1.2 UserManual Vision PDF

Technical Documentation
Element Inspection (AOI)
Rohwedder Micro Assembly GmbH

Main entrance Opelstrae 1
Delivery address Lanzstrae 2
68789 St. Leon-Rot - Germany
Phone: +49 (0) 6227 / 3412- 0
Fax: +49 (0) 6227 / 3412- 9905
Mail: vision@rohwedder.com
November 2013
UM_ElementInspection-AOI-Vision_01.doc

Page 1 of 2
Chapter List
Station
Chapter Title
Date of Issue
Vision Control (Visio Self-test)
2009-11-01
Stone Detection in Station 1
2009-09-16
1 and 5
Chipped and Broken - Creation of Masks and

Contours for ROI Evaluation
2009-05-20
1 and 5
Big Impressions Real Width Measurement
2006-03-07
2 and 3
Saddle Edge Improvement (One Image)
2010-06-24
2 and 3
Gap Measurement
2011-09-29
Nop Inspection
2006-06-22
Saddle Surface
2010-07-14
November 2013
UM_ElementInspection-AOI-Vision_01.doc

Page 2 of 2
User's Guide
VisionControl (Vision Self-test)
Customer:
VDT Bosch Tilburg
Order Number:
Version:
30013005
As from V05-0-1
Rohwedder AG I Vision Technologies

Schiestattweg 1 I 88677 Markdorf I Germany
T +49 75 44 95 93-0 I F +49 75 44 95 93-88
vision@rohwedder.com I www.rohwedder.com
All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any
means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Rohwedder AG.
November 2009
EN_Description_VisionControl_V04_1a.doc
User's Guide
Page 1 of 20
Contents
1
ElementeAdmin Operation..........................................................................................3
1.1
Reference Run and Control Run Settings ..........................................................4
1.2
Control Run Sequence .........................................................................................5
1.3
Control and Reference Data ................................................................................6
Element2Cam Operation .............................................................................................9
2.1
Remote Data Access ............................................................................................9
2.2
New Vision Operators ........................................................................................10
2.2.1
Analyse Focus...............................................................................................10
2.2.2
Control Classify Line......................................................................................12
2.2.3
Control Classify PatMax ................................................................................13
2.2.4
Control Classify Caliper .................................................................................13
2.2.5
Control Classify FrontBack ............................................................................13
2.2.6
Control Classify SaddleEdge.........................................................................14
2.2.7
Control Classify Torsion ................................................................................14
2.2.8
Control Classify SaddleSurface .....................................................................14
2.3
Measured Values Listing....................................................................................15
2.3.1
Overview .......................................................................................................15
2.3.2
Measuring Range Representation (Schematic).............................................16
2.4
Setting Up VisionControl and Configuration ...................................................17
2.4.1
Element2Cam................................................................................................17
2.4.2
ElementeAdmin .............................................................................................19
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User's Guide
Page 2 of 20
VisionControl
Definition: The equipment is checked to see whether changes can be determined
between two measurements made at different times. This serves as hardware verification
for the Vision System. After a failed control run, the equipment must be checked by suitable
specialist technicians and readjusted, if required.
ElementeAdmin Operation
VisionControl is performed during the ongoing inspection. It is not necessary to terminate

inspection.
Remark: Inspection must be stopped only during a reference run to perform the setting in
the Setup dialog.
November 2009
User's Guide
Page 3 of 20
1.1 Reference Run and Control Run Settings

1.)
2.)
Change user
User level: Service
Click "Setup" to open the Setup dialog
3.)
Configuration
2 states must be differentiated when VisionControl is used:
1. Control run
2. Reference run
Either a control run or a setup run can be selected in the Setup dialog. If the
program is restarted, the control run is set as default.
A reference run serves to determine the nominal values.
A control run serves to determine the actual values.
The generated reference data and control data are filed in the following folder
system (see also Section 1.3):
.. \ ElementeAdmin \ Control \ Reference_[inspection program]
.. \ ElementeAdmin \ Control \ Actual_[inspection program]
November 2009
User's Guide
Page 4 of 20
1.2 Control Run Sequence

The procedure is fixed and has 3 sections:
1. Equipment: (Mechanics and control elements)
2. Vision:
(User interface Admin or element software)
3. PLC:
(User interface control)
PLC:
Vision:
Stop the equipment (stop after cycle)

Setting of control run or reference run
No settings have to be made for a control run. The following steps
must be performed for a reference run:
Vision or PLC: Stop inspection
Vision: Open the Setup dialog and select Reference run
Vision or PLC: Start inspection
Remark: The reference run remains set until the software is restarted
or the control run selected using the Setup dialog.
Equipm.: Feed the control element to the input rail (equipment is NOT run to
empty)
PLC:
Activate the control run (click the "Control" button)
Vision: Display via the Admin status bar (see below)

PLC:
Start the equipment
Equipm.: The equipment stops automatically
Equipm.: Take the control element out of the fail bin
PLC:
View messages (NOK messages are shown by means of an own
dialog)
PLC:
Acknowledge messages (if NOK messages are shown, suitable
special technicians must be consulted)
Vision:
The last control run result is additionally shown on the Admin
The results of the individual cameras are shown per station (1 - 6)

(OK = green / NOK = red / not inspected = amber)
Vision:
Sequence for evaluation of the control results

- View Last VisionControl Result
- Switch to station and camera with error and click "Result
Request" (see Section 2.1)
November 2009
User's Guide
Page 5 of 20
1.3 Control and Reference Data

A set of data records (folder) comprises the camera images and measured values.
The folder is named as follows:

Jahr.Monat.Tag.Stunde.Minute.AnlageLinie
(Year.Month.Day.Hour.Minute.Equipmentline)
Images
The images are stored in the "Images" folder for each station and camera. (Name for
example S1_C1 = Station1_Kamera1)
Measurements
The measurements are stored in the "Measurements" folder for each station and
camera (name for example S1_C1 = Station1_Camera1)
November 2009
User's Guide
Page 6 of 20
Example file Measurements_S1_C1.csv
A = measured value ID
B = measured value name
C = measured value
D = min. tolerance (absolute)
E = max. tolerance (absolute)
Tolerances and Nominal

At least 2 files are required for the measured value comparison:
1. Nominal_Inspection_XX-XX.txt
2. Tolerances.txt
The storage location is under
The "Nominal_Inspection_XX-XX.txt" file contains the nominal values, these are

entered into the file automatically during a reference run.
The "Tolerances.txt" file contains the tolerance values, these must be entered
manually.
November 2009
User's Guide
Page 7 of 20
Example
Nominal.txt
Tolerances.txt
[Section_1] (Station_1/Cam_1)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT 60.511
GREYVAL_ROI_UPPER 83.747
FOCUS_WIDTH_[PIX]
Nominal
0.314
-0.426
0.047
4.126
59.395
5.000
POSITION_X_[PIX]
0.000
POSITION_Y_[PIX]
0.000
ANGLE_[DEGREE]
0.000
RESOLUTION_[MM]
0.000
GREYVAL_ROI_BACKLIGHT_EDGE 0.000
GREYVAL_ROI_BACKLIGHT
0.000
GREYVAL_ROI_ELEMENT
0.000
Position_X_[pixels]
10.563
Position_Y_[pixels]
10.313
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_UPPER
FOCUS_WIDTH_[PIX]
Tol(-)
-50.000
-50.000
-50.000
-0.060
-20.000
-20.000
-20.000
-2.000
Tol(+)
50.000
50.000
50.000
0.060
20.000
20.000
20.000
2.000
[Section_2] (Station_2/Cam_1)5
POSITION_X_[PIX]
-50.000 50.000
POSITION_Y_[PIX]
-50.000 50.000
ANGLE_[DEGREE]
-5.000 5.000
RESOLUTION_[MM]
-0.060 0.060
GREYVAL_ROI_BACKLIGHT_EDGE -20.000 20.000
-20.000 20.000
GREYVAL_ROI_ELEMENT
-20.000 20.000
The following data are stored in the files for measured value
"Position_X_[pixels]"
Nominal.txt
Nominal
= 0.314
Tolerances.txt
Tol(-) = Min. tolerance

Tol(+) = Max. tolerance
= -50.000
= 50.000
This results in the following limit values for the ACTUAL values (calibration
run)
Lower limit value
Upper limit value
November 2009
= "Nominal value" + "Min. tolerance"" = - -49.686

= "Nominal value" + "Max. tolerance"" = - 50.314
User's Guide
Page 8 of 20
2 Element2Cam Operation
2.1 Remote Data Access
1.)
Switch to the "Control run" screen (change user "System")
2.)
The Calibration screen has several operating and display elements
Camera
selection
Result
display
Result
request
Camera selection
This operating element allows access to the second camera in a 2 camera
system.
Result display
Consists of two display windows. The left window shows the reference image.
The right window shows the current control image.
Result request
Clicking the "Result Request" button retrieves and displays the image data
administered centrally on the Admin screen.
November 2009
User's Guide
Page 9 of 20
2.2 New Vision Operators

2.2.1 Analyse Focus
Description:
The Operator compute the edge width with the grey value course. The edge width is
comparable with the focus value.
Focus value = 3
Focus value = 19
Grey value course
Search ray
Edge
ROI
The result can be improved when several search rays are used within the ROI. The results
of the search rays are averaged.
November 2009
User's Guide
Page 10 of 20
Parameter:
Graphic:
Select the graphic
All = The result of each search ray is shown
Settings Median Filter:
Median filter
FHS X: Adjusting the filter size in x-direction
FHS Y: Adjusting the filter size in y-direction
Settings Search Ray:
Adjusting search ray
Rotation: Determine the direction of the search ray (0 - 180)
Number FHS: Adjusting the number of the search rays.
FHS
November 2009
FHS
User's Guide
Page 11 of 20
Distance: Adjusting the distance of the search rays.

