Page 1 DecoSpector 360™ Training Guide DecoSpector 360™ Training Guide | 6.1.8 Software Part Number 80737 Rev. 01...
Page 2 No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including pho- tocopying and recording, for any purpose, without the express written permission of Pressco Technology Inc. The contents of this manual are furnished for informational use only, are subject to change without notice, and should not be con- strued as a commitment by Pressco Technology Inc.
Page 3: Table Of Contents
Control Enclosure and Operator Interface Hardware USB Ports Power On and Off at the Control Enclosure Lockout Procedure Accessing the Internal Components with Power Off Accessing the Internal Components with the Power On Components Inside the Control Enclosure Vision Processor Panel ©2020 PRESSCO TECHNOLOGY INC.
Page 4 Statistics on the Control Panel Views from the Control Panel Notepad Language Screen Capture Help Overview Panel Graphs View Live Images and Defects Color Borders Around Images Hold an Image On Screen Freeze on Defect Controls ©2020 PRESSCO TECHNOLOGY INC.
Page 5 Rejector - DecoSpector Reject Settings Forced Reject I-O Diagnostics Settings Overview Display View System Calibration System Settings System Utilities Global Utilities Lighting Settings Log Viewer Reports Schedule Reports Create Instant Report Report Schedule Settings Report Viewer ©2020 PRESSCO TECHNOLOGY INC.
Page 6 Mandrel Correlation Print Blanket Correlation Individual Part Correlation Correlation Diagnostics Chapter 7 System Maintenance and Troubleshooting Preventive Maintenance Frequency Clean the Control Cabinet Filters Service Frame Use the Service Frame to Lift the Module for Maintenance ©2020 PRESSCO TECHNOLOGY INC.
Page 7 New Part (First Time Inspecting a Part) Relearn Inspection Zones Inspection Zones Example Color Zones - Manual, optional Chapter 8 Load Part Images Chapter 9 Color Analysis Color Measurements Color Analysis Graphs Color Analysis for One Color - Automatic Color Mode ©2020 PRESSCO TECHNOLOGY INC.
Page 8 Color Display Selection Adjust Color Inspection Sensitivity Color Trend Graphs Color Alarms and Specification Limits Adjust Color Alarm Limits Chapter 10 Print Quality Screen Retro-Spec Graph View Defects on Images Defect Classification Adjust Inspection Settings View Inspection Results ©2020 PRESSCO TECHNOLOGY INC.
Page 9: Chapter 1 Introduction
Chapter 1 Introduction Welcome! Congratulations on your purchase of a Pressco DecoSpector 360™ system! The DecoSpector is an inspection system that performs extensive product quality checks on 100% of the decorated surface area of printed beverage cans. The DecoSpector system locates the following on cans: Printing flaws (voids, spots, smears, cut blanket, etc.)
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Page 11: Chapter 2 Hardware Overview
Chapter 2 Hardware Overview Deco Interconnect Diagram This diagram shows a typical DecoSpector 360™ system configuration. Blue Ethernet = Camera. Green = PDN. Chapter 2- Page 11...
Page 12: Original Cabinet
Original Cabinet For systems with cabinet part numbers 75000 - 75003 Chapter 2- Page 12...
Page 13: Control Enclosure And Operator Interface
Control Enclosure and Operator Interface Original cabinet 1) Touch screen monitor 2) Biometric login device (under monitor) 3) Keyboard tray 4) Power indicator LED 5) Power switch 6) Interlock 7) Vision processor (inside control enclosure) 8) Air conditioner Chapter 2- Page 13...
Page 14: Usb Ports - Original Cabinet
USB Ports - Original Cabinet There are USB ports available to back up or transfer data, and also to connect the optional mechanical keyboard. They are located on the left side of the monitor (also on the remote monitor). Chapter 2- Page 14...
Page 15: Power On And Off
Power On and Off To power on the system: Turn on the switch on the side of the cabinet. The software will start automatically. (You must log in and put the system online to begin inspection) Note: it takes about a minute for the computer to start after the main power switch is turned ON To power off the system: Turn off the switch on the side of the cabinet.
Page 16: Accessing The Internal Components
Original cabinet To access the components inside of the DecoSpector 360™computer, you will need two keys, which are supplied with the system. The standard key opens the locks on the system, and the interlock key opens the Interlock for computer door.
Page 17: Components Inside The Control Enclosure - Original Cabinet
Components Inside the Control Enclosure - Original Cabinet 1) TB1 - terminal block 1 2) DISC1 - Lockable disconnect switch 3) Vision processor computer 4) Air conditioner 5) TB2 - terminal block 2 6) GB1 - ground bus 1 7) TB3 - terminal block 3 8) 8PDN ethernet switch 9) TB4 - terminal block 4 10) Extended I/O...
Page 18: Components Inside The Cabinet Door
Components Inside the Cabinet Door Original cabinet 1) Interlock switch 2) Defeater lock 3) ON light 4) TB5 - terminal block 5 5) UPS Chapter 2- Page 18...
