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Mitsubishi MELFA 4D-2CG5100-PKG-E Instruction Manual

Network vision sensor
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Mitsubishi Industrial Robot
Network Vision Sensor Instruction Manual
ＣＲｎ-５００ Series
4D-2CG5100-PKG-E
4D-2CG5400-PKG-E
4D-2CG5401-PKG-E
4D-2CG5403-PKG-E
4D-2CG5400C-PKG-E
4D-2CG5400R-PKG-E
BFP-A8520-*

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Summary of Contents for Mitsubishi MELFA 4D-2CG5100-PKG-E

  • Page 1 Mitsubishi Industrial Robot ＣＲｎ-５００ Series Network Vision Sensor Instruction Manual 4D-2CG5100-PKG-E 4D-2CG5400-PKG-E 4D-2CG5401-PKG-E 4D-2CG5403-PKG-E 4D-2CG5400C-PKG-E 4D-2CG5400R-PKG-E BFP-A8520-*...
  • Page 4 ■ Revision History Printing Date Instruction Manual No. Revision Contents 2006-10-02 BFP-A8520-* First Edition...
  • Page 5 ■Preface Thank you for purchasing this network vision sensor for CRn-500 series Mitsubishi Electric industrial robots. The network vision sensor is an option that is used in combination with a CRn-500 series controller to make it possible to detect and inspect work through visual recognition. Before using this sensor, please read this manual well so that you utilize the contents of this manual when using this network vision sensor.
  • Page 6 Safety Precautions Always read the following precautions and the separate "Safety Manual" before starting use of the robot to learn the required measures to be taken. CAUTION All teaching work must be carried out by an operator who has received special training. (This also applies to maintenance work with the power source turned ON.) Enforcement of safety training CAUTION...
  • Page 7 The points of the precautions given in the separate "Safety Manual" are given below. Refer to the actual "Safety Manual" for details. CAUTION Use the robot within the environment given in the specifications. Failure to do so could lead to a drop or reliability or faults.
  • Page 8 Do not stop the robot or apply emergency stop by turning the robot controller's main CAUTION power OFF. If the robot controller main power is turned OFF during automatic operation, the robot accuracy could be adversely affected.Moreover, it may interfere with the peripheral device by drop or move by inertia of the arm.

  • Page 10: Table Of Contents

    Contents SUMMARY ..............................1-2 What A Network Vision Sensor Is....................1-2 1.1. Features............................1-3 1.2. Applications ........................... 1-4 1.3. Explanation of terms........................1-6 1.4. SYSTEM CONFIGURATION........................2-7 Component Devices........................2-7 2.1. Network vision sensor basic set composition and accessories ............. 2-7 2.1.1.
  • Page 11 VISION SENSOR SETTINGS ........................6-29 Vision Sensor Initial Settings ...................... 6-29 6.1. Work recognition test ........................6-32 6.2. Starting MELFA-Vision (network vision sensor support software) ..........6-32 6.2.1. Image adjustment......................... 6-37 6.2.2. Image processing settings ......................6-40 6.2.3. ROBOT CONTROLLER SETTINGS ......................7-53 Robot Controller Parameter Settings..................
  • Page 12 Templates provided for MELFA-Vision..................9-116 9.3.1. Image processing - blobs......................9-118 9.3.2. Image processing – Color ......................9-121 9.3.3. Using image processing for which there is no template ............9-130 9.3.4. To shorten the time for transferring data with the robot controller ..........9-131 9.3.5.

  • Page 13: What A Network Vision Sensor Is

    1 Summary 1. Summary 1.1.  W hat A Network Vision Sensor Is The network vision sensor is an option that makes it possible to discriminate the position of various types of work and transport, process, assemble, inspect, and measure work with MELFA robots. What A Network Vision Sensor Is 1-2...

  • Page 14: Features

    1 Summary 1.2.  F eatures The network vision sensor has the following functions. (1) Position detection through high-speed image processing ・High-speed image processing makes it possible to detect the work at high speed, not only when the angle is not detected, but even when the work includes 360˚ rotation. ①...

  • Page 15: Applications

    1 Summary 1.3.  A pplications Here are major applications of the network vision sensor. (1) Loading/Unloading Machined Parts Figure 1-1 Example of Loading/Unloading Machined Parts (2) Processed Food Pallet Transfer Figure 1-2 Example of Processed Food Pallet Transfer (3) Lining Up and Palletizing Electronic Parts Figure 1-3 Example of Lining Up and Palletizing Electronic Parts Applications 1-4...
  • Page 16 1 Summary (4) Small Electrical Product Assembly Figure 1-4 Example of Small Electrical Product Assembly (5) Lining Up Parts Figure 1-5 Example of Lining Up Parts (6) Small Electronic Parts Mounting Figure 1-6 Example of Small Electronic Parts Mounting 1-5 Applications...

  • Page 17: Explanation Of Terms

    1 Summary 1.4.  E xplanation of terms This section explains the terms used in this manual. CCD (Charge Coupled Device) ･ This is the most general pickup element used in cameras. Degree of matching (score) ･････ This value indicates the degree to which the image matches the registered pattern.

  • Page 18: System Configuration

    2 System configuration 2. System configuration 2.1.  C omponent Devices 2.1.1.  Network vision sensor basic set composition and accessories The composition of the network vision sensor basic set that you have purchased is shown in "Table 2-1 List of Network Vision Sensor Basic Set Composition”. Table 2-1 List of Network Vision Sensor Basic Set Composition Set format -2CG5100...
  • Page 19 2 System configuration Table 2-2 List of Network Vision Sensor Related Options Option name Model Ethernet interface card 2A-HR533 Expansion option box CR1-EB3 Network cable 0.6m CCB-84901-1001-00 CCB-84901-1002-02 CCB-84901-1003-05 CCB-84901-1004-10 CCB-84901-1005-15 CCB-84901-1006-30 Breakout cable CCB-84901-0101-02 CCB-84901-0102-05 CCB-84901-0103-10 CCB-84901-0104-15 Camera cable CCB-84901-0303-05 CCB-84901-0304-10 CCB-84901-0305-15...
  • Page 20 2 System configuration The composition of the basic set(All-in-one design) are shown in figures. Lens cover O ring Thread guard In-sight vision sensor Breakout cable Network cable In-Sight Software CD-ROM MELFA-Vision CD-ROM Installation guide Figure 2-1 Basic set(All-in-one design) composition 2-9 Component Devices...
  • Page 21 2 System configuration The composition of 4D-2CG-5400R-PKG(Remote Head) are shown in figures. Remote Head Camera Camera Cable Network Vision sensor Breakout Cable Network Cable MELFA-Vision CD-ROM In‑Sight Software CD‑ROM  Installation guide Figure 2-2 Basic set(Remote Head Type) composition Component Devices 2-10...

