CVA Users Guide

Common Vision
Application
(CVA)

Users Guide
Version 1

For COGNEX VisionPro Applications

Last updated 6/27/06

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Table of Contents

I. Introduction ..............................................................................................................4
II. Setup PC..................................................................................................................4
A.) Hardware .........................................................................................................4
B.) Software ..........................................................................................................4
1. Installation ICW – KC Windows XP Professional .............................................4
2. Accessing the KC LAN.....................................................................................4
3. Recommended Installation Procedure for All Drivers .......................................5
4. Installation of Network and Audio Drivers (as required)....................................5
5. Installation of Video Card Drivers.....................................................................5
6. Installation of Remaining Hardware .................................................................5
7. Install VisionPro Software ................................................................................6
8. Install VisionLinxEIP for EthernetIP communication .........................................6
9. Install the Reflective Memory Driver.................................................................6
10. Install VisionPro Application Executable, Configuration and DLL files ..........6
11. Setup configuration AMPS number ..............................................................7
12. Setup database connection string ................................................................7
13. Obtain database file from KCAPPS folder ....................................................7
14. Setup MSDE and attach local database.......................................................8
15. Auto Login Setup .......................................................................................10
16. Virus Protection..........................................................................................11
III. Upgrade Application to a New Version...............................................................11
IV. Run Vision Application.......................................................................................11
V. Run Communication card ..................................................................................12
VI. I/O Check ..........................................................................................................12
VII. Communication Check.......................................................................................13
1. EIP Diagnostic Screen.......................................................................................13
2. Reflective Memory Diagnostic Screens..............................................................13
VIII. Camera Check...................................................................................................16
IX. Application Setup...............................................................................................16
A.) Configuration .................................................................................................16
B.) Calibrate Cameras.........................................................................................18
C.) Adjust Lens....................................................................................................20
D.) Setup Tools Offline ........................................................................................21
X. Online Display options .......................................................................................23
A. Tool Graphic Display Options ............................................................................23
B. Lines and Fixtures .............................................................................................23
C. Auxiliary Display Options ...................................................................................24
XI. Adjust (Optimize) Tool Settings Online ..............................................................26
A. Editing Tools Online...........................................................................................26
B. Kick Start ...........................................................................................................30
XII. Acquiring Reference Images..............................................................................32
XIII. Image Save & Playback.....................................................................................33
XIV. Image Freeze ....................................................................................................35
1. No Freeze......................................................................................................35
2. Manual Freeze...............................................................................................35
3. Freeze on Each Defect ..................................................................................35
4. Freeze on 1st Defect Until Reset ...................................................................36
5. Freeze on Specific Defect Until Reset............................................................36
XV. Engineering .......................................................................................................36

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XVI. Go Offline ..........................................................................................................36

XI. Proper Shutdown Procedure..............................................................................37
XII. Proper Startup Procedure ..................................................................................37
XIII. Grade Change Procedure..................................................................................38
XIV. Good Run Settings ............................................................................................39
XV. Troubleshooting.................................................................................................39
Appendix .......................................................................................................................40
A. Application Software Structure...........................................................................40
B. Application Timing Diagram ...............................................................................40
C. Application Panel Structure................................................................................40
D. Memory Map – Data In/Out................................................................................40
E. Online Error Messages ......................................................................................40
F. Application Files ................................................................................................41
G. Creating a Disk Image for Vision Computers (Disaster Recovery) .....................41
H. Plants Spare Vision PC Setup ...........................................................................41
I. Installing Virgin Microsoft Windows XP SP2 verses ICW OS .............................42

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I. Introduction

II. Setup PC
A.) Hardware
All cards should be removed from the computer during the ICW
installation to prevent driver issues. The only card that might be necessary
is a network card if the onboard network card driver is not included in the
GDBoot disk. After completion of the ICW install hardware may be
inserted and additional driver loaded.

B.) Software
1. Installation ICW – KC Windows XP Professional
• Procedure located on IT Services web site.

http://www.kcc.com/mis/compsvcs/edt/GD2000/allfiles/Buildinstallati
on.doc

• More information about ICW can be found at the following web site.

http://www.kcc.com/mis/compsvcs/edt/GD2000/allpages/ICW/icwho
me.htm

• Add the group “KCUS\NeenahAdminICWAdmin” to the

administrators group so that staff personnel can access your Machine
vision computer remotely to aid in troubleshooting.
• During the setup if the computer places a “New Hardware Found” box
on the screen just close it. This may or may not happen depending on
the version of the ICW image at that time, depending on if the drivers
for that device are included in the ICW image. Any additional drivers
will be loaded on completion of the ICW install.
• At the end of the install “Kiosk Configuration” will be open. For now
just close this window. Later in this setup procedure we will configure
this screen. Note: The install procedure may hang around 69% this
may be cause by the interruptions from drivers or the “Kiosk Config”
screen. It is OK to cancel and restart the computer at this point.

2. Accessing the KC LAN

• Map \\KCAPPS\Share and other necessary drives from “My
Computer”. KCAPPS is the drive containing all other vision drivers
and software.
• It may be necessary to add your S-ID and\or B-ID to the group rights
of a desired network drive. For rights to the machine vision software
drive referred to in this document, contact the Machine Vision Team.