Page 19: Ups Information
UPS Information The Uninterruptible Power Supply (UPS) provides battery backup power for temporary system operation in case of a power failure. The cabinet door will not open (due to the solenoid lock) until the UPS has powered down. A programmed power-down sequence ensures that the system shuts down properly whenever the Main AC Power Switch is turned OFF.
Page 20: New Cabinet
New Cabinet This section is for systems with cabinet part numbers 77769 - 77770 Chapter 2- Page 20...
Page 21: Control Enclosure And Operator Interface Hardware
Control Enclosure and Operator Interface Hardware New cabinet 1) Touch screen monitor 2) Biometric login device 3) Keyboard tray 4) Power indicator LED 5) Power switch 6) Locks (Accessing the internal components with power OFF) 7) Vision processor (inside control enclosure) 8) Air conditioner Chapter 2- Page 21...
Page 22: Usb Ports
USB Ports There are USB ports available to back up or transfer data. Chapter 2- Page 22...
Page 23: Power On And Off At The Control Enclosure
Power On and Off at the Control Enclosure New Cabinet Power on: Turn on the switch [1] on the front of the cabinet. The power indicator [2] will illuminate. The software will start automatically. (You must log in and put the system online to begin inspection) Note: it takes about a minute for the computer to start after the main power switch is turned ON...
Page 24: Lockout Procedure
Lockout Procedure New Cabinet To prevent power from being applied while the cabinet door is open: 1. Make sure the handle is in the OFF position 2. Push the red piece of the handle out from the back 3. Secure up to three locks Chapter 2- Page 24...
Page 25: Accessing The Internal Components With Power Off
Accessing the Internal Components with Power Off New cabinet To access the components inside of the control cabinet, you will need the keys (supplied by Pressco). WARNING - When the system is powered down, there is still voltage present at the UPS. Only AUTHORIZED PERSONNEL should attempt to open the system.
Page 26: Accessing The Internal Components With The Power On
Accessing the Internal Components with the Power On New cabinet The disconnect switch has an override feature allowing you to open the cabinet door while the switch is in the ON position. WARNING - Only AUTHORIZED SERVICE PERSONNEL should access the inside of the computer while the power to the unit is still applied.
Page 27: Components Inside The Control Enclosure
Components Inside the Control Enclosure 1) DC Power panel, TB2 2) Power Entry Panel, DISC1, TB1 3) Vision Processor Panel 4) Air conditioner 5) Gland plate 6) Extended I/O board 7) 8-channel part tracker board 8) Power switch, DISC1 (connected by a rod to the disconnect on the rear of the cabinet) 9) UPS 10) PLC Correlation, Extended I/O, and Opto Relays 78746...
Page 28: Vision Processor Panel
Vision Processor Panel 1) Vision Processor rear panel 2) Managed Ethernet switch 3) Remote I/O output module 4) Remote I/O coupler module Chapter 2- Page 28...
Page 29: Biometric Login Device
Biometric Login Device The Biometric Identification login device is used to log in and out of the Pressco system. This device is optional and must be purchased with the system. To log in with this device, press your finger to the device. The following are conditions for use: You must use the same finger as initially set up by your administrator If you do not know how your account was set up (or which finger you used), contact your administrator If, after three tries, the Pressco does not recognize your finger print, you must log in using the...
Page 30: Inspection Module
Inspection Module WARNING - Keep hands away from the Vortex cooler [3] to avoid risk of burns. 1) DecoSpector 360™ inspection module 2) air connection for Vortex cooler 3) Vortex cooler 4) mechanical stop for the service frame 5) gear box for moving the service frame...
Page 31: Port I-O Box
REJ1, REJ2 - rejector 1 and 2* RC1, RC2 - reject confirm 1 and 2* (optional) *DecoSpector 360™ does not use rejector 2 nor reject confirm 2 4 Port I-O Box The I/O box is usually mounted near the correlation sensors. The cable from this box is plugged into the bottom of the control enclosure, connector PKT - pocket detector MP1 - MP3 - machine parts.
Page 32: Chapter 3 Software Overview
Chapter 3 Software Overview Control Panel "Log In" below 2) System status "Online and Offline" on the next page "Job Management" on page 106 - to change the part you are inspecting "Relearn" on page 110 "Statistics on the Control Panel" on the next page "Views from the Control Panel"...
Page 33: Online And Offline
If you have a biometric account, press your finger on the biometric device to log in. You must use the same finger that you used when you created the account. Online and Offline The button changes depending on system status and whether a user is logged in. Logged in: System is offline.
Page 34: Views From The Control Panel
Views from the Control Panel Select what to display in the Overview Panel (the big part of the screen). - Select for the Home screen, or "Overview Panel" on page 36 - Select for the "Print Quality Screen" on page 137 - Select for "Color Analysis"...
Page 35: Language
Language - Select the user interface language. Your language preference is saved with your user account, so your default language is auto- matically loaded when you log in. This button is normally used to override the current language, or when no one is logged in. Screen Capture - Capture a screen image for reference, troubleshooting, or to send to Pressco technical support.
Page 36: Overview Panel
Overview Panel 1) Statistics Graphs - see "Graphs" on the next page "Correlation" on page 90 "Color Trend Graphs" on page 129 (only if Color Zones are configured) 4) You can select what to display from "Overview Dis- play View" on page 53 "View Live Images and Defects"...
