extracted characters. Supports a library that can store a maximum of 200 characters including 20 user defined characters. Tolerances can be based on alphanumeric comparison, date & time and encrypted data time / shift codes with zero suppression and offset capabilities. Supports reading up to 512 characters of a 2D code (QR code: Model1, Model 2, Micro QR, DataMatrix/rectangle DataMatrix (ECC200)) and up to 16 reference judgement conditions. Supports data splitting into 8 partitions and calendar reference (zero suppress and offset functions included). Printed information quality inspection function (relative evaluation based on ISO/IEC 15415, AIM DMP-1-2006, and SAE AS9132). Supports reading up to 128 characters of a 1D code (Code39, Code128, EAN/JAN/UPC, GS1 Databar Omnidirectional, GS1 Databar Truncated, GS1 Databar Stacked, GS1 Databar Stacked Omnidirectional, GS1 Databar Limited, GS1 Databar Expanded, ITF, Codabar (NW7), and PharmaCode) and up to 16 reference judgement conditions. Supports data splitting into up to 8 partitions and calendar references (zero suppress and offset functions included). Supports X, Y +/- 180 degree adjustment data from units, calculations and variables for positional correction of other tools based on 1 or 2 point correction. Branch/Join Conditional branching of the flowchart (up to 64 splits). Also supports parameter variable referencing. Looping Repeatable unit processing. Also supports parameter variable referencing. Break Loop exit End Finish image processing flowchart. Direct input of up to 5000 characters for multi calculation and scripting purposes. Individual result based on time out settings and overall result (ANS) ANS. Basic functions: addition, subtraction, multiplication, division, surplus, power Conditional binary operators: inverse (NOT), logical multiplication (AND), logical sum (OR), exclusive OR (XOR) Comparative operators: equal to, not equal to, greater than, lesser than, greater than or equal to, lesser than or equal to Mathematical functions: absolute value, circular variable substitution, straight-line variable substitution, positional variable substitution, character encoding conversion, average, average array processing, average index, average index (array processing), rounding up, radian -> angle conversion, Napier's number (e), rounding down, natural logarithm, common logarithm, maximum value, maximum value (array processing), maximum value index, maximum value index (array processing), minimum value, minimum value (array processing), minimum value index, minimum value index (array processing), circumference ratio (pi), angle -> radian conversion, rounding, sort, square, square root, sum (array processing) Trigonometric functions: sine value, cosine value, tangent value, arcsine value, arccosine value, arc tangent value, arc tangent value (P1/P2) Geometric operation functions: centre angle, 2 point angle, angle range conversion, angle width, circle detection (3 point specification), circle detection (array processing), circle tangent point detection, coordinate system conversion, coordinate system conversion 2, distance between two points, intersection point of 2 circle, intersection point of circle and line, straight-line detection (2 point specification), straight-line detection (array processing), angle of two lines, straightline angle, distance between a point and straight-line, distance between a point and a straight-line (signed), intersection point with a perpendicular line, bisector, centre point, rotation, centre of rotation, perpendicular bisector, pixel coordinates -> world coordinate conversion, world coordinates -> pixel coordinate conversion, multiple point calibration, multiple point calibration 2, vector addition, vector subtraction, vector cross product, vector inner product, acquisition of information from calibration data, XYθ to UVW coordinate conversion Calendar functions: date offset (year/month/day) Bit functions: logical multiplication (AND), inversion (NOT), logical add (OR), exclusive OR (XOR), bit combining Statement: FOR, FOR TO, NEXT, EXIT FOR, IF, IF THEN, END IF, DO WHILE, LOOP, EXIT DO, User comments, row continuation Other: Calculation results, variable value zero-clear, variable value initialisation. Supports error checking functionality. Create images based on multi image processing or through mathematical processing. Image operation: conducts operations between images, supporting combinations 1x1, nx1 and nxn (to a maximum of 32 images). Conversion: conducts processing on a single image. Image Operation Functions: Add, Subtract, Absolute Difference, Average, Multiply (with normalisation), Multiply (without normalisation), Max, Min, AND, OR, XOR, NAND, NOR, XNOR Conversion Functions: Add, Subtract, Absolute Difference, Multiply, Rotate/Translate, Zoom, Trapezoid Adjustment, Pixel Value Conversion, Blob Filter, NOT, AND, OR, XOR, NAND, NOR, XNOR, Right Bit Shift, Left Bit Shift C language source files can be compiled for both controller and PC simulation environments. (Supported compilers: For the controller: Texas Instruments C6000 Code Generation Tools 6.0.11, For the PC: Microsoft Visual Studio 2005/2008/2010, Visual C++ 2008/2010 Express Edition.) Supports access to pixel values from the specified image variable. Local variables, global variables, system variables values, setting parameters, and result data can be passed for referencing and rewriting. Supports Visual Studio debugging. Correction of images and processing due to lens distortion and camera placement. Supports both correction of coordinate position and image for correct processing. Supports adjustable calibration via multiple images (up to 16), data point selection (up to 4000 points per image) and region selection. Calibration teaching pattern (grid and dot pattern) is also available to be printed out. OCR 2D Code Reader 1D Code Reader Position Adjustment Flowchart Control RGB and HSB colour space measurements. Numerical/Scripting Calculation & Image Processing Image Operation C Plug In Calibration The number of possible settings amongst all listed items depends on the main unit memory capacity. 