  • Page 22: Equipment Provided By Customer

    2 System configuration 2.1.2.  Equipment provided by customer In addition to this product, the system also includes equipment provided by the customer. “Table 2-3 List of Equipment Provided by Customer" shows the minimum necessary equipment. The equipment for the customer to provide depends on the system. For details, see “2.2 System configuration example”. Table 2-3 List of Equipment Provided by Customer Device name Recommended product...

  • Page 23: System Configuration Example

    Table 2-4 List of Configuration When One Camera Is Used Part name Format Manufacturer Q'ty Remarks Robot controller CRn-500 series Mitsubishi Software: K6 or later Electric Robot main unit All models Expansion option box CR1-EB3 For CR1 controller Ethernet interface card...

  • Page 24: Configuration With One Robot Controller And Two Vision Sensors

    Table 2-5 List of Configuration When Two Cameras Are Used Part name Format Manufacturer Q'ty Remarks Robot controller CRn-500 series Mitsubishi Software: K6 or later Electric Robot main unit All models Expansion option box CR1-EB3 For CR1 controller Ethernet interface card...

  • Page 25: Configuration With Three Robot Controllers And One Vision Sensor

    Table 2-6 List of Configuration When One Camera Is Used with Three Robots Part name Format Manufacturer Q'ty Remarks Robot controller (*4) CRn-500 series Mitsubishi Software: K6 or later Electric Robot main unit All models Expansion option box CR1-EB3 For CR1 controller...
  • Page 26 2 System configuration (*4) Up to three robot controllers can be connected at the same time to one vision sensor, so prepare the "necessary quantity" for the number of robot controllers you use. 2-15 System configuration example...

  • Page 27: Specifications

    3 Specifications 3. Specifications 3.1.  N etwork vision sensor specifications Here are the specifications of the network vision sensor by itself. Table 3-1 Network Vision Sensor Stand-Alone Specifications High-Perfor High-resolution Standard Color Remote Head mance 5100 5400C (*1) 5400R (*1) 5401 (*1) 5403 (*1) 5400...

  • Page 28: External Dimensions Of Network Vision Sensor(5100/5400/5401/5403/5400C)

    3 Specifications 3.1.1.  External Dimensions of Network Vision Sensor(5100/5400/5401/5403/5400C) Externals dimensions of Network Vision Sensor(5100/5400/5401/5403/5400C) is shown below. please refer when you fix the Vision sensor. Figure 3-1 External Charts of Network Vision Sensor(5100/5400/5401/5403/5400C) 3-17 Network vision sensor specifications...

  • Page 29: External Dimensions Of Network Vision Sensor 5400R

    3 Specifications 3.1.2.  External Dimensions of Network Vision Sensor 5400R Externals dimensions of Network Vision Sensor 5400R is shown below. please refer when you fix the Vision sensor. Unit:mm Figure 3-2 External Charts of Network Vision Sensor 5400R (Processor part) Network vision sensor specifications 3-18...
  • Page 30 3 Specifications Unit:mm Figure 3-3 External Charts of Network Vision Sensor 5400R (Remote Head part) Unit:mm Figure 3-4 External Charts of Network Vision Sensor 5400R (Blacket part) 3-19 Network vision sensor specifications...

  • Page 31: Robot Controller Specifications

    3 Specifications 3.2.  R obot controller specifications The robot controller specifications related to the network vision sensor is shown below. Table 3-2 Robot Controller Specifications Item Specifications Software Robot controller: Ver. K6 or later (*) RT Toolbox: No specification (*2) Applicable robot controllers All CRn-500 series controllers (*3) Connectable robots All robots (*4)

  • Page 32: Melfa-Vision

    3 Specifications 3.3.  M ELFA-Vision 3.3.1.  Features MELFA-Vision is software that provides support for those using vision sensors for the first time and support for connections between robot controllers and vision sensors. Below are the basic functions and features of MELFA-Vision.

  • Page 33: Work Charts

    4 Work Charts 4. Work Charts This chapter explains the work procedure for building a vision system using our robots. Check the following procedure before working. Start of work Step1 Equipment preparation and connection (Chapter 5) Prepare and connect the required equipment and install the software (p.5-23) Step2 Vision Sensor Initial Settings...

  • Page 34: Equipment Preparation And Connection

    Table 5-1 List of Configuration When One Camera Is Used Part name Format Manufacturer Q'ty Remarks Robot controller CRn-500 series Mitsubishi Software: K6 or later Electric Robot main unit All models Teaching box R28TB 2A-HR533 Ethernetinterface card（*1）...

  • Page 35: Equipment Connection

    5 Equipment preparation and connection 5.2.  E quipment connection This section explains how to connect the equipment prepared. 5.2.1.  Expansion option box installation (for CR1 controller) A CR1 expansion option box is required in order to connect the Ethernet card to the CR1 controller. If the controller is a CR1 or CR1B, first install the expansion option box.
  • Page 36 5 Equipment preparation and connection (7) Connect the Ethernet straight cable to the hub and the other end to the robot controller's Ethernet interface card. Ethernet Cable Figure 5-1 Ethernet Cable Connection In-Sight5100/5400 24V power supply PC Tool ハ ブ Robot Robot controller Extended box...

  • Page 37: Software Installation

    5 Equipment preparation and connection 5.3.  S oftware installation This product comes with two CD-ROMs (In-Sight and MELFA-Vision). Each CD-ROM contains software necessary for starting up the vision system. This section explains how to install this software. 5.3.1.  Vision sensor dedicated software (In-Sight Explorer) installation This section explains how to install the vision sensor dedicated software (In-Sight Explorer).

