Operator manual
IR-S / IR-D
© Notice
This document is copyrighted, 2011, by XPAR Vision BV. All rights are reserved. XPAR Vision BV reserves the
right to make improvements to the products described in this manual at any time without notice.
No part of this manual may be reproduced, copied, translated or transmitted in any form or by any means
without the prior written permission of XPAR Vision BV. Information provided in this manual is intended to
be accurate and reliable. However, XPAR Vision BV assumes no responsibility for its use, or for any
infringements upon the rights of third parties that may result from its use.
Laan Corpus den Hoorn 300
9728 JT Groningen
PO box 7080
9701 JB Groningen
The Netherlands
Tel. +31 (0) 50 3162888
Fax. +31 (0) 50 3162999
www.xparvision.com
[email protected]
© 2011 Xpar Vision B.V.
Revision History
P/N:
Date
Based on version
This Document
Rev 0
March 2011
6.1.0.xx
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Contents
1 OPERATOR SOFTWARE .................................................................................................................................... 4
1.1 | OPERATOR LOG-ON SCREEN ............................................................................................................................ 4
1.2 | SOFTWARE NAVIGATION................................................................................................................................. 5
Keypad Usage ................................................................................................................................................ 5
Keyboard Usage ............................................................................................................................................ 6
Mouse Usage.................................................................................................................................................. 6
Function keys and special option keys ........................................................................................................ 7
1.3 | OVERVIEW SCREEN ......................................................................................................................................... 8
Overview screen layout................................................................................................................................. 8
1.3.1 ALARM AND WARNING TYPES........................................................................................................................... 9
Intensity warnings and alarms..................................................................................................................... 9
Asymmetry warnings and alarms ................................................................................................................ 9
Verticality and Shape alarms ....................................................................................................................... 9
Missing ........................................................................................................................................................... 9
Rejects .......................................................................................................................................................... 10
1.3.2 MOULD INFORMATION SCREENS................................................................................................................... 10
Intensity screen............................................................................................................................................ 11
Intensity Charts ........................................................................................................................................... 12
Asymmetry Charts ....................................................................................................................................... 13
Verticality Charts......................................................................................................................................... 14
Shape Charts................................................................................................................................................ 15
Intensity Variation screen........................................................................................................................... 16
Asymmetry Variation screen ...................................................................................................................... 17
Verticality Variation screen ........................................................................................................................ 18
Shape Variation screen ............................................................................................................................... 19
1.4 | LAST REJECTS SCREEN .................................................................................................................................. 20
1.5 | REJECT STATISTICS SCREEN ........................................................................................................................... 21
1.6 | TRANSPORT SCREENS ................................................................................................................................... 22
Ware Spacing ............................................................................................................................................... 22
Ware Position (only available in the double camera system IR-D).......................................................... 26
1.7 | MACHINE CHART .......................................................................................................................................... 27
1.8 | POP-OP MENU ............................................................................................................................................. 28
1.9 | MANUAL REJECTION ..................................................................................................................................... 29
1.10 | TEMPORARY REJECTS ................................................................................................................................. 30
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1 Operator Software
1.1 | Operator log-on screen
At the start-up of the software the “Log
on” screen appears. The user must enter
his name and password in order to log in
to the system.
When the log in is completed by the user the overview
screen is shown.
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1.2 | Software Navigation
Keypad Usage
A 35 key keypad for use with the Operator software is mounted on the
outside of the Production Line Console. The codes below apply to this
keypad. By pressing the [5] (MENU) key a menu will pop up on the
screen. Various options or screens can be selected via this menu.
Cursor Up
(8)
Shortcuts to various
operator screens
F9 opens the Help
menu
Escape
Previous screen
Backspace
Cursor right
(6)
Cursor left
(4)
Menu
(5)
Intensity graph filters
(key 1,3,7,9)
Next screen
(Enter)
Cursor Down
(2)
Commonly used keys
[5]
[Enter]
[Escape] or [Backspace]
[F1]…[F5]
[Fn + F9]
[Arrow keys]
Menu for corresponding screen,
Used to view details of selected item,
Return to overview screen,
Various screens which are also available from the menu,
Opens the Help menu (to close this screen use [Shift] + [F4]
Used to switch cavities in detail screens and navigate the menu popup.
* Additional information on function keys and special option keys at page 7 of this manual.