Settings Gradient Ray:
Adjusting of the grey value derivation
FHS Grad: Minimal recognition of the structure width.
Settings Search Ray Maximas:
Search of the strongest edge
Threshold: Explicitness of the edge which is used.
Distance: Reducing of local maxima. Consecutive maxima must be at least this distance
apart.
Relative Stop: At this value the actual maximum is valid. After this the next maximum can
be searched within the search ray.
Actual value < ( Relative Stop x Max. Value )
Excample for derivate grey value course and maxima search:
Threshold = 10
Distance
= 10
Relative Stop= 0.5
Distance < 10
Stop
Maxima 1
Stop
Stop
Maxima 2
Threshold
Maxima 3
2.2.2 Control Classify Line

Description:
Presence Verification of the Controlelement with the line results.
Line present Controlelement present Result OK
Line not present Controlelement not present Result NOK
Parameter:
None
November 2009
User's Guide
Page 12 of 20
2.2.3 Control Classify PatMax

Description:
Presence verification of the Controlelement with the patmax result.
Patmax result present Controlelement present Result OK
Patmax result not present Controlelement not present Result NOK
Parameter:
None
2.2.4 Control Classify Caliper

Description:
Presence verification of the Controlelement with the Caliper results.
Number of points enough Controlelement present Result OK
Number of points to less Controlelement not present Result NOK
Parameter:
Number Thres: Adjust the number of points for verify the presence of the Controlelement
( used at Station 4 Number of the Laserlines )
2.2.5 Control Classify FrontBack

Description:
Collect the following results:
"POSITION_X_[PIX]"
"POSITION_Y_[PIX]"
"ANGLE_[DEGREE]"
"RESOLUTION_[MM]"
"GREYVAL_ROI_LEFT"
"GREYVAL_ROI_RIGHT"
"GREYVAL_ROI_UPPER"
"FOCUS_WIDTH_[PIX]"
Parameter:
ID for Station (1 or 5): Selection of the station
November 2009
User's Guide
Page 13 of 20
2.2.6 Control Classify SaddleEdge

Description:
"POSITION_X_[PIX]"
"POSITION_Y_[PIX]"
"ANGLE_[DEGREE]"
"RESOLUTION_[MM]"
"GREYVAL_ROI_BACKLIGHT_EDGE"
"GREYVAL_ROI_BACKLIGHT"
"GREYVAL_ROI_ELEMENT"
"FOCUS_WIDTH_[PIX]"
Parameter:
ID for Station (2 or 3): Selection of the station
2.2.7 Control Classify Torsion

Description:
"POSITION_Y_[PIX]"
"ANGLE_[DEGREE]"
"RESOLUTION_[MM]"
"LASER_WIDTH1_[MM]"
"LASER_WIDTH2_[MM]"
"LASER_BRIGHTNESS1_[GREYVAL]"
"LASER_BRIGHTNESS2_[GREYVAL]"
2.2.8 Control Classify SaddleSurface

Description:
Collect the following results
"POSITION_X_[PIX]"
"POSITION_Y_[PIX]"
"ANGLE_[DEGREE]"
"RESOLUTION_[MM]"
"GREYVAL_ROI_LEFT"
"GREYVAL_ROI_RIGHT"
"GREYVAL_ROI_BACKGROUND"
"FOCUS_WIDTH_[PIX]"
November 2009
User's Guide
Page 14 of 20
2.3 Measured Values Listing

2.3.1 Overview
Station
ID
1
Back
10
11
12
13
14
15
16
17
20
21
22
23
24
25
26
27
30
31
32
33
34
35
36
38
40
41
42
43
44
45
46
2
SaddleEdge
Left
(2 cameras)
3
SaddleEdge
Right
(2 cameras)
4
Torsion
5
Front
6
SaddleSurface
(2 cameras)
50
51
52
53
54
55
56
57
60
61
62
63
64
65
66
67
Measured value
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_UPPER
FOCUS_WIDTH_[PIX]
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_BACKLIGHT_EDGE
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
LASER_WIDTH1_[MM]
LASER_WIDTH2_[MM]
LASER_BRIGHTNESS1_[GREYVAL]
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_BACKGROUND
FOCUS_WIDTH_[PIX]
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
FOCUS_WIDTH_[PIX]
November 2009
Tolerance
Min
-50
-70
-5
-0.060
-20
-20
-20
-2
-50
-70
-5
-0.060
-20
-20
-20
-2
-50
-70
-5
-0.06
-20
-20
-20
-2
-70
-5
-0.06
-0.1
-0.1
-20
-20
-50
-70
-5
-0.060
-20
-20
-20
-2
-50
-70
-5
-0.060
User's Guide
-20
-20
-20
-2
Tolerance
MAX
+50
+70
+5
+0.060
+20
+20
+20
+2
+50
+70
+5
+0.060
+20
+20
+20
+2
+50
+70
+5
+0.06
+20
+20
+20
+2
+70
+5
+0.06
+0.1
+0.1
+20
+20
+50
+70
+5
+0.060
+20
+20
+20
+2
+50
+70
+5
+0.060
+20
+20
+20
+2
Unit
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Pixels
Degree
mm
mm
mm
0-255
0-255
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Page 15 of 20
2.3.2 Measuring Range Representation (Schematic)

Measured value names can be associated using the ID and the Measured Value
Table shown in Section .2.3.1
Cameras and stations which have similar measuring principles are described
with a common Figure (marked with square brackets).
16
17
14
24
20
21
22
10
11
13 12
23
15
27
26
Station 1
[Station 5 ]
25
Station 2 / Camera 1
[Station 2 / Camera 2]
43
40 41 45
44
46
42
66
60
61
62
Station 4
November 2009
64
63
65
67
Station 6 (Camera 1)
User's Guide
Page 16 of 20
2.4 Setting Up VisionControl and Configuration

Note: Only well-trained personnel shall perform the configuration.
Important: Make a back-up copy of the "Bosch" folder (e.g. Bosch_VorVisionControl)
2.4.1 Element2Cam
1.)
Install the "Element2Cam.exe" program version as from V05-0-0
2.)
Delete the contents of file "ImgOpDescription.dfn"
3.)
Install the new Element2Cam.err
4.)
Inspection_XX-XX.prm must be adapted. The layout of the inspection programs

has changed. The inspection program has the following layout:
The inspection program contains 3 inspection sequences: 1. ControlDetector
2. Control
3. Inspection
The previous inspection sequence can be taken over from the old inspection
program:
Procedure:
Open the old inspection program

Change to the "TeachIn" screen and open "Inspection BV"
Export the inspection sequence
(Storage location:
E:\Applications\Bosch\Element2Cam\Parameter\*.prg)
Open the new inspection program (already contains the ControlDetector
and Control sequence)
Change to the "TeachIn" screen and open "Inspection BV"
Import the inspection sequence
Save the inspection program
5.)
Delete Workpiece_Calib
6.)
Start Element2Cam.exe and terminate again (Element2Cam.ini was updated)
November 2009
User's Guide
Page 17 of 20
7.)
The "Element2Cam.ini" file must be modified:

// Adaptation of settings
[RemoteFromAdmin]
StationID=0
// The StationID must be set as follows

Station Backside
Station SaddleEdgeLeft
Station SaddleEdgeRight
Station SaddleEdgeTorsion
Station SaddleEdgeFront
Station SaddleEdgeSaddleSurface
=0
=1
=2
=3
=4
=5
// Adaptation of settings
[VisionControl]
Eject_Active=FALSE
Sim_Active=FALSE
// Ejection if control element is recognized (only Station 6 = TRUE)

// Set VisionControl to active (normally with MMI (PLC))
// Remark: Required only for Rohwedder AG for debugging!
// Addition of operators
[Operators_BV]
CImgOpAnalyseFocus
CImgOpControlClassifyTorsion
CImgOpControlClassifyLine
CImgOpControlClassifySaddleSurface
CImgOpControlClassifySaddleEdge
CImgOpControlClassifyFrontBack
CImgOpControlClassifyCaliper
CImgOpControlClassifyPatMax
CImgOpRotate
8.)
Test the inspection programs
November 2009
User's Guide
Page 18 of 20
2.4.2 ElementeAdmin
1.)
2.)
3.)
4.)
5.)
6.)
Install the "ElementeAdmin.exe" program version as from V5-0-0

