Summary of Contents for Sacmi CVS Series
- Page 1 T E C H N I C A L D O C U M E N T A T I O N INSTRUCTIONS MANUAL 004AZ011B VISION SYSTEM FOR AUTOMATIC INSPECTION OF CAPS Original Instructions...
- Page 3 004AZ011B INSTRUCTIONS MANUAL VISION SYSTEM FOR AUTOMATIC INSPECTION OF CAPS MANUFACTURER S.C. Via Selice Provinciale, 17/A 40026 IMOLA (Bologna) - ITALY www.sacmi.com RELEASE DATE 21.12.2015 - 21.09.2017 VERSIONS CVS001 - CVS051 - CVS052 - CVS053 - CVS054...
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Page 5: Table Of Contents
004AZ011B TABLE OF CONTENTS Page GENERAL INFORMATION ..........................1-1 INTRODUCTION ........................1-1 WHERE TO KEEP THE MANUAL ....................1-1 HOW TO USE THE MANUAL .....................1-2 USERS OF THE MANUAL ......................1-2 WARRANTY ..........................1-3 ATTACHMENTS ..........................1-3 KEY TO THE SAFETY SYMBOLS USED ON THE ELECTRONIC EQUIPMENT AND/OR IN THE MANUAL ..........................1-4 POSITION OF THE SAFETY SIGNS ...................1-5 IDENTIFICATION PLATE FOR THE ELECTRONIC EQUIPMENT ..........1-6... - Page 6 004AZ011B TABLE OF CONTENTS Page SAFETY EQUIPMENT AND PRECAUTIONS ....................3-1 SAFETY DEVICES ........................3-1 3.1.1 GENERAL STANDARDS ......................3-1 3.1.1.1 Required environmental conditions for correct electronic equipment operation ......3-1 3.1.2 LOCKOUT/TAGOUT ........................3-2 SAFETY RULES FOR HANDLING ....................3-4 3.2.1 LIFTING ............................3-4 3.2.2 MOVEMENT ..........................3-4 3.2.3 PLACING THE LOAD .........................3-4 INSTALLATION ...........................3-5...
- Page 7 004AZ011B TABLE OF CONTENTS Page USE OF THE ELECTRONIC EQUIPMENT ....................6-1 START-UP/SHUTOFF .........................6-1 6.1.1 NORMAL START-UP ........................6-1 6.1.2 START-UP WITH MODIFICATIONS MADE TO THE SOFTWARE CONFIGURATION ....6-1 6.1.3 START-UP WITH MODIFICATIONS MADE TO THE SOFTWARE CONFIGURATION AND THE IMAGE SHOOTING STATION ..................6-2 6.1.4 SHUTTING OFF THE SYSTEM ....................6-2 ADJUSTMENTS ............................7-1...
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Page 9: General Information
Notwithstanding the electronic equipment is equipped with active and passive safety devices, all risks resulting from incorrect use cannot be avoided. SACMI shall not be held responsible for failure to heed to safety precautions and accident prevention rules and standards specified throughout this manual and property damage and personal injury caused by unintended, inappropriate and erroneous use of the electronic equipment. -
Page 10: How To Use The Manual
004AZ011B GENERAL INFORMATION HOW TO USE THE MANUAL The information and instructions provided in this manual are grouped together organized in chapters and paragraphs. The subject of interest can be easily located by consulting the table of contents. Read the information preceded by the symbols below with care as they are essential for the health and safety of the operators as well as for the efficiency of the electronic equipment. -
Page 11: Warranty
GENERAL INFORMATION WARRANTY SACMI shall be held responsible only for the electronic equipment as it was configured at the time of delivery. Any operations that alter the configuration of the electronic equipment or work cycle must be carried out or duly authorized by SACMI's Engineering Dept. -