Page 37: Graphs
Swipe the graphs or use the buttons to display the different graphs. Graphs The DecoSpector system has several graphs for you to monitor production. The following are examples: Reject Rate and Part Rate Graph Chapter 3- Page 37...
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Reject Rate (per 1000 parts) Graph Print Blanket Correlation Chapter 3- Page 38...
Page 39: Chapter 3- Page 39
Graphs for Mandrel and Pin correlation are also available. Statistics Grid Chapter 3- Page 39...
Page 40: View Live Images And Defects
View Live Images and Defects - View live inspection images. Put the system online to inspect parts. The live images are updated in the part area. Swipe in the image area or tap the dots below the image to switch between the inspected image and the "error" image. The error image shows only the defects, if any. (Example of an error image: "View Defects on Images"...
Page 41: Color Borders Around Images
Color Borders Around Images The DecoSpector system displays a different color border around each image depending on the inspection status. This key is displayed in the "Print Quality Screen" on page 137. Green = good part Dark Green = a part passed, but it also had defects (example: a shadow detected on a part that had an adjacent can.
Page 42: Freeze On Defect Controls
Freeze on Defect Controls To enable Freeze on Defect Controls: Enable the controls from the Settings menu: Select Show Freeze on Defect Controls. The Freeze on Defect Controls are displayed on the home screen. Select when to freeze a defect on screen. Chapter 3- Page 42...
Page 43: Chapter 3- Page 43
Latest Defect Freeze the image of the last defective part. Each subsequent failing part freezes on the screen until another part fails. Latest Defect - Auto-Release Freeze the last defective image for up to the specified number of seconds, which is selectable next to Release Time. First Defect Freeze the image of the first defective part after going online.
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Select Defects controls Select the type of defects to freeze on screen (used with Freeze on Defect). = on. Any Defect Display any defect. Print Quality Defects Display only Print Quality defects, which include: wrong color, scuff, shadow, color void, and too much color. Color Check Defects These defects occur when the part fails the tests for Color Zones.
Page 45: Chapter 4 System Tools
Chapter 4 System Tools Alarms - Select the alarm icon to clear, configure, or view alarms. Each alarm is user-configurable to: enable the alarm, turn on the light tree, sound the horn, turn the rejector off, and many other options. Some alarms, including Inspection speed too slow, General failure, and System power loss cannot be disabled, because they are neces- sary for system operation.
Page 46: Rejector - Decospector
To see more information about the active alarm, select the alarm name in the left column. More information will be displayed on the right side of the screen. Rejector - DecoSpector *Administrator only* - Tap the rejecter icon to change settings. - This icon indicates that the rejecter is disabled.
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Tip: you can set an alarm feature to Turn the Rejector Off if too many parts are rejected, or some other alarm condition. In Alarms, make sure "Perform Special Action" is enabled for the alarm | and enable "Turn Rejector Off" under Perform Special Action. Note: Pressco recommends that you enable both Reject Registration Errors and Reject Orientation Errors.
Page 48: Forced Reject
Reject Color Errors Color Errors occur when the part fails the tests for Color Zones. Color Zones are optional and are based on your plant spe- cifications. Reject Empty Pockets The system tests to see if a part is present before proceeding with inspection. If a part is not present, then this is called an Empty Pocket.
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3. To select a different option than what is displayed, select the drop-down menu and make another selection. Tap the Select button to select different machine parts. A graphic with machine parts is displayed. [shown below] 5. Tap each machine part that you want reject correlated parts from. In the example below, mandrels 2 and 10 and print blanket 4 are all selec- ted.
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6. Tap Apply to save changes and exit. The correlation graphic at the top of the Home (Overview) screen highlights the selected machine parts. To use Forced Reject: Put the system online to inspect parts. Tap the Start Forced Reject button. The system rejects those parts correlated to the selected machine parts and con- ditions you selected.
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Notes about Forced Reject: To reset the Forced Reject options to the default values, select the Reset Selected button. (If the system is still in Forced Reject mode, you may need to cancel Forced Reject before making changes) The system uses an OR function to reject parts. That is, if you select mandrel 2 and print blanket 4, the system will reject the first part cor- related to either machine part.
Page 52: I-O Diagnostics
I-O Diagnostics | System Utilities| I/O Diagnostics - View the I/O port activity. You must be logged in as an Operator or higher, and running actual hardware. You can also view the part rate and encoder rate. Chapter 4- Page 52...
Page 53: Settings
Settings - Adjust system settings. A grayed out item means that only higher user levels have permission to access that item. "Overview Display View" below "System Calibration" on the next page "System Settings" on page 55 "System Utilities" on page 56 "Global Utilities" on page 56 Overview Display View Select what to display on the Overview screen.
Page 54: System Calibration
System Calibration *Administrator only* To get to this menu: | System Calibration. Adjust the hardware settings for the following: 1) System Position Calibration: *Pressco Technician access only* "Part Present Delay" on page 77 "Reject Delay" on page 78 4) Reject Confirm Calibration "Reject Settings"...