Install the ElementeAdmin.err
Create folder ElementeAdmin\Control
Delete folder ElementeAdmin\Calib (first, make a back-up copy if still required by
VDT)
Start ElementeAdmin.exe and terminate again (ElementeAdmin.ini was updated)
The "ElementeAdmin.ini" file must be modified:
// Language setting for MMI
[MMI-Communication]
Languages=EN,NL,DE
// The languages to be supported by MMI

can be set here. Language support for:
EN=English, NL=Dutch, DE=German
// Settings for VisionControl (leave default settings)
[VisionControl]
ReferenceDirectory=Reference
ActualDirectory=Actual
ImagesDirectory=Images
MeasurementsDirectory=Measurements
FileSetting=Settings
FileMeasurement=Measurements
FileImages=Image
NumOfMeasurementVals=100
7.)
Adaptation of Tolerances.txt (ElementeAdmin\Control\)

The tolerances must be adapted. The standard values are as follows:
(The exact settings must be determined during operation and are included in the
performance scope of the VDT-Vision Team)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_UPPER
FOCUS_WIDTH_[PIX]
Tol(-)
-50.000
-70.000
-50.000
-0.060
-20.000
-20.000
-20.000
-2.000
Tol(+)
50.000
70.000
50.000
0.060
20.000
20.000
20.000
2.000
[Section_2] (Station_2/Cam_1)5
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
POSITION_X_[PIX]
-50.000
50.000
November 2009
User's Guide
Page 19 of 20
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
LASER_WIDTH1_[MM]
LASER_WIDTH2_[MM]
-50.000
-50.000
-5.000
-0.100
-0.100
-20.000
-20.000
50.000
50.000
5.000
0.100
0.100
20.000
20.000
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_UPPER
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
November 2009
User's Guide
Page 20 of 20
16.09.2009
Operating Instructions
Stone Detection in Station1
Customer:
VDT Bosch Tilburg
Order Number:
Version:
304312
As from V04-3-9

T +49 75 44 95 93-0 I F +49 75 44 95 93-88
All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by
any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Rohwedder AG.
16.09.2009
Page 1 / 5
16.09.2009
Contents
1
Stone Detection in Station 1.....................................................................................3

1.1
Task .....................................................................................................................3
2 Description of Test Program Modifications ............................................................3
3 Description of Test Program Steps..........................................................................4
3.1
Cognex Blob.........................................................................................................4
3.2
Classify Backside .................................................................................................5
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16.09.2009
1 Stone Detection in Station 1

1.1 Task
Detection of stones that are within the nop. The layout of the Station is not adapted. The
modifications are performed only in the test sequence and in the software.
2 Description of Test Program Modifications

There are 3 essential modifications:
1. Test step "Cognex Blob" is added in the test program for Station 1 for stone
detection.
2. Control elements for "Stone" are added within operator "Classify Backside" ( or
"Classify Backside New" when "Chipped ROI" is used ).
3. The existing control elements for "Stone" are removed within operator "Classify
Frontside".
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16.09.2009
3 Description of Test Program Steps

3.1 Cognex Blob
Task:
Detection of bright areas ( = stones) within the nop
Parameter Settings
Note the areas marked in red.

Segmentation
- Hard Threshold (Fixed)
- Light blobs, Dark background
- Threshold = 120
Region Shape
- CogCircle
- CenterX, CenterY, Radii must be adapted to the image.
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16.09.2009
3.2 Classify Backside

Task:
Classification of segmented areas as "Stone" depending on the area.
Parameter Settings
The "Threshold Area" box serves to show the area in which a stone is recognized.
16.09.2009
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14.10.2010
Chipped Mdofication - Stations 1/5
User's Manual
Chipped and Broken Creation of Masks and
Contours for ROI Evaluation
Customer
VDT Bosch Tilburg
Order No.
Version:
304312
ab V04-3-9

T +49 75 44 502-271 I F +49 75 44 502-0
20.05.2009
Translated October 2010
Page 1/12
14.10.2010
Contents
1
Chipped and Broken Modification ...........................................................................3

1.1
Taks .....................................................................................................................3
1.2
Setup....................................................................................................................3
1.2.1
Creation of Mask and Contour ......................................................................3
1.2.2
Tasks Prior to First Use.................................................................................3
1.2.3
Integration of Mask and Contour into the Inspection Sequence ....................5
2 Description of the CreateContour Inspection Program......................................6
2.1
Sequence .............................................................................................................6
3 Description of the AnalyseContour Program Part ..............................................7
3.1
Sequence .............................................................................................................7
3.2
Load Contour Chain Code....................................................................................7
3.2.1
Function ........................................................................................................7
3.2.2
Description of the Parameters.......................................................................8
3.2.3
Overview of Inputs and Outputs ....................................................................8
3.3
Analyse Contour ROI ...........................................................................................9
3.3.1
Function ........................................................................................................9
3.3.2
Description of the Parameters.......................................................................9
3.3.3
Overview of Inputs and Outputs ..................................................................11
3.4
Classify Backside (New) / Classify Frontside (New)...........................................12
3.4.1
Changes......................................................................................................12
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14.10.2010
1 Chipped and Broken Modification

1.1 Taks
- Recognition of "chipped" and "broken" defects within user-defined ROIs only.
- Creation of masks and contours is done by means of RVT software.
1.2 Setup
1.2.1 Creation of Mask and Contour
Mask and contour are created by the inspection program in Teach-in Mode. Frontside and
backside are considered differently. For creating the mask and the contour, two pictures
of different elements are required. These elements must not show any defects.
1.2.2 Tasks Prior to First Use

If an element type is used for the first time, the Patmax must be trained first by means of
the skeleton. To do so, the core inspection program is loaded and the OK pictures are
loaded to operators 1 & 4. Exit the program > save. Teach Patmax(2) with the picture
loaded, exit program and save. Teach Patmax(5) with the loaded picture, exit the program
and save. Execute the entire program and save the skeleton picture. Remove the
ramifications from this picture (if present) and then repeat the loading and teach
procedure with the skeleton. This increases precision.
Frontside
In the Teach In dialogue, parameter set creat_front_1 is loaded.

In program steps 1 & 4 (the ImageFromFile operator) the pictures of the two elements
are loaded. Then the program is executed. If an element type is used for the first time,
perform the steps prior to first use described in paragraph 1.2.2. In program step 19
GenerateLineMask a contour is output (the crosspiece of this contour is cut). The
pictures CutContour and CutSkelet are selected in the right-hand display and saved by
means of the Save Picture buttons.
Touch-up tasks on the saved picture must be done manually using MS Paint.
The gaps to the left and to the right of the contour must be connected by a white line, so
that the contour is closed. If the mask for the Nop is not completely white, this must also
be changed manually.
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14.10.2010
Contour with gap
Closed contour
If there are small "hairs" on the contour, these must also be removed in order to obtain a
smooth contour.
Contour with errors
Contour after correction of errors
The picture of the closed and corrected contour is loaded to the ImageFromFile operator in
the creat_front_2 parameter set, the path for saving is indicated in operator
"ContourChainCode". Then the program is executed.
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14.10.2010
The contour code is saved automatically, the mask picture ("mask") is saved using the
"SavePicture" button.
Backside:
Mask and contour for Backside are created in two steps. First the parameter set creat_back_1
is loaded. The pictures of the OK elements are loaded to operators 1 & 4. Then the program
is executed. The CutContour and CutSkelet pictures are saved using the Save button, if
branches are present these must be processed in the same way as with the frontside
pictures.
Then the Contour picture is loaded to the creat_back_2 parameter set using ImageFromFile.
The path is entered in the ContourChainCode operator, then the program is executed. The
contour code is saved automatically, the mask picture ("mask") is saved using the
"SaveButton".
1.2.3 Integration of Mask and Contour into the Inspection Sequence

For the inspection program, the skeleton picture, the contour data file and the mask are
required.
Teaching of PatMaxOperator (1) is done using the CutSkelet skeleton picture. It is important
that the inspection program is saved immediately after teaching the operator. The mask
picture is loaded to operator 6 (ImageFromFile). The contour data file is loaded to
LoadContourChainCode.
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14.10.2010
2 Description of the CreateContour Inspection Program

2.1 Sequence
create_back_1
create_back_2
create_front_1
create_front_2
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14.10.2010
3 Description of the AnalyseContour Program Part

3.1 Sequence
Backside:
Frontside
3.2 Load Contour Chain Code

3.2.1 Function
Loading of the contour data file and provision of the contour points for the subsequent
operators.
Layout of the contour dataq file *.dat
X Coordinate
0 to 1024
20.05.2009
Y Coordinate
0 to 1024
ChainCode
0 to 7
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X standard
-1 to 1
Y standard
-1 to 1
14.10.2010
3.2.2 Description of the Parameters
The file to be loaded is selected by means of Load Chain Code.
3.2.3 Overview of Inputs and Outputs
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14.10.2010
3.3 Analyse Contour ROI

3.3.1 Function
It segments contour errors by means of up to 3 features (features can be de-selected). The
assignment to the "Chipped" or "Broken" groups is done manually by the operator.
3.3.2 Description of the Parameters
General Parameter
The output list can be deleted by means of the Delete Object List field. This is required only
for the first inspection step.
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14.10.2010
Graphic
Selection of the ROIFiltered ROI picture is done by means of the selection list on the
display.
The "GOO selection field allows viewing of search areas and edge points in the ROI picture.
The selection field Filter ROI Image allows viewing of intermediate pictures of the ROI.
Filter ROI Parameters