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3. Recommended Installation Procedure for All Drivers

• Although it is possible to install these drivers from the network
location, the recommendation is to create a folder on the C:\ drive and
copy the driver to this location then initiate installation from there. In
some cases running “setup.exe” is not enough, you may have to go
through Device Manager and point to the location of the “unpacked”
installation files.

4. Installation of Network and Audio Drivers (as required)

• Transferring network driver from a USB device or other means may be
necessary.
• Install any drivers for devices not satisfied by Windows install.
• The machine vision team will store drivers for recommended
computers at the following location. The drivers will be stored by
computer model (dc7600…)

\\kcapps\share\Corporate\Engineering\Shared Applications\Program
Files\Infant Care\Machine Inspection\Machine Vision PC Files

5. Installation of Video Card Drivers

• Video card drivers are store in the following location by card name:

\\kcapps\share\Corporate\Engineering\Shared Applications\Program
Files\Infant Care\Machine Inspection\Machine Vision PC Files

• Ensure Display Settings are set to 16-bit. If they are set to 32-bit the
overhead of drawing the extra colors will slow the application speed.
• The resolution of the screen is application dependent. The following
apply:
o DA1 – 1280 x 1024
o FVI – 1024 x 768

6. Installation of Remaining Hardware

• After all outstanding drivers are loaded shutdown the computer and
install all remaining vision hardware, also remove any network cards
that may have been used to initiate setup.
• If your configuration contains a Reflective Memory card then you
should set up your node ID now. Refer to project team or plant
support personnel for correct node ID.
• The vision processor should be installed in the topmost slot followed
by the communication card and then the Vision IO card.
• Connect the supplied ribbon cable between the Vision processor and
the IO card.

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• Connect the supplied power cable to the PC power supply and the IO
card.
• Ensure all cards are seated correctly and connections are tight then
close computer case.

7. Install VisionPro Software

• Install latest version of Cognex VisionPro software from the following
location:

\\kcapps\share\Corporate\Engineering\Shared Applications\Program
Files\Infant Care\Machine Inspection\VisionPro

8. Install VisionLinxEIP for EthernetIP communication

• Install latest version of Cognex VisionLinx for EIP software from the
following location. If your application is not using EIP you will still
need to install this driver to satisfy the program references.

\\kcapps\share\Corporate\Engineering\Shared Applications\Program
Files\Infant Care\Machine Inspection\VisionPro\EIP

9. Install the Reflective Memory Driver

• Install the correct version of Reflective Memory driver from the
following location:

\\kcapps\share\Corporate\Engineering\Shared Applications\Program
Files\Infant Care\Machine Inspection\Machine Vision PC
Files\Reflective Memory

• Ensure you are installing the correct driver for your card type. The
vision application will run the VMIPCI-5576 (1G transfer rate) and the
VMIPCI-5565 (2G transfer rate).
• Run “setup.exe” from the driver folder to install the RFM utility.
• Install the card driver through Device Manager by pointing to this
folder from the update driver option for this device.

10. Install VisionPro Application Executable, Configuration

and DLL files
• Create a folder at the following location: “C:\Vision”
• Copy the following files from the below folder on KCAPPS and place
them into the folder created above. Be sure to copy the files for the
application and version that your machine will be running.

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\\kcapps\share\Corporate\Engineering\Shared Applications\Program
Files\Infant Care\Machine Inspection\DA1

o KC.Eng.CVA.XXX.exe
o KC.Eng.CVA.XXX.exe.config
o XXXInitConfig.config
o KC.Eng.Comm.EthernetIP.dll
o KC.Eng.Comm.RFM1.dll
o KC.Eng.Comm.RFM2g.dll
o KC.Eng.CVA.UISharedCode.dll
o KC.Eng.CVA.Controls.dll
o KC.Eng.CVA.Client.dll
o KC.Eng.CVA.Server.dll
o KC.Eng.CVA.Shared.dll
o eFoundation.G1.Client.dll
o eFoundation.G1.Server.dll
o eFoundation.G1.Shared.dll
o Microsoft.Practices.EnterpriseLibrary.Common.dll
o Microsoft.Practices.EnterpriseLibrary.Configuration.dll

where XXX is the application mnemonic

11. Setup configuration AMPS number

• Edit xxxInitConfig.config file with Notepad and insert the correct
AMPS number from the table for your machine.
• Setup table in here that describes a base AMPS number for each
MACHINE.

12. Setup database connection string

• In the C:\Vision folder open the KC.Eng.CVA.XXX.exe.config file
with notepad.
• Ensure the server value of the connection string is set to
“localhost\CVA” (with the quotations). The remainder of the setup of
this connection will take place in the following steps.

13. Obtain database file from KCAPPS folder

• Navigate to the following link and get a copy of the database file
(cva0nedb.mdb) and database log file (cva0nedb.ldf).

\\kcapps\share\Corporate\Engineering\Shared Applications\Program
Files\Infant Care\Machine Inspection\VisionPro\CVA VisionPro
Database

• Place the database files in the root of the C: drive. (C:\cva0nedb)

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14. Setup MSDE and attach local database

These instructions pertain to installing the CVA (Common Vision

Application) database on a local computer using MSDE. MSDE is a free
database engine that can be downloaded from Microsoft (link is below).
Kimberly-Clark has a corporate wide license for Microsoft SQL Server
which contains the Enterprise Manager software that will be used at all
KC development workstations. As of now CVA deployments are
expected to run the database locally using MSDE, for the protection of
data. Network connectivity will only be necessary for the transfer of setup
files, unless other transfer methods are used.