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Keyboard Usage
The KEYPAD codes also apply to the numerical keypad on a keyboard.
All functions available for the operator can be accessed using the
keypad only.
Exceptions for using the keyboard are when using difficult login names.
Operator console keyboard
Right and left mouse key
The KEYPAD codes also apply to the numerical keypad on a keyboard.
In combination with the left and right mouse button the trackball works
as a mouse. All other options are the same as on a normal keyboard.
The functionality of the keyboard depends on the user level.
Mouse Usage
When you’re using a mouse the following applies to the mouse keys.
When you press the right mouse button you get the pop up menu.
Right mouse key
Menu (same as key 5 of
the key pad)
To select an item, move the mouse pointer to the desired location and
left click on it.
In an information screen you can left click on the lower orange bar to
simulate the [Enter] keystroke, when you left click on the upper orange
bar you simulate the [Esc] keystroke.
A specialist will use the mouse for settings and additional features that
are not available for an operator.
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Function keys and special option keys
F1 selection last rejects images
F2 selection statistics last rejects
F3 selection ware handling
F4 selection machine curve
F5 selection variation overview
F12 or [Shift] + [F2] selection manual reject
Key “B” switches border on/off
Key “P” Changes color palette
Key ”M” shows measurement report in last rejects
Key “C” switches image main and satellite
Key “5” Enables menu
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1.3 | Overview screen
Overview screen layout
When logged on as an operator you normally enter the Operator overview screen.
The layout will be explained below. This example shows a 12 sections, triple gob IS-Machine.
Date and time
Current Reject status
Line number
Selected cavity
Cavity number
Section 10
Selected cavity
Username
Pack Rate
Cut gobs
Product name
The overview screen shows you the different alarms and warnings for the cavities.
Other information you can see on this screen is:
Date and time
Current reject status
Line number
Selected cavity
Username
Pack Rate
Number of cut gobs
Product name
Displays the system date and time
Indicates if the rejects are switched on or not
The line number
The currently selected cavity (shaded in white).
Displays the user name of the user that is currently logged on.
the hot end pack rate that is defined as: over the last 4500
(Nr of cut gobs) – Missing – Rejects
(Nr of cut gobs)* 100%
The number of cut gobs since the system was switched on
The name of the product currently running on the production line
With the arrow keys or the mouse you can select a cavity (shaded white).
If you press the [Enter] key the first cavity information screen of the selected cavity will be displayed.
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1.3.1 Alarm and warning types
Intensity warnings and alarms
1.
2.
3.
4.
5.
Green
Yellow
Red
Light blue
Dark blue
: no deviation
: warning: intensity too high
: alarm: intensity too high
: warning: Intensity too low
:.alarm: intensity too low
Asymmetry warnings and alarms
1.
2.
Yellow
Red
: warning asymmetry
: alarm asymmetry
Verticality and Shape alarms
1.
2.
Red
Red rim
: alarm verticality
: alarm shape
Missing
A black bottle in the overview screen indicates that the
XPAR system has not found a bottle of the cavity
concerned (missing bottle).
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Rejects
Rejected products will be animated in the overview
screen. The main reason for rejection will be displayed in
the centre of the product.
Displayed at the right you will see;
- Rejected for high intensity in the upper body
- Rejected for abnormal verticality
- Not rejected
- Rejected for low intensity at the bottom
- Rejected for defects (stones, blisters, bird swings)
1.3.2 Cavity information screens
When present in the operator overview screen you can press the [ENTER] key on the keyboard or the keypad
to switch between the cavity information screens. Figure 1.3 displays the navigation order in a flowchart.
Figure 1.3: Navigation flowchart
When the Escape (Esc) button is pressed from any of these screens you will return to the operator overview
screen.
The following cavity information screens are available:
1.
2.
3.
4.
5.
Intensity variation
Intensity chart
Asymmetry chart
Verticality chart
Shape chart
In all the information screens the last bottle of the selected cavity is displayed.in real time
The pack rate in an information screen relates to the selected cavity.
You can quickly change the selected cavity by pressing the left [←] or right [→] arrow keys.
Each cavity information screen will be explained in detail (next pages).
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Intensity screen
The intensity screen allows you to view the intensity variation per cavity.
Last measurement
(Thick black lines)
Deviation from
reference
Alarm level
(Red lines)
Warning level
(Yellow lines)
Variation
Variation
range
(Green bars)
Reference level
(Black line)
Calculate averages from X
number of bottles
Next to the image you can see the intensity variation screen of the zone’s.