Page 12: Key To The Safety Symbols Used On The Electronic Equipment And/Or In The Manual
004AZ011B GENERAL INFORMATION KEY TO THE SAFETY SYMBOLS USED ON THE ELECTRONIC EQUIPMENT AND/ OR IN THE MANUAL WARNING SIGNALS General hazard. E0004 Risk of electrocution. D0000004_00 ALERT SIGNS Indicated point must be effectively grounded. E0006 Lift point E0038 Instructions manual must be read. E0167 OTHER SIGNS When discarding electric and electronic equipment separate them to permit correct recycling and prevent... -
Page 13: Position Of The Safety Signs
004AZ011B GENERAL INFORMATION POSITION OF THE SAFETY SIGNS NOTICE D0003275_00 The type of signs may vary in relation to the laws in force in the country the equipment is installed in. -
Page 14: Identification Plate For The Electronic Equipment
004AZ011B GENERAL INFORMATION IDENTIFICATION PLATE FOR THE ELECTRONIC EQUIPMENT If the electronic equipment is equipped with good sized cameras, identification plates are provided on them. The serial number stamped on these plates is the same as the serial number given on the plate attached to the personal computer or to the main cabinet with the addition of extensions /0/1 and so on. -
Page 15: Conformity Declaration
004AZ011B GENERAL INFORMATION 1.10 CONFORMITY DECLARATION (Only in the European Economic Community or in cases where required) The Declaration of Conformity, when provided, accompanies the electronic equipment. 1.10.1 NON-INTEGRATED VISION SYSTEM S.C. declares: that this equipment complies with the European Directives indicated below (the references to standards are to be considered extended also to the next amendments and/or supplements): 2014/30/EU;... - Page 16 004AZ011B GENERAL INFORMATION...
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Page 17: Features
004AZ011B FEATURES FEATURES DESCRIPTION OF THE ELECTRONIC EQUIPMENT The CVS vision systems are electronic equipment used in the automatic and visual inspection of CAPS. They consist of one or more cameras, either black/white and/or color, that check the quality of plastic and/or metal caps by means of an image capture system. -
Page 18: Main Devices
004AZ011B FEATURES 2.1.1 MAIN DEVICES 2.1.1.1 Main electrical cabinet (optional) Open the front door of the main electrical cabinet to access the Personal Computer 1. The operator can interface with it by entering data with the touch screen 3 and can export data with the USB pen drive. An air-conditioner 4 is mounted in the front door. -
Page 19: Industrial-Grade Personal Computer
004AZ011B FEATURES 2.1.1.2 Industrial-grade Personal Computer. The Personal Computer is the foundation of the vision system. The exact configuration of the Personal Computer varies according to individual applications and vision system version. The Personal Computer 5 hardware includes an ATX main board 4 equipped with CPU 8 and memory 9. The cards 1 and 2 are mounted in the main board slots. - Page 20 FEATURES 2.1.1.3 PCI S32P I/O board The S32P is a half-size board designed by SACMI to regulate light intensity and carry out the input/output interface tasks during the process. This board, interfaced with other peripherals, is used to: interface the vision system with the encoder;...
