Intellispec Training Guide: The Vision To Innovate, The Technology To Excel™

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INTELLISPEC TRAINING
GUIDE
the vision to innovate, the technology to excel™

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Outline
SECTION
SECTION TITLE PAGES
#
1 INTELLISPEC SYSTEM OVERVIEW 3-8
2 VISION INSPECTION THEORY & CONCEPTS 9-18
3 INSPECTION SYSTEM USER INTERFACE 19-84
4 DISCOVERY SOFTWARE 85-92
5 CHROMAPULSE LIGHTING 93-98
6 SYSTEM TIMING / PART TRACKING 99-108
7 COMMONLY PERFORMED TASKS 109-116
8 SERIES 5 HARDWARE AND MAINTENANCE 117-133
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SECTION 1
INTELLISPEC SYSTEM
OVERVIEW
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Intellispec Cabinet and User Interface

24” Diagonal color LCD with
Mounted on the side optional touch screen. An
of the user interface on-screen keyboard (OSK) is
is a USB port. displayed when needed.
Trackball with two Vision

sets (left-handed processor
or right-handed) of on/off
buttons, a select switch.
button and an
information
button.
Inside the cabinet is an
Ethernet switch, the
vision processor and a
mechanical keyboard
(MKB). It is expected
Mechanical keyboard is stored
that the MKB will be
inside the cabinet.
used for system level
tasks only.
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Typical Chromapulse Module
LIGHT TREE
Red – Alarms
On/Off Amber – Warning
switch for
camera Green – Online
module
Blue - Power
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TOPIC NOTES
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SECTION 2
VISION INSPECTION THEORY
AND CONCEPTS
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Sequence
of
Events
Image Processed
Part Reject Decision
Detected Image Acquired
Part Movement
Reject Position
Part Width Camera 1 Position
Part Present Delay
Reject Time Delay
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640
 Pixel is an acronym for
Picture Element and is the X X
smallest element in a
Y X=0 X=640
digitized image. The Y=0 Y=0
Y
layout of pixels is known
as the Cartesian grid
system.
1 Pixel
 Each pixel has an X,Y
address that corresponds
to its location on the grid. 480
Software uses these
coordinates to inspect the
image against the
inspection algorithm.
 Each pixel is assigned a

grayscale or grayshade X=0
value that is proportional Y Y=480
X=640 Y
Y=480
to its brightness.
Grayshade is a value
between 0-255 where 0 is
X 256 Shades of Gray X
black, 255 is white, and
every other number is
some shade of gray.
0 to 255
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Gray Level Distribution
255-
Gray Scale
0-
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190 190 187
186 190 192 185 188
189 191 193 191 190
185 115 112 105 115 183 189
180 105 10 10 107 180 185
185 103 10 10 106 182 188
186 115 112 105 115 185 187
188 185 188 184 185 186 188
188 189 188 190 189
190 188 192 191 190
191 190 190
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Gradient
The difference in grayshade between two pixels. In our inspections we
establish a gradient limit. It is adjustable between 1 and 255 and has a
default value of 30. If the actual gradient found while inspecting a product
exceeds the value of our limit we have found what’s called an “edge point”.
In the example below, if the gradient in our inspection is set at 30, the
inspection found 4 locations where a gradient of 30 was exceeded and
therefore 4 edges were found. (95, 110, 100, 105)
0 5 95 110 5 100 105 0 5 10
200 205 200 210 105 100 100 200 205 200 210 210
Delta of 2
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Delta
The difference between pixels whose shades are being compared when seeking an
edge point. It is adjustable between 1 and 180 with a default value of 2. In the
example below, if the delta is 2, the shades from the first and the third pixels in the
region are compared seeking a difference equal to the gradient. If the delta is 3, then
the first and fourth are compared. GENERALLY SPEAKING, as the delta is increased
the sensitivity of the inspection is increased because it allows you to find more
edges. In the example below, if the gradient in an inspection is set at a value of 30,
when the delta is set at 1 there are 4 edges, when the delta is set at 2 there are 6
edges, and when the delta is set at 3 there are 7+ edges (more edges would be
found as you continue the scan).
Delta of 2
1 5 59 175 118 3 3 122 170 50
240 235 241 240 180 65 62 68 65 190 235 240
0 55 176 178 112 0 125 167 175
240 235 241 240 180 65 62 68 65 190 235 240