The FHS Median Ground fields allows for setting of the FilterHalfSize of the Median Filter,
which is used for determination of the background. The FHS Median Noise field allows for
setting of the FilterHalfSize of the Median Filter, which is used for reducing noise pixels.
With the "Theshold Binarize" the binarization threshold is increased.
Search Parameters
The Search Inside field allows for setting the area which is searched towards the inside
(within the element).
The Search Outside field allows for setting the area which is searched towards the outside
(outside the element).
NOTE With the GOO field the SearchRange search area can be displayed.
Fine Correction Parameters
The Search Dist field allows for setting the max. area (x ay) which may be correctd
(translation only).
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14.10.2010
Classification Parameters
The Object Type selection field allows to specify if Chipped or Broken objects shall be
searched.
Features:
These features are features which allow for segmentation of an object. There are three object
features.
1.
Hole
With the Hole feature, the contour is open (disrupted)
2.
Distance
With the distance Distance feature, the actual contour is further

away from the set contour than the allowed distance as specified in
Thres Distance
3.
N-Edges
With the N-Edges feature more than 1 contour point is detected at

the same spot
The features can be set as desired and are OR-linked. The following setting would make
sense:
Chipped:
Broken:
Hole / Distance / N-Edges (optional)

Hole
3.3.3 Overview of Inputs and Outputs
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14.10.2010
3.4 Classify Backside (New) / Classify Frontside (New)

3.4.1 Changes
Chipped and Broken classification is done exclusively by means of the object length. Preselection takes place in the Analyse Contour ROI inspection step.
20.05.2009
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Tanslated:
Nov. 2013
Big Impressions
Operating Instructions
Big Impressions Real Width Measurement
Customer:
VDT Bosch Tilburg
Order number:
Created:
Updated:
Valid for version:
RW/007229
07/03/2006
07/03/2006
V03-1-2

Haupteingang Opelstrae 1
Lieferanschrift Lanzstrae 2
Phone: +49 (0) 6227 / 3412- 0
Fax: +49 (0) 6227 / 3412- 9905
Created: March 2006
Page 1 / 9
Tanslated:
Nov. 2013
Big Impressions
Contents
1
Measuring Impressions Backside (up to Version V03-1-1) .................................... 3

1.1
Previous Impression Measurement ...................................................................... 3
1.2
Problem when Measuring the "Real" Width of an Impression .............................. 3
1.3
Solution Approach ................................................................................................ 3
2 Description of Operators and Inspection ................................................................ 4
2.1
Blob Image Output (Cognex Blob with BlobImage) .............................................. 4
2.1.1
Functional Method......................................................................................... 4
2.1.2
Description of Parameters ............................................................................. 4
2.2
Measuring the Width (CogMeasureBlob) ............................................................. 5
2.2.1
2.2.2
2.3
Classification (BackClassify) ................................................................................ 7
2.3.1
2.3.2
Created: March 2006
Page 2 / 9
Tanslated:
Nov. 2013
Big Impressions
1 Measuring Impressions Backside (up to Version V03-1-1)
1.1
Previous Impression Measurement
The previous classification was performed using area and length. The area
is shown using the contour profile (marked red), the length refers to the
rectangle with smallest possible dimension (marked green). The "real"
width shall be implemented as a further classification criterion.
1.2
Problem when Measuring the "Real" Width of an Impression
The width of an error cannot be determined exactly using the rectangle (shown green).
This effect is very distinct especially for crescent-shaped errors.
Crescent-shaped error example:
B1 = width determined using the rectangle
B2 = real width of the error
B1
B2
B2 is much smaller than the measured width B1.
1.3
Solution Approach
The principle axis is calculated for the impression to be measured. The edges of the
impressions are then searched perpendicularly to the principle axis. The "real" width can
now be calculated as approximation calculation.
A much more complex algorithm would have to be used to calculate the exact width of an
impression but this is not feasible due to the available machine time.
Approach: - Calculate a skeleton of the impression instead of the principal axis
- Scan the edges starting with the skeleton depending on the curvature
angle of the contour or skeleton
Created: March 2006
Page 3 / 9
Tanslated:
Nov. 2013
Big Impressions
2 Description of Operators and Inspection

2.1 Blob Image Output (Cognex Blob with BlobImage)
2.1.1 Functional Method
Status:
95% finished (production run still to be performed)
IP functions: Segmentation
Task:
This operator segments the impression image into background and

impressions which results in a blob image. The blob image results are stored
in a list.
Realization:
Segmentation of the background and impressions
Input: Impression image
Output: Blob image
2.1.2 Description of Parameters
Created: March 2006
Page 4 / 9
Tanslated:
Nov. 2013
Big Impressions
Segmentation:
Provides different selection options for the graphic
Connectivity:
Provides additional IP preprocessing work steps.
NEW: Min Area:
50 pixels
Morphology Operations:
Provides additional IP preprocessing work steps.
NEW: Close Square
2.2 Measuring the Width (CogMeasureBlob)

Status:
IP functions: Measurement
Task:
This operator tries to measure the width of each blob. The maximum and
minimum widths of the impression are calculated.
Realization:
Step 1
The principal axis is calculated for each blob segmented beforehand and then rotated so
that the principal axis runs parallel to the x-axis of the image (see images).
Y-axis
X-axis
Input: Blob image

Created: March 2006
Blob with principal axis indicated

Page 5 / 9
Tanslated:
Nov. 2013
Big Impressions
Y-axis
X-axis
Blob rotated accordingly so that the principal axis is parallel to the x-axis of the image
Step 2
The blob is scanned from above and below for each column along the x-axis. The
maximum and minimum widths of the blob are calculated from the scan values. To
visualize the results, the calculated widths as well as the first maximum width found are
indicated (see image).
Blob with widths (blue) as well as maximum width (orange) indicated
Step 3
Reverse transformation to visualize as blob image and camera image.
Output: Camera image with calculated widths visualized

Created: March 2006
Page 6 / 9
Tanslated:
Nov. 2013
Big Impressions
Graphics:
Provides two different selection options (Standard: FALSE)
TRUE:
FALSE:
Visualization shown
Visualization not shown, only the
maximum width is indicated
Results:
Representation of results
Max Width:
Mean Width:
Maximum width of a blob

Mean width of a blob
2.3 Classification (BackClassify)

Status:
IP functions: Classification
Task:
The operator classifies the impressions.
Created: March 2006
Page 7 / 9
Tanslated:
Nov. 2013
Big Impressions
Changing the classification:

The operator classifies the impressions found in two classes
1. OK
2. NOK
(no error)
(error)
The length and width are the classification characteristics (NEW).
Classification rule:
1. The maximum width is used (default = active)
Result = [ Length AND Width (Min) ] OR Width (Max)
(Min) = lower threshold (reduction of FalseReject through scratches)
(Max) = upper threshold (erroneous part when impression very wide)
2. The mean width is used (default = deactive)

Result = [ Length AND Width (Min Mean) ] OR Width (Max Mean)
(Min) = lower threshold (reduction of FalseReject due to scratches)
(Max) = upper threshold (error part if impression is very wide)
Created: March 2006
Page 8 / 9
Tanslated:
Nov. 2013
Big Impressions
Changing the measurement for GRR:
File layout:
Workpiece-ID, Station-ID, SPSCycle-ID, length, max. width, mean width...
Example:
28 ,0 ,12 ,4.3 ,0.48 ,0.33 ,3.2 ,0.27 ,0.15 , timestamp
Designation
Workpiece-ID
Station-ID
SPSCycle-ID
Object 1: Length
Object 1: Maximum width
Object 1: Mean width
Object 2: Length
Object 2: Maximum width
Object 2: Mean width
Timestamp
Created: March 2006
Value
28
0
12
4.3
0.48
0.33
3.2
0.27
0.15
Page 9 / 9
Value range
Serial number
1-6
0 - 15
05.07.2010
Bedienungsanleitung
User manual
SaddleEdge Improvement
( One Image )
Kunde:
VDT Bosch Tilburg
Auftragsnummer:
Erstellung am:
Aktualisiert am:
Gilt fr Version:
14333
23/06/2010
05/07/2010
V06-0-1
Rohwedder AG
Vision Technology
Kesselbachstr. 1
88697 Bermatingen
Tel.: (0 75 44) 502-100
Fax: (0 75 44) 502-271
www.rohwedder.com
05.07.2010
Seite 1/7
05.07.2010
Bedienungsanleitung
Inhaltsverzeichnis
Check sequence ....................................................................................................... 3
Description Operators .............................................................................................. 4

2.1
Cognex FindLineSegment ................................................................................ 5
2.1.1
Function........................................................................................................ 5
2.1.2
In/Outputs..................................................................................................... 5
2.2
FindSaddleEdgePoints (OneCam).................................................................... 6
2.2.1
Function........................................................................................................ 6
2.2.2
Parameter..................................................................................................... 7
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05.07.2010
Bedienungsanleitung
1 Check sequence
1.
Cognex FindLineSegment
Elementedge search and determine
(Coarse search)
Input/Output
Image
Edgeline (LineSegment)
2.
FindSaddleEdgePoints (One Cam)

Elementpoints search and determine
(Fine search)
Input/Output
Image
Global Properties
Pointlist of edge
3.
MeasureSaddleEdge (One Cam)