  • Page 38: Melfa-Vision Installation

    5 Equipment preparation and connection 5.3.2.  MELFA-Vision installation This section explains how to install MELFA-Vision (network vision sensor support software). Install this product with the following procedure. ◆ When "MELFA-Vision" is installed in the personal computer, ". NET Framework 1.1" is installed. ◆...
  • Page 39 5 Equipment preparation and connection Below are the contents of the CD-ROM. ＼： Setup.exe The files for installation of “MELFA-Vision”. ： ： ： Instruction Manual(pdf) ・・・・・・・ This folder contains user registration Misc ・・・・ application form(for faxing) (4) Installation check When the installation is complete, the installed software can be started from the Windows Start menu.

  • Page 40: Vision Sensor Settings

    6 Vision Sensor Settings 6. Vision Sensor Settings This chapter explains the vision sensor settings for recognizing work images. 6.1.  V ision Sensor Initial Settings The first time you use your vision sensor, if you use a DHCP server, just switching on the power for the vision sensor automatically sets its IP address, but if you are not using a DHCP server, it is necessary to make this initial setting with the "In-Sight Connection Manager"...
  • Page 41 6 Vision Sensor Settings (3) Input the MAC address listed on the vision sensor main unit sticker, then click the [Add] button. When connecting multiple vision sensors, add a MAC address for each vision sensor connected. Also, if you restart by switching Off, then On the power for all the vision sensors set, the MAC addresses are automatically displayed in a list.
  • Page 42 6 Vision Sensor Settings (6) Input the vision sensor [New Name] (host name) and [New IP], then click the [Next] button. Check with your network administrator for the IP address to set. Here is an example in which an IP address of "10.50.0.100" is set. (7) Click the [Configure] button, cut off the power for the vision sensor, wait at least 5 seconds, then switch the power back on again.

  • Page 43: Work Recognition Test

    6 Vision Sensor Settings 6.2.  W ork recognition test This section explains how to register the work to be recognized with the vision sensor and how to test recognition of this work. 6.2.1.  Starting MELFA-Vision (network vision sensor support software) This section explains the procedure for starting MELFA-Vision, which can easily execute a work recognition test.
  • Page 44 6 Vision Sensor Settings This section explains the MELFA-Vision main screen. For details on the MELFA-Vision functions, see "9.2 MELFA-Vision Function Details”. Title Window (3) Menu (4) Tool buttons (5) Vision Sensor Information (6) Job Editing (8) Camera image (7) Calibration data creation (9) Status bar Figure 6-2 Main Screen (1) Window...
  • Page 45 6 Vision Sensor Settings (3) Menu Table 6-1 MELFA-Vision Menu List Menu Item Sub-item Explanation File Exit Exits MELFA-Vision. View Refresh Job Files Updates the job list display on the left of the screen. Refresh Calibration Data Updates the calibration data list display at the bottom left of the screen.
  • Page 46 6 Vision Sensor Settings (4) Tool buttons Figure 6-3 Tool Bar Table 6-2 Tool Button List Button Tool tip Explanation Logon/Logoff On: Logged on Off: Logged off Online/Offline On: Online Off: Offline Manual Trigger Each time this button is clicked, the image is shot. Live Mode On: Live display underway Off: Live display ended...
  • Page 47 6 Vision Sensor Settings (6) Job Editing A list of the job files for the logged on vision sensors is displayed and job files are managed (created, edited, name changed, updated). Figure 6-6 Job (Vision Program) List (7) Calibration data creation A list of the calibration for the logged on vision sensors is displayed and calibration data is created.

  • Page 48: Image Adjustment

    6 Vision Sensor Settings 6.2.2.  Image adjustment This section explains how to adjust the brightness and Diaphragm for the image captured by the vision sensor. (1) Check the image shot with MELFA-Vision [Camera Image]. From MELFA-Vision menu, click [Sensor] – [Live Mode] or click from the tool bar to put MELFA-Vision into live image mode.
  • Page 49 6 Vision Sensor Settings (3) If the brightness is not appropriate, adjust the lens "Diaphragm". Figure 6-12 Camera Lens adjustment If the appropriate brightness can not be achieved by just adjusting the Diaphragm, provide different lighting. ① Too bright Figure 6-13 Example in Which the Image Is Too Bright ②...
  • Page 50 6 Vision Sensor Settings (4) If the focus is not appropriate, adjust the lens "focus". Figure 6-15 Example in Which The Image Is Out of Focus 6-39 Work recognition test...