36 SPECIFICATIONS (SOFTWARE) Model XG-H7NE1 (XG VisionEditor) Timing and Processing Control Pause Pauses the processing flow for a specified time (0 ms to 1 hour). Also supports parameter variable referencing. Timer Start a user defined timer (0-7). Timer conditions apply Pauses the processing flow until the expiration of a user time (0-7). Pauses the processing flow based on the AND / OR conditional changes of terminal block and parallel input, output signals (edge/level, ON/OFF, falling edge, rising edge). Supports CC-Link and EtherNet/IP communication. Pauses the processing flow based on the AND / OR conditional comparison of variables and numerical values. Terminal I/O Delay Variable Delay User Menu Delay Graphics Command Execution Pauses the flow until the opened menu is closed. Display characters (fixed, numerical, active text, decimal conversion), graphics (rectangle, rotated rectangle, circle, oval, ring, arc, point, line, table, polygon), result data and variables. Along with support for parameter variable referencing. Assign data and results to 28 I/O terminals, with support for cyclic strobing (up to 8 cycles) through multiple series of data. Enables the output of up to 256 data results to one of the following destinations: SD card, RS-232C, Ethernet, CC-Link, EtherNet/IP, PROFINET, PLC-Link, PC applications and FTP server. Allows for changes to the amount of data outputs for array results in response to the number of detected items. Includes support for skipping of non-processed units, filenames, folder allocation, customised output data format and processing (image/output) priority. Allows the output of images to different locations including SD cards, FTP and PC applications. Includes support for filenames, folder allocation and processing (image/output) priority. Issue various commands for controller functions based on image processing. Total Status Processing Overall output giving a logical OR result output based on allocated units results. On-screen Graphics Terminal / I/O Output Data Output Outputs Image Output Command Common to All Units Screens Total Error Processing Overall error output giving a logical OR result output based on allocated units error results. Screens Up to 100 screens per programme, with support for external switching and access via user group / user accounts. Frames Up to 99 frames per programme to host graphics, data and values, with support for external switching. Up to 5 image displays for associating with displaying camera images, registered images or archived images. Support for displaying different process views of images and unit processing. Image display, base frame, page frame Basic elements (values, characters, active character, horizontal lines, vertical lines, points, rectangles, circles, polygons, ruled lines) Built-in elements (Image display, inspection date, inspection time, camera screen information, zoom information, OK/NG status, logo (BMP file), vision unit results, non-vision unit results, variable list, unit judgement list, unit list) Allows for the creation of up to 900 users defined menus per programme with support for external control and display. Menus can be used to interact with settings via variables and support numerous command functions as well as other menus display operation. Text, numerical input box, drop-down menu, normal button, confirmation button Region setting dialogue, image registration menu, colour extraction menu, statistical analysis menu, image archive menu, library character registration menu, unit edit menu, view toolbar, image bar, function menu, programme conversion menu, file management menu, I/O monitor menu, RS-232C monitor menu, user login menu, date/time setting menu, save settings menu, rename programme menu, copy/delete programmes menu, loading/saving programmes menu, SD Card 2 removal menu, resources menu, setting operation dialogue, variable settings menu, total status settings menu, unit total error settings menu, scaling settings menu, image buffer menu, statistical analysis settings menu, image archive settings menu, camera selection menu, FTP settings menu, variable changing settings. The region settings, colour extraction, library character registration menu support changes based on direct unit selection. The image registration menu supports re-referencing of position adjustment parameters. Supports direct changes to unit settings based on allowed unit editing settings except for C Plug In units. Supports the selection of files and processing of files for cutting, copying and pasting to various SD locations. Define up to 10000 variables (numerical, positional, line and circle based) per programme each being able to be set as an array (up to 10000 elements) and having support for comments and value retention during programme changes. Define up to 1024 variables (numerical, positional, line and circle based) per controller (dependent on controller menu) each being able to be set as an array and having support for comments and value retention during programme changes. Define up to 512 variables (image) per programme each being able to be set as an array (up to 512 elements) and having support for comments and image operation processing. Enables offline simulation of BMP, JPEG images (256 maximum) that have either been stored on a PC or loaded in through a connected controller. Enables online simulation based on live images being obtained from a connected controller via Ethernet or USB. Also supports external trigger synchronisation and image archive. Enables reproduction of inspections based on image archive images (BMP, JPG, 256 maximum) and result data that has been previously recorded. Enables offline simulation on a PC, working with the GUI of the XG controller operating through the XG VisionEditor software, allowing the testing of up to 50000 images and processing of statistical data. Supports mouse operation. Creation, editing and deletion of all components used in image processing in a flowchart format. Supports split view, zoom, multiple unit