Note: The fourth character in cva0nedbo is a zero.

1) Obtain the latest version of MSDE (Microsoft SQL Data Engine) from
KCAPPS. This program allows the vision application to access the local
database.

\\kcapps\share\Corporate\Engineering\Shared Applications\Program
Files\Infant Care\Machine Inspection\Machine Vision PC
Files\MSDERelA

2) Copy the files to the “C:\MSDERelA” folder.

3) The C:\MSDERelA\Setup.ini file should be configured as the following,

if not then change the file to match the setting below:

4) Save the C:\MSDERelA\Setup.ini file and double-click

C:\MSDERelA\Setup.exe.

5) After Setup is complete, restart the computer. When the computer boots
up, there will be an icon in the system tray that resembles a server with a
“play button” on it. The green “play button” icon indicates that the
Microsoft SQL Data Engine is running.

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6) Access to MSDE is achieved by using a command prompt program

called OSQL. To launch OSQL we first need a command prompt. Open
the start menu and click on “Run”. Type “cmd” in the text field and
click “OK”.

7) For ease of reading the command prompt type “CD..” until you read
“C:\>”.

8) To launch OSQL type the following:

This will log you onto the CVA instance of MSDE as the security
administrator using the password specified in the setup.ini file above.
This login will be used for all operations in OSQL.

9) To attach the database to the instance of MSDE that is running type the
following:

10) To check that the database was successfully attached type the following:

A list of all the databases contained in the CVA instance will be

returned. Ensure that cva0nedb is included in this list.

11) To add the cva0nedbo login to the master perform the following:

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The above step can be skipped and the following step will create the
login in the master but that procedure was not tested.

12) The next step involves linking the security identifiers for cva0nedbo
login in the master to the cva0nedbo login that is in the cva0nedb
database. In the “exec” command line below the fields are
‘UserNamePattern’, ‘LoginName’, and ‘Password’. A ‘NULL’ will be
entered for ‘LoginName’.

More information on SQL commands can be found at the following link:

http://msdn.microsoft.com/library/default.asp?url=/library/en-
us/tsqlref/ts_sp_ca-cz_8qzy.asp

The following website was helpful in creating these instructions:

http://www.codeproject.com/database/ConfigureMSDE.asp#4

Once complete, type Exit to exit out of OSQL and then Exit again to exit
out of the DOS command prompt.

15. Auto Login Setup

• Run “Kiosk Configuration”, navigate to “C:\Program Files\Enterprise
Desktop\GDPTW Admin Tools” and double-click “Kioskcfg”.
o The user name and password will be the generic logon that will
be obtained from MIS. This logon will automatically login
during startup and run the vision application.
o Set Persistent Application to None.
o Set Screen Saver to Disable.
o Set Power Management to Disable
o Set Remote Desktop to Enable (allows remote support from
staff).

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o Click Apply Settings.

• Place a shortcut to C:\Vision\KC.Eng.CVA.XXX.exe in the Windows
Startup menu so that during a reboot the Vision Application
automatically loads and begins running. This can be accomplished by
creating a shortcut on the desktop, then dragging it into the Start menu
and dropping it in the Startup menu.

16. Virus Protection

With ICW, virus pattern files Windows security updates are automatically
pushed to the PC. They will not be loaded onto the PC until someone
manually does so.

III. Upgrade Application to a New Version

1. Repeat procedural steps in section II, 10-12.
2. Stop the MSSQL server database, repeat step 13 in section II, and then re-start the
server.
3. Repeat procedural steps in section II, 14, but only sub steps 6, 7, 8 & 12. The
message shown below will appear, indicating the database has been fixed.

IV. Run Vision Application

1. Place a shortcut of the application executable, C:\Vision\KC.Eng.CVA.XXX.exe,
on the desktop. Double-click on this icon if the application is shutdown and needs
to be re-started without having to re-boot the PC.
2. The AMPS (Application-Machine-Product-Step Size) number defines what
parameters the application will start up with. Check the application users’ guide on

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what #’s are available for the particular machine the application is running. Edit the
XXXInitConfig.config file using notepad, entering in the appropriate AMPS #.

V. Run Communication card

The communication cards are initialized and run within the vision application. They do
not need to be started on their own. The communication utilities that come with the
card drivers can be used to verify proper operation without running the vision
application.

VI. I/O Check

The Hardware Diagnostics interface enables the user to test and determine whether the
discrete inputs and outputs on the vision system are working properly. Use the
following procedure to open the Hardware Diagnostics.

1. Go offline. Click on “Go Offline!” in the online menu bar and confirm that you
want to go offline by pressing the "Yes" button.

2. From the offline menu click on “Diagnostics” > “Hardware.”

3. When the Hardware Diagnostics interface appears the user can monitor the number
of triggers that are being received on the individual inputs and toggle the outputs on
and off to ensure they are being set properly. Note: Outputs 4 – 7 cannot be fired
manually as they are tied directly to the 4 camera inputs.

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4. If a linescan camera is connected to the framegrabber board, an encoder check

button should be visible. Click on this button to get a current count of the encoder
position. Spin the encoder and press the button again to verify the count value
changes.

5. To exit the interface click on “Exit” in the menu bar.

VII. Communication Check

1. EIP Diagnostic Screen

2. Reflective Memory Diagnostic Screens

A) RFM1

The Reflective Memory Tests interface enables the user to access the local
Reflective Memory (RFM) card directly to test communications over the RFM
network. Communication can be verified by writing data to the local node
and sending it to other nodes on the network or reading data from the local
node written from other nodes on the network.