  • Page 51: Image Processing Settings

    6 Vision Sensor Settings 6.2.3.  Image processing settings This section explains how to make the image processing settings, using pattern matching image processing (only one robot, results output as robot absolute coordinate values) as an example. For details on other image processing, see "9.3.1 Templates provided for MELFA-Vision".
  • Page 52 6 Vision Sensor Settings (2) Execute the work in order of the tabs from left to right on the displayed "Job Editing" screen. First, adjust the image with the [Adjust Image] tab. Track bar (3) When you change all the displayed items, then click the [Test] button, the picture is displayed for when the setting is changed to the main screen [Camera Image], so adjust for clear contrast between the work and the background.
  • Page 53 6 Vision Sensor Settings Trigger Camera This specifies the image take-in trigger for when the vision Continuous sensor is "online". External [Camera] Manual The image is taken in at the rising edge detected at the Network camera hardware trigger input port. [Continuous] Images are taken in continuously.
  • Page 54 6 Vision Sensor Settings (4-1)Determining the search area When you click the "Search area" [Image] button, the focus shifts to the main screen and a red frame is displayed around [Camera Image] on the main screen. The registered work is detected from the area enclosed by the red frame. The area in which the work is detected can be changed with the mouse or keyboard.
  • Page 55 6 Vision Sensor Settings (4-2)Determining the recognition pattern When you click the "Pattern select" [Image] button, the focus shifts to the main screen and a red frame is displayed around [Camera Image] on the main screen. The registered work is enclosed by the red frame. For operations, use the mouse or keyboard. If you use the keyboard, each time the [F9] key is pressed, the "area adjustment mark"...
  • Page 56 6 Vision Sensor Settings (4-3)This specifies the work coordinates sent to the robot. When you click the "Output position setting" [Image] button, the focus shifts to the main screen and a red circle is displayed at [Camera Image] on the main screen. Move this circle with the mouse or keyboard to specify what position to send to the robot for the registered work.
  • Page 57 6 Vision Sensor Settings (5) This determines the recognition conditions. When you click the "Job Editing" screen [Processing Condition] tab, the conditions for searching for the registered work are set. When you change a displayed setting item, then click the [Test] button, the results of image processing under the specified conditions are displayed at the main screen [Camera Image], so check whether or not the work is correctly recognized.
  • Page 58 6 Vision Sensor Settings (5-1)This shows setting examples for the maximum detection count. ◆When 10 is set When you click the "Job Editing" screen [Test] button, the 6 pieces of work captured in the image are recognized and they are displayed with "+" pointer mark and a number from 0 in order of highest degree of match attached to each piece of work.
  • Page 59 6 Vision Sensor Settings (5-2)This shows setting examples for the threshold. The higher the threshold, the greater the precision of the detection. ◆When 40% is set as the threshold Maximum detection count of 10: Threshold of 40%: When you click the "Job Editing" screen [Test] button, even though there is one piece of work at the top left, two pieces of work are recognized.
  • Page 60 6 Vision Sensor Settings (5-3)This shows setting examples for the start angle and end angle. ◆When Start angle: –45˚, end angle: 45˚ is set When you click the "Job Editing" screen [Test] button, only work is detected that is within the ±45˚...
  • Page 61 6 Vision Sensor Settings (5-4)This shows setting examples for the sort direction. ◆Sort direction: X When you click the "Job Editing" screen [Test] button, the recognized work is displayed with a number from 0 in order of the +X direction (from top to bottom in the figure above) of the frame specified with the search area specification.
  • Page 62 6 Vision Sensor Settings (6) The "Job Editing" screen [Image log] tab is explained in "9.2.2Job Editing screen ([Image Log] tab)"; the [Results Cell Position] tab is explained in "9.2.3Job edit screen ([Result Cell Position] tab)". (7) When you want to check not only the image but also the numeric data in the image processing results, click [Sensor] –...
  • Page 63 6 Vision Sensor Settings (8) If the recognition results are not what was expected, change the recognition conditions with the "Job Editing" screen [Processing Condition]. (9) If the recognition results are what was expected, click the "Job Editing" screen [Save] button to save the image processing conditions set up till now to the vision sensor.

  • Page 64: Robot Controller Settings

    7 Robot Controller Settings 7. Robot Controller Settings This chapter explains the items set in the robot controller, using a system with one vision sensor and one robot controller as an example. 7.1.  R obot Controller Parameter Settings In order for the robot controller to control the vision sensor, it is necessary to set the parameters for the communication connection with the vision sensor.
  • Page 65 7 Robot Controller Settings (4) This makes the settings for the robot controller and MELFA-Vision to communicate. Click the "Communications server" displayed on the Windows taskbar to display the "Communication Server" screen. (If the communication parameters have not been set yet, all the information is written in red.）...
  • Page 66 7 Robot Controller Settings Click the [Set(Save and Close)] button to store the communication settings you have set. Check that all the frames on the "Communication Server" main screen become light blue. If a frame is green, redo the setting. (5) This sets the parameters for the robot controller and vision sensor to communicate.
  • Page 67 7 Robot Controller Settings From the "Device List", select [OPT15], then click the [Change] button. On the displayed "Device Setting" screen, switch On the [Change the Parameter to connect Vision] checkbox, then input the vision sensor IP address as the IP Address. Click the [OK] button and check that a "*"...
  • Page 68 7 Robot Controller Settings If you click [Yes], the parameters are written to the robot controller. A message is displayed that the controller power will be switched Off, then On again to put the parameter change into effect. Click the [Yes] button and wait for the robot controller power supply to be reset. When the robot controller starts, click the [Read] button on the "Communication Setting”...

  • Page 69: Calibration Setting

    7 Robot Controller Settings 7.2.  C alibration Setting Calibration is a function that converts the vision sensor coordinate system into the robot coordinate system. This calibration work is necessary for recognizing what position in the robot coordinate system the recognized work is at.
  • Page 70 7 Robot Controller Settings (4) Exit the live image. From the MELFA-Vision menu, click [Sensor] – [Live Mode] or from the MELFA-Vision tool bar, click to exit live image mode. (5) From the MELFA-Vision main screen, select [No. 1] in the [Calibration Data List]. This section explains [No.
  • Page 71 7 Robot Controller Settings (7) Specify the first point on the vision sensor. Click the [Image] button for the first point. Mark 1 Use the mouse or the [arrow keys] to move the mark to mark 1, then press the [Enter] key. Mark 1 Calibration Setting 7-60...
  • Page 72 7 Robot Controller Settings (8) Specify the second point on the vision sensor. Click the [Image] button for the second point. Mark 2 Use the mouse or the [arrow keys] to move the mark to mark 2, then press the [Enter] key. Mark 2 7-61 Calibration Setting...
  • Page 73 7 Robot Controller Settings (9) Specify the third point on the vision sensor. Click the [Image] button for the third point. Mark 3 Use the mouse or the [arrow keys] to move the mark to mark 3, then press the [Enter] key. Mark 3 Calibration Setting 7-62...
  • Page 74 7 Robot Controller Settings (10) Specify the fourth point on the vision sensor. Click the [Image] button for the fourth point. Mark 4 Use the mouse or the [arrow keys] to move the mark to mark 4, then press the [Enter] key. Mark 4 7-63 Calibration Setting...
  • Page 75 7 Robot Controller Settings (11) Specify the first point with the robot. Use the teaching box to move the robot hand to the first point. * For this work, the use of a pointed-tip object in the hand is recommended. On the "Create Calibration Data"...
  • Page 76 7 Robot Controller Settings (14) Specify the fourth point with the robot. Use the teaching box to move the robot hand to the fourth point. On the "Create Calibration Data" screen, click the [Position] button for the fourth point to acquire the robot's current position.
  • Page 77 7 Robot Controller Settings (18) The calibration data is set for the created job and the recognized work is displayed with the robot coordinate system. From the MELFA-Vision main screen "Job(Vision Program)List", select "Job1.job", then click the [Edit] button. On the displayed "Job Editing" screen, click the [Processing Conditions] tab. Click the "Calibration No."...
  • Page 78 7 Robot Controller Settings Place the work under the vision sensor, then click the "Job Editing" screen [Test] button. From the MELFA-Vision menu, when you click [Sensor] – [Recognition Test Results], the coordinates for the recognized work are displayed with the robot coordinate system. 7-67 Calibration Setting...
  • Page 79 7 Robot Controller Settings (19) The "Job Editing" screen "Calibration" specification has been changed, so the recognition conditions are saved. Click the "Job Editing" screen [Save] button. (20) Close the "Job Editing" screen. Click the "Job Editing" screen [Exit] button. Calibration Setting 7-68...