movement, multi region alignment, grouping of units (including locking), repeat pasting, selective pasting, unit ID renumbering, breakpoint setting, step control, group viewing, editing and control directly on the controller. Facilitates displaying of differing image types based on processing in the flowchart including live images, single unit processing, multi unit processing, colour extraction (colour camera), image enhance filters and contrast display. Management of screens, elements and menu interfaces available on the controller in a hierarchal format. Supports the verification of user group screens, the editing of screens and menus, and the displaying of result components sorting. Allows for elements and menus to be used and dragged while creating the GUI. Supports writing/reading display patterns, frames and elements allowing for screen parts to be freely moved, positioned, edited and layered accordingly. Grid or free formatting can be used for aligning elements correctly. Provides a list of all the available parts (units, functions, commands, screens etc) that can be called up during the development of a solution. Specify the logging of up to 256 items each with a maximum of 100000 data points for statistical analysis. Data can be viewed, analysed and limits changed based on user group and account access permissions. Specify up to 8 image archives for storing images and data from inspections. Each archive has the ability to be customised to save a set number of images based on a particular condition. Image archives support series image and data accumulation, preceding image and data accumulation and replay modes both on controller and in XG VisionEditor. Images and results can also be output to SD cards, PC applications and FTP servers for storage and retesting. Customisation of the buffer and handling of images captured while other processing is being performed. Can set arbitrary values that execute confirmation or rewriting in the variable changing dialogue on the controller. Supports confirmation of item names, grouping, and rewrite contents and the setting of update timing. Ability to edit controller system settings including: controller naming, controller language settings, registered image format, menu opacity, controller unit processing, operational settings on the flow display screen, default camera settings, I/O (including terminal assignment, %JAHold signal customisation (oneshot, latching, synchronisation with STO), output file name, processing errors, busy conditions, customised commands, handheld controller operation, accounts, operation logs, and OCR date/time encryption Password protection of programme files allowing programme editing via XG VisionEditor only. Cross referencing of individual unique controller ID's for copyright protection. Image Displays Elements Menu settings GUI Interface Menu elements Menus Built-in Menus Local Variable Variables Global Variable Image Variable Offline Simulation Mode Simulation XG-H7NE1 (VisionEditor) Online Simulation Mode Image Archive Mode Simulator+ Offline simulation Flowchart/Programme Processing View Screen Management Screen Editor Parts List Development Functions Creation Statistical Settings Image Archive Settings Buffer/Processing Control Variable Changing Dialogue Settings System Settings Password Protection and Security The number of possible settings amongst all listed items depends on the main unit memory capacity. 37 SPECIFICATIONS (SOFTWARE/CONTROLLER) Model XG-H7NE1 (XG VisionEditor) Unit Results Verify unit parameters, results, local and global variable initial and current values from processing during simulation. Also supports the changing of variables. Watch Combine multiple data into 1 of 4 views for verification of multiple parts of the process during simulation. Log Continual log of unit results and errors or units processed during simulation Variable Reference List Verification of variable referencing throughout the image processing flowchart. Check Verification of version, settings and finding of errors in the image processing flowchart and screen. Displays error location and details for easy quick debugging. Search for unit references, variables, setting parameters and result data used in the image processing flowchart. Summarised results display of find function for referencing and locating of results. Summarised list of unit settings from units used in the image processing flowchart with support for changing parameters. Find Testing and Debugging Unit List Copy to Clipboard Show statistical results from simulation including summary data (maximum, minimum, standard deviation, 3σ, OK/NG frequency, yield), trend graphs (supporting the simultaneous comparison display of 4 items) and histograms for up to 1000 data points. Support for the changing of upper and lower limits of any monitored data. Up to 16 views for displaying differing image types based on user selection including live images, single unit processing, multi unit processing, colour extraction (colour camera), image enhance filters and contrast display. Displaying % resources used of each memory (programme memory, image memory, processing memory) based upon current programme settings. Displays the mouse position, HSB and RGB values when over an image and image processing buffer parameters. Customisation of 5 different XG VisionEditor screen layouts each with the ability to be reset. Various setup data and data files can be uploaded to and downloaded from connected and registered controllers through the Ethernet or USB interface. The active inspection settings can be switched and various setup files of multiple controllers can be managed from a workspace on a PC. The importing and exporting of a variety of setup data are supported. Setup data can be copied to multiple destinations at the same time (1:n copying). Registered controllers can be grouped. Gives the ability to create supporting documentation by copying various settings to the Windows clipboard for the pasting in another Windows programme. Version Control Control and upgrading of programme and other file