The colour of the bar indicates an alarm or warning and corresponds with the alarm or warning on the
overview screen.
The width of the bar shows the range (RANGE in table) over which the intensity varies.
The centre of the bar shows the deviation (DEV in table) of the intensity from the reference level.
The yellow lines indicate the intensity warning level for the zone.
The red lines indicate the intensity alarm level for the zone.
At the bottom the user can select over how many bottles the information is averaged.
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Intensity Charts
The intensity Chart screen shows the intensity chart for each zone over the last hour.
Alarm level
(Red lines)
Warning level
(Yellow lines)
Reference level
(Black line)
Intensity graph
Bottom zone
On the right, the intensity charts of the zones are displayed.
The black line is the reference level, the yellow lines the warning levels and the red lines the alarm levels.
In case more than four zones are present, you can scroll through the zones using the up [↑] and down [↓]
arrow keys.
History Mode
Access History mode if you want to view the charts back in
time. Use the arrow keys, right [→] and left [←] to scroll
through time.
Access History menu in
history mode you can set
the time views and steps
(1, 2 or 5 hours).
Note:
History mode is
available in every Chart
view.
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Asymmetry Charts
The asymmetry chart shows the asymmetry chart for each zone for the last hour.
Alarm level
(Red lines)
Warning level
(Yellow lines)
Reference level
(Black line)
Asymmetry graph
Body zone
On the right you can see the asymmetry charts of the zones.
The yellow lines indicates the asymmetry warning levels and the red lines the alarm levels.
In case more than four zones are present, you can scroll through the zones using the up [↑] and down [↓]
arrow keys.
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Verticality Charts
The verticality chart shows the verticality charts (Min.1 zone and max.7 zones and always one Total Verticality
chart), over the last hour.
Verticality line
Reject level
(Black line)
Verticality chart
Total
Verticality chart
Neck section
Alarm level
(Red line)
Reference level
(Black line)
Verticality chart
Body zone
The red lines indicate the alarm levels and the black lines the reject levels.
The learned border of the bottle is shown as a white line and the measured border as a green line.
The system calculates the total verticality.
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Shape Charts
The shape chart shows the shape chart from each zone over the last hour (Min 1 zone max 8 zones).
Shape outline
Shape chart
Finish zone
Reject level
(Black line)
Shape chart
Neck section
Alarm level
(Red line)
Shape chart
Shoulder section
Shape graph
The red lines indicate the alarm levels and the black lines the reject levels.
The measured border of the bottle is shown in green, when the border is out of limit it will be shown in red
and the learned border is shown white.
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Intensity Variation screen
The intensity variation screen allows you to view the intensity variation per cavity in one zone.
Last measurement
(Thick black lines)
Deviation from
reference
Alarm level
Reference level
(Black line)
Warning level
Variation
Variation
range
(Green bars)
Calculate averages from X
number of bottles
Zone selector
In the image above you can see the intensity variation screen of the cavity of one selected zone.
The colour of the bar indicates an alarm or warning and corresponds with the alarm or warning on the
overview screen.
The width of the bar shows the range (RANGE in table) over which the intensity varies.
The centre of the bar shows the deviation (DEV in table) of the intensity from the reference.
The black dotted lines indicate the intensity warning and alarm levels for the zone.
At the bottom the user can select over how many bottles, the information is averaged and can select the
zone.
To see the asymmetry, verticality and shape variation screen you have the same navigation system as the
intensity screen and asymmetry, verticality and shape chart, press [enter] you go to the next screen, press
[escape] you go back to overview screen.
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Asymmetry Variation screen
The Asymmetry Variation screen allows you to view the asymmetry variation per cavity in one zone.
Last measurement
(Thick black lines)
Reference level
(Black line)
Deviation from
reference
Alarm level
Warning level
Variation
Variation
range
(Green bars)
Calculate averages from X
number of bottles
Zone selector
In the image above you can see the asymmetry variation screen of the cavity of one selected zone.
The colour of the bar indicates an alarm or warning and corresponds with the alarm or warning on the
overview screen.
The width of the bar shows the range (RANGE in table) over which the asymmetry varies.
The centre of the bar shows the deviation (DEV in table) of the asymmetry from the reference.