  • Page 80: Robot Program Writing

    7 Robot Controller Settings 7.3.  R obot Program Writing In order to start (execute) image processing with the vision sensor from the robot, it is necessary to execute commands controlling the vision sensor in a robot program written in MELFA-Basic IV. 7.3.1. ...
  • Page 81 7 Robot Controller Settings (1) The evaluation position, work grasping position, and work placement position are taught in order to operate the robot. Use the teaching box to open the stored robot program and open the position edit screen. ① With the teaching box (R28TB), turn the key switch in the "Enable" direction. ②...

  • Page 82: Executing The Automatic Operation Test

    7 Robot Controller Settings 7.4.  E xecuting the automatic operation test This section explains automatic operation that starts the program created with “7.3 Robot Program Writing” and transports the work recognized with the vision sensor. 7.4.1.  Put the vision sensor online. In order for the robot controller to control the vision sensor, it is necessary to put the vision sensor "online".

  • Page 83: Starting A Robot Program

    7 Robot Controller Settings 7.4.3.  Starting a Robot Program This section explains the work for starting the stored robot program "1" with the robot controller operation panel (O/P). Turn the operation panel key switch in the "Auto (Op)" direction. ① Press the [CHNG DISP] button to display the override at the Status Number.
  • Page 84 7 Robot Controller Settings The main screen [Camera Image] displays the recognition results and the robot transports all the ⑨ work recognized by the vision sensor. After transporting, the robot program stops. 7-73 Executing the automatic operation test...

  • Page 85: When The Robot Can Not Grasp The Work Normally

    7 Robot Controller Settings 7.5.  W hen the robot can not grasp the work normally This section explains what to do if the robot program started normally, but the robot could not grasp the work normally. 7.5.1.  Check the MELFA-Vision [Camera Image]. Check if the position of the work recognized by the vision sensor is correct.
  • Page 86 7 Robot Controller Settings (2) From the main screen menu, click [Controller] - [Monitor] to display the "Monitor of Controller" screen. This screen monitors the controller's dedicated status variables for the vision sensor. (3) Select the line connecting the robot controller and the vision sensor (in the explanation up till now "COM2:"), then click the [Recognition Details] button.

  • Page 87: Maintenance

    8 Maintenance 8. Maintenance This chapter explains vision sensor data backup and restoration, the image log function, vision sensor cloning, the startup function, and user list registration overall maintenance. 8.1.  V ision Sensor Data Backup The backup function stores on a PC all the files (*.job, *.bmp, *.jpg, proc.set and hosts.net) stored on the vision sensor.
  • Page 88 8 Maintenance (3) If you select a vision sensor other than the one currently logged on the "User Name And Password" screen is displayed, so input the user name and password for the vision sensor to be backed up, then click the [OK] button. This screen is not displayed if the currently logged on vision sensor is selected with the "Sensor List".

  • Page 89: Vision Sensor Data Restoration

    8 Maintenance 8.2.  V ision Sensor Data Restoration The restore function takes the files backed up to the PC with the backup function and returns them to the vision sensor. The restored files are all the files that were backed up. This function can be used with the vision sensor either logged on or logged off.
  • Page 90 8 Maintenance (4) A confirmation screen is displayed, so check the contents, then click the [Yes] button. (5) A confirmation screen is displayed to ask whether or not to enable restoration of the vision sensor network setting files. To restore the vision sensor setting file (proc.set) and the host table file (hosts.net) vision sensor network setting file too, click the [Yes] button.
  • Page 91 8 Maintenance (7) When the restoration is complete, the completion message is displayed. To reflect the restoration settings, restart the vision sensor. When the [OK] button is clicked, display returns to the [Backup from Vision Sensor] screen. Vision Sensor Data Restoration 8-80...

  • Page 92: Vision Sensor Cloning

    8 Maintenance 8.3.  V ision Sensor Cloning The cloning function can create multiple vision sensors with the same files as the original one vision sensor. This function can be used with the vision sensors either logged on or logged off. Also, although this function can be used with the vision sensors either Online or Offline, since the robot and vision sensor access can be slowed by file transfer operations, it is recommended to restore with the vision sensor offline.
  • Page 93 8 Maintenance (4) A confirmation screen is displayed, so check the contents, then click the [Yes] button. (5) When the cloning work starts, the indicator progresses as on the screen below. To cancel cloning work that is underway, click the [Stop] button. (6) When the cloning is complete, the completion message is displayed.

  • Page 94: Image Log Acquisition Settings And Reception Start/End

    8 Maintenance 8.4.  I mage Log Acquisition Settings and Reception Start/End The image log acquisition function is a function that stores the images captured by the vision sensor with the conditions set with the job (Always/OK images/NG images) while the vision sensor is communicating with the controller in online mode.

  • Page 95: Vision Startup Settings

    8 Maintenance 8.5.  V ision Startup Settings The startup settings are a function that sets the startup conditions for when the power supply to the vision sensor is switched On (select whether to start up online or offline and select the job to load). This section explains the work for setting the startup using MELFA-Vision.

  • Page 96: User List Settings

    8 Maintenance 8.6.  U ser List Settings The user list settings function is the function that sets the access rights for users that use the vision sensor, the FTP read and write rights, and password settings. This section explains the work for setting the user list using MELFA-Vision. (1) Display the MELFA-Vision "User List"...
  • Page 97 8 Maintenance (3) To add a user, click the [Add] button on the "User List" screen; to edit an existing user, select the user from the list and click the [Edit] button. The "User" screen is displayed, so set the required items and click the [OK] button. (4) To delete an existing a user, select the user from the "User List"...