versions. Remote Connection Remote control and operation (via keyboard or mouse) of a connected controller (via Ethernet or USB) using the XG GUI. Image Archive Variable Re-Write Verification and management of image archive and result data of a connected controller (via Ethernet or USB). Enables you to save the inspection settings, flow, unit, commands, collection of terminal operation conditions and log data of the controller connected via Ethernet or USB. Capability for rewriting local, global and system variables in online mode for a connected controller (via Ethernet or USB). Mode Changing Verify and switch modes (online mode/offline mode/remote capture mode) of a controller connected (via Ethernet or USB). Processing Management Allocation of memory and resources for online unit editing and use of the UT command. Selection of which units can be edited directly on the controller. Control over the level of changes capable based on user group and accounts. Control over the using of commands for displaying unit edit menus. Microsoft Windows XP Home Edition/Professional SP2 or later Microsoft Windows Vista Home Basic, Home Premium, Business, Ultimate, Enterprise Microsoft Windows 7 Home Premium, Professional, Ultimate, Enterprise Supports the 64-bit version of Microsoft Windows 7 only. For all other operating systems, only the 32-bit version is supported. - CPU Minimum requirements: Core 2 Duo 1.06 GHz or higher; Recommended: Core 2 Duo 1.80 GHz or higher - RAM: 2 GB or higher - HDD: Minimum 500 MB of free space* Space is required for saving separate image data - Monitor: 1024x768 dots or higher (1280x1024 dots or higher is recommended) - DVD drive: A CD/DVD drive capable of reading the software CD-ROM - USB port: USB 2.0 required. Either an internet connection or means of receiving the activation code licence electronically. Licence required for full activation. Information for receiving a licence / activation code includes, company details, user ID and CD serial number. Statistical Analysis User Processing View Status bar Development Functions Layout File Transfer/System/ Programme Management Controller Management Controller Adjustment System View Trace log viewer Edit Unit Settings Operating Systems PC Specifications PC Licensing XG Vision Terminal Additional Software Licence free remote support, data logging (image and data output), and file management PC software for use with up to 8 connected controllers (via Ethernet or USB). USB driver (licence free) specifically for connecting a XG-7000 controller via USB to either the XG VisionEditor, XG Vision Terminal or XG Simulator+ software. Supplied with XG VisionEditor, Vision Terminal and Simulator+. USB Driver The number of possible settings amongst all listed items depends on the main unit memory capacity. ❚ Controller ( XG-7701(P)/7501(P)/7001(P)/7001A) Model Supported Resolution Camera Connectivity NPN XG-7701 XG-7501 XG-7001 XG-7001A PNP XG-7701P XG-7501P XG-7001P —*1 • W ith XG-H500C/H500M connected 5 mega-pixel mode: 2432(H) x 2050(V), approx. 4.99 mega-pixels • W ith XG-200C/S200C/H200C/200M/ S200M/H200M connected 2 mega-pixel mode: 1600(H) x 1200(V), approx. 1.92 mega-pixels 1 mega-pixel mode: 1024(H) x960(V), approx. 980,000 pixels • W ith XG-H100C/H100M connected 1000(H) x 1000(V), 1 mega-pixel • W ith XG-035C/S035C/H035C/035M/ S035M/H035M connected 310 k pixel mode: 640(H) x 480(V), approx.310,000 pixels 240 k pixel mode: 512(H) x480(V), approx. 240,000 pixels • W ith XG-200C/S200C/H200C/200M/ S200M/H200M connected 2 mega-pixel mode: 1600(H) x 1200(V), approx. 1.92 mega-pixels 1 mega-pixel mode: 1024(H) x 960(V), approx. 980,000pixels • W ith XG-H100C/H100M connected 1000(H) x 1000(V), 1 mega-pixel • W ith XG-035C/S035C/H035C/035M/ S035M/H035M connected 310 k pixel mode: 640(H) x 480(V), approx. 310,000 pixels 240 k pixel mode: 512(H) x 480(V), approx. 240,000 pixels Two colour/monochrome cameras (Compatible with XG-H500C/200C/S200C/H200C/H100C/ 035C/S035C/H035C/H500M/200M/ S200M/H200M/H100M/035M/S035M/ H035M, mixed connection possible) Two colour/monochrome cameras (Compatible with Two colour/monochrome cameras XG-200C/S200C/H200C/H100C/ (XG-035C/S035C/H035C/035M/ 035C/S035C/H035C/200M/ S035M/H035M can be connected. S200M/H200M/H100M/035M/ Mixed connection is possible.) S035M/H035M, mixed connection possible) • 3 10 k pixel mode: 640(H) x 480(V), approx. 310,000 pixels • 240 k pixel mode: 512(H) x 480(V), approx. 240,000 pixels Two extra cameras and up to four cameras total can be connected by using expansion unit XG-E700. Trigger input Two monochrome cameras (CA-CM20: KEYENCE or • XC-HR50/XC-HR57/XC-56/XC-ST50/ XC-ES50/XC-E51/ XC-EI50/XC-EI30/ XC-EU50 : Sony • C S8550Di/CS8570D/CS8560D: Toshiba Teli) Two extra cameras and up to four cameras total can be connected by using expansion unit XG-E700A. 4-camera simultaneous capture/ individual 4-camera simultaneous capture/individual capture can be selected (when XG-E700 is not connected, images from up to two cameras can capture can be selected (when XG-E700A be captured at the same time). is not connected, images from up to two cameras can be captured at the same time). Image Processor DSP (High-speed) Programme Memory SD cards 1 and 2 can each hold 1000 programmes (depending on the size of the SD card and the size of the programmes), external switching possible. DSP DSP (High-speed) Screen Capacity Maximum 1000 screens for each programme (depending on SD card size), Image compression also available. Programme Editing Editing Supports the creation, deletion, copying and renaming of programmes in edit mode, adding/editing units/flowchart (image acquisition/vision tools/position adjustment/programme control/operations/timing/display/commands), variable settings/total judgement settings/Unit total error settings/scaling adjustment settings/camera model settings/image buffer settings/statistical settings/image archive settings/FTP output settings /variable changing dialogue/registered image batch updating/position adjustment reference position batch updating/screen editing. System Settings