1. Go offline. Click on “Go Offline!” in the online menu bar and confirm
that you want to go offline by pressing the "Yes" button. You should now
be offline.

2. From the offline menu click on “Diagnostics” > “Communication” >

“RFM Tests.” The Reflective Memory Test interface appears as shown in
below.

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The follow provides a brief description of each item in the Reflective

Memory Tests interface:

• Endian Control Used to select the format of the data. This is set
by default to Byte Swap and cannot be changed.
• Data Size Used to select the length of data words. This is
set by default to 16 Bit Word and cannot be
changed.
• Information The information button displays the
configuration information of the RFM board
such as: Board ID, Node ID, RFM Size, and the
RFM registers.
• Offset The Offset textbox is used to enter and display
the starting address (in hexadecimal format) of
the memory location you are accessing. The
Offset defaults to the beginning of the
inspection application node: for FVI Node 59 =
EC00 Hex and for NDC Node 61 = F400 Hex.
This value must be set to a multiple of the Data
Size.

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• Length The Length textbox is used to enter and display

the number of words (in hexadecimal format)
starting from the Offset address to access. The
Length defaults to 200 Hex (512 words) which
is the length of one entire node. This value
must be set to a multiple of the Data Size.
• Write The Write button is used to write the value in
the Write/Poke textbox to the entire Length of
the memory location starting at the Offset.
• Poke The Poke button is used to write the value in the
Write/Poke textbox to only the first word of
memory location starting at the Offset.
• Peek The Peek button is used to display the value of
only the first word of the memory location
starting at the Offset.
• Read The Read button is used to display all the values
for the entire Length of the memory location
starting at the Offset.

3. From To exit the interface click on “Exit” in the menu bar.

B) RFM2g

Same as RFM1, but note that RFM2g can write the first 40Hex addresses,
where RM1 cannnot.

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VIII. Camera Check

Display Live Image

1. Go offline. This can be done by pressing the "Offline" button, confirm that the
system will go offline by pressing the "YES" button.

2. From the menu bar click on “Setup” and select “Camera” and click on “Live Image.”

Need image

3. In the Live Image window, click on camera to view.

4. Click on “Exit” in the live image menu bar to exit when done.

IX. Application Setup

A.) Configuration

SharedConfig
Need image

The following options are available:

1. Operator Side – Select which side of the screen the operator side of the
product the image will be on. This is dependent on the camera orientation
mounting and should only be changed to match the design specification.

2. Machine Direction – Select which side of the screen the machine direction is.
This is dependent on the camera orientation mounting and should only be
changed to match the design specification.

3. Camera Lighting Setup – Select between back and front lighting. This setting
is used in the calibration routine if Auto Detect Target is disabled. It will
automatically set the background to light if back lit is selected and dark if
front lit is selected.

4. Enable/Disable the appropriate inspections and tools that are required. Note
that some tools depend on certain fixtures and may not run unless the tool
AND it’s associated fixture tool are enabled.

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Communication

1. Communication Type: Select which communication type to send data.

Options are None, EIP, RFM1 or RFM2g.

2. Send Data on Trigger: This setting determines if the data should be sent on
the trigger event or at the end of the inspection.

3. Data Buffered: This setting determines if data is buffered before being sent
out. If data buffering is enabled, it will be delayed by 2 products.

4. Data In Polling Enabled: This setting will determine if the system should
automatically poll incoming data while the inspection is online. It is setup to
read data every X triggers when the machine is running and read every 1
second if the machine is down, detected by the absence of triggers.

5. Auto Save Online Edits on Machine Down: This setting is only available if
data in polling is enabled. If the machine is down, detected by a bit sent over
the communication network, any online edits that have been performed since
the last machine down will be automatically saved. If no edits were
performed, the save process will not be executed.

6. Auto Save Cull Specifications: This setting is only available if data in polling
is enabled. If cull specifications are being sent across the network, enable this
feature to automatically read them.

Simulator Mode
Need image
1. Select the Simulator button if the application is not being run on a machine.
This will enable calibration to be done from an image file.

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B.) Calibrate Cameras

NOTE: It is important to calibrate the cameras for the vision tool measurements
to be accurate. In addition, tools may be placed on to the acquired image based
on the calibration setup. If this is the case and the application is re-calibrated,
expect that the vision tools will be placed at a different location and need to be
moved and re-sized accordingly.

1. Verify the height of the camera. Measure the distance from the lens to the web.
This should be a fixed distance for the widest field of view for the largest product.

2. Go Offline.

3. Select Setup -> Camera -> Calibration. The following display will appear:

4. From the menu bar select the camera to calibrate.

5. Place a calibration square of known size under the camera, flat on the belt or
deadplate. Placing the calibration square on top of the web will add error to the
calibration value. Select ‘CD Calibration’ under the Initial Calibration heading.

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6. Enter the calibration square width in millimeters into the “Enter CD Calibration
Size” text box.

7. A ‘live image’ will appear on the screen. The machine does not need to be
running to display this image. The software is setup to accept a software trigger
and a test encoder (both internal to the program). While in live mode you will see
an image fill 1024 x 1250 pixels which is the largest image possible with our
setup. Place the calibration square flat and aligned in the field of view of the
camera.