  • Page 98: Detailed Explanation Of Functions

    9 Detailed Explanation of Functions 9. Detailed Explanation of Functions This chapter explains the functions of this product in detail. 9.1.  V ision Sensor Dedicated Commands and Status Variables The robot controller has status variables and dedicated commands for controlling vision sensors. This section explains these dedicated commands and status variables.
  • Page 99 9 Detailed Explanation of Functions (1) NVOPEN (network vision sensor line open) [Function] Connects with the specified vision sensor and logs on to that vision sensor. [Format] NVOPEN□“<COM number>”□AS□#<Vision sensor number> [Term] <Com number> (Can not be omitted): Specify the communications line number in the same way as for the Open command. "COM1:"...
  • Page 100 9 Detailed Explanation of Functions password for all of them. 5) The state of communications with the network vision sensor when this command is executed can be checked with M_NVOPEN. For details, see the explanation of M_NVOPEN. 6) If the program is cancelled while this command is being executed, it stops immediately. In order to log on to the vision sensor, it is necessary to reset the robot program, then start.
  • Page 101 9 Detailed Explanation of Functions (2) NVPST (Network vision program start) [Function] Starts the specified vision program and obtains the results. The data received from the vision sensor is stored in the robot controller robot status variables. [Format] NVPST□#<Vision sensor number>,"<Vision program (job) name>" , "<Recognition count cell>", "<Start cell>", "<End cell>", <Type>...
  • Page 102 9 Detailed Explanation of Functions About details of a set value, see the " Table 9-2 Preservation specification to state variable by <Type> specified value". Table9-2 Preservation specification to state variable by <Type> specified value Specified value State of cell Two or more of comma(,) district switching off data／...
  • Page 103 9 Detailed Explanation of Functions [Sample sentence] 100 IF M_NVOPEN(1)<>1 THEN 'If vision sensor number 1 log on is not complete NVOPEN “COM2:” AS #1 'Connects with the vision sensor connected to COM2. 120 ENDIF 130 WAIT M_NVOPEN(1)=1 ' Connects with vision sensor number 1 and waits for logon to be completed.
  • Page 104 9 Detailed Explanation of Functions Example: Handling of vision sensor information on two multi-mechanism mode <J96> and <R98> are specified as the <Start cell> and <End cell>. When "1' is specified as the type with the NVPST command, it is stored in M_NVS1(30,10) as follows.
  • Page 105 9 Detailed Explanation of Functions 【Example assembling system with two robots and one vision sensor】 ②Image capture request ⑥Image capture request ③Data reception ⑦Data reception ⑤Using ON ⑧UsingOFF ①UsingON ④UsingOFF Controller Controller <Procedure> ①The controller using the vision sensor checks that the vision sensor is not being used by another controller and outputs the "Using"...
  • Page 106 9 Detailed Explanation of Functions 18) If the communications line is cut while this command is being executed, an "abnormal communications" error occurs and the robot controller side line is closed. 9-95 Vision Sensor Dedicated Commands and Status Variables...
  • Page 107 9 Detailed Explanation of Functions (3) NVLOAD (network vision sensor load) [Function] Loads the specified vision program into the vision sensor. [Format] NVLOAD□#<Vision sensor number>,”<Vision program (job) name>” [Term] <Vision sensor number> (Can not be omitted) This specifies the number of the vision sensor to control. Setting range: 1 - 8 <Vision program (job) name>...
  • Page 108 9 Detailed Explanation of Functions (4) NVTRG (network vision sensor trigger) [Function] Requests the specified vision program to capture an image. [Format] NVTRG□#<Vision sensor number>,<delay time>, <encoder 1 value read-out variable> [,[<encoder 2 read-out variable>][,[<encoder 3 value read-out variable>] [,[<encoder 4 read-out variable>][,[<encoder 5 value read-out variable>] [,[<encoder 6 read-out variable>][,[<encoder 7 value read-out variable>] [,[<encoder 8 read-out variable>] [Term]...
  • Page 109 9 Detailed Explanation of Functions [Errors] (1) If data type for an argument is incorrect, a "syntax error in input command statement" error is generated. (2) If there is an abnormal number of command arguments (too many or too few), an "incorrect argument count"...
  • Page 110 9 Detailed Explanation of Functions (5) NVRUN (network vision sensor run) [Function] Starts the specified vision program. [Format] NVRUN□#<Vision sensor number>,"<Vision program (job) name>" [Term] <Vision sensor number> (Can not be omitted) This specifies the number of the vision sensor to control. Setting range: 1 - 8 <Vision program (job) name>...
  • Page 111 9 Detailed Explanation of Functions [Errors] 1) If data type for an argument is incorrect, a "syntax error in input command statement" error is generated. 2) If there is an abnormal number of command arguments (too many or too few), an "incorrect argument count"...
  • Page 112 9 Detailed Explanation of Functions (6) NVIN (network vision sensor input) [Function] Receives the results of the recognition by the vision sensor. The data received from the vision sensor is stored in the robot controller robot status variables. [Format] NVIN□#<Vision sensor number>,[<Vision program (job) name] , <Recognition count cell>,<Start cell>,<End cell>,<Type>...
  • Page 113 9 Detailed Explanation of Functions [Explanation] 1) Receives the recognition results from the specified vision program of the specified vision sensor. 2) Within the timeout time, does not move to the next step until the results are received from the vision sensor.
  • Page 114 9 Detailed Explanation of Functions (7) NVCLOSE (network vision sensor line close) [Function] Cuts the line with the specified vision sensor. [Format] NVCLOSE□[[#]<Vision sensor number>[,[[#]<Vision sensor number>・・・] [Term] <Vision sensor number> (Can be omitted) Specifies a constant from 1 to 8 (the vision sensor number). Indicates the number for the vision sensor connection to the COM specified with the <COM number>.