Page 55: System Settings
System Settings | System Settings External I/O for Defects This provides the ability to track the number of times certain defects hap- pen, through the External I/O. It is only used in specific plant locations. Leave this disabled unless oth- erwise instructed by a Pressco engineer.
Page 56: System Utilities
System Utilities | System Utilities. "I-O Diagnostics" on page 52 Disk Management - *Pressco Technician access only* Help Access the help files About View the software and firmware versions. This information may be required if you request Technical Sup- port assistance. UPS Information View remaining battery life and other information about the UPS backup device.
Page 57: Lighting Settings
Default Job Settings - *Pressco Technician access only* "Lighting Settings" below "Part Locate Settings" on page 81 "Job Management" on page 106 (optional feature) Lighting Settings *Administrator only* Adjust lighting, only if lighting is not adequately set up during Auto Learn. | Global Utilities | Lighting Settings Chapter 4- Page 57...
Page 58: Chapter 4- Page 58
1) Lighting Zones Adjust lighting manually if auto-adjust lighting does not work properly. For shorter cans, you might shut off lighting for the Upper Zone, to reduce reflections from adjacent cans. Check the Saturation in the graphs at the bottom of the screen to make sure the image is not too bright. Use the lock button to adjust all lighting zones together, or unlock it to adjust lighting zones independently.
Page 59: Chapter 4- Page 59
Select a color to display the saturation pixels. The pixels should stand out against the color of your part. 5) Shape This shape is used to define the area used to measure lighting. Select a rectangle or a line for the shape of the image analysis tool. You can click and drag the shape to measure the lighting in the area. If using a rectangle, adjust it to cover most of the part.
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To adjust lighting: 1. Select Continuous [6]. You should see images updating on the screen. 2. (If needed) Adjust yellow rectangle or line [3] so that it does not fall outside of the parts. You may need to unlock the rectangle or change shapes [5].
Page 61: Log Viewer
6. Select Save to save changes and exit. Log Viewer |System Utilities | Log Viewer. View the system logs, including inspection changes, alarms, and errors. Chapter 4- Page 61...
Page 62: Reports
System reports provide statistical information about the performance over a period of time. The reports are saved that they can always be viewed within the DecoSpector 360™ system. Reports can also be saved to a file or printed (if a printer is connected to the system).
Page 63: Schedule Reports
Reject reasons Camera error breakdown Correlation statistics Color zone statistics (Delta E, Delta L, Delta H and Delta C). Schedule Reports *Administrator only* Log in. Take the system offline (so the icon is not blue). | System Utilities | Schedule Reports. This screen shows the available report schedules and options for creating / editing / deleting report schedules.
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To schedule a report: 1. Select a report in the left column, or Select New Schedule, enter a name for the new schedule, then save. Then select the new report from the left column. 2. Select Edit Schedule. Report Schedules: Chapter 4- Page 64...
Page 65: Create Instant Report
The list of available reports. = enabled. = disabled Report Schedule Options: New Schedule – Create a new schedule. This adds to the Report Schedules list. You must Edit the Schedule. Edit Schedule – "Report Schedule Settings" on the next page Delete Schedule –...
Page 66: Report Schedule Settings
1) Report name 2) Destination. Select a printer (if one is connected to the DecoSpector 360™ system). OR: 3) File path. You may save the file to the system, your network (if connected), or to a USB device (if connected).
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= enabled. = disabled Report Name Select the name to change it if desired. Report Schedule Enabled Enable the scheduled reports. Schedule By: By Time Period – The report is generated after the specified number of hours. To change a value, press and hold a number and use the Chapter 4- Page 67...
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keyboard icon from the pop-up menu. Time Interval (in hours) – You can schedule reports between 1 and 72 hours. Synchronize Hour – Synchronize to a specific hour of the day. Enter in military time of 0 to 23. If you want shift reports every 12 hours that start at 7 AM you would set the time interval to 12 and the synchronize hour to 7 as shown above.
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Default Destination This identifies where the report is sent. Printer Print the report (if a printer is attached and configured). File Path Select the folder you wish to save the reports to. Otherwise, the report is sent to the destination displayed on screen. Text File Saves the report to a text (.txt) file.
Page 70: Report Viewer
Include Correlation Details – The correlation defect count list. Include Defect Details – This includes: Print Defects, Color Defects, Register Defects, Orient Defects, Empty Pockets and Forced Rejects. Include Color Details – The color statistics information about each configured color zone. Color statistics includes: Delta E, Delta L, Delta H and Delta C.
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List of Reports To view a report, click on the report and press Report Details. You can Save and Print Reports from the details view. Filter Options This allows you to filter by date and time as well as report type. Delete This allows you to delete old reports.
Page 72: Save Images To Usb Drive
It is possible to have multiple jobs displayed for one report period. Save Report: Save the report to the default location of C:\Pressco\Deco\Reports, unless otherwise specified in the report schedule. Print Report: This allows you to print the report to any connected printer. Save Images to USB Drive You may need to transfer images from the DecoSpector system to your computer or send to Pressco technical support.
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Note: The images must already be saved to system hard drive, or have occurred within the last 100 parts inspected. To save images to an external device: 1. Plug a USB device into one of the USB Ports. Select Print Quality. 3.