8. If the tool is unable to find the correct edges of the calibration square, go to the
menu bar and select Setup -> Auto Detect Target to un-check the “Auto Detect
Target” function.

9. If you are calibrating a back lit camera, select “Light” in the “Background”
section so the calibration look for a light to dark and then dark to light transition
in order to find the calibration square. If you are calibrating a front lit camera,
select “Dark” in the “Background” section so the calibration tool edges will be
switched to look for a dark to light and then light to dark edge

10. When the tool in the image finds the two edges of the calibration square, press the
“CD Calibrate” button. In the vision software the calibration square size in mm is
divided by the number of pixels found by the calibration tool to find the CD
mm/pixel calibration value.

11. Measure the length of one product at the point of inspection under draw
conditions. This will give a stretched diaper length. It is suggested to measure
from one fixed component of one diaper, like the edge of an ear, to the same fixed
component of the next diaper.

12. Enter the length of the product in millimeters into the “Enter MD Calibration
Size” text box and press the “MD Calibrate” button.

13. Press the “Accept” button to accept the new calibration scale factors and save
changes when exiting the calibration screen. If the camera height is adjusted or
bumped, then the CD calibration should be re-done. If the machine draws are
changed significantly, the MD calibration should be re-done.

14. After the machine is running, verify that the vision measured distances for ear
length MD and outer cover CD dimensions are accurate to hand measurements.
Use the vision measurement display on the operator interface (Wonderware) or
check the values in Reliance.

15. If the measurements are not accurate, return to the calibration screen to fine tune
the calibration. In the “Scale Factor” section, use the “-“and “+” buttons under

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the “X mm/pix” text box to fine tune the CD calibration and use the “-“and “+”
buttons under the “Y mm/pix” text box to fine tune the MD calibration.

16. When fine tuning is complete, press the “Accept” button and save changes when
exiting the calibration screen. Re-verify that the vision measurements are more
accurate when the machine runs again.

17. Repeat the procedure above for all other cameras.

C.) Adjust Lens

1. Go to the “Display Live Mode’ again.

2. Check if the image looks blurry. It is best to place an object in the field of view and
verify if the edges of that object look crisp. If they are, the focus is set properly. If
they are not, adjust the focus ring on the lens to obtain a clear image.

3. Check if the image is too red, indicating the area is over saturated with light. If it is,
adjust the aperture. Increase the f-stop # on the lens to let less light through. If the
image is too blue, indicating the area is under saturated with light, then adjust the
aperture again. Decrease the f-stop # on the lens to let more light through.

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D.) Setup Tools Offline

1. Normal Setup

Edge and light meter tool parameters - score, strength, rankings,

polarity, filter size and mean

2. Advanced Setup
Some tool parameters are not available in the normal tool setup
screen. These additional parameters are available here, but this
screen must be used with caution. Therefore, it can only be
accessed through a password entered on the online menu. If one
does not know how to properly adjust settings here, it is not
recommended to use this screen. Unintended consequences can
occur. This screen allows changes to the camera acquisition tool.

Parameters such as the Dalsa linescan camera high gain settings

are adjusted here. High Gain will give a 4x light level gain for all

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pixel values. Check the camera lens aperture value. If the lens is
within 1 F-stop of fully open it is recommended to select high gain.
After clicking the box and accepting you will want to readjust the
lens.

Cull Specifications

Tool Failures

A Tool Failure screen can be accessed from the Main Menu or from an online
button when the machine is down to review the number and percentage of failures
for each tool. It also displays the number of culls that have occurred since the last
time the RESET button was pressed for certain culls that are determined within
the vision application.

Cull Tracking

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X. Online Display options

A. Tool Graphic Display Options

These options will determine what tool graphics to overlay on the display
image.

1. IMAGE ONLY
Do not display any tool graphics.

2. FAILED REGIONS
Display tool graphics for only those tool’s that fail. Failed edge tool
graphics show up as a red region.

3. EDGE LOCATION
Display tool graphics for all tools that pass. Edge tool graphics show up
as a green cross hair, indicating the location of the detected edge.

4. EDGE LOCATION AND REGIONS

Display tool graphics for all tools that pass and fail. Passing edge tool
graphics show up as a green cross hair, indicating the location of the
detected edge, as well as a purple region. Failed edge tool graphics show
up as a red region. Passing histogram tools show up as a green region.

B. Lines and Fixtures

1. MD Reference Line

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Display the product MD reference line. This line is fixed when running
online and considered the good run position. Each application will
determine how the MD reference line is positioned. This line can only be
changed when re-setting up the tools offline. Re-acquire a new reference
image to ensure offline setup is done properly.
2. CD Reference Lines
Display the product CD reference lines. These lines are fixed when
running online and considered good run positions. Each application will
determine how the CD reference lines are positioned. These lines can
only be changed when re-setting up the tools offline. Re-acquire a new
reference image to ensure offline setup is done properly.
3. Machine Center Line
Display the machine CD center line based on the machine centerline edge
tool. This line is fixed when running online and considered the good run
position. It can be changed by re-acquiring a new reference image and re-
setting up the machine centerline tool offline. A reference line must be
placed in the field of view of the image exactly where the machine
centerline position is located. This reference line can be a piece of
keystock or another narrow object that will show up as a line down the
middle of the display. It only needs to be in place when a reference image
is obtained.
4. Fixtures
Display any fixtures used in the tool group.