  • Page 115: Robot Status Variables

    9 Detailed Explanation of Functions 9.1.3.  Robot status variables Here are the status variables for vision sensors. Be careful. The data for these status variables is not backed up by the RT ToolBox backup function. Table 9-3 Vision Sensor Status Variable List Variable name Array elements Contents...
  • Page 116 9 Detailed Explanation of Functions (2) M_NVNUM [Function] Indicates the number of pieces of work detected by the vision sensor. [Array meaning] Array elements (1 - 8): Vision sensor numbers [Explanation of values returned] Work detection count (0-255) [Explanation] 1) Indicates the number of pieces of work detected by the vision sensor with the NVPST command or NVIN command.
  • Page 117 9 Detailed Explanation of Functions (3) P_NVS1 - P_NVS8 [Function] Stores the data recognized by the vision sensor in position data format. In an NVPST command or NVIN command, when a <type> of "0" is specified, the data in the cell range specified with <Start cell>...
  • Page 118 9 Detailed Explanation of Functions [Explanation] 1) In an NVPST command or NVIN command, when a <type> of "0" is specified, the data recognized by the vision sensor is stored in position data format. 2) When this variable is used, write the vision program to store the data in the order X, Y, and C. Example: 3) The stored data is held until the next NVPST command or NVIN command is executed.
  • Page 119 9 Detailed Explanation of Functions (4) M_NVS1 - M_NVS8 [Function] Stores the data recognized by the vision sensor in numeric data format. In an NVPST command or NVIN command, when a <type> of "1" or "3" or “5” or “7” is specified, the data in the cell range specified with <Start cell>...
  • Page 120 9 Detailed Explanation of Functions [Explanation] 1) In an NVPST command or NVIN command, when a <type> of "1" or "3" or “5” or “7” is specified, the data recognized by the vision sensor is stored in numeric data format. 2) The stored data is held until the next NVPST command or NVIN command is executed.
  • Page 121 9 Detailed Explanation of Functions (5) C_NVS1 - C_NVS8 [Function] Stores the data recognized by the vision sensor in text string data format. In an NVPST command or NVIN command, when a <type> of "2" or "3" or “6” or “7” is specified, the data in the cell range specified with <Start cell>...
  • Page 122 9 Detailed Explanation of Functions [Explanation] 1) In an NVPST command or NVIN command, when a <type> of "2" or "3" or “6” or “7” is specified, the data recognized by the vision sensor is stored in text string format. However, kanji codes can not be acquired.

  • Page 123: Melfa-Vision Function Details

    9 Detailed Explanation of Functions 9.2.  M ELFA-Vision Function Details This section explains MELFA-Vision functions other than those explained in "Chapter 5 - 0. 9.2.1.  MELFA-Vision Main Screen For explanations concerning the MELFA-Vision main screen, see "6.2.1 Starting MELFA-Vision (network vision sensor support software)".

  • Page 124: Job Editing Screen ([Image Log] Tab)

    9 Detailed Explanation of Functions 9.2.2.  Job Editing screen ([Image Log] tab) On the job edit screen [Image Log] tab, the conditions are set for the PC in which the images captured with the vision sensor are stored to the PC. It is necessary to start the FTP server on the PC storing the images For explanations concerning the MELFA-Vision main screen, see "8.4 Image Log Acquisition Settings and Reception Start/End".

  • Page 125: Job Edit Screen ([Result Cell Position] Tab)

    9 Detailed Explanation of Functions 9.2.3.  Job edit screen ([Result Cell Position] tab) The “Job Editing” screen [Result Cell Position] tab displays "Found Number Cell", "Start", and "End" specified with the dedicated MELFA-BASICIV command for the network vision sensor. A cell is a position indicated by the column character and row character in the vision program.

  • Page 126: Vision Sensor Network Settings

    9 Detailed Explanation of Functions 9.2.4.  Vision sensor network settings The vision sensor network settings can be changed. From the MELFA-Vision menu, click [Sensor] – [Connection] – [Communication Setting] to display the "Network Settings" screen. Check with your network administrator for the items to set. Figure 9-4 MELFA-Vision "Network Settings"...

  • Page 127: Vision Program Detailed Explanation

    9 Detailed Explanation of Functions 9.3.  V ision program detailed explanation MELFA-Vision provides a number of programs (job files) as templates. This section explains the templates provided. 9.3.1.  Templates provided for MELFA-Vision The table below shows the templates provided for MELFA-Vision. Table 9-7 List of Job Templates Provided No.
  • Page 128 9 Detailed Explanation of Functions (*4) There are two types of output coordinates. Table 9-8 List of Coordinates Output to Robot Output method Explanation Absolute The detected pattern position is output converted to the robot coordinate system. coordinate output Relative The detected pattern position is output with the robot coordinate system offset coordinate quantities for the relative position based on the registered pattern position.

  • Page 129: Image Processing - Blobs

    9 Detailed Explanation of Functions 9.3.2.  Image processing - blobs This section explains how to make the blob image processing settings, using pattern matching image processing (only one robot, results output as robot absolute coordinate values) as an example. (1) In the [Job(Vision Program)List] on the left side of the main MELFA-Vision screen, click [New]. From the "Image Processing Method"...
  • Page 130 9 Detailed Explanation of Functions (2) Execute work order tabs from left to right on the displayed "Job Editing" screen. For details on the [Adjust Image] tab, see "6.2.3 Image processing settings". (3) When you click the "Job Editing" screen [Search Area & Condition(1)] tab, the conditions for executing blob image processing are set.
  • Page 131 9 Detailed Explanation of Functions (4) When you click the "Job Editing" screen [Processing Condition(2)] tab, the conditions for executing blob image processing are set. When you change a displayed setting item, then click the [Test] button, the results of image processing under the specified conditions are displayed at the main screen [Camera Image], so check whether or not the work is correctly recognized.