Supports the editing of system settings during offline mode, general (controller name/date and time settings/language settings/registered image type/menu opacity/unit execution/ startup mode) basic camera (camera settings/white balance settings), I/O settings (external terminals/Ethernet (TCP/IP)/RS-232C/PLC link/CC-Link/EtherNet/IP/PROFINET), date/ time encryption (OCR), and custom command settings. Retest Supports retest that uses accumulative history images, selected image files, and master images (selected from the image bar) and inspection setting editing (nonstop option selection available). Supports the interlocking function with statistics through batch test. SD Card Specifications • 2x SD Card slots (SDHC compatible) • 2x SD Card slots (SDHC compatible) • C ompatible with OP-87133 (512MB), CA-SD1G (1GB: installed standard to SD1), • Compatible with OP-87133 (512MB: installed standard to SD1), CA-SD1G (1GB), and CA-SD4G (4GB:SDHC) and CA-SD4G (4GB:SDHC) *1 For information on the PNP output type, contact the nearest KEYENCE office. 38 640(H) x 480(V), approx. 310,000pixels SPECIFICATIONS (CONTROLLER) NPN Model PNP Image Processing Area Image Capture Settings Scanning method (monochrome cameras only) CCD start/end function Camera gain adjustment Image and Processing Correction White balance adjustment (colour camera only) Image Inversion Scaling Statistics Results Support Functions Screen Magnification Edge Waveform Display Profile Display Stability Display Character Extraction Display Defect Waveform Display Feature display Variable Changing Dialogue Data Save Functionality Communication Monitor Function Other Assignable Input Assignable Output Monitor output Operation indicators RS-232C PLC link Interface Ethernet USB CC-Link EtherNet/IP PROFINET Handheld Controller Touch panel Language Illumination control Power supply voltage Rating Environmental resistance Current consumption Ambient temperature Ambient operating humidity Weight XG-7501 XG-7001 XG-7001A XG-7001P Specify a 240,000-pixel area (512 (H) x 480 (V)) or a 310,000-pixel area (640 (H) x 480 (V)) in any position as the processing area within 320,000 pixels.*2 —*1 Not applicable Progressive/Interlace (XC-ST50, XC-E*** are fixed interlace) Start/End lines cannot be specified. Enables the choosing of the start/end line within the image capture range. CCD area is predetermined by camera Possible to variable reference the capture start line (possible to change each image capture in the capture startup line). specification settings. (The XG-H200C and H200M do not allow less than 100 lines to be specified.) (XC-ST50, XC-E*** area is fixed.) Camera CCD sensitivity, offset and span adjustments. Also supports the changing of the shift and span of the CCD for 16 different levels (including separate RGB elements when using colour cameras). Progressive/Interlace Manual setting with white target Supports inverting the image to the left or right. Allows the setting and application of individual scaling values to X, Y and length result data, along with the support for using variables. Data Points Image Archive Programming Assistance XG-7701 XG-7701P XG-7501P Specify a 980,000-pixel area (1024 (H) x 960 (V)) in any position as the image processing area within 1,920,000 pixels (1,000,000-pixel mode). Specify a 240,000-pixel area (512 (H) x 480 (V)) or 310,000-pixel area (640 (H) x 480 (V)) in any position as the processing area within 320,000 pixels.*2 Maximum of 100,000 points per item, maximum of 256 items (supports exporting to SD card/maximum of 1024 points per item for the retest statistics function) Maximum, minimum, average value, deviation (σ, 3σ), summary of processing, including OK/NG count Enables the accumulation of archived images (specified below) to the main controller memory. - Up to 1013 images (monochrome camera, 240,000 pixels) - Up to 501 images - U p to 501 images (monochrome camera, 310,000 pixels) (monochrome camera, 240,000 pixels) - Up to 245 images - U p to 245 images (monochrome camera, 1,000,000 pixels) (monochrome camera, 310,000 pixels) - Up to 117 images - U p to 117 images - U p to 501 images (monochrome camera, 2,000,000 pixels) (monochrome camera, 1,000,000 pixels) (monochrome camera, 240,000 pixels) - Up to 40 images - U p to 53 images - U p to 245 images (monochrome camera, 5,000,000 pixels) (monochrome camera, 2,000,000 pixels) (monochrome camera, 310,000 pixels) Up to 245 images - Up to 1008 images - U p to 496 images - U p to 496 images (CA-CM20: 310,000 pixels) (colour camera, 240,000 pixels) (colour camera, 240,000 pixels) (colour camera, 240,000 pixels) - Up to 498 images - U p to 242 images - U p to 242 images (colour camera, 310,000 pixels) (colour camera, 310,000 pixels) (colour camera, 310,000 pixels) - Up to 240 images - U p to 112 images (colour camera, 1,000,000 pixels) (colour camera, 1,000,000 pixels) - Up to 112 images - U p to 48 images (colour camera, 2,000,000 pixels) (colour camera, 2,000,000 pixels) - Up to 35 images (colour camera, 5,000,000 pixels) Enables the simultaneously running up to 8 image archives that can reference different targets. Supports the overwriting or accumulation of the data modes. Supports result data accumulation to correspond with the images for replaying the image archive. Supports outputting of the image archive to SD cards, PC applications and FTP servers. Gives the ability to magnify the screen from 4% to 2500% during operation, while enabling the control of the display position of via external controls depending on the commands issued (individual magnification settings possible for multiple screen displays). Enables the display of the edge differential waveform graph and associated numerical data during operation. Enables the display of the detected profile for the trend edge position, trend edge width, and trend edge defects during operation. Enables the display of the stain detection (stain level) contrast view during operation. Enables the display of the automatic extraction projection waveform graph of OCR during operation. Enables the display of the defect level