The black dotted lines indicate the asymmetry warning and alarm levels for the zone.
At the bottom the user can select over how many bottles, the information is averaged and he can select the
zone.
Press [enter] you go to the Verticality Variation screen, press [escape] you go back to overview screen.
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Verticality Variation screen
The Verticality variation screen allows you to view the verticality variation per cavity in one zone.
Last measurement
(Thick black lines)
Deviation from
reference
Reference level
(Black line)
Alarm level
Variation
Variation
range
(Green bars)
Calculate averages from X
number of bottles
Zone selector
In the image above you can see the verticality variation screen of the cavity of one selected zone.
The colour of the bar indicates an alarm and corresponds with the alarm on the overview screen.
The width of the bar shows the range (RANGE in table) over which the verticality varies.
The centre of the bar shows the deviation (DEV in table) of the verticality from the reference.
The black dotted line indicate the verticality warning level for the zone.
At the bottom the user can select over how many bottles, the information is averaged and he can select the
zone.
Press [enter] you go to the Shape Variation screen, press [escape] you go back to overview screen.
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Shape Variation screen
The Shape Variation screen allows you to view the Shape variation per cavity in one zone.
Last measurement
(Thick black lines)
Deviation from
reference
Alarm level
Reference level
(Black line)
Variation
Variation
range
(Green bars)
Calculate averages from X
number of bottles
Zone selector
In the image above you can see the Shape variation screen of the cavity of one selected zone.
The colour of the bar indicates an alarm or warning and corresponds with the alarm or warning on the
overview screen.
The width of the bar shows the range (RANGE in table) over which the shape varies.
The centre of the bar shows the deviation (DEV in table) of the shape from the reference.
The black dotted lines indicate the shape alarm level for the zone.
At the bottom the user can select over how many bottles, the information is averaged and he can select the
zone.
Press [enter] and you go back to the Intensity Variation screen, press [escape] you go back to overview
screen.
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1.4 | Last Rejects Screen
Last rejects
Press the [F1] key from within any screen to display the |Last Reject| screen.
The last reject screen allows you to view the bottles that where rejected in the last 60 minutes.
You can browse through the images with the arrow keys or with the mouse.
For every bottle rejected the following information is displayed:
•
•
•
•
Time of reject
Mould (cavity) where the bottle came from
Cause of the reject
Info about the parameter which caused the reject
If you have selected an image you can directly go to the corresponding cavity by pressing the [Enter] key.
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1.5 | Reject statistics screen
Reject statistics
Press the [F2] key from within any screen to display the |Reject Statistics| screen.
The reject statistics screen allows you to view reject statistics per cavity.
On the left chart you see the reject cause, on the right chart the reject distribution over the cavities.
You can select a chart (white background) with the left [←] and right [→] arrow keys (or mouse pointer).
In the selected chart you can select a bar (orange bar) with the up [↑] and down [↓] arrow keys (or mouse
pointer).
When you select a cause on the left you see on the right the distribution of that cause over the cavities.
When you selected the reject distribution chart you can select a cavity and see on the left causes of the
reject for that cavity.
At the bottom you can switch between percentage or the number of bottles rejected.
You can also change the time frame over which the rejects are displayed, 15 minutes, 30 minutes 1 hour or
Current shift.
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1.6 | Transport screens
Ware Spacing
Press the [F3] key from within any screen to display the |Transport| screens.
The ware spacing shows the X-axis positions of the bottles on the conveyor belt.
Figure 1.6.1: Visualisation Ware Spacing.
Figure 1.6.1 shows three products. Each product has his own drop window on the conveyor. The ideal
position of the product is the centre of this drop zone. The left bottle is early considering that the conveyor is
moving from left to right. Value A represents the positive deviation from the ideal position.
The centre product is places on the ideal position. The right product is late, value B represents the negative
deviation from the ideal position. Furthermore, the right product entered the alarm zone within the drop
window. Therefore it is displayed in red.
Latest
measurement
Alarm
levels
Section average
(Blue bars)
Latest measurement
Deviation (DEV)
from ideal position
Ideal position
Variation
Variation
(RANGE)
(Green
(Greenbars)
bars)
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- The width of the bars shows you how much the position changes (RANGE in table).
- The centre of the bars shows the average position (DEV in table) of the bottles.
- The colour of the bar indicates if the position is within (green) or out (red) of limits.
- The last position measured of a bottle is shown as a small vertical line.