Delta of 3
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Size
The difference between how many pixels are grouped together and are being
compared when seeking an edge point. It is adjustable between 1 and 20 and has
a default value of 2. In the example, if the size is 2, the shades from the first two
pixels are averaged and compared with the average of the third and fourth pixels
in the region. If the size is 3, then the first, second, and third pixels are grouped
together and compared with a group comprising the fourth, fifth, and sixth pixels.
Gradient = 1.5 Gradient = 26 Gradient = 8.5
(13 + 8) / 2 = 10.5 (6 + 18) / 2 = 12 (25 + 22) / 2 = 23.5 (42 + 57) / 2 = 49.5 (51 + 31) / 2 = 41 (45 + 54) / 2 = 49.5
13 8 6 18 25 22 42 57 51 31 45 54
Size of 2
Gradient = 12.7 Gradient = 8.7
(13 + 8 + 6) / 3 = 9 (18 + 25 + 22) / 3 = 21.7 (42 + 57 + 51) / 3 = 52 (31 + 45 + 54) / 3 = 43.3
13 8 6 18 25 22 42 57 51 31 45 54
Size of 3
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TOPIC NOTES
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SECTION 3
INSPECTION SYSTEM
USER INTERFACE
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USER INTERFACE DISPLAY

The display on the user interface has four levels for viewing:
System Overview Screen
Displays information that represents the complete system as well as a thumbnail
line for each Lane that is configured.
Lane Overview Screen
Displays information for a particular Lane as well as a thumbnail line for each
sensor used in that Lane.
Sensor Overview Screen
Displays information for a particular sensor, including an image area, a graphics
area that displays information as determined by the user, and the list of
inspections used for that sensor.
Inspection Screen
By double left-clicking on any inspection this final view is opened. This view allows
the user to see inspection parameters and if necessary make changes.
All four of the screens described above are shown on the following pages.
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Lane System Overview Screen Favorites

Statistics System Settings
Left-click to go to Login Alarms Wizards
Lane Overview Home Language
Online/
Offline
Help
Menu
Walk By
Part Heartbeat Graphic
Program Image
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Switch to Switch to System
Sensor View Overview
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Double click to Sensor View Screen Switch to System

open Inspection Overview
Switch to Lane
View
Overview
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Inspection Screen
To close the
Inspection View
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Log-In / Log-Out Icon
To Log In:
• Left-click here to open
the dropdown menu
shown
• Left-click on the down
arrow to display the list of
available users
• Select user – select your
name from the displayed
list, type in the correct
password, and you will be
logged onto the system at
the appropriate level
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Once logged in, if the

user clicks on this icon
a dropdown box will
appear. Depending on
the access level of the
user, the dropdown
will contain a different
list of available tasks.
The complete list is
described on the next
page.
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ALL USERS CAN:
• Logout - Will log out whoever is logged in
• Switch user - Allows user to switch from one user to another
• Change Password- Allows user to change his or her password only
• User Settings – This is not currently configured
YOUR LOG-IN ACCESS LEVEL MUST BE GIVEN PERMISSION TO:

Manage Users – Used to assign, remove, or edit users. This is also
where users are given access to specific tasks, i.e. one user is given
the access to edit inspections and another is not given this access
Import/Export - Allows user to import and export user profiles from
one Intellispec to another
Manage Permissions– This is where the system can be configured
to allow pre-defined tasks to be performed per role (Operator,
Mechanic, Administrator, Designer), per user, or with no log-in
Setup Auto Logout– This feature will automatically log-out the user
if there is no activity for a prescribed amount of time
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Menu Toolbar
HOME HELP
ALARMS LANGUAGE
SYSTEM WIZARDS
SETTINGS
FAVORITES
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Menu Toolbar
HOME – Anytime this icon is left-clicked it will take the
user back to the System Overview Screen. The only
exception to this is that if an inspection window is
open it must be closed before anything else can be
selected.
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ALARMS – Clicking on this icon displays a different window