Edgeobjects search and measure
(Segmentation and Measuring)
Input/Output
Image
Pointlist of the edge
Global Properties
Resolution of the camera in X and Y-direction (Calibration)
List of the Edgeobjects (Segmentation)
4.
ClassifySaddleEdge
Edgeobject classification
(Classification)
Input/Output
Image
List of the edgeobjects
Global Properties
Result
05.07.2010
Seite 3/7
05.07.2010
Bedienungsanleitung
2 Description Operators
In the following description only the changes are explained, which are caused of reducing
from two cameras to one camera. For further information look to description
Bedienungsanleitung_SaddleEdge-Verbesserung.
Two camera
05.07.2010
One camera
Seite 4/7
05.07.2010
Bedienungsanleitung
2.1 Cognex FindLineSegment

2.1.1 Function
The operator is similar as the Operator Cognex FindLine. It only differ in the result. This
operator compute the segment of the founded line. That means, the line have a start- and
endpoint. The line is limited with the search line, showed in next image.
Startpoint
Endpoint
Attention: When you reduce the search line in this operator you also reduce the search
region in the following operators, look to the next sections.
2.1.2 In/Outputs
05.07.2010
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05.07.2010
Bedienungsanleitung
2.2 FindSaddleEdgePoints (OneCam)

2.2.1 Function
The operator is similar as the Operator FindSaddleEdgePoints. It includes the same
functions only a checking method for the element position was added.
Position of the Element is OK, the element-line (blue line) is above the nest-line (red line)
Position of the Element is NOK, the element-line is below the nest-line
05.07.2010
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05.07.2010
Bedienungsanleitung
2.2.2 Parameter
Position Check Settings:

Check the position of the element
With the parameter Thres Y you adjust the virtual nest-line in the y position. If the
element-line intersect the virtual nest-line the position of the element is wrong. You can
activate or deactivate this check.
With the element end you can also check the position of the element. When two ends are
detected the element position is OK. When one end is detected the element position is
NOK. When no end is detected the nest is empty. You can activate or deactivate this
check.
05.07.2010
Seite 7/7
Gap Measurement
Operating Manual
Gap Measurement
Client:
VDT Bosch Tilburg
Version Admin:
Version BV-Server:
from V06-0-0
from V07-0-2
Rohwedder Macro Assembly GmbH I Vision Technology

Kesselbachstr. 1 I 88697 Bermatingen I Germany
T +49 75 44 502-0 I F +49 75 44 502-271
All rights, including translation rights, reserved. No part of this publication may be reproduced in any form (print, copy, microfilm
or any other process) without the written permission of Rohwedder Macro Assembly GmbH or using electronic systems, be
processed, copied or distributed.
September 2011
Page 1/15
Gap Measurement
Contents
1
2
Description................................................................................................................. 3
Operators and Testing .............................................................................................. 4
2.1
Rough determination of element head edges (Cognex FindLineSegment
) ... 4
2.1.1
Operation ...................................................................................................... 4
2.1.2
Description of the parameters ....................................................................... 5
2.1.3
Overview of In- and Output ........................................................................... 7
) ..................................... 8
2.2
Rotation of the image (RotateByLineSegmentAngle
2.2.1
Operation ...................................................................................................... 8
2.2.2
2.2.3
Overview of In- and Output ........................................................................... 9
2.3
Measuring the gap (SaddleEdge MeasureRift
) .............................................. 9
2.3.1
Operation ...................................................................................................... 9
2.3.2
2.3.3
Overview of In- and Output ......................................................................... 13
2.4
Classification (Classify SaddleEdge
) ........................................................... 14
2.4.1
Operation .................................................................................................... 14
2.4.2
Description of the parameters ..................................................................... 14
2.4.3
Overview of In- and Output ......................................................................... 15
September 2011
Page 2/15
Gap Measurement
1 Description
In this documentation, the new test "gap measurement" for stations 2 & 3 of the element
system, is described.
This test is to separate those elements whose distance from the SaddleEdge to the head
of the element is too big.
To this end, three operators were inserted into the test sequence and the classifier was
amended.
New operators in the test sequence
Brief overview of the new sections of the test:

Firstly, the edge of the element head is located with the use of a Find-Line tool (similar to
the 001 operator, where the SaddleEdge is sought). The camera image is rotated, based
on the information of the location of the SaddleEdge, so that it lies horizontally in to the
image. At the SaddleEdge, Calipers are placed at a parameterizable distance from each
other and the distance from the SaddleEdge to the element head is determined. The
smallest distance will be passed on to the classifier, which checks whether the distance
meets a predetermined value.
Below, the individual operators and their functions will be explained.
September 2011
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Gap Measurement
2 Operators and Testing

2.1
Rough determination of element head edges (Cognex FindLineSegment
2.1.1 Operation
Image processing scope: Detection
Task:
Rough determination of the element head edge
Realization:
Probing with the Find-Line tool
Find-Line tool lined up with the edge of the element head
September 2011
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Gap Measurement
Located Line-Segment (depicted in green)
The operator scans the upper edge of the element head with the aid of edge locators
(calipers). A straight line (line segment) is generated, using the located points or edge
transitions.
2.1.2 Description of the parameters
September 2011
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Gap Measurement
Important Parameters:
Number of Calipers:
Number of edge locators (calipers) used to find the element head edge
Default value: 15
Search Length:
Length of the edge locators (calipers) along the search direction

Default value: 400
Projection Length:
Width of the edge locator (caliper)

Default value: 20
Number to Ignore:
Number of located points which are not used for the straight line calculation
Default value: 3
September 2011
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Gap Measurement
Edge Mode:
Mode: Finding one or more edge transitions
Default value: Single Edge
Edge 0 Polarity:
Edge transition from black to white or vice versa
Default value: Light to Dark
Contrast Threshold:
Threshold for the minimum contrast which an edge must have
Default value: 20
Filter Half Size Pixels:
Indicates the size of the filter
Default value: 10
2.1.3 Overview of In- and Output
September 2011
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Gap Measurement
2.2
Rotation of the image (RotateByLineSegmentAngle
2.2.1 Operation
Image processing scope: Geometric transformation
Task:
Rotation of the image
Realization:
It is the operators task, to rotate the object, so that the SaddleEdge of the input image is
horizontal (see pictures below). The angle of rotation, stems from the Line-Segment of the
SaddleEdge (determined by the operator Idx. 001). The original image is not changed
during this operation, as a new image is created.
Optionally, the angle (in radians) by which the image is rotated, is output as a variable.
Camera image
Rotated camera image

There are no adjustable parameters available.
September 2011
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Gap Measurement
2.3
Measuring the gap (SaddleEdge MeasureRift
2.3.1 Operation
Image processing scope: Measuring
Task:
Measuring the minimum distance between the SaddleEdge

and head of an element
Realization:
The operator measures the distance between various points between the SaddleEdge
and the head of the element. The minimum distance is filtered from the results of the
measured points and are output for further analysis.
Parameter: RVT Params:

September 2011
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Gap Measurement
Graphic:
Default value: Basic
Basic: Nothing is shown in the image.

CaliperRegions: The regions where the gap will be measured is shown (see
image below).
Measured Values: The located edges of the gaps are shown, as well as the result
in pixel of each measured section (see image below).
September 2011
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Gap Measurement
Zoomed extract of image
Note: All the previously mentioned objects will only be shown in the image, if you are
located in the operator, i.e. not during inspection.
Caliper Settings:
Number:
Number of calipers that are used to measure the gap.

Default value: 25
Width:
Width of the caliper in pixel.

Default value: 25
Height:
The height of the calipers is determined by the two Line-Segments.
However, as they are directly over the transition edge, they must be enlarged. The
parameter specifies a percentage factor by which the amount the height of the
caliper is increased.
Default value: 30
Caliperlist: Displays the measurement results of the individual calipers in pixels.

In addition, individual results of the calipers can be viewed, by marking the
appropriate caliper and then switching to the tab "Cognex Params"
September 2011
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Gap Measurement
Parameter: Cognex Params:
Edge Mode:
Mode: Finding one or more edge transitions
Default value: Edge Pair
Edge 0 Polarity:
Default value: Dark to Light
Edge 1 Polarity:
Default value: Light to Dark
Edge Pair Width:
The distance which must be present between the two edges ( in pixel ).
Default value: 400
September 2011
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Gap Measurement
Contrast Threshold:
Threshold for the minimum contrast which an edge must have
Default value: 50
Indicates the size of the filter
Default value: 25
Maximum Results:
Maximum permissible valid results.
Default value: 1
September 2011
Page 13/15
Gap Measurement
2.4
Classification (Classify SaddleEdge
2.4.1 Operation
Image processing scope: Classification
Task:
Via the operator, the thresholds for all classification features

can be parameterized
Format of the classification:

On the basis of the classification threshold, the operator calculates whether it is an IO or a
NIO part:
1. I.O. (no errors)
2. N.I.O. (errors)
Newly added classification feature:
-
The minimum size of the gap between the SaddleEdge and the
element
Rift Settings
September 2011
Page 14/15
Gap Measurement
Active: Switching gap measurement on or off

Default value: TRUE
Classification threshold: Minimum gap ( in mm )