Page 74: Create Deco Support Package
7. Select the USB drive ("Removable Disk" or other named device) from the directory. The system will fill in the field next to "Where to save images." 8. Make other desired selections in the Image Save dialog box and select Save. The images are saved to the device. Create Deco Support Package A support package is a set of files gathered by the system to help find system problems.
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3. Browse to the USB device. 4. Rename the file if desired. Select Save. The DecoSpector system will create a support package zipped file. The status window will be removed from the screen when the process is complete. 5. Remove the USB flash drive. 6.
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1. Attach the USB drive to your computer. 2. Send an e-mail to techsupport@pressco.com and attach the support package files. Pressco service/ tech support will respond within one business day, if possible. Chapter 4- Page 76...
Page 77: Chapter 5 Part Tracking
Chapter 5 Part Tracking Part Tracking Terminology Part Width The number of encoder ticks that the part sensor "sees" the part. Part Present Delay The distance (in encoder ticks) from the part detect sensor to the camera centerline. If a PDX is used, this is the number of encoder ticks from the part detect pulse out of the PDX to the camera centerline.
Page 78: Reject Delay
To calibrate the Part Present Delay: | System Calibration | Part Present Delay. 2. Select Start Calibration. (this button toggles with Stop Calibration) 3. Place a part onto the conveyor or into the part stream. The part will trigger the part detect sensor, then the system will count the number of encoder ticks and take a picture.
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During Reject Delay calibration, the reject device will activate for each part that flows through the system. Ensure that the rejector is activated prop- erly and that each part is rejected properly. After calibration, ensure that adjacent parts are not being rejected (example, from too long a reject dwell time), nor being knocked off by the rejected part.
Page 80: Simulation Settings
1. Stop production with the conveyor still running. 2. Select Start Calibration. (this button toggles with Stop Calibration) 3. Place a part on the running conveyor or into the part stream. After the number of encoder ticks shown in the Reject Delay box, the rejector will be activated.
Page 81: Part Locate Settings
IMPORTANT - If you use simulated settings, be sure to disable them before using the system in production. Otherwise, inspection and cor- relation statistics will not be correct. Part Locate Settings *Administrator only* This menu ensures that the system properly locates each part. The cans need to be centered and spaced well. This ensures: good inspection results minimal false defects cans are inspected.
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TIP: if the system shows an error: "Locate status: Unable to locate the part, check your edge setup," this could mean that Can Settings have not yet been set up for the part. Check the . To adjust part locate settings: 1.
Page 83: Chapter 5- Page 83
4. Select inside the Stage 1 box [3]. The system looks for the top edge of the can. If this looks OK (see picture below), then move to Stage 2. Otherwise, adjust the values in Stage 1 until the magenta edges fall near the top edge of the can as shown below. 5.
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6. Select inside the Stage 4 & 5 box [5]. The system looks for the top edges of the can, with more sensitivity. If this looks OK as shown below, then move to Stage 6 & 7. Otherwise, adjust the Stage 4 & 5 values until the system finds the top of the can on all four images properly. You can move the search regions with arrows at the bottom of the screen once you click inside the Stage 4 &...
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7. Select inside the Stage 6 & 7 box [6]. The system looks for the side edges of the can, with more sensitivity. If this looks OK as shown below, then move to step 8. Otherwise, adjust the Stage 6 & 7 values until the system finds the sides of the can on all four images properly. Chapter 5- Page 85...
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8. Select Adjacent Can for Setup Mode [2]. 9. Make sure Perform Adjacent Can Check is enabled. This checks for adjacent cans and makes sure that the system does not reject parts based on reflections or shadows on the sides of the can (which are caused by adjacent cans). 10.
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11. Select inside the Adjacent Can - Right Search box to move and adjust the size of the right search region. Adjust clipping as necessary. 12. Select Save to save changes and exit the menu. Clipping Clipping is used to change gray shades to a specified value. It allows the system to ignore light reflections or normal grain in a part, to provide easier defect detection.
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[1] = no clipping Clip Dark [2] – set a dark gray shade value. A value of 100 makes all pixels with gray levels of 0-99 a gray level of 100. Clip Light [3]– set a light gray shade value. A value of 150 makes all pixels with gray levels of 151-255 a gray level of 150. Chapter 5- Page 88...
Page 89: Proper Part Handling
Proper Part Handling Make sure that the cans are properly centered and spaced along the conveyor. Cans that are too close together may have shadows reflections that can cause : false rejects cans to not be inspected or rejected You can view how well the parts are spaced through the Adjacent Can screen. Go to Settings | Part Locate Settings.
Page 90: Chapter 6 Correlation
Chapter 6 Correlation The DecoSpector system provides correlation to the following machine parts: Mandrel, Print Blanket, and Pin Chain Note: Correlation is set up using Correlation Settings. This is usually performed during installation by Pressco. The correlation graphic on the Home (Overview) screen shows the status of machine parts. 1) The large dots with numbers show the alarm condition of the machine part.
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To see a larger graph, click the graph in the upper screen. The graph will be displayed in the lower screen. The correlation graphs are color coded based on the reason the parts failed. The legend is displayed when you view a larger graph in the lower screen.