depending on what screen you are on. From the System
Overview screen, you get the dropdown shown below.
UPS Shutdown Time – the

number of seconds that the
UPS will maintain power to
the system if AC power has
been lost. This allows for a
normal Windows shutdown.
CPU Temperature – displays

the current, warning, and
shutdown temperatures
associated with the
computer CPU. If a multiple
core computer is used it
displays the highest
temperature.
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ALARMS – From the Lane or Sensor View screens, when this

icon is selected you will get a dropdown menu for alarms
View/Clear Alarms – Selecting this

displays a pop-up that lists all
alarms, shows which ones are
active, which ones are in an
alarming state, and allows reset
To view the sensor alarms select

the appropriate sensor by either
clicking on the dropdown or
clicking on the desired sensor LED.
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ALARMS – From the Lane or Sensor view screens (continued)
Lane/Sensor Alarm Configuration –

Selecting either of these displays a
pop-up listing all alarms associated
with the Lane or Sensor. From this
pop-up the user configures each
alarm, i.e. enables or disables:
• the alarm itself
• the audible horn,
• the red light on the light tree
• Outputs that can be used to
drive PLC’s
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SYSTEM SETTINGS – Clicking on this icon displays a different

window depending on what screen you are on. From the
System Overview screen, you get the dropdown shown below.
Log Reader – Opens the Intellispec log for review by the user
Reset System Statistics – Allows user to reset the entire system statistics
(all Lanes) at once
Disk Imaging Software – Opens Acronis Echo software for backing up
system hard drive
CPU Temperature – Displays temp. in °C of each computer core
UPS Information – Displays UPS info. and settings
Hardware Web Pages – used by Pressco Engineers for electronic board
troubleshooting
Chart Configuration –Determines what parameters are used for the
chart displayed on the System Overview screen and the number of
divisions displayed on horizontal axis
Defect Database – Not currently supported
Exit System – Shuts down Intellispec software
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SYSTEM SETTINGS - From the Lane Overview screen, you

get the dropdown shown below.
The following pages will describe

each of these line items.
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SYSTEM SETTINGS - Lane Overview – Tools Menu - Reporting
• Lane Summary Report sends report

with total lane defect statistics to a
printer or a location chosen by user
using a format chosen by the user.
• Lane Detail Report sends report with
lane and sensor defect statistics
broken down to inspection level to a
printer or a location chosen by user
using the format chosen by the user.
• Schedule Reports allows user to set up
automatic generation of reports.
• Log Reader opens the Intellispec log
for review by the user (see next page).
• Sensor Missed Statistics displays the
number of missed parts for the lane
(see next page).
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SYSTEM SETTINGS - Lane Overview – Tools Menu - Reporting
Sensor Missed Statistics displays the number of:

1. Missed Results- inspections aren’t done when part is at the
rejecter
2. Lost Part Tracking - no communication from the host PC for
the number of parts as set by the Missing Packets Exception
3. Part Tracking Closed- no communication from the part tracker
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SYSTEM SETTINGS - Lane Overview – Tools Menu – Part Setup

• Advanced Adjust Lighting and Basic Adjust Lighting will be
discussed in the, “Chromapulse Lighting” section
• Clear All Defect Images removes all images from the
Reject Images buffer for that lane
• Change Part Type selects the type of part being displayed
on the Walk By for that Lane
• Set Cost Per Part sets the currency and cost of each
product, used with “Defect Cost” on the trend chart
• Image Analysis allows user to determine the exact
grayscale value for any pixel in the image, this is
discussed in detail later
• Part Width Calibration is described in the “Part Timing”
section
• Select Inspections For Charts selects up to 8 inspections
to be available for the Trend Chart and Timing Trend seen
on the Sensor View
• Select Measurements for SPC currently not used
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SYSTEM SETTINGS - Lane Overview – Tools Menu – Lane Setup
• Chart Configuration – sets the number of columns in the Trend