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Page 21: Pci S32P I/O Board
004AZ011B FEATURES FIGURE 2.1.1.3 - PCI S32P I/O BOARD Mini DIN8-Triggers connector Opto type DSUB37 output/input connector Status leds Auxiliary signal connectors EPLD Acex (programmable logic) Flash Board programming connector FLASH EPLD DBG1 DBG2 3.3 Volt DBG0 STATUS CONFIG. ERROR ERROR ERROR T3385... -
Page 22: Image Capture Card
004AZ011B FEATURES 2.1.1.4 Image capture card The image capture cards indicated below can be installed in the CVS systems: “D” type (FRAME GRABBER CARD X64-CL iPRO); “E” type (FRAME GRABBER CARD X64-CL iPRO LITE); “F” type (FRAME GRABBER CARD X64-XCelera PCIex4). Refer to the customization documents in the corresponding disk to know the actual configuration. -
Page 23: Additional Electrical Cabinet
004AZ011B FEATURES 2.1.1.5 Additional electrical cabinet The additional cabinet is placed near the operator interface cabinet. It houses the components employed to communicate with the lighting units, ejectors and image capture signal. The following components are housed in the cabinet: A card set up to control 6 lighting units, 2 ejectors, 5 inputs (sensors, encoders) and a status indicator tower. -
Page 24: Image Shooting Station
004AZ011B FEATURES 2.1.1.6 Image shooting station The “image shooting station” refers to the electronic, optical and mechanical equipment used for lighting and image capture. This equipment varies as it can be constructed to satisfy the customers' requests. The fundamental concepts along with a brief description of the devices are given in this chapter. -
Page 25: Cameras And Lenses
004AZ011B FEATURES 2.1.1.6.1 Cameras and lenses The model of the camera and lense installed along with their configuration varies according to the application and machine version. Further information regarding the cameras and lenses is given in the enclosed documentation and in the customization documentation, as indicated in chapter 1 - GENERAL INFORMATION, paragraph ATTACHMENTS. -
Page 26: Auxiliary Equipment
004AZ011B FEATURES 2.1.1.7 Auxiliary equipment The term “auxiliary equipment” refers to all the control devices, generally sensors and actuators, connected to the switchboard that carry out auxiliary functions. For more detailed information, consult chapter 6 - USE OF THE ELECTRONIC EQUIPMENT. 2.1.1.7.1 Image shooting sensors As explained in chapter 6 - USE OF THE ELECTRONIC EQUIPMENT, introduction to the CVS, a sensor that starts... -
Page 27: Intended, Prohibited And Misuse Of The Machine
UNINTENDED AND PROHIBITED OPERATIONS No other use is intended unless duly authorized by the manufacturer. SACMI will not be held responsible for any personal injury, equipment damage or malfunctions caused by use manners different from those specified in this manual. -
Page 28: Overall Dimensions
004AZ011B FEATURES OVERALL DIMENSIONS The approximate dimensions of the personal computer + UPS and of the main electrical cabinet (optional) are shown in the figure. FIGURE 2.2 - OVERALL DIMENSIONS Personal computer + UPS Image shooting station (the dimensions vary according to how it is installed) Electrical cabinet (optional) T6784 2-12... -
Page 29: Technical Features
004AZ011B FEATURES TECHNICAL FEATURES 2.3.1 TECHNICAL DATA General specifications Supply voltages 200 / 220 / 380 / 400 / 415 / 440 / 460 / 480 VAC Cylinder-shaped fuses 10X38 type gG 16 / 16 / 10 / 10 / 10 / 10 / 10 / 10 A IP protection level 54 (inside electrical cabinet) Power requirements (50/60 Hz) -
Page 30: Acceptable Fluctuations
004AZ011B FEATURES 2.3.2 ACCEPTABLE FLUCTUATIONS ELECTRIC Voltage ±5% Frequency ±2% 2.3.3 RATING PLATE FIGURE 2.3.3 - RATING PLATE M A D E I T A L Y Matr.Nr. Cod. Serial No. Mat. O.d.V Order No. E0004 S A C M I I M O L A S . C . V I A S E L I C E P R O V I N C I A L E 1 7 / A I M O L A - I T A L I A 04076375 E0159 T6779... -
Page 31: Diagrams
004AZ011B FEATURES DIAGRAMS The functional block diagrams are given in this chapter. They are supplied to aid in the description of the devices. See also the attached wiring diagram of the main electrical cabinet, as indicated in chapter 1 - GENERAL INFORMATION, paragraph ATTACHMENTS. -