Default value: 3.000
September 2011
Page 15/15
Translated:
Nov. 2013
Nop Inspection Station 5
User's Manual
Customer:
VDT Bosch Tilburg
Order number:
Version:
30007776
As from V03-2-3
Haupteingang Opelstrae 1
Lieferanschrift Lanzstrae 2
Fon: +49 (0) 6227 / 3412- 0
Fax: +49 (0) 6227 / 3412- 990
Created: June 2006
Translated:
Nov. 2013
Contents
1
Detecting Nop Damage (up to V03-2-2) ................................................................... 3

1.1
Task ..................................................................................................................... 3
1.2
Previous Detection of Nop Damage ..................................................................... 3
1.3
Solution Approach ................................................................................................ 3
2 Description of Operators and Inspection ................................................................ 4
2.1
Measuring the Nop Circle (Measure Nop
) ...................................................... 4
2.1.1
2.1.2
2.1.3
Inputs and Outputs Overview ........................................................................ 6
2.2
Classification (Classify Frontside
) .................................................................. 7
2.2.1
2.2.2
2.2.3
Inputs and Outputs Overview ...................................................................... 11
Created: June 2006
Translated:
Nov. 2013
1 Detecting Nop Damage (up to V03-2-2)

1.1 Task
Detection of nop damage using the surface (compare with Impression), roundness and
radius. Detection runs on Station 5 parallel to impression, chipped und broken
inspections.
1.2
Previous Detection of Nop Damage
In previous versions to detect nop damage, a masked area of the

nop was examined for impressions and these then classified
according to length and area. According to VDT Bosch, nop
damage is often characterized by the fact that the nop no longer
has an ideal round shape. For this reason, a new classification
parameter is to be implemented to evaluate the nop for
roundness. A further check should examine the radius resp.
diameter of the nop and compare it against a reference value. This should also detect and
exclude, for example, nops pressed flat showing no impressions at all and that are round
as well.
1.3
Solution Approach
Roundness:
Circular edge searchers, so-called calipers, are laid in the nop area. These scan the edge
of the nop from the inside to the outside and find the edge points for the inner nop circle in
this manner (found circle). These interpolation points serve to approximate a best circle.
The shape characteristic roundness is calculated using the difference between these two
circles.
Radius:
The "best circle" approximated in the previous Section is used to check the radius of the
nop.
Created: June 2006
Translated:
Nov. 2013

2.1
Measuring the Nop Circle (Measure Nop

IP functions: Measurement
Task:
Measure the inner nop circle and calculate the roundness.
Realization:
Measuring the nop
Input: Caliper to scan the NOP Output: Result as graphic:

- Unbroken line (best circle)
- Single crosses (found circle)
This operator scans the inner rounding of the nop with edge searchers (calipers). A best
circle is calculated from the caliper results. The individual differences between the
calculated "best circle" and the actual "found circle" are squared and added together and
then the root taken. The result is regarded as roundness (shape factor).
Roundness =
Radius bestcirclei Radius foundcirclei

i
Created: June 2006
Translated:
Nov. 2013
Important parameters:
Number of Calipers:
Number of round-shaped edge searchers arranged in the nop
Default value: 25
Search Length:
Length of the edge searcher in search direction
Default value: 60
Projection Length:
Width of the edge searcher
Default value: 10
Created: June 2006
Translated:
Nov. 2013
Important parameters:
Edge Mode:
Mode: Search one or more edge transitions
Default value: Single Edge
Edge 0 Polarity:
Default value: Dark to Light
Contrast Threshold:
Threshold for the minimum contrast the edge must show
Default value: 30
Specifies the filter size
Default value: 10
2.1.3 Inputs and Outputs Overview
Created: June 2006
Translated:
Nov. 2013
2.2
Classification (Classify Frontside

IP functions: Classification
Task:
Set the parameters for thresholds for all classification characteristics using
the operator.
Classification layout:
This operator uses the classification thresholds to check whether the part is an OK or
NOK part:
1. OK
(no error)
2. NOK (error)
The classification characteristics used are:
-
Created: June 2006
Size of impressions on the element front side

Size of impressions in the nop area
Roundness of the nop
Diameter of the nop compared with a default value
Contour inspection Broken
Contour inspection Chipped
Translated:
Nov. 2013
Parameters Impression Params:

Graphic:
Graphic mode: Show error objects or all found objects
NEW Default value: 1. Failure Objects
Remark:
No changes to remaining parameters.
Created: June 2006
Translated:
Nov. 2013
Parameters NOP Params:

General Settings: Inspection NOP:
Switch nop inspection on or off
Default value: TRUE
NOP-Impression Settings: Min. Size [mm]:
Classification threshold nop impression length
NOP-Impression Settings: Min. Area [mm]:
Classification threshold nop impression area
NOP-Roundness Settings: Inspection Roundness:
Switch nop inspection with roundness check on or off
NEW Default value: TRUE
Created: June 2006
Translated:
Nov. 2013
NOP-Roundness Settings: Round. [RMS]:

Threshold value nop roundness
NEW Default value: 1.25
NOP-Radius Settings: Inspection Radius:
Switch nop inspection with radius check on or off
NEW Default value: TRUE
NOP-Radius Settings: Radius [pixels]:
Classification threshold nop radius
Average radius value in pixels of the respective element type
NEW Default value: 24-element: 27 pixels
NEW Default value: 30-element: 32.6 pixels
NOP-Radius Settings: Tolerance [pixels]:
Classification threshold nop radius
Tolerance band within which average values can deviate
Example: 3 pixels for 24-element 27 pixels 3 pixels
NEW Default value: 2 pixels
Created: June 2006
Translated:
Nov. 2013
Parameters Broken and Chipped Params:

Remark:
No changes to parameters.
Created: June 2006
14.07.2010
SaddleSurface Station 6
Users Guide
SaddleSurface
Customer:
VDT Bosch Tilburg
Order Number:
Version:
Revision:
30008431
ab V04-0-0
2008.11.06
T +49 75 44 95 93-0 I F +49 75 44 95 93-88
14.07.2010
Page 1/45
14.07.2010
Contents
Fault Specification.....................................................................................................4
1.1
General Conditions...............................................................................................4
1.2
Fault Types ..........................................................................................................4
2 SaddleSurface Improvements ................................................................................12
2.1
Task ...................................................................................................................12
2.2
HW Layout .........................................................................................................12
2.3
Inspection Program Sequence ...........................................................................13
3 Description of Operators and Inspection ..............................................................16
3.1
Find SaddleSurface............................................................................................16
3.1.1
Functional Method.......................................................................................16
3.1.2
Description of Parameters...........................................................................16
3.1.3
Inputs and Outputs Overview ......................................................................17
3.2
Surface Filtering .................................................................................................18
3.2.1
3.2.2
3.2.3
3.3
Saddle Surface Equalize ....................................................................................26
3.3.1
3.3.2
3.3.3
3.4
Cognex Blob.......................................................................................................30
3.4.1
3.4.2
3.4.3
3.5
Convex Outline...................................................................................................32
3.5.1
3.5.2
3.5.3
3.6
Convex Mask IPP...............................................................................................33
3.6.1
3.6.2
3.6.3
3.7
Analyse Contour.................................................................................................34
3.7.1
3.7.2
3.7.3
3.8
Analysis Surface.................................................................................................37
3.8.1
3.8.2
3.8.3
3.9
Connect Surface/Contour...................................................................................39
3.9.1
3.9.2
1
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3.9.3
3.10 Find Asperity ......................................................................................................40
3.10.1 Functional Method.......................................................................................40
3.10.2 Description of Parameters...........................................................................41
3.10.3 Inputs and Outputs Overview ......................................................................42
3.11 Classify SaddleSurface ......................................................................................44
3.11.1 Functional Method.......................................................................................44
3.11.2 Description of Parameters...........................................................................44
3.11.3 Inputs and Outputs Overview ......................................................................45
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1 Fault Specification
1.1 General Conditions
1. The saddle surface must be constantly free of dirt otherwise the fault detection
may not work properly.
2. It must be possible to differentiate faults over sufficient contrast from the
background.
3. The fault size must be clearly specified:
a) The fault area must always exceed 0!
b) The fault dimension must always ( at least in one dimension ) exceed the
disturbing textures (rolled texture)!
1.2 Fault Types

Type
Fault description
Statistic description
Impression/Abriss: reject
Abriss / Impression
Impression/Abriss: Erlenmeyer Effect
Abriss / Impression
3
4
5
Impression/Abriss: Flat faults ( in the rounding only partly )

Rounding: Inspection to the end of the saddle ( change of radius is not
detected )
Einriss
Asperity
Width measurement ( rejection of filler elements )
14.07.2010
Abriss / Impression
Auenriss
Einriss
Asperity
Page 4/45
Width
14.07.2010
1. Impression/Abriss: Reject
X Mean
Z Rect
X Open
X Rect
Limits:
X-Rect
Z-Rect
X-Open
X-Mean
Contrast
Asperity
Reject Limit
> 4.0 mm
> 0.5 mm
--AND
> tbd
> 40
?
Accept. Limit
< 0.2 mm
< 0.2 mm
--< tbd
< 40
?
OR
Classification:
Abriss is detected when ( X-Open > 0 ) AND ( X-Open top )
Impression is detected when
( X-Open > 0 ) AND ( X-Open bottom )
Range:
Abriss and Impression are detected within the red search area.
Caution: Intersection to the blue search area Abriss respectively Impression
Abriss / Vorriss
Rounding
X-Curve
Value
1,0 mm
X-Curve
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14.07.2010
2. Impression/Abriss: Erlenmeyer Effect