Chart and sets the currency type used in “Cost per Part”
• Change Lane/Sensor Name - assigns names to lanes and sensors
• Image Display Configuration – described on following pages
• Machine Part Correlation – described on following pages
• Manage Part Programs –described on following pages
• Misc. Configuration – described on following pages
• Rejecter Disable – described on following pages
• Select Sensor Rejecter – if more than one rejecter is used this
allows selection of which one is to be used by this lane
• Start/Stop Forced Reject – described on following pages
• Statistics Configuration – described on following pages
• Statistics Grid Configuration – described on following pages
• Walk By Setup - allows user to set up the group names,
inspections assigned to each group, and when the walk by image
turns green/yellow/red, described on following pages
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SYSTEM SETTINGS - Lane Overview– Lane Setup –

Image Display Configuration
Displays how often the
If correlation is used, checking this
image in the sensor view
box enables correlation info to be window is updated.
displayed on the Big Live Image view
This allows the user to

orient images. The image
can be rotated 0, 90, 180,
or 270° with respect to
camera position, or if an
orientation is used the
image rotated with
respect to an orientation.
They cannot be rotated
and oriented. This can
apply to the reject
images, sensor display
images (heartbeat), and
the Big Live Images.
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Machine Part Correlation
From this screen the user can

configure up to 4 different
machine parts for correlation.
Each machine part can be
named, assigned the correct
number of stations, and then
the offset bar is for calibrating
the displayed part with the
actual machine part.
This feature is usually set up by
the Pressco installer.
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Manage Part Programs
From this screen the user creates

new part programs or deletes,
edits, renames, imports and
exports existing part programs for
all the different products
inspected with the system.
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Miscellaneous Configuration
• Reject Missed Results – If checked,

any part that is seen as a “Missed
Result” will be rejected.
• Disable Inspection Warnings – If
checked, this disables the warning
feature if assigned to an inspection.
• Defect Database - This database is
not supported at this time. When
configured this will store the
information for rejected product.
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SYSTEM SETTINGS - Lane Overview– Lane Setup – Rejecter

Disable
From this screen the user
can disable the rejecter
at the Lane level or at
the Sensor level (if
multiple sensors are
configured on a lane):
• If one or more Sensors
is checked, the reject
for all inspections
performed by those
Sensors is disabled
• If all Sensors are
checked, the reject is
disabled at the Lane
level and an icon will
appear next to the Lane
window.
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SYSTEM SETTINGS - Lane Overview– Lane Setup – Start /

Stop Forced Reject
• Here the user can select to reject one

part, ‘N’ parts, or a continuous reject
from a specific machine part.
• If ‘Use Interval Between Parts’ is
checked user can insert the number of
parts in between rejects, i.e. if 3 is used
the system will reject every 3rd part.
• If ‘Use Correlation’ is checked user can
select which machine part from the list
below to reject.
• This toggles btwn. Start and Stop
• If more than one rejecter is enabled
user can select which rejecter is to be
used.
• If ‘Stop Forced Reject’ is selected it will
close the Forced Reject software.
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Statistics Configuration
• Last N – determines the value

for ‘N’ displayed on the
Statistics Grid (100-10,000).
• Parts per Update –
determines how often the
Trend Chart and Timing Trend
Charts are updated if “Parts”
is selected (500-10,000).
• Time per Update -
determines how often the
Trend Chart and Timing Trend
Charts are updated if “Time”
is selected in minutes (1-60).
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Statistics Grid Configuration
Checking these boxes determines

what information is shown on
the Statistics Grid screen.
These two slidebars allow the

user to enable/disable and
determine the setting for
warning and error limits applied
to the Statistics Grid screen.
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SYSTEM SETTINGS - Lane Overview– Lane Setup – Walk By Setup
This screen allows the user to set

up the Walk By Image. Each Lane
can be set up differently if needed.
Each area of the part graphic
display is:
• Assigned a group name
• assigned the correct
inspections for that group
• configured to turn the area
green, yellow, or red when
defined defect statistics are
achieved
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SYSTEM SETTINGS - Lane Overview – Tools Menu – Hardware Setup
• Camera Focus and Aperture allows adjustment of the focus