waveform for trend edge defects during operation. Enables ShapeTrax2 registration and input characteristics display during operation. Enables the verification/changing of selected local variables, global variables, and system variables values (only verification for system variables). Supports grouping setting and specifying display patterns during operation. The direct saving of data results, judgement results, number of failures (NG), data images (compression possible), archive images (compression possible), captured images (compression possible), statistical analysis data, RS-232C communication logs, Ethernet communication logs, setting details, the direct saving of operation logs during inspections (not including setting details), and the current image from any camera during offline mode are supported. I/O monitor, RS-232C monitor (including log saving function), EtherNet/IP memory monitor, PROFINET memory monitor, PLC-link memory monitor, CC-Link memory monitor and Ethernet monitor (including log saving function) Image capture function, user account switching function, file management function • 20 (including four high speed designed for trigger input) • Input rating 26.4V or lower, 2 mA or grater (3 mA or grater for high speed input terminal ) • 28 (including four high speed outputs designed for pulse outputting to external device) • NPN type: NPN open collector Maximum 50 mA (30 V or less) PNP type: PNP open collector 50 mA (30 V or less)* 1 Analogue RGB output, SVGA 800 x 600 (24 bit colour, 60 Hz) Power, Error LED display Numerical data output and control input/output enabled, up to a maximum baud rate of 115200 bps (Cannot be used with CA Series touch panel). The delimiter can be changed during numerical value output and control input/output. • Numerical data output and control input/output enabled via the RS-232C port or Ethernet port (Cannot be used with CC-Link, EtherNet/IP or PROFINET) • F ollowing PLCs are supported via link unit:* 3 KEYENCE: KV-700 Series, KV-1000 Series, KV-3000 Series, KV-5000 Series, KV-5500 Series, Mitsubishi Electric: A Series (RS-232C only), Q Series, L Series OMRON: SYSMAC C Series (RS-232C only), CP1/CS1/CJ1/CJ2 Series, YASKAWA Electric Corporation: MP900 Series (only RS-232C available)/MP2000 Series • Numerical data output, and control input/output enabled. • Uploading and downloading programme settings, simulations, data, including image data can be sent or received. • 1000BASE-T/100BASE-TX/10BASE-T • Compatible with FTP server (when image archive is used). • Supports VNC server function (for non-PC clients, only the display of the monitor screen is supported). • Supports BOOTP function. • Uploading and downloading programmes settings, simulations, data, and images when using KEYENCE PC software. • USB2.0 • B y connecting the optional CC-Link expansion module CA-NCL10E, numerical value input/output and control input/output are enabled. Do not use to connect to PLC-Link, EtherNet/IP or PROFINET. • Compatible to the Ver.1.10 remote device station, and Ver.2.00 remote device station. • Numerical value and control input/output using the Ethernet port enabled. • Maximum connections: 32. • Cyclic (implicit) communication (max. 1436 bytes) possible. • In conformity with conformance test Version.A7. • Explicit message communication possible. • Cannot be used in conjunction with PLC-link/CC-Link/PROFINET. • Numerical value and control input/output using the Ethernet port enabled. • Cyclic communication (max. 1408 bytes) possible. • Non-cyclic (record data) communication possible. • In conformity with Conformance Class A. • Cannot be used in conjunction with PLC-link, CC-Link, and EtherNet/IP. • By using the optional OP-84231 (OP-84236 blank version) direct interaction with the controller and programme settings is possible. • Buttons can be assigned individual operations. • Buttons can be activated/deactivated based on user groups. Operation settings are possible from the CA Series touch panel, which uses the RS-232C port (Using non-procedural RS-232C communication, cannot be used with a PLC link) Supports specialised touch menu, operation button. Japanese/English/Simplified Chinese/Traditional Chinese/German By connecting the optional illumination expansion module CA-DC21E, Control usage and intensity of LED illumination (12 V, 24 V) is possible 24 VDC positive and negative to 10% • 2.4 A (2 cameras at maximum load) • 3.2 A (4 cameras at maximum load) • F or two cameras connected: 0 to 50°C (0 to 45°C with min. 1 mega-pixel camera connected) • For four cameras connected: 0 to 45°C 35 to 85% RH (no condensation) Approx. 1250 g • 2.2 A (2 cameras at maximum load) • 2.8 A (4 cameras at maximum load) • 2.2 A (2 cameras at maximum load) • 2.6 A (4 cameras at maximum load) 0 to 50°C 0 to 50°C (With four cameras connected: 0 to 45°C) Approx. 1300 g *1 For information on the PNP output type, contact the nearest KEYENCE office. *2 310,000 pixels when connecting XG-H035C/H035M, so 640 (H) x 480 (V) cannot be selected. *3 PLC models that have a built-in Ethernet port support a direct connection. 39 SPECIFICATIONS (CAMERA) ❚ Camera (XG-H500C/XG-H500M/XG-H200C/XG-H200M) Camera (XG-H500C/XG-H500M) *1 2/3-inch colour CCD image receiving element, 11x high-speed reading using square-pixel, 5,050,000 pixels (XG-H500C)/ 2/3-inch monochrome CCD image receiving element, 11x high-speed reading using squarepixel, 5,050,000 pixels (XG-H500M)/Unit cell size 3.45 μm x 3.45 μm 4,990,000 pixels 2432 (H) x 2050 (V) Progressive (61.2 ms) Interlace: XG-H500M only (40.3 ms) 130 MHz (65 MHz x 2 ch) Model CCD Resolution Scanning system Pixel transfer frequency Camera (XG-H200C/XG-H200M) *1 1/1.8-inch colour CCD image receiving element, 7x high-speed reading using square-pixel, 2,010,000 pixels (XG-H200C)/ 1/1.8-inch monochrome CCD image receiving element, 7x high-speed reading using squarepixel, 2,010,000 pixels (XG-H200M)/Unit cell size 4.4 μm x 4.4 μm 1,920,000 pixels 1600 (H) x 1200 (V) *2 Progressive (29.2 ms: 2,000,000-pixel mode 24.2 ms: 1,000,000-pixel mode) Interlace: XG-H200M only (16.1 ms: 2,000,000-pixel mode 13.6 ms: 1,000,000-pixel mode) 82 MHz (41 MHz x 2 ch) Transfer system Digital serial transfer Electronic shutter 1/15, 1/30, 1/60, 1/120, 1/240, 1/500, 1/1000, 1/2000, 1/5000, 1/10000, 1/20000 0.05 msec to 9000 msec can be set with numeric values Lens mount Environmental resistance C mount Ambient temperature 0 to 40°C Relative humidity 35 to 85%RH (No condensation) Weight Approx. 