Page 92: Mandrel Correlation
Gray = Empty Pocket Blue = Adjacent Can Cyan = Out of Round Orange = Register Issue Red = Print Defect Magenta = Color Defect Mandrel Correlation Mandrel Correlation Graph Chapter 6- Page 92...
Page 93: Print Blanket Correlation
The mandrel numbers are located on the bottom of the graph. This is sorted in descending order, left to right, from the highest number of failed parts to the lowest number of failed parts. Print Blanket Correlation The print blanket numbers are located on the bottom of the graph. This is sorted in descending order, left to right, from the highest number of failed parts to the lowest number of failed parts.
Page 94: Individual Part Correlation
Individual Part Correlation View the Results window on the Print Quality screen to see the correlation data of each inspected part. To see this window, "Show Results Win- dow" must be enabled. In this example, the part was correlated to Mandrel 24, Print Blanket 12, and Pin 72. Correlation Diagnostics Check to make sure the system is tracking the correlation of all machine parts.
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When the system is online, you will see the correlated machine part numbers update with colored dots. The dots toggle between blue and green so that you can see where the current part is in the production line. If a machine part is skipped, you see that the machine part dot does not change.
Page 96: Chapter 7 System Maintenance And Troubleshooting
Chapter 7 System Maintenance and Troubleshooting Preventive Maintenance Frequency IMPORTANT - The windows inside the inspection tunnel need to be cleaned regularly. The frequency depends on plant conditions, and could be as much as three or four times per shift. Frequency - Number of times per: Shift Day Week Month...
Page 97: Clean The Control Cabinet Filters
Clean the Control Cabinet Filters The filter should be cleaned once a month for best results. The filter is located on the side of the cabinet. Replace with a new filter when neces- sary. Note: You may need to clean the filters weekly depending on plant conditions What you need: Recommended: "RP Super Filter Coat Adhesive."...
Page 98: Service Frame
Service Frame The service frame is used during inspection module maintenance and calibration. WARNING - This product contains no operator serviceable parts. Contact Pressco for service. How to Contact Pressco - Do not open the gearbox enclosure. Oil may spill from the gearbox if it is opened. - KEEP OFF the service frame.
Page 99: Clean The Tunnel Windows
A) handle B) gear box C) direction switch on handle When you are finished with maintenance: 1. Push to release the locking mechanism [F]. 2. Use the switch [C] on the handle to change directions. 3. Crank the handle [A] to lower the module. Turn handle [A] counter-clockwise = module moves down. D) mechanical stop E) service frame does not move after reaching the mechanical stop F) locking device holds the module in place while you work...
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What you need: Soft, clean, oil-free cloths. Recommended: Part number: 74284 - Kit Window Cleaning DS2 (includes plexiglass cleaner and lint-free wipes) Mild soap and water solution Flashlight to see inside tunnel area Stopped production line - only for a short time when you swing the tunnel open and closed Do NOT use: Regular paper towels to clean the surfaces.
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4. If desired, signal to someone in your plant to restart production, while you clean the windows. 5. Using a soft cloth and mild cleansing solution, clean all inspection and lighting windows inside the tunnel. Make sure all grease, oil, and other debris is removed.
Page 102: Replace The Filter-Regulator Filters
9. Crank the handle to lower the module back into place. 10. Start production. 11. Select the Relearn button in the DecoSpector 360™ software, so that the system learns parts with the newly cleaned windows. Replace the Filter-Regulator Filters The filter/ regulator assembly shown below is installed with the inspection module. Replace filters.
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Pressco part number Description Replace at least: Filter/ regulator. No filter change necessary. 2 67620 Filter oil removal Every 2000 hours 3 67621 Filter oil vapor removal Once per year Kit (contains one each of 67620 and 67621) 67622 It is easier to replace both of these filters at the same time Chapter 7- Page 103...
Page 104: Best Practices
Best Practices This section includes practices you can use regularly to keep the DecoSpector 360™ and the inspection process running smoothly. How to Avoid False Rejects Learn and Adjust: Use the Relearn button to relearn the part. If the system is not programmed to go online automatically, select Show Templates.
Page 105: Adjusting For The System Missing Defects
Large voids: to detect large ink voids, select a high defect size (300 - 1500) and low defect sensitivity (35 - 55). Adjusting for the System Missing Defects If the DecoSpector is missing defects on your parts: 1. Load the last 100 images in Print Quality. 2.
Page 106: Chapter 8 Job Management
Chapter 8 Job Management - Tap the job name icon (in the control panel) to open the job menu. Note: You will learn new cans each time you change production. When you save a job, the lighting and inspection settings are saved. 1) New"New Part (First Time Inspecting a Part)"...
Page 107: New Part (First Time Inspecting A Part)
Step Button or Menu Item 5. Select Load to load the job. The icon turns blue while the system loads the job. Wait until the job is loaded. 6. Select Relearn. Wait while the system learns the label. 7. Select Show Templates*. Make sure the images are clear, and they resemble your label. If not, select Relearn again.
Page 108: Chapter 8- Page 108
1. Select Type a Job Name. 2. Select a Job Can Size and Can Style. Select Create. 3. Wait until the system prompts you to align the print blanket. Select OK. To learn how to align the print blanket, see Align the Print Blanket.