X Rect
X Open
X Mean
Z Rect
Limits: see 1. Impression/Abriss: Rejects

Classification: see 1. Impression/Abriss: Rejects
Range: see 1. Impression/Abriss: Rejects
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3. Impression/Abriss: Flat fault
Rounding
Z Rect
X Mean
X Rect = X Open
Flat inclined faults are not detected in the rounding range. Due to the production flow, the
contour gradient in this range is subject to wide variation.
Limits: see 1. Impression/Abriss: Reject

Classification: see 1. Impression/Abriss: Rejects
Range: see 1. Impression/Abriss: Rejects
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4. Rounding: Inspection Auenriss ( Change of radius is not detected )
Z Rect
Z Rect
L Open
L Open
Depth
X Rect
X Rect
Limits:
X-Rect
Z-Rect
L-Open
Depth
Contrast
Asperity
Reject Limit
> 0.4 mm
> 0.4 mm
> tbd
AND
> none
> 40
?
Accept. Limit
< 0.2 mm
< 0.2 mm
< tbd
none
< 40
?
OR
Classification:
Auenriss is detected when
( L-Open > 0 )
Range:
The Auenriss is detected within the blue search area.
Caution: Intersection to the red search area no Auenriss but Abriss respectively
Impression
Rounding
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Abriss / Vorriss
Page 8/45
14.07.2010
5. Einriss
Z Mean
Z Rect
X Rect
Limits:
X-Rect
Z-Rect
Z-Mean
Contrast
Asperity
Ratio X/Z
Reject Limit
> 4.0 mm
> 0.4 mm
AND
> tbd
> 40
?
Accept. Limit
<
<
<
<
?
0.2 mm
0.2 mm
tbd
40
Classification:
Einriss is detected when a connection to the outer edge is inexistent.
Range:
Einriss is detected within the blue and red search area.
Rounding
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Abriss / Vorriss
Page 9/45
OR
14.07.2010
6. Asperity
Z Rect
X Rect
Limits:
X-Rect
Z-Rect
Flche
Contrast
Asperity
Reject Limit
> 0.005 mm
> 0.005 mm
AND
>0.020 mm
> 40
?
<
<
<
<
?
Accept. Limit
0.002mm ?
0.002mm ?
OR
0.010 mm ?
40
Range:
Asperity is detected within the blue and red search area.
Rounding
14.07.2010
Abriss / Vorriss
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14.07.2010
Exception:
Remark: Will be detected most likely in the red search area as flat Impression/Abriss fault
Dirt
Remark: Additional classification characteristic(s) is/are necessary

e.g. edge asperity, contrast gradient etc.
Rolled texture
Remark: Accepted Limit must exceed the rolled textures
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14.07.2010
2 SaddleSurface Improvements
2.1 Task
Detection of SaddleSurface faults at IP station 4, see as well chapter Fault Specification.
2.2 HW Layout
No modification necessary.
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14.07.2010
2.3 Inspection Program Sequence

1. Find SaddleSurface
Position determination (rotation and start point), width measurement
(Preprocessing)
Inputs/outputs
Camera image
LineSegment
Global Params
Width
Abort
2. Surface Filtering
Refining of the input image, orient horizontal, ROI-generation
(Preprocessing)
Inputs/outputs
Input image
LineSegment
Width
GlobalParams
ImgRot
ImgRotFilterMedian
ImgRotFilterHighP1
ImgRotFilterHighP2
ImgMask
Trafo
PointOutside
Length
3. Saddle Surface Equalizer
Brightness equalization (Preprocessing)
Inputs/outputs
ImgRotFilterMedian
ImgRot
ImgMask
ImgRotMedianEqual
ImgRotEqual
4. Cognex Blob (Segmentation)
Inputs/outputs
ImgMask
BlobMask
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14.07.2010
5. Convex Outline
Calculate convex cover
(Preprocessing)
Inputs/outputs
ImgRot
BlobMask
ConvexPolygon
Polygon
6. Convex Mask IPP
Calculate convex mask
(Preprocessing)
Inputs/outputs
ConvexPolygon
ImgRot
ImgMaskConvex
7. Convex Mask IPP
Calculate contour mask
(Preprocessing)
Inputs/outputs
Polygon
ImgRot
ImgMaskContour
8. Analyse Contour
Calculate contour objects
(Segmentation)
Inputs/outputs
ImgRot
ImgMaskConvex
ImgMaskContour
Polygon
ConvexPolygon
PointOutside
Calibration data
GlobalParams
ContourList
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9. Analysis Surface
Define surface objects
( Segmentation )
Inputs/outputs
ImgRotEqual
ImgRotMedianEqual
ImgMaskConvex
SurfaceList
10. Connect Surface/Contour
Summarize contour and surface objects
( Segmentation )
Inputs/outputs
ImgRot
SurfaceList
ContourList
ConnectList
11. Find Asperity
Summarize contour and surface objects
( Segmentation )
Inputs/outputs
ImgRot
Calibration data
ImgRotFilterHighP1
ImgRotFilterHighP2
ImgMaskConvex
Width
AsperityList
12. Classify SaddleSurface
(Classification)
Inputs/outputs
Camera image
Calibration data
Trafo
AsperityList
ConnectList
Width
Length
Result
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14.07.2010

3.1 Find SaddleSurface
IP function: Presence control, position determination
Task:
Realization:
This operator calculates the rotation and the start point of the saddlesurface.
In a first step the direction ( Rotation ) of the saddle surface is specified by
means of a linefit and the Element width is determined. The start point
(Point outside) is defined in the second step.
Graphic:
No alternative
General Settings:
Selection of element type and camera
The selection box SearchType serves to select the element type.
The selection box Search Direction serves to select the camera.
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Remark: The settings are saved as GlobalParams, so the information can be used by
following Operators.
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3.2 Surface Filtering

IP function: Preprocessing
Task:
The Operator calculates the rotated ROI-image, the median image, the
high-pass image, the mask image and the element length.
Realization:
In this Operator all filter functions which are necessary for the program run
are effected.
Rotated ROI image:

Input image
The input image is reduced (ROI = Region of Interest) and rotated. Every
following calculation is effected on the basis of this image or from the
images derived.
Median image:
Rolled textures are filtered out by median filtering ( vertical textures )
High-pass images:
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Horizontal texture transitions are displayed via high-pass filter. The direction
of the edge transitions is considered and displayed inverse in both images.
High-pass image 1:
Edge transitions from dark to bright are displayed bright.
High-pass image 2:
Edge transitions from bright to dark are displayed bright.
Mask image:
The mask image is calculated from the median image ( Rolled textures have
no effect on the mask). The target is to generate a mask which separates
the background clearly from the saddle surface. However, dark faults shall
be masked additionally, i.e. be black in the mask image.
Local histogram threshold:

Since the proper mask calculation is crucial for the following calculations,
great importance has been attached to this range.
It is necessary to calculate various local thresholds for a clear separation of
the object from the background, i.e. if necessary even per pixel. A global
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binarization threshold for the complete image cannot equalize differences in

brightness on the object, see example.
Example:
Rotated input image
Globale Binarisierungsschwelle
Global threshold
Histogram threshold
By means of the
histogramm the image is
evaluated segment by
segment and the
binarization threshold is
calculated.
Threshold image
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14.07.2010
Settings Median:
Settings for the calculation of the median image
The filter sizes are set with the two Median X boxes. Since the indication is made in
pixel and corresponds to the half filter size (FilterHalfSize), it is possible to state the
filtered out texture width directly in pixel. For example, if a vertical texture with a width of
up to 10 Pixel ( = 0,11 mm ) shall be filtered out, then the Median X must be set to not
less than 10.
The median filtering is subdivided into 2 sections:
1. Range Outside (see yellow box)
2. Range Inside (see blue box)
Therefore different filter sizes may be used for both ranges. As a result rolled texture
which, depending on production, occurs more often in the inner range, can be filtered out
better ( see example ).
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Example:
Input image
Settings: MedianX ( Outside ) = 10 / MedianX ( Inside ) = 10
Settings: MedianX ( Outside ) = 10 / MedianX ( Inside ) = 15
Rolled texture
existent
Rolled texture
filtered out
The Inside Size X box specifies the factor of the range Inside expressed as a
percentage of the total length, e.g. 0,3 = 30% of the total length.
The Median Y box reduces the effect of horizontal textures. Due to the calculation time
the value should not exceed 5.
Settings Mask:
Settings for the mask calculation
Histo Width
Steps = 10
Histo
Height
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14.07.2010
Binarization threshold (calculated column by column, interim value linear interpolated)

The Thres. Range box specifies the position of the binarization threshold relative to the
histogram maxima. The binarization threshold adjusts itself dynamically to the brightness
gradient of the saddle surface and the background, see example:
Histogram
range
Histogram
Max.
Background
Max.
SaddleSurface
Thres. Range
of e.g. 30%
Quantity
Binarization
threshold
255
Grey-scale
value
The Fill Length box fills in the inner border area of the mask ( designation is made in
Pixel ).
Point Inside
Original mask
Fill Length
Filled in mask
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14.07.2010
Settings Border Points:

Settings for the calculation of Point Inside and Point Outside
The Thres Horz box serves to affect the position of the inner and outer point (Point
Inside/Outside) Remark: The mask generation is also affected, see Fill Length.
The calculation is made via a relative consideration of the grey scale value, i.e. in
calculating the X-coordinate of the inner and outer point the position is found, when the
grey scale value has reached the background brightness + Thres Horz.
Example:
In the lower image the background brightness is of
Inside
Outside
= 53
= 51
the Thres Horz is set to

Thres Horz = 35
so the grey scale value for the edge transition (X-coordinate) is of
Point Inside
Point Outside
14.07.2010
= 53 + 35 = 88
= 51 + 35 = 86
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3.3 Saddle Surface Equalize

Task:
The Operator equalizes the irregularities in the brightness gradient, dark

faults remain unchanged. The target is to simplify the calculation of the
following steps and to reduce the FalseReject.
Realization:
The visible surface brightness of the saddle surface originates from the
combination of various surface characteristics and environmental
conditions, e.g. :
Faults
Textures (rolled texture)
Lighting gradient (shadow / reflection)
Surface roughness
Dirt
Figure
On the detection of faults it is crucial that they are definitely distinguishable

from the environment using the grey scale value. The difference may
become insufficient due to effects like illumination gradient, dirt, etc.
Therefore it is very important to filter these interfering surface effects out,
see example.
Original image / equalized image
Median image / Median equalized image
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Changes in brightness which interfere the detection are brought to a

defined standard brightness by means of various filtering steps, i.e. areas
which are darker than the standard brightness are lifted and areas which
are brighter are lowered. The standard brightness should be in the middle
of the grey scale value ( = 128 ).
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The Subsampling Factor box serves to specify the subsampling factor.

The Median Filter Half Size box serves to set the filter size. Since the indication is
made in Pixel and corresponds to the half filter size (FilterHalfSize), it is possible to state
the filtered out texture width directly in Pixel.
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3.4 Cognex Blob

IP function:
Presence control, Position determination
Task:
The operator calculates the rotation and the start point of the saddle surface.
Realization:
In a first step the direction ( Rotation ) of the saddle surface is defined via a
line fit and the element width. The start point (Point outside) is defined in
the second step.
Graphic:
No alternative
General Settings:
Selection of element type and camera
The selection box SearchType serves to select the element type.
The selection box Search Direction serves to select the camera.
Remark: The settings are saved in GlobalParams, so the information can be used by
following operators.
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14.07.2010
3.5 Convex Outline

Task:
Realization:
The operator calculates the convex outer contour of the saddle surface, i.e.
contour damages are selected.
The contour gradient is extracted over the Blob of the afore defined mask.
The convexe cover is calculated from the contour gradient by means of an
appropriate method.

No parameters necessary
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3.6 Convex Mask IPP

Task:
The operator calculates the mask from the convex cover.

Convex cover
Mask

Inexistent Parameters
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3.7 Analyse Contour

IP function:
Segmentation, classification
Task:
The operator segments the contour faults.
Realization:
The definition of the contour faults is realized by comparing the masks.

Thereto both masks(contour and convex contour) are set against each
other.
Rotated input image
Convex mask
Contour mask
Difference between both of the masks
The Blob Tool defines the contour faults from the differential image.
Result: Segmentated contour fault
The blue and red range is used for the classification.

In the blue range the objects are classified only as Auenrisse.
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In the red range the objects are classified as follows:

Abriss is detected when an object is situated at the upper contour.
Impression is detected when an object is situated at the lower contour.
RVT Params:
The X-Curve box serves to set the range for the Auenriss
Segmentation:
Parameter see CognexBlober
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3.8 Analysis Surface

IP function: Segmentation, classification
Task:
The operator segments the surface faults.
Realization:
The definition of the surface faults is realized by rough/fine search. Thereto

the rotated and equalized input image is Median filtered and serves to a
rough definition of surface faults, i.e. fault existent or not existent.
Rough search
The surface faults are measured by means of fine search. However, the
existing texture and dirt may cause pseudo detections.
Fine search
Segmented objects (masked background)
Therefore the results are linked with the rough search UND in order to
select the pseudo objects without changing the measuring result for the
worse.
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RVT Params:
The Erode box serves to reduce the mask, i.e. the masked range (background and
contour range) can be adjusted.
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3.9 Connect Surface/Contour

IP functions: Segmentation, classification
Task:
The operator links the detected contour objects with the surface objects. As
a result a definite classification is realized.

Inexistent parameters
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3.10 Find Asperity

3.10.1
Functional Method
IP-functions: Segmentation, classification

Task:
The operator segments and classifies the Asperity faults.
Realization: A multilevel procedure is implemented to detect the asperity faults in order to

reduce the pseudo detection as far as possible.
In a first step the input image is vertically high-pass filtered and an image is
genereated for each direction.
In a second step the possible edge transitions are independently segmented

for both directions, see blue and yellow rectangle.
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In a third step pairs are searched, i.e. a positive (yellow) and a negative
(blue) edge transition form a pair if they match in a specified assembly.
Should this be the case a new search region (ROI), in which both edge
transitions are located, will be defined.
In a fourth step a bright Object is searched for in the ROI. Since the
parameter settings take dynamically place it is not necessary to make
manual settings. The found object is classified via characteristic vectors, see
Settings Small.
3.10.2
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Description of Parameters
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Setting Mask:
The Erode box serves to reduce the mask, i.e. thereby the masked area (background
and contour area) can be adjusted.
Settings Big Asperity:
The Area box serves to specify the area where a Big Asperity can be found. If a Big
Asperity is found, it is checked after the second step whether a significant edge transition
is present in the upper range of the saddle surface.
The Search Length Y box serves to specify the height of the search area.
Settings Small:
The Area (virtual) box serves to specify the minimum area of the Asperitys. Virtual
means that the area depends on the contrast. The higher the contrast, the higher the area
is to be weighted.
The Contrast box serves to specify the minimum contrast.
The Elongation box serves to specify the maximum proportion (Width/Height).
The Contour Outside box serves to specify the maximum luminosity of the
environment. The calculation is carried out with a 2 pixel distance to the object contour.
3.10.3
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Inputs and Outputs Overview

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3.11 Classify SaddleSurface

3.11.1
Functional Method
IP fuctions: Classification
Task:
The operator classifies the segmented objects.
3.11.2
Description of Parameters
Reject Limit:
Accepted Limit:
If a value is exceeded, a NIO classification takes place.

If a value is under-run, a IO classification takes place.
Remark:
The Accepted Limit exceeds the Reject Limit
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3.11.3
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Inputs and Outputs Overview
Page 45/45

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Technical Documentation

Element Inspection (AOI)

Rohwedder Micro Assembly GmbH

Element Inspection (AOI)

Vision Control (Visio Self-test)

Stone Detection in Station 1

Chipped and Broken - Creation of Masks and

Big Impressions Real Width Measurement

Saddle Edge Improvement (One Image)

Element Inspection (AOI)

VDT Bosch Tilburg

Rohwedder AG I Vision Technologies

Reference Run and Control Run Settings ..........................................................4

Control Run Sequence .........................................................................................5

Remote Data Access ............................................................................................9

VisionControl is performed during the ongoing inspection. It is not necessary to terminate

1.1 Reference Run and Control Run Settings

1.2 Control Run Sequence

Stop the equipment (stop after cycle)

The results of the individual cameras are shown per station (1 - 6)

Sequence for evaluation of the control results

1.3 Control and Reference Data

The folder is named as follows:

Example file Measurements_S1_C1.csv

Tolerances and Nominal

The "Nominal_Inspection_XX-XX.txt" file contains the nominal values, these are

Tol(-) = Min. tolerance

= "Nominal value" + "Min. tolerance"" = - -49.686

Switch to the "Control run" screen (change user "System")

The Calibration screen has several operating and display elements

2.2 New Vision Operators

Grey value course

Distance: Adjusting the distance of the search rays.

2.2.2 Control Classify Line

2.2.3 Control Classify PatMax

2.2.4 Control Classify Caliper

2.2.5 Control Classify FrontBack

2.2.6 Control Classify SaddleEdge

2.2.7 Control Classify Torsion

2.2.8 Control Classify SaddleSurface

2.3 Measured Values Listing

2.3.2 Measuring Range Representation (Schematic)

2.4 Setting Up VisionControl and Configuration

Install the "Element2Cam.exe" program version as from V05-0-0

Delete the contents of file "ImgOpDescription.dfn"

Install the new Element2Cam.err

Inspection_XX-XX.prm must be adapted. The layout of the inspection programs

Open the old inspection program

Start Element2Cam.exe and terminate again (Element2Cam.ini was updated)

The "Element2Cam.ini" file must be modified:

// The StationID must be set as follows

// Ejection if control element is recognized (only Station 6 = TRUE)

Test the inspection programs

Install the "ElementeAdmin.exe" program version as from V5-0-0

// The languages to be supported by MMI

// Settings for VisionControl (leave default settings)

Adaptation of Tolerances.txt (ElementeAdmin\Control\)

Stone Detection in Station 1

VDT Bosch Tilburg

Rohwedder AG I Vision Technologies

Stone Detection in Station 1

Stone Detection in Station 1.....................................................................................3