Ideally the blue bars (average of the section) should be on the “IDEAL” line and the width of the bars should
be as small as possible.
Use the up [↑] and down [↓] arrow keys to change the reference cavity (use AVG→Average
as default).
Use the left [←] and right [→] arrow keys to select over how many “Machine period cycles” the averages are
calculated.
If the blue bars are not at the “IDEAL” position you can advance or delay the pushers by the degree indicated in the
DEV(°) column.
Also shown in this screen is the conveyor belt speed. If you don’t have a measuring device for the conveyor belt
speed you can use this number to keep the speed constant in time!
Spacing Overview screen
Press the [Enter] key from within the |Ware Spacing| screen to display the |Spacing Overview| screen.
Cavities
Min. and max. value
based on selected
number of cycles
Ideal, calculated, spacing
based on belt speed and the
diameter of the product
Minimal spacing (input
in IS advanced menu)
Latest measurement
The green mark shows previous
measurements. Further back in
time the mark will be smaller
Spacing between
the cavities
Press [5] or right click the mouse from within the |Ware Spacing| screen to navigate through the different
the ware spacing menu screens.
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Show Machine Order
Variation in arrival time can be viewed in machine order.
The products furthest away from the camera are a longer period of time on the conveyor belt. If the speed of
the belt is not consistent the arrival time of that cavity has a bigger variation in the arrival time at the
camera.
Example:
An unstable conveyor belt speed will show an
increase of variation.
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Show Candlestick
Option candlestick shows the minimum and maximum positions related to the selected number of cycles.
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Ware Position (only available in the double camera system IR-D)
Press the [Enter] key from within the |Spacing Overview screen| screen to display the |Ware Position|
screen.
The ware position shows the Y-axis positions of the bottles on the conveyor belt.
Figure 1.6.2: Visualisation Ware position.
Figure 1.6.2 shows three products. Each product has his own drop window on the conveyor. The ideal
position of the product is the centre of this drop zone. The left bottle’s Y-axis position is clearly not centred.
Value A represents the positive deviation from the ideal Y-axis position.
The centre product is places on the ideal position. The right product’s Y-axis is not centred either. Value B
represents the negative deviation from the ideal position. Furthermore, the right product entered the alarm
zone within the drop window. Therefore it is displayed in red.
The ware position screen layout equals the ware spacing screen described earlier except for the section
averages. Section averages are unusable information in this particular screen.
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1.7 |
Machine chart
Machine chart
Press the [F4] key from within any screen to display the |Machine Chart| screen.
The IS machine chart shows the average intensities of the various zone’s.
An example of a IS machine chart is shown below. The chart will rise or fall depending on the cavity nearest
to the Camera (in this case section 1 is the closest section to the camera).
Timeframe for
averages
Selected
cavity
Key functions
Key
[7] and [9]
[↑] and [↓]
[←] and [→]
[Enter]
[Esc]
[5]
Function
Go back and forward in time average.
Change the timeframe for calculating the averages.
Select cavity.
View selected cavity.
Return to the overview screen.
Show machine chart menu
The machine chart menu is displayed to the right. It contains some additional features;
Flat / Curve
Show / Hide Setpoints
Reset Chart
Main
Satellite
Display mode.
Show or Hide cooling curve (averages).
Reset the chart.
Show machine chart Main Camera
Show machine chart Satellite Camera
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1.8 | Pop-op menu
Pop-up menu
By pressing the 5 key (Keyboard) or click right mouse button a popup menu appears
The items of the pop-up menu will differ depending on:
•
•
•
the current screen the user is in
the software version.
the level of the user
The most important items are described in this manual. The others
are self-explanatory.
•
•
•
•
Machine Chart
Transport
Manual Rejection
Temporary Rejects
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1.9 | Manual rejection
Manual rejection
With the manual rejection menu, cavities and/or sections can be
selected to have products rejected by the system. Click with the
mouse arrow on the corresponding button
Select all cavities
Select Section
Select single cavity
Selected section
Selected single
cavity
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1.10 | Temporary Rejects
Temporary Rejects
The temporary reject screen has the options to mark which reject function must remain using the temporary
reject. The option will be activated when IS machine is marked. Press escape to go back to the Main Overview
Marked IS-machine
Marked reject
function
The main overview background will be yellow and on top of the screen the remark “temporary rejects on”
will appear.
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