Page 109: Chapter 8- Page 109
1. Select Show Templates. Make sure the images are clear, and they resemble your label. If not, select Relearn again. 2. Select Job Ready to finish the learn process. 3. Put the system online to inspect parts. Note: An Administrator can enable or disable the automatic online feature from Settings | System Settings | Go Online After Job Learn. Chapter 8- Page 109...
Page 110: Relearn
Relearn Relearn icon Use Relearn: during part changeover, when a job already exists if you have been running the same part for several hours, to detect subtle process changes if inspection is not working correctly. First, "Clean the Tunnel Windows" on page 99, and then Relearn.
Page 111: Inspection Zones
*The system may prompt you to align the print blanket, only if the consistency data for the part is out of specification. Move the image so that it looks like your print blanket. **The system must be set up to go online automatically. If not: Put the system online to inspect parts. Note: An Administrator can enable or disable the automatic online feature from Settings | System Settings | Go Online After Job Learn.
Page 112: Chapter 8- Page 112
4. Move the zone to where you would like to adjust the sensitivity. (You can set up more than one zone) 5. Adjust the sensitivity: Tip: The sensitivity values are locked together by default, which provides the best overall inspection. Typical settings are 120% for more sens- itive, and 80% for less sensitive.
Page 113: Chapter 8- Page 113
a and b represent red as it starts drifting towards yellow or blue Hue 1 affects Red and Green. If you expect to see red, but the can color is printing orange or purple, OR you expect to see green, but the can color is printing greenish-yellow or aqua, then increase Hue 1.
Page 114: Inspection Zones Example
See also: "Inspection Zones Example" below Inspection Zones Example This example shows that a Large Color Void was found within the inspection zone. Chapter 8- Page 114...
Page 115: Chapter 8- Page 115
You can see the defect more clearly by looking at the "error" image. Click the appropriate dot under the image. Chapter 8- Page 115...
Page 116: Color Zones - Manual, Optional
Color Zones - Manual, optional Note: if your system is configured to "Use Automatic Colors," then you will not see this screen nor set up colors. The system does that auto- matically. Use Color Zones to monitor specific colors over time. You may choose up to eight colors, and the system will monitor how closely each image com- pares to the original image To set a color zone: 1.
Page 117: Chapter 8 Load Part Images
Chapter 8 Load Part Images Note: The images must already be saved to system hard drive, or have occurred within the last 100 parts inspected. To load part images (in Print Quality or Color Analysis): - Tap the load icon. 2. Select images to load for Data Set A (left side of the graph) and Data Set B (right side of the graph). Note: when you select Custom Set (from disk), up to 49 images from the selected folder are loaded.
Page 118: Chapter 8- Page 118
Any Defect switches all options on or off. 4. After the images are loaded, tap one of the bars at the top of the screen to see the corresponding image, which is displayed below the graph. In the Color Analysis screen, the graph looks different than below. You can select any point on the graph to select a part. 5.
Page 119: Chapter 9 Color Analysis
Color Measurements The DecoSpector 360™ takes several color measurements. Use the measurement that best matches your plant's color measurement process. In the following examples, the "standard color" is Blue: RGB: 28, 82, 162. The color squares represent different measured values. The numbers under the squares represent the number shown on the scale to the left of the DecoSpector graph.
Page 120: Chapter 9- Page 120
Delta L Lightness. On the Delta L graph, a negative number represents a color that is darker than the standard. A positive number represents a lighter color than the standard. Chapter 9- Page 120...
Page 121: Chapter 9- Page 121
Delta H Hue. The attribute of color that enables an observer to classify it as red, green, blue, purple, etc., and excludes white, black, and shades of gray. [Source: http://www.thefreedictionary.com/hue] On the Delta H graph, the higher the number, the further away that color is from the standard. Chapter 9- Page 121...
Page 122: Chapter 9- Page 122
Delta C Colorfulness. The system may find an area to be more blue or less blue, for example. On the Delta C graph, a negative number means that the measured area is less colorful than the standard. A positive number means that the measured area is more colorful than the standard.
Page 123 Chapter 9- Page 123...
Page 124: Color Analysis Graphs
Color Analysis Graphs This example graph shows the default setup. To see parts, select the Load icon and select a set or sets of part images. Tip: If your system is excessively rejecting a specific color, select Color Display Selection. Then disable the problem color. 1) Data Set A - our example loaded Last 100 Images 2) Data Set B - our example loaded Latest...
Page 125: Chapter 9- Page 125
To see the information for one color: Chapter 9- Page 125...
Page 126: Color Display Selection
1. Select one part (bar) in the Retro-Spec graph. 2. Only the selected color graph is shown at the top of the screen (Delta E, etc.) 3. Select the desired color block 4. The selected color is highlighted in cyan on the image 5.
Page 127: Chapter 9- Page 127
The selected colors will be displayed below the image as Can Color and Master Color. The graphs at the top of the screen will show only the selected color(s). Chapter 9- Page 127...