Page 32: Block Diagram Illustrating How The Ejection Devices And Led Lighting Units Are Piloted
004AZ011B FEATURES 2.4.1 BLOCK DIAGRAM ILLUSTRATING HOW THE EJECTION DEVICES AND LED LIGHTING UNITS ARE PILOTED The led-type lighting unit consists of a parallel-connected number of leds and a heating element, fed by pulse voltage. Brightness is adjusted by varying the amount of time the flash is emitted while keeping the voltage constant at 48 VDC. -
Page 33: Block Diagram Illustrating The Image Shooting Sensors And Encoder Interface
004AZ011B FEATURES 2.4.2 BLOCK DIAGRAM ILLUSTRATING THE IMAGE SHOOTING SENSORS AND ENCODER INTERFACE The position of the product to be inspected can be tracked by the system in different ways depending on the configuration and whether or not an encoder is used. Presence sensor SR informs the system a product has passed by. -
Page 34: Operational Features
004AZ011B FEATURES OPERATIONAL FEATURES 2.5.1 TYPE OF CHECKS 2.5.1.1 Standard checks The CVS vision system can identify several types of defects regarding the aesthetic and/or mechanical quality of plastic and/or metal caps like: visible overflow; visible spots; deformations; ovalization; off-center decorations; mixed decorations;... -
Page 35: Safety Equipment And Precautions
It is severely forbidden to alter, tamper with or lock out in any way the safety system provided. SACMI shall not be held responsible for any personal injury or property damage resulting from tampering or failure to use the safety devices provided. -
Page 36: Lockout/Tagout
004AZ011B SAFETY EQUIPMENT AND PRECAUTIONS 3.1.2 LOCKOUT/TAGOUT Energy Position Action Check Perform the LockOut/TagOut All types procedure of the machine in which the vision system is installed. Try to start the system; the - Turn the switch to OFF (or O). system should NOT start. - Page 37 004AZ011B SAFETY EQUIPMENT AND PRECAUTIONS FIGURE 3.1.2 - LOCKOUT/TAGOUT T6912...
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Page 38: Safety Rules For Handling
004AZ011B SAFETY EQUIPMENT AND PRECAUTIONS SAFETY RULES FOR HANDLING SAFETY INSTRUCTIONS D0003276_00 Only specially trained authorized personnel may lift and handle the device. No one should be near the hanging load or within the range of action of the lift equipment while the electronic equipment is being lifted and handled. -
Page 39: Installation
If electronic converters are present in the electrical control cabinet, the differential protective devices installed on the cabinet’s power supply line must ensure protection against leakage currents. SAFETY INSTRUCTIONS D0003276_00 SACMI shall not be held responsible for any property damage or personal injury resulting from improper installation. -
Page 40: Operator Training
004AZ011B SAFETY EQUIPMENT AND PRECAUTIONS OPERATOR TRAINING 3.4.1 COMPANY USING THE EQUIPMENT SAFETY INSTRUCTIONS D0003276_00 The electronic equipment is designed for professional use. The company using the electronic equipment must prevent access by unauthorized personnel. The company using this equipment must see that their personnel: read and understand the manual in its entirety are adequately instructed and trained on how to safely carry out their tasks receive specific training on how to operate this machine correctly... -
Page 41: Operation, Adjustments And Maintenance
To assure top electronic equipment performance and proper and safe operation, routine maintenance must be performed at the intervals and in the modes specified by SACMI. In particular, regularly check all the safety devices for proper functioning. Also check the insulation of the electrical cables, replacing them if necessary, and make sure the ground connections are effective. - Page 42 NOTICE D0003275_00 SACMI shall not be held liable for any personal injury or property damage and all warranties shall be void if: spare parts different from the ones originally installed in the electronic equipment are used; spare parts are incorrectly installed;...