C. Auxiliary Display Options

1. Product Index Number

Get image
This will display the product index number on the screen. Note that the
index number is incremented once per acquisition counting from 0 to
32767 and then rolls back over to 0 again.

2. Defect Message

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This will display tool failure results, cull defects and communication
feedback. See Appendix for further explanations of common defect
messages that are displayed.

Two dialog boxes will appear that allow the user to setup the defect
message display. The first will allow the user to set up to 3 defect
messages to be displayed at one time. The second will hold a defect
message displayed for up number of products entered. The defect
message will be displayed up to that many products unless another defect
occurs.

3. Image Direction

Get image
This will display which side of the image is the Operator Side of the
machine and what the Machine Direction is. This is based on the
orientation of the camera and is setup on the Shared Configuration screen.

4. Timers
Get image
This will display the approximate time it takes each camera inspection
code to run. It will also enable/disable certain discrete outputs used for
testing purposes.

5. Data In/Data Out

Get image
This will display all incoming and out coming data read by the inspection
system. The refresh rate can be changed to determine the # of products to
update the display. If a 0 is selected, data for every product will be
displayed. If 1 is selected, data for every other product will be displayed.

6. Tool Parameters
Get image
This will display the actual tool results. In particular, tool locations, edge
thresholds such as score and strength, and histogram thresholds like mean
and standard deviation will be shown.

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XI. Adjust (Optimize) Tool Settings Online

A. Editing Tools Online

1. From the online menu select “Adjust” > “Tool Parameters.”

2. In the “Edit Parameters” interface, scroll to the tool edit and select the property to
adjust.

3. Here is a brief description of what each button does.

• Tool List The name seen inside the text box is the tool that is
currently being edited.
• Next This will select the next tool in the tool list for editing.
• Previous This will select the previous tool in the tool list for
editing.

• Accept This will be enabled once an edit is made to the

selected tool. Once all edits are made to the tool press
the “Accept” button to keep the edits and move on to
the next tool.
• Cancel Pressing this button will restore the tool to the original
parameter (before any changes were made to it). All
parameters for that tool will be restored to the setting
that was there before changes were made.

You will not be able to select another tool for editing

until the “Accept” or “Cancel” button is pressed.
• Exit This will exit from the online tool editing menu and
return to the online menu.

• Fine Enables fine adjustments of tool parameters.

• Coarse Enables coarse adjustments of tool parameters.

• Size Allows the adjustment of the size of the edited tool.

Fine and coarse adjustments are 1 and 5 pixels.
• Location Allows the adjustment of the location of the edited tool.
Fine and coarse adjustments are 1 and 5 pixels.
• Rotation Allows the adjustment of the rotation of the edited tool.
Fine and coarse adjustments are 1 and 5 degrees.

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• Threshold Allows the adjustment of tool thresholds. For caliper tools,

this is the Minimum Strength and Minimum Score. For
Histogram tools, this is the Minimum and Maximum Mean
and Standard Deviation. It also allows for Scale Factor
Adjustment that is used for the Kick Start feature.

Fine and coarse adjustments settings are as follows:

Minimum Strength: 1 and 5
Minimum Score: 1 and 5
Minimum/Maximum Mean: 1 and 5
Minimum/Maximum Standard Deviation: .1 and .5
Minimum Strength and Score Scale Factor: 1 and 5
Min/Max Mean and Std Dev Scale Factor: 1 and 5

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• Ranking Allows the adjustment of the ranking constraint of the

edited caliper tool. Constraint options include edge
strength, window start, window center, or expected size
(for edge pairs only).
• Polarity Allows the adjustment of the edge polarity of the edited
tool. Options include light to dark (L->D), dark to light (D-
>L), or Either transition.

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• Filter Size Allows the adjustment of the filter half size of the edited
caliper tool.
• Exp Size Allows the adjustment of the expected size of the edited
tool. This option is only available for edge pair caliper
tools.
• Step & Repeat Allows the edited tool to be re-run, if it fails, up to the
Number of Steps. This option is currently only available
for edge caliper tools.

• The other buttons not described will change depending on what feature is
being edited on the tool. (Size, Location, Rotation, Threshold, Ranking,
Polarity, Filter Size, Exp Size)

4. Any edits performed online take effect the instant they are made. So as the layout
of the tool changes, the program is using the new layout.

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B. Kick Start

Kick Start is a feature that allows tools to be trained on runtime results. The
program averages tool data and uses it to determine minimum and maximum
threshold settings based on the entered scale factors. Tools need to be passing in
order for this to work.

1. Click on “Adjust” > “Kick Start” in the online menu bar.

2. Setup the sample size to average the tool parameters for the Kick Start feature.
The default setting is 32.
3. Select which tool thresholds to Kick Start. Options are Edge Thresholds,
Histogram Thresholds, Expected Size of dual edge tools or All.
*Note that Expected Size is currently not available at this time.

The kick start function only works when all of the tools pass. Therefore, the
number of products to kick-start is not always consecutive. A new average is
calculated only when the tools pass for the number of products equal to the
sample size. If this does not occur in the number of products equal to 10 x the
sample size, the function will abort and the settings will remain as they were.