Page 128: Adjust Color Inspection Sensitivity
Adjust Color Inspection Sensitivity *Administrator only* Move the red bar(s) to adjust inspection sensitivity. In the Delta E graph, moving the red line up decreases sensitivity (fewer failed parts). Moving the red line down increases sensitivity (more failed parts). Note: when you move the Error Limit bar, it affects all monitored colors. To see all color plots on the graph, click on the image outside of a color zone.
Page 129: Color Trend Graphs
Color Trend Graphs On the home screen, you can view several color monitoring graphs. Swipe over the graph or select one of the dots under the graph to select different graphs. A dot is added to the chart every 1000 parts to indicate how the color is trending. You can set the Error and Warning limits for these graphs in the Color Analysis screen.
Page 130: Chapter 9- Page 130
1. Select the graph in the upper right corner of the home screen to view it as a large graph in the center of the screen. 2. Click on the graph to bring up the zone setup screen. 3. Select the rightmost dot to view the user-selectable graph. If you are using Automatic Colors: Chapter 9- Page 130...
Page 131: Chapter 9- Page 131
Select a color from the drop-down menu. Select a color measurement (Delta E, Delta L, Delta H, or Delta C). If you are using Manual Color Zones: Select one of the color zones on the image (yellow circle turns blue when you select it). The Zone Name is displayed in the upper right of the screen.
Page 132: Color Alarms And Specification Limits
To move the graph to the upper right of the home screen, select the part image. The graph and the part image will switch places. Color Alarms and Specification Limits The Color Merit Warning and Color Merit Error alarms are used to notify you when the colors are going out of specification. The alarms use the average Delta E value for each color zone to determine when the colors are exceeding your set limits.
Page 133: Chapter 9- Page 133
The Color Merit Warning alarm is also linked to the Delta E limit line, but is automatically reduced to 80% of the set limit. You can also monitor the values when you use Alarm Monitor. Chapter 9- Page 133...
Page 134: Adjust Color Alarm Limits
See also "Alarms" on page 45. Adjust Color Alarm Limits *Administrator only* The Delta E Error Limit determines the alarm value for the Color Merit Error alarm. See also "Color Alarms and Specification Limits" on page 132 In the Color Analysis screen, Load images, and make sure Delta E is selected to the left of the part image: Chapter 9- Page 134...
Page 135: Chapter 9- Page 135
Use the Retro-Spec graphs to adjust the Delta E limits. Click and drag the limits bar. Or press the red line and hold, to enter a number. This value matches the Zone E Error limit bar. The Color Merit Warning value (in Alarms) [also called Zone E Warning in the Overview Panel graph] is automatically computed (it is 80% of the Zone E Error value).
Page 136: Chapter 9- Page 136
1) Delta E Error Limit 2) Delta E Warning Limit (automatically computed) The other color measurements, Delta L, H, and C, also have limit adjustments through the Retro-Spec graphs. Those limits are displayed in the corresponding graphs on the Overview Panel. There are no alarms connected to Delta L, H, or C. Chapter 9- Page 136...
Page 137: Chapter 10 Print Quality Screen
Chapter 10 Print Quality Screen This screen allows you to view recently inspected parts through the Retro-Spec interface. This allows you to see trends in inspection. It also allows you to change inspection settings and try them on images without interfering with current inspection. You must be an Administrator to save changes.
Page 138: Retro-Spec Graph
"View Inspection Results" on page 143 As a system administrator, you can also: "Adjust Inspection Settings" on page 141 Retro-Spec Graph - Tap the Print Quality icon to see the Retro-Spec interface. To view parts on the Print Quality screen, "Load Part Images" on page 117.
Page 139: View Defects On Images
View Defects on Images There are two images available for each part: 1) part image, and 2) error image. Swipe, or use the navigation dots or arrows under the image to switch between images. A part image is shown below. The circles on the image indicate where the defects are found. An error image example is shown below.
Page 140: Defect Classification
Defect Classification When you view the Error image in the Retro-Spec interface, you can see what type of defect occurred on each part. The defects are color-coded in the Error image. You can select the type of defect to view. The Overview selection shows all defect types. Note: one defect can fall into more than one classification.
Page 141: Adjust Inspection Settings
Note: The system determines the strongest classification for each pixel and colors it accordingly. You may see one defect show up in multiple classification views (example, shadow and too much color). This means the pixels in the defect area had strong characteristics in multiple clas- sifications.
Page 142: Chapter 10- Page 142
Inspection settings can be adjusted while you examine print quality. Tap the Print Quality icon to see the Retro-Spec interface. - Tap the load icon to load images. For information about load- ing images, see "Load Part Images" on page 117 Make changes as necessary.
Page 143: View Inspection Results
Tap the Save icon after you make changes to save the new settings to your job. View Inspection Results View the inspection results of each part. Use the Options button to select which results to view. If the Results are not on your screen, enable it by selecting Options | Show Results Window | exit the menu. Chapter 10- Page 143...
Page 144: Chapter 10- Page 144
Tip: look at the camera images. This helps you determine print quality on the parts. To see camera images: Select Options | Show Camera Images (from the right side of the menu). Select Exit. Chapter 10- Page 144...
Page 145 Chapter 10- Page 145...

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