and aperture settings on auto-focus/auto-aperture lenses
• Delay Configuration provides a single location for all part
tracking info. (for Pressco Field Service Engineers only).
• I/O Diagnostics see following pages
• Extended I/O Diagnostics see following pages
• Correlation Diagnostics see following pages
• Offline Imaging see following pages
• Part Present Delay Calibration defined in Part Tracking sect.
• Part Tracker Simulation see following pages
• Reject Delay Calibration defined in Part Tracking section
• PDX Configuration only used by PDX users, defined in the
associated Training Addendum.
• Missed Packets Exception – see following pages
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I/O Diagnostics
This screen is used to verify the presence
of input and output signals.
The green lights are input signals (signals

that originate outside the Intellispec and
are communicated to the system). When
an input is received the light is on.
The red lights are output signals (signals

that originate inside the Intellispec and are
transmitted out of the system). When an
output is generated the light is on. An
output signal can be manually turned on
and off by left-clicking on the appropriate
light.
Part rate & encoder rate are also displayed.
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Extended I/O Diagnostics
This screen displays the inputs and outputs available on the extended I/O board if one
is installed on your system.
If one of the extended I/O ports is used it must be enabled here in the software as well
as the hardware being connected appropriately.
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Correlation Diagnostics
For those systems that have correlation

sensors, this screen is used to verify the
correlation sensor information is being
received by the system. It is a
troubleshooting tool.
As the production unit is operating, if the

correlation sensor is transmitting pulses
they will count up in the appropriate
window. For example, if you have a cavity
sensor attached to machine part 1 (MP1)
and are running a 8-cavity blow molder, you
will see MP1 increment up from 1-8
repetitively.
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Offline Imaging
Offline Imaging allows the user to snap
images when the Lane is offline.
• Continuous – using input from the
part detect sensor, pictures are taken
continuously at the rate established
on “Image Update Interval “
• Single Snap – using the part detect
sensor, an individual picture is taken
every time the button is clicked.
• Immediate – NOT using the PD
sensor, an individual picture is taken
every time the button is clicked
• Continuous Snap – camera and light
array take continuous pictures at the
rate determined by where you set
the Image Update Interval
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Part Tracker Simulation
• Part Tracker Simulation allows the user to

insert a simulated part rate in ppm (parts per
minute).
• This could be useful during troubleshooting
or if a part detect sensor is bad and a
simulated part rate would allow inspection to
continue.
• To do this you would left-click in the check
box and then enter the desired part rate in
the window.
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Missed Packets Exception
• For each part and for each camera, two
packets of information are communicated:
1. The part tracker sends the host PC a
signal stating the camera has been
triggered (correlation signal)
2. The host PC then sends a pass/fail
signal back to the tracker (results
signal) when the inspections are done
• A missed packet exception occurs when the
part tracker has sent out X number of
correlation signals without receiving any
results signals back from the PC. The default
is set at 21.
• When this number has been met a “Lost Part
Tracking” input is received on the Missed
Parts / Results software.
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FAVORITES - From the Lane Overview screen, you get the

dropdown shown below.
• The Defect Database is currently not supported until

the Intellispec operating system is converted to
Windows 7 with 64 bit memory.
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WIZARD -
From this icon the user can select wizards that assist in setting up certain features. At
the present time the only wizard configured is for setting up the Walk By image.
Selecting this line allows the user to select group names, inspections assigned to each
group, and what values turn the image green, yellow, or red, as discussed previously in
System Settings.
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LANGUAGES - From the Lane Overview screen, you get

the dropdown shown below.
In the future, as translations are completed,

they will be made available for selection here.
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HELP - From the Lane Overview screen, you get the

• Help Documents – Available

documentation is viewed here.
• Create Support Package –
described on following pages.
• Remote Support –for remote
support connectivity.
• About - Displays information on
the version of Intellispec
software that is loaded.
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HELP - Lane Overview – Help Icon – Help Menu – Create

Support Package
A Support Package is a tool that can be used if a software or computer-related problem

exists. It gathers a pre-designated set of files, zips these files into a smaller packet of
information, allows the user to download this zipped packet to a different medium, and
then this can be e-mailed to Pressco. Pressco software Engineers could then unzip this
packet to view the files and therefore troubleshoot the problem.
Step 1: displays Pressco contact information
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HELP - Lane Overview – Help Icon – Help Menu – Contact