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Page 43: Guidelines For Operation And Maintenance
004AZ011B SAFETY EQUIPMENT AND PRECAUTIONS 3.5.2 GUIDELINES FOR OPERATION AND MAINTENANCE 3.5.2.1 Residual electric risks WARNING D0003273_00 D0000004_00 The main cabinet and display console may be energized even when the main switch is in position OFF and/or the cabinet is open due to malfunctions: the UPS, if provided, continues feeding the Personal Computer. 3.5.2.2 Residual risks from light flashes WARNING... -
Page 44: Decommissioning And Dismantling The Machine
Use only adequate lift means and equipment that comply with current regulations and standards. NOTICE D0003275_00 If the electronic equipment has to be moved from one factory to another, contact SACMI Technical Service to obtain information about packing and shipment. 3-10... -
Page 45: Dismantling
004AZ011B SAFETY EQUIPMENT AND PRECAUTIONS 3.6.2 DISMANTLING SAFETY INSTRUCTIONS D0003276_00 Follow the instructions given in paragraph DISMANTLING in chapter 9 - DISMANTLING in compliance with current regulations. SAFETY INSTRUCTIONS D0003276_00 Only skilled personnel properly trained on how to work on and handle the machine are authorized to dismantle it. Use only adequate lift means and equipment that comply with current regulations and standards. - Page 46 004AZ011B SAFETY EQUIPMENT AND PRECAUTIONS 3-12...
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Page 47: Installation
004AZ011B INSTALLATION INSTALLATION SHIPPING, LIFTING AND POSITIONING THE MACHINE 4.1.1 DIVISION OF THE ELECTRONIC EQUIPMENT The electronic equipment is divided into various blocks to meet shipping and installation requirements. 4.1.2 DIMENSIONS AND WEIGHTS The weights and dimensions are approximate therefore they are given for reference purposes only. FIGURE 4.1.2 - DIMENSIONS AND WEIGHTS Personal computer + UPS Image shooting station... -
Page 48: Part Handling
The most appropriate methods and systems for lifting the heaviest and bulkiest parts or parts that require special attention and equipment supplied by SACMI are indicated in the figure. When lifting the smaller parts and packages, be careful and use the most suitable equipment observing the safety precautions. - Page 49 004AZ011B INSTALLATION INSTALLATION Place and assemble the various electronic equipment parts as shown in the installation layout. Lift the main cabinet and display console and put it in the required position. Position the image shooting stations and connect them to the conveyor system according to the arrangements made for personalizing the system.
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Page 50: Connections
NOTICE D0003275_00 The various electronic parts can be connected and hooked up to the mains only by specialized personnel instructed by SACMI. 4.3.1 ELECTRIC CONNECTIONS The customer must assure the electronic equipment is connected to an electrical system equipped with a device that protects against surges. -
Page 51: Plugging In The Power Cords For The Cameras
004AZ011B INSTALLATION 4.3.1.1.1 Plugging in the power cords for the cameras Connect the camera 3 to the capture card with the relevant cable 1. Fit the corresponding CAMERA LINK connector. If several cameras are employed, each one has to be connected to the relevant image capture card with the relative cable. - Page 52 004AZ011B INSTALLATION FIGURE 4.3.1.1 - CONNECTING THE ELECTRIC CABLES CAMERA LINK T6785...
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Page 53: Ground Connection
004AZ011B INSTALLATION 4.3.1.2 Ground connection Connect the parts marked with symbol (417-IEC-5019) in the electronic equipment directly to an effective E0006 earth-ground point. Only specially trained personnel are authorized to make the connections in the areas specified on the relative nameplates. -
Page 54: Software Installation
In any case several CD ROMs are supplied with this manual. These allow the software supplied with the electronic equipment to be reinstalled. If the software is lost, a copy can be obtained by contacting SACMI’s Customer Service Department. -
Page 55: Start-Up
NOTICE D0003275_00 SACMI shall not be held liable for any personal injury or property damage and all warranties shall be void if: spare parts different from the ones originally installed in the electronic equipment are used; spare parts are incorrectly installed;... -
Page 56: Start-Up Procedure