Sample kick start calculations are as follows:

1. Caliper (Edge) Tool Thresholds

Calculations are as follows:

Min Score Result = Average * Score Scale Factor

Min Strength Result = Average * Strength Scale Factor

Example:
Score Average = 100
Strength Average = 20
Score Scale Factor = .5 (50%)
Strength Scale Factor = .75 (75%)

Min Score Result = 50

Min Strength Result = 15

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Note that if the tool’s are continually failing because they aren’t in the
correct location to find an edge or the strength of the edges are below the
current minimum threshold, kick start will not work until the tool passes.

2. Histogram Tool Thresholds

Calculations are as follows:

Max Result = Average + (Average * Scale Factor)

Min Result = Average – (Average * Scale Factor)

Example:
Mean Average = 100
Mean Scale Factor = .2 (20%)

Mean Max Result = 120

Mean Min Result = 80

Standard Deviation Average = 1.0

Standard Deviation Scale Factor = 1.1 (110%)

Standard Deviation Max Result = 2.1

3. Expected Size
for dual caliper (edge) tools
Calculations are as follows:

Exp Size Result = Average * Exp Size Scale Factor

Exp Size Max Result = Average * Exp Size Max Scale Factor
Exp Size Min Result = Average * Exp Size Min Scale Factor

Example:
Average = 100
Exp Size Scale Factor = 1.01 (101%)
Exp Size Max Scale Factor = 1.1 (110%)
Exp Size Min Scale Factor = .5 (50%)

Exp Size Result = 101

Exp Size Max Result = 110
Exp Size Min Result = 50

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XII. Acquiring Reference Images

The vision tools are set up using a typical image from the process. This typical
image is referred to as a “training” image. To have a typical image make sure
that:

• Machine is running and all appropriate components are being applied to

the diaper.
• Component placement, in both the MD and CD direction, are acceptable.
• Component presentation is good (no folding or flopping around).
• The trigger is phased in the right position to acquire the appropriate image

1. Select the appropriate camera

2. Hit the Acquire button.

The reference image will be saved and will freeze the image display for 20
products. The message box will indicate once the image has been saved. Note
that it will not be written to the database unless you allow it to when prompted
going offline.

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XIII. Image Save & Playback

A. Image Save

The default file path to save images is C:\CogImages. Ensure this folder has
been created before proceeding. The default file names are CamXImages.idb,
where X is the camera number.

1. Select which camera to save images from.

2. Enter in the # of images to be saved. Note that if a large number is
entered, images will be save over an extended period of time, which will
load up the processor usage and negatively affect the performance of the
inspections. This typically will cause continuous culls due to missed
inspections.
3. Hit the Save button.

The message box will display which image is currently being saved.

Save on Reject: Not currently available.

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B. Image Playback

Note: Image playback is a development and simulation function that should

not typically be used on the machine. Real-time inspection will not occur
while the system is in playback mode.

1. Select which image database (.idb) file to playback images from. Note
default image save files are named CamXImages.idb, where X is the
camera number.
2. Select the trigger mode, either Software or Hardware. Hardware trigger
mode requires an external trigger signal to playback images and will
initiate playback as soon as it is selected.
3. If Software trigger mode is selected, the user must manually trigger the
system. Either select Continuous mode, entering in the trigger interval, or
hit the Previous/Next buttons to increment through the images. Note that
if the interval is set to quickly, the inspection may not be able to keep up
and the inspection will become inoperable.

The message display will indicate which image is being played back and
also the total number of images in the file.

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XIV. Image Freeze

1. No Freeze

This option can be found in the online menu bar under the “Freeze” menu. This
option will display every product that is inspected.

2. Manual Freeze

This option can be found in the online menu bar under the “Freeze” menu. This
option allows the user to freeze the display at any time by pressing the “Freeze”
button. It will hold the current product image on the screen until the “UnFreeze”
button is pressed.

3. Freeze on Each Defect

This option can be found in the online menu bar under the “Freeze” menu. This
option will display every product that is inspected until a defective product is
found. It will hold the defective product image on the screen along with a
description of why it is defective until another defective product is found. It will
continue to display only the defective product images and the defect description.

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4. Freeze on 1st Defect Until Reset

This option can be found in the online menu bar under the “Freeze” menu. This
option will display every product that is inspected until a defect is found. It will
hold the defective product image on the screen along with a description of why it
is defective until the “Reset” button is pressed. Once the “Reset” button has been
pressed it will continue to display each product until a defective product is found.

5. Freeze on Specific Defect Until Reset

This option can be found in the online menu bar under the “Freeze” menu. This
option will display every product that is inspected until the selected specific
defect is found. The defect can either be a tool failure and/or a cull. The specific
defect(s) can be selected from the list of defects that appears when this display
option is enabled. It will hold the defective product image on the screen along
with a description of why it is defective until the “Reset” button is pressed. Once
the “Reset” button has been pressed it will continue to display each product until a
product with the selected specific defect(s) is found.

XV. Engineering

Some adjustments are not allowed unless you are logged on as an Engineer. To do
so, enter the correct password in the dialog box, as seen below.

XVI. Go Offline
When going offline, the user will be prompted to confirm this selection. When the
application is offline, the application will not be inspecting product and the machine
will go into a constant cull.

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If online edits have occurred, new reference images saved or menu options
modified since the last time the application was offline, the application will prompt
if the user would like these settings saved to the database.

XI. Proper Shutdown Procedure

A. Shutdown the vision application through the offline menu.

B. Close down any other applications on the PC.
C. Shutdown the PC
i. Select Start on the bottom left-hand corner of the screen.
ii. Select Shutdown to pop up the shutdown window.
iii. Select ‘Shut down the computer?’ and hit Yes.