Support
Step 2: provides a block where the user can type a description of the problem. This
description will be attached to the data packet. It is always helpful to be as detailed
as possible when describing the problem in that it makes the troubleshooting effort
more efficient.
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Support
Step 3: this step occurs automatically to gather all of the pre-designated files
and zip them into a compact data packet.
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Support
Step 4: this step tells you the data packet is stored on the Intellispec hard drive at
C:\Pressco\Support, and gives the user the ability to copy this packet to another
media so that it can be e-mailed to Pressco.
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HELP - From the Lane Overview screen, you get the

Remote Support is used to allow remote access to the Intellispec software. This
is the method used by Pressco to provide remote system support if a
Maintenance Agreement is purchased for that Intellispec. With this software
Pressco can log-in and operate the Intellispec remotely.
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Online / Offline
• Going online/offline
applies to each Lane. If
multiple lanes are
configured, one can be
offline while another is
online.
• The stoplight is the
online/offline indicator. A
red light indicates the
lane is offline, a green
light indicates the lane is
online.
• To place the lane online
or offline, left-click on the
stoplight.
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These tabs determine the parameters displayed on the horizontal and
vertical axis of the Trend Graph as well as the parameter being graphed
These buttons
determine what
is displayed in
Lane the lane
Statistics graphics
window to the
left
Additional Lane
Sensor
Statistics
info. can be
displayed by
selecting “More
Lane
Information”
(see next page)
These tabs determine what is displayed in the sensor

graphics windows above
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Lane Overview Screen (cont’d.)

When “More Lane Information” is selected two additional graphic windows open so that the
user can simultaneously display multiple and different lane graphics as seen below.
These buttons
determine what
info. is displayed in
the graphics
windows to the left.
(the next several
pages describe the
available options)
To return to the
default lane
overview screen
display, select
“Sensor Information”
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Reject Images –
displays the last 100
rejected images from
that lane. Left-clicking
on an image
1)opens the sensor
view for that part
2)shows what
inspection failed
3)allows magnification
of the image
Trend Graphs – displays a

trend chart using input
from the 3 dropdown
selections: 1-vertical axis
using parts or time; 2-
horizontal axis using
defect count, %, or cost;
3-parameter being
Statistics– displays a chart graphed using lane,
showing the defect statistics for sensor, or group.
sensors or groups
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Right-clicking on the lane
statistics box opens the
following dropdown menu:
•Reset Lane Statistics – re-
zeros all lane statistics
• Reset Lane Statistics and
Clear Images – resets
statistics and empties the
defective image buffer
• Print Lane Report – prints
or downloads the Lane
Summary Report
• Statistics Last Reset –
displays date and time of
when statistics were last
reset
Left-clicking on a sensor box
will open the Sensor View
Screen (next page)
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Sensor View Screen INSPECTION TREE

The Sensor View Screen
displays a view of the
product as well as the
inspection tree.
Two additional menu
items appear:
•Timing Trend –a
trend chart displays
the time required to
run inspections
• Big Live Image –
displays a larger than
normal image of the
last part inspected
Timing Trend and Big
Live Image are shown
Left-clicking the View Icon –
• In the Edit Mode the inspection tree shows on the next two pages
sensor box sends you
back to the Lane inspections only
Overview Screen • In the Designer View the inspection tree shows
regions, inspections and enhancements
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Sensor View Screen (cont’d.)

Timing Trend –
• Horizontal axis – can
be selected to either
Parts or Time
• Vertical axis – the

time in ms
• Series – can be
selected to either
Sensor Total (up to 8
inspections for that
sensor), or any
individual inspection
out of the 8 selected
for that sensor
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Big Live Image –

• This is selected by
left-clicking on the
associated button
• Big Live Image will

display a large image
of the last part that
was inspected
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From the Sensor View Screen, when the “Reject Images” view is selected the
following image enhancements can be selected:
1. Left-clicking on the screen opens a magnifier which can be
moved by moving the mouse.
2. Right-clicking on