4, 5, 6, 7, 8 have to be repeated entirely or in part. Read the attached user manual for further details as indicated in chapter 1 - GENERAL INFORMATION, paragraph ATTACHMENTS. NOTICE D0003275_00 The basic functions of the SACMI inspection software should be know so as to perform the indicated operations. -
Page 57: Use Of The Electronic Equipment
004AZ011B USE OF THE ELECTRONIC EQUIPMENT USE OF THE ELECTRONIC EQUIPMENT SAFETY INSTRUCTIONS D0003276_00 It is imperative that the directions given in this manual and all safety precautions detailed are closely followed. START-UP/SHUTOFF Assuming that the software and image shooting station have been set-up at least once, it is now necessary to restore the initial operating conditions. -
Page 58: Start-Up With Modifications Made To The Software Configuration And The Image Shooting Station
004AZ011B USE OF THE ELECTRONIC EQUIPMENT 6.1.3 START-UP WITH MODIFICATIONS MADE TO THE SOFTWARE CONFIGURATION AND THE IMAGE SHOOTING STATION This type of start-up means that modifications have been made to the software configuration used when the system was shut off along with the settings for the image shooting stations; this is the case in which a change of the mechanical format of the product to be inspected is made. -
Page 59: Adjustments
004AZ011B ADJUSTMENTS ADJUSTMENTS CHECKING CVS VISION SYSTEMS 7.1.1 PROCEDURE FOR CHECKING THE CAPTURE AND EJECTION DEVICES This procedure is carried out to verify the sensor/encoder and reject device work correctly. A box of products to be inspected must be at hand (it does not matter if the pieces are defective or defect-free). Select the page for advanced settings of the tracking line on the interface. -
Page 60: Procedure For Checking The Capture And Ejection Mechanism
004AZ011B ADJUSTMENTS FIGURE 7.1.1.1/B - ADJUSTING THE FRONT-BACK IMAGE SHOOTING STATION Note: images are given for reference only and may change in relation to the type of vision system installed. 7.1.2 PROCEDURE FOR CHECKING THE CAPTURE AND EJECTION MECHANISM The purpose of this procedure is to verify that the vision system properly ejects all the defective products and none of the good quality ones. -
Page 61: Procedure For Checking Product Inspection
004AZ011B ADJUSTMENTS 7.1.3 PROCEDURE FOR CHECKING PRODUCT INSPECTION The following are needed to carry out this test: at least ten samples of each defect the vision system has to detect and reject; at least one hundred good quality sample products, in any case more good quality samples have to be provided than defective ones, the percentage should be approximately 10% defective products and 90% good quality ones. - Page 62 004AZ011B ADJUSTMENTS...
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Page 63: Maintenance
NOTICE D0003275_00 SACMI shall not be held liable for any personal injury or property damage and all warranties shall be void if: spare parts different from the ones originally installed in the electronic equipment are used; spare parts are incorrectly installed;... -
Page 64: Scheduled Maintenance
004AZ011B MAINTENANCE SCHEDULED MAINTENANCE 8.1.1 ROUTINE MAINTENANCE Every X hours Unit and intervention point Action taken When 1440 8460 25920 required • Illuminator 8.1.1.1 Cleaning • Camera cover 8.1.1.2 Cleaning • Touch screen 8.1.1.3 Cleaning • Fuses 8.1.1.4 Replacement (1) Refer to the paragraphs that deal with the operation. (2) The time interval is approximate: perform this operation when required. -
Page 65: Special Maintenance Operations
004AZ011B MAINTENANCE SPECIAL MAINTENANCE OPERATIONS Special training is required to perform special maintenance work which may therefore be carried only by the manufacturer’s expert personnel. For this reason, these types of operations are not dealt with in this manual. - Page 66 004AZ011B MAINTENANCE...
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Page 67: Dismantling
Close the electrical cabinet doors to prevent damage from tampering and dust from getting in. NOTICE D0003275_00 If the electronic equipment has to be moved from one factory to another, contact SACMI Technical Service to obtain information about packing and shipment. - Page 68 004AZ011B DISMANTLING DISMANTLING SAFETY INSTRUCTIONS D0003276_00 Only skilled personnel properly trained on how to work on and handle the machine are authorized to dismantle it. Use only adequate lift means and equipment that comply with current regulations and standards. If the electronic equipment is to be dismantled, first of all, make it in operative as instructed below: Use the factory main switch to cut off electrical power.