XII. Proper Startup Procedure

A. Turn on power to the PC.
B. If the PC is setup properly, automatic login should occur. In addition, the
vision processor will be automatically started and the application will boot up
and be ready to run. If not, follow the steps in the AutoLogin section.
C. If data communication has been enabled, then the online error message box
will display the status if it has been initialized or not.

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XIII. Grade Change Procedure

A) Perform Grade Change

If database parameters already exist for the new settings, then this will re-
load these settings to the current application. If these settings have not yet
been created, an error message pops-up. You must Save Current To New
before you Perform Grade Change.
B) Save Current To New
This will copy all current settings to the new settings.

Note that one cannot perform a grade change to a code that has not been defined
in the database. Consult with staff in order to add new grades.

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The offline screen displays general information, as seen below, about the
application that is running.

XIV. Good Run Settings

Once the application has run for a period of time and the vision tools have been
adjusted to the proper location and optimal settings, it is recommended to record
all the vision tool parameters. This can be done by going offline to the Tool
Parameter Summary screen. The parameters for all tools will be displayed for
each camera. A snapshot can be taken using <ALT> <Print Screen> on the
keyboard of the vision PC, which will capture the image, allowing one to paste
this into Microsoft Paintbrush and eventually save it to a file. A Print feature is
also available that will automatically setup a printer, if available and not already
done, and print the current camera’s display to the printer.

XV. Troubleshooting
See separate troubleshooting guide using the following link:

Need link

Also see the offline tool failure screen to determine tool performance.

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Appendix
A. Application Software Structure

B. Application Timing Diagram

C. Application Panel Structure

D. Memory Map – Data In/Out

Common data includes the beginning and ending index # as well as the acquisition
failure bits.

E. Online Error Messages

The following errors are common to all applications. The specific tool error
messages should be described in the application specific design guide.

Acquisition
Description Defect Message Priority
Camera X Acquisition Overrun: 0
Excessive Triggers
Camera X Acquisition Overrun: 0
Trigger Could Not be Serviced
Camera X Acquisition Missed 0
Camera X Acquisition Failed 0
Abnormally
Camera X Images not Available 0
Camera X Images Buffered and 0
Dropped
Camera X Encoder Overrun 0

A defect message priority of 0 is the highest priority assignment. If multiple defects

occur with the same priority assignment, the first one programmed in the code will be
displayed. A defect message priority of 98 is the lowest priority.

A defect message priority of 99 or greater will disable the message from being
displayed. Messages for such tools as fixtures and lines may not want to be
displayed.

Note the encoder overrun error is only for linescan cameras.

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Communication
Description Defect Message Priority
EIP Communications Initialized n/a
EIP Communications Not n/a
Initialized
RFM Communications Initialized n/a
RFM Communications Not n/a
Initialized

Message Boxes
Communication Not Initialized Properly

F. Application Files
• The data for the application is saved in database file: C:\cva0nedbo.mdf
• The application files are located in the C:\Vision folder.
• A temporary folder is created only when the application is running. This folder
contains the reference images, iXimage.idb and all tool files, *.vpp that are in the
database.

G. Creating a Disk Image for Vision Computers (Disaster Recovery)

Jon?

H. Plants Spare Vision PC Setup

Use one common database amongst machines.

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I. Installing Virgin Microsoft Windows XP SP2 verses ICW OS

1. Restore the image from the Win XP SP2 corporate CD. Follow the WinXp
Harddrive Restoration and Imaging Procedure.doc for restoring the image.
\\KCFILES\SHARE\Infant Care\Projects\Improved Cull
System\Engineering\Software\Software Procedures\WinXp Harddrive
Restoration and Imaging Procedure.doc
2. After the image has been restored different hardware will not be
recognized until the drivers are loaded which is done in later steps or
earlier steps.
3. Right Click Display Properties, turn off the screen saver, modify the
power settings, home/office, turn off monitor never, turn off hard disk
never, turn off system standby never. Under Advanced uncheck the
prompt for password when computer resumes.
4. The video resolution must be changed to 1280x1024. Right-click on the
desktop and click Properties. Click Settings tab. Ensure the color settings
are set to High Color (16 bit) and then use the slider to select 1280x1024
and click OK and keep the seetings.
5. Right Click My Computer, under System Properties, Restore, turn off
system restore by checking the box.
6. Under Automatic Update tab disable automatic updates.
7. Under the Remote tab disable allow remote assistance and remote desktop.
8. Under Computer Name change the computer name to a meaningful name
such as B12INS1 within a workgroup.
9. To enable AutoLogon, click Start and then Run and type control
userpasswords2 select OK, select account, uncheck users must enter a
username and password and press enter.
10. Windows does not recognize the PCI 5565-2G network controller so the
drivers will be installed. Install the reflective memory software to the PC
and using device manager browse to the RFM folder with the drivers and
update.
11. Add the background wallpaper for the appropriate processor. Follow the
procedure detailed in the WinXp Harddrive Restoration and Imaging
Procedure.doc.
12. ICONS My Computer, Recycle Bin, RFM2G.Util will be displayed on the
desktop.
13. From the C:\Vision folder drag and drop KC.ENG.CVA.DA1 to Startup.
Click on KC.ENG.CVA.DA1 navigate to Start, All Programs, Startup and
drop the file.

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