  • Page 132: Image Processing - Color

    9 Detailed Explanation of Functions 9.3.3.  Image processing – Color This section explains how to make the Color image processing settings, using pattern matching image processing (only one robot, results output as robot absolute coordinate values) as an example. (1) In the [Job(Vision Program)List] on the left side of the main MELFA-Vision screen, click [New]. From the "Image Processing Method"...
  • Page 133 9 Detailed Explanation of Functions (2) Execute the work in order of the tabs from left to right on the displayed "Job Editing" screen. (3) [White Balance] button of [Adjust Image] tab is clicked, and a standard color is specified. [White Balance] button is displayed only in case of the color image processing.
  • Page 134 9 Detailed Explanation of Functions (4) The condition of executing the color image processing is set in [Color] tab of "Job Editting" screen. When [Test] button is clicked after the displayed set item is changed, the result of processing the image on [Camera Image] of the main screen and the condition of specifying it is displayed.
  • Page 135 9 Detailed Explanation of Functions (4-1)Color Area Setting is specified. When [Image] button of “Color Area Setting” is clicked, foci move to the main screen, and Area adjustment mark is displayed in [Camera Image] . The color which wants to be recognized from the area enclosed with this Acawac is detected. Enclose the color which wants to be recognized with Acawac.
  • Page 136 9 Detailed Explanation of Functions (4-2)Changes to the gray-scale imagery by the color which specifies [Camera Image]. [Select Filter] CheckBox is ON, and [Test] button is clicked. Specified color is displayed in white putting the same filter as the specified color. 9-125 Vision program detailed explanation...
  • Page 137 9 Detailed Explanation of Functions (4-3)Color is adjusted. Value of "Threshold" is changed, and [Test] button is clicked. For instance, when green is recognized more emphatically the value of "Green" is increased, and other items are decreased. Refer to "Histogram" value for the value. Vision program detailed explanation 9-126...
  • Page 138 9 Detailed Explanation of Functions (4-4)When work is recognized specifying not only Hue but also Saturation and Intensity, "Representation" is changed. "Representation" CheckBox is ON, all the values of the item of "Threshold" are set to "-1", and [Test] button is clicked.
  • Page 139 9 Detailed Explanation of Functions (4-5)Color is adjusted. Value of "Threshold" is changed, and [Test] button is clicked. For instance, when recognize the vivid color work the value of "Saturation" is increased, and other items are decreased. Refer to "Histogram" value for the value. Vision program detailed explanation 9-128...
  • Page 140 9 Detailed Explanation of Functions (5) Pattern and Search Area are specified. [Pattern & Search Area] tab is displayed, and the recognized work is registered. Refer to "6.2.3 Image processing settings" for registration method. (6) The condition of recognizing it is specified. [Pattern &...

  • Page 141: Using Image Processing For Which There Is No Template

    9 Detailed Explanation of Functions 9.3.4.  Using image processing for which there is no template The only templates provided for MELFA-Vision are pattern matching and blobs. * When using a robot using other image processing, write the vision program using "In-Sight Explorer" installed on the PC with "5.3.1 Vision sensor dedicated software (In-Sight Explorer) installation".

  • Page 142: To Shorten The Time For Transferring Data With The Robot Controller

    9 Detailed Explanation of Functions 9.3.5.  To shorten the time for transferring data with the robot controller The image processing templates prepared for MELFA-Vision use the mechanism of transferring the information on recognized work to the robot controller one set at a time (three communications, X, Y, and C per piece of work).
  • Page 143 9 Detailed Explanation of Functions <Robot program change example> Change the program example in "7.3.2 Writing a Sample Robot Program" as follows. The parts of the program in the boxes are the locations changed. 10 ' The work grasping position P1, and the work placement position P2 must have been taught beforehand. 20 ' Example: P0=(+250.000,+350.000,+500,000,-180.000,+0.000,+0.000)(7,0) 30 ' P1=(+500.000, +0.000, +300,000, -180.000, +0.000, +10.000)(7,0)
  • Page 144 9 Detailed Explanation of Functions DLY 0.1 ' Wait time of 0.1 second HCLOSE 1 'Closes hand 1. DLY 0.2 ' Wait time of 0.2 second MVS P10,10 ' Moves to 10 mm above the work grasping position P10. MOV P2,10 ' Moves to 10 mm above the work placement position P2.

  • Page 145: Detailed Explanation Of Systems Combining Multiple Vision Sensors And Robots

    9 Detailed Explanation of Functions 9.4.  D etailed explanation of systems combining multiple vision sensors and robots The systems explained in Chapter 5 through Chapter 0 were systems with one vision sensor and one robot controller. With this system it is also possible to construct systems with one robot controller and up to seven vision sensors and systems with one vision sensor and up to three robot controllers.

  • Page 146: Systems With One Vision Sensor And Multiple Robot Controllers

    9 Detailed Explanation of Functions (2) Write the vision program for each vision sensor. Log onto the connected vision sensors and write the vision program for each vision sensor. For details on the logon method and vision program writing method, see "6.2 Work recognition test". (3) Write the robot program to control multiple vision sensors.
  • Page 147 9 Detailed Explanation of Functions (3) Set the calibration number. Specify the calibration number for [Robot 1] and [Robot 2] in [Calibration No.] on the "Job Editing" screen [Processing Condition] tab. (4) Write the robot program <Robot 1> 10 IF M_NVOPEN(1)<>1 THEN NVOPEN “COM2:” AS #1 'Connects to vision sensor 1 (COM2).

  • Page 148: Troubleshooting

    10 Troubleshooting 10. Troubleshooting This chapter lists the errors that can occur in using network vision sensors and explains the causes of and solutions to these errors. 10.1. Error list Below are the messages for error numbers, their causes, and the solutions. The meanings of the error levels in the table are as follows.
  • Page 149 10 Troubleshooting Table 10-3 List of Errors Only for Vision Sensors Level Error No. Error contents Cause Solution 8600 Vision sensor There is no vision sensor Check the specified vision connected connected to the specified program number, "COMDEV" COM number. parameter, etc.
  • Page 150 10 Troubleshooting 8635 There is no comma within There is no comma on the cell Check the value set to Type or the specified range of the which specifies it for Start Cell Start Cell and End Cell. cell. and End Cell though the range from 4 to 7 is specified for a value of Type.

  • Page 151: Appendix

    11 Appendix 11. Appendix 11.1. Performance of this product (comparison with built-in type RZ511 vision sensor) Below is a comparison of the performance of this product with that of our built-in type vision sensors. 11.1.1.  Comparison of work recognition rate (1) Comparative results by work shape and conditions Table 11-1 Comparative Results by Work Shape and Conditions Work condition Network vision sensor...

  • Page 152: Factors Affecting The Processing Time

    11 Appendix 11.1.3.  Factors affecting the processing time Factors affecting the processing time (1) Delay in communication time by hub and communication time when no hub used There is almost no difference in communication time due to a hub. There is no problem with any hubs, but when an old hub is used, there is a possibility of some variation in communication time.

  • Page 153: Calibration No. Marking Sheet

    11 Appendix 11.2. Calibration No. marking sheet This is a marking sheet used in calibration work. Enlarge or reduce it as necessary to match the size of the field of vision of the image. Calibration No. marking sheet 11-142...
  • Page 154 HEAD OFFICE : MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100-8310 NAGOYA WORKS : 1-14, YADA-MINAMI 5, HIGASHI-KU, NAGOYA, JAPAN OCT.2006 MSW-BFP-A8520 Printed in Japan on recycled paper. Specifications are subject to change without notice.

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