130 g (not including the lens) *1 Only the high-speed camera cable can be used (CA-CHxx). *2 In 1,000,000-pixel mode 980,000-pixels (1024 x 960) serve as the processing area. ❚ Camera (XG-H100C/XG-H100M/XG-H035C/XG-H035M) Model CCD Resolution Scanning system Pixel transfer frequency Camera (XG-H100C/XG-H100M) *1 Camera (XG-H035C/XG-H035M) *1 2/3-inch colour CCD image receiving element, 1/3-inch colour CCD image receiving element, 7x high-speed reading using square-pixel, 340,000 pixels (XG-H035C)/ 7x high-speed reading using square-pixel, 1,040,000 pixels (XG-H100C)/ 2/3-inch monochrome CCD image receiving element, 7x high-speed reading using square-pixel, 1/3-inch monochrome CCD image receiving element, 7x high-speed reading using square-pixel, 1,040,000 pixels (XG-H100M)/Unit cell size 7.4 μm x 7.4 μm 340,000 pixels (XG-H035M)/Unit cell size 7.4 μm x 7.4 μm 1,000,000 pixels 1000 (H) x 1000 (V) 310,000 pixels 640 (H) x 480 (V) *2 Progressive (20.5 ms) Progressive (4.7 ms) Interlace: XG-H100M only (13.9 ms) Interlace: XG-H035M only (2.5 ms) 80 MHz (40 MHz x 2 ch) Transfer system Digital serial transfer Electronic shutter 1/15, 1/30, 1/60, 1/120, 1/240, 1/500, 1/1000, 1/2000, 1/5000, 1/10000, 1/20000 0.05 msec to 9000 msec can be set with numeric values Lens mount Environmental resistance C mount Ambient temperature 0 to 40°C Relative humidity 35 to 85%RH (No condensation) Weight Approx. 120 g (not including the lens) *1 Only the high-speed camera cable can be used (CA-CHxx). *2 In 310,000-pixel mode, 310,000 pixels (640 x 480) serve as the processing area. In 240,000-pixel mode, 240,000 pixels (512 x 480) serve as the processing area. ❚ Camera (XG-200C/XG-200M/XG-S200C/XG-S200M) Camera (XG-200C/XG-200M) *1 Model Camera (XG-S200C/XG-S200M) *1 1/1.8-inch colour CCD image receiving element, 1/1.8-inch colour CCD image receiving element, square-pixel/all-pixel reading, 2,010,000 pixels (XG-200C)/ square-pixel/all-pixel reading, 2,010,000 pixels (XG-S200C)/ 1/1.8-inch monochrome CCD image receiving element, square-pixel/all-pixel reading, 1/1.8-inch monochrome CCD image receiving element, square-pixel/all-pixel reading, 2,010,000 pixels (XG-200M)/Unit cell size 4.4 μm x 4.4 μm 2,010,000 pixels (XG-S200M)/Unit cell size 4.4 μm x 4.4 μm 1,920,000 pixels 1600 (H) x 1200 (V) *2 Progressive (58.5 ms: 2,000,000-pixel mode 47.6 ms: 1,000,000-pixel mode) Progressive (58.5 ms: 2,000,000-pixel mode 47.6 ms: 1,000,000-pixel mode) Interlace: XG-200M only (32.7 ms: 2,000,000-pixel mode 27.0 ms: 1,000,000-pixel mode) Interlace: XG-S200M only (32.7 ms: 2,000,000-pixel mode 27.0 ms: 1,000,000-pixel mode) 40 MHz CCD Resolution Scanning system Pixel transfer frequency Transfer system Digital serial transfer Electronic shutter 1/15, 1/30, 1/60, 1/120, 1/240, 1/500, 1/1000, 1/2000, 1/5000, 1/10000, 1/20000 0.05 msec to 9000 msec can be set with numeric values Lens mount Environmental resistance C mount Ambient temperature Special mount (M15.5 P0.5 male) Head: 0 to 40°C, relay unit: 0 to 40°C (However, 35°C maximum in partial capturing 50 lines or lower) 0 to 40°C Relative humidity 35 to 85%RH (No condensation) Weight Approx. 110 g (not including the lens) Head: Approx. 210 g (including the cable, not the lens), relay unit: Approx. 70 g *1 The camera cable CA-CN17/L/R (17 m) and repeater cable CA-CN17X/17LX/RX (17 m) cannot be used. *2 1,000,000-pixel mode 980,000 pixels (1024 x 960) serve as the processing area. ❚ Camera (XG-035C/XG-035M/XG-S035C/XG-S035M) Model CCD Resolution Scanning system Pixel transfer frequency Transfer system Electronic shutter Lens mount Ambient temperature Environmental resistance Relative humidity Weight Camera (XG-035C/XG-035M) Camera (XG-S035C/XG-S035M) *1 1/3-inch colour CCD image receiving element, 1/3-inch colour CCD image receiving element, 2x high-speed reading using square-pixel, 350,000 pixels (XG-035C)/ 2x high-speed reading using square-pixel, 350,000 pixels (XG-S035C)/ 1/3-inch monochrome CCD image receiving element, 2x high-speed reading using square-pixel, 1/3-inch monochrome CCD image receiving element, 2x high-speed reading using square-pixel, 350,000 pixels (XG-035M)/Unit cell size 7.4 μm x 7.4 μm 350,000 pixels (XG-S035M)/ Unit cell size 7.4 μm x 7.4 μm 320,000 pixels 656 (H) x 492 (V) *2 Progressive (16.0 ms) Interlace: XG-035M only (8.8 ms) Progressive (16.0 ms) Interlace: XG-S035M only (8.8 ms) 24.5 sMHz Digital serial transfer 1/15, 1/30, 1/60, 1/120, 1/240, 1/500, 1/1000, 1/2000, 1/5000, 1/10000, 1/20000 0.05 msec to 9000 msec can be set with numeric values C mount Special mount (M10.5 P0.5 male) 0 to 50°C Head: 0 to 50°C, relay unit: 0 to 40°C 35 to 85%RH (No condensation) Approx. 100 g (not including the lens) Head: Approx. 160 g (including the cable, not the lens) relay unit: Approx. 70 g *1 The camera cable CA-CN17/L/R (17 m) and repeater cable CA-CN17X/17LX/RX (17 m) cannot be used. *2 310,000-pixel mode 310,000 pixels (640 x 480) serve as the processing area. 240,000-pixel mode, 240,000 pixels (512 x 480) serve as the processing area. ❚ Light control expansion module CA-DC21E Light control method Intensity range Number of connection points Output Voltage Capacity 12 VDC/24 VDC [DIP switch conversion] Maximum 40 W (however, 30 W/1 CH) FLASH output synchronisation / continuous lighting [ Controller setting conversion ] Response speed (1) Constant voltage control Under 10 ms During 12 V output Under 20 ms During 24 V output (2) pulse width modulation method Under 1 ms During 12/24 V output Input Forced light stop LED display Environmental resistance *1 255 level digital [ Controller setting conversion ] 2 CH (Enables LED connector connection and terminal block connection) Synchronisation Display Rating (1) Constant voltage control method (direct current light) (2) pulse width modulation method (emission frequency 100 kHz) [ Controller setting conversion ] Input rating maximum 26.4 V, minimum 2 mA Light intensity display green/orange (over 128) Error displayed red (all lit) Power voltage Power consumption 24 VDC ±10% 3.0 A (12 V output at maximum load) 6.5 A (24 V output at maximum load) 0 to 50°C *2 Ambient temperature Relative humidity 35 to 85%RH (No condensation) Weight Approx. 590 g *1 The environmental resistance of the LED lighting is ambient temperature of 0 to 40°C, relative humidity 35 to 65% (no condensation) *2 You will be restricted by the ambient temperature tolerance of the connected controller * Each company name, system name, and product name in the catalogue is generally a registered mark or a trademark of each company. Neither [(tm)] nor [(r)] is indicated in the texts or in the charts in the catalogue. 40 DIMENSIONS Unit: mm Controller When mounting camera expansion module XG-7701(P)/7501(P)/7001(P) XG-E700 (23.5) 92.4 (99.9) 132.5 115.5 (128.5) 132.5 DIN rail mounting DIN rail mounting 153 35.9 83.3 35.9 153 83.3 65.3 65.3 6 6 (88) (88) 117 17 80 117 4-M4 Depth 6 70 (77.5) ( ) refers to the XG-7001A 16.5 80 When mounting CC-Link module When mounting light expansion module CA-NCL10E CA-DC21E 124.5 (132) 132.5 132.5 DIN rail mounting section 153 35.9 35.9 65.3 137.5 (145) 65.3 153 6 83.3 83.3 6 Camera XG-S035CH/XG-S035MH When using a mounting bracket 46.8 35 12 12 12.5 17.5 CCD shooting distance in air 4.0 Special mount (M10.5 P0.5) A 5.5 29.1 54 2-M3 Depth 4 max. ø12.6 ø6.0 Cable length 2 m 12.5 (46) 22.1 A B C Lens insertion slot ø12 Special mount M10.5 P=0.5 female screw 7.2 21.3 15.9 12.9 16.7 11.5 8.5 8 ø12 20.4 10.2 7.2 3-M1.6 Lens fixing screw 27 13.2 10.2 3 4.2 ø12 Object 3 13.7 Side viewer attachment OP-51503 Polarisation filter OP-51502 B C 10 11.25 5 6.25 Lens CA-LSx 46.8 35 Optical axis Object (internal light path 9.7 length =15.3) Lens insertion depth 4.5 6.25 ø20 2.8 14.9 14.7 21 3 4-M1.6 Lens fixing screw 10 17.5 2-M2 Depth 5 Camera XG-S200CH/XG-S200MH When using a mounting bracket 42.7 30.7 17 17 17.5 Close-up ring OP-51500 (5 mm)/ OP-51501 (10 mm)/ OP-66830 (5 mm)/ OP-66831 (10 mm) 42.7 30.7 A 22.5 CCD shooting 9 distance in air 6.0 Special mount (M15.5 P0.5) 7.5 25.3 5 54 14 2-M3 Depth 4 max. D Special mount B E Special mount øC ø12.6 ø7.0 Cable length 2 m 11.6 21.2 (47) Lens CA-LHSx A 12.5 9.5 B C ø17 Special mount M15.5 P=0.5 female screw A B C 40.4 28.6 19.6 23.9 17.9 8.9 24.9 18.6 9.6 40.4 27.1 18.1 24.9 Side viewer attachment OP-66833 2.6 27.4 A B C D E 5 10 5 10 8 13 8 13 12 12 17 17 M10.5 P=0.5 female screw M15.5 P=0.5 female screw M10.5 P=0.5 male screw M15.5 P=0.5 male screw Polarisation filter OP-66832 ø17 Lens insertion slot 3-M1.6 Lens fixing screw 8 4.2 3 ø17 Object Optical axis 15 (internal light path length =25.8) Lens insertion depth 5 4-M1.6 Lens fixing screw 9.5 23.3 31.8 3 ø25 15 30 Object 3.1 2-M2 Depth 8 41 DIMENSIONS Unit: mm Camera control unit Camera XG-S200CU/XG-S200MU/XG-S035CU/XG-S035MU XG-035C/XG-035M 48.3 7.5 8-M3 30 ø2818 30 When using a mounting bracket 33 29.7 ø6.1 40 10 10.8 13.5 3-M2.5 2-M4 42 24 20 1/4-20UNC 112.6 105 98 9 11.5 26 2-ø3.6 through hole 11 6 2-M3 6 11.5 18 13.5 21.5 3.5 19 3.5 With cable connected 13.2 23.3 29.5 33.4 Controller side 33 (85) (202) Camera side 29.7 2-ø3.6 through hole ø6.1 Camera (76) (86) 11.5 XG-H500C/XG-H500M/XG-H200C/XG-H200M/XG-200C/XG-200M/XG-H100C/XG-H100M/ XG-H035C/XG-H035M 30 7.5 30 60 8-M3 ø2818 29.7 ø6.1 10.8 13.5 When using a mounting bracket 33 1/4-20UNC 2-M3 18 11.5 13.5 44.5 9 10 42 23 20 40 2-M4 3-M2.5 (Cable dimensions differ for high-speed cameras) 13.2 23.3 29.5 33.4 (85) Camera cable CA-CN1 (1 m)/ CA-CN3 (3 m)/ CA-CN5 (5 m)/ CA-CN10 (10 m)/ CA-CN17 (17 m) High-flex camera cable CA-CN3R (3 m)/ CA-CN5R (5 m)/ CA-CN10R (10 m)/ CA-CN17R (17 m) Cable dedicated for high-speed cameras CA-CH3 (3 m)/ CA-CH5 (5 m)/ CA-CH10 (10 m) High-flex cable dedicated for high-speed cameras CA-CH3R (3 m)/ CA-CH5R (5 m)/ CA-CH10R (10 m) B D E øC øA F Cable length (1 m, 3 m, 5 m, 10 m, 17 m) CA-CNx CA-CNxR CA-CHx CA-CHxR A 12.5 14.0 12.5 14.0 B 43 54 43 54 C 6.1 6.6 7.2 7.6 D 42 42 41 41 E 33 33 31 31 F 29.7 29.7 31.4 31.4 L-shaped connector camera cable CA-CN3L (3 m)/ CA-CN5L (5 m)/ CA-CN10L (10 m)/ CA-CN17L (17 m) L-shaped connector cable for high-speed cameras CA-CH3L (3 m) / CA-CH5L (5 m)/ CA-CH10L (10 m) øD G C øA B F E Cable length (3 m, 5 m, 10 m, 17 m) L-shaped connector camera cable CA-CNxL L-shaped connector cable for high-speed cameras CA-CHxL A B C D E F G 14 38 30 6.1 42 33 29.7 14 38 30 7.2 41 31 31.4 Please refer to the "Vision System Peripheral Equipment catalogue" in regards to any dimensional diagrams of additional devices that have not been included here. 42 21 The ever-evolving KEYENCE imaging system continues to offer the solutions and support that meet global customer's needs. KEYENCE DEUTSCHLAND GmbH KEYENCE INTERNATIONAL (BELGIUM) KEYENCE (UK) NV/SA LIMITED KEYENCE CANADA INC. KEYENCE INTERNATIONAL TRADING (SHANGHAI) CO., LTD. KOREA KEYENCE CO., LTD. KEYENCE FRANCE SAS KEYENCE CORPORATION KEYENCE (THAILAND) CO., LTD. KEYENCE CORPORATION OF AMERICA KEYENCE ITALIA S.p.A. KEYENCE MEXICO S.A. DE C.V. KEYENCE INDIA PVT. LTD. KEYENCE TAIWAN CO., LTD. KEYENCE (MALAYSIA) SDN BHD KEYENCE (HONG KONG) CO., LTD. KEYENCE SINGAPORE PTE LTD. KEYENCE BRASIL KEYENCE Corporate Offices Distributors Image processing solutions used by the professionals Complete selection including peripherals and free trials Instant delivery throughout the world Direct support from a highly trained team Peripheral Equipment The majority of the extensive product line up such as cameras, controllers, lighting equipment and peripherals are available for immediate delivery. KEYENCE offers a complete solution and the support for all your image processing needs. Vision System Illumination Lens Monitors 43 www.keyence.com Copyright (c) 2012 KEYENCE CORPORATION. All rights reserved. XG4.2-WW-C2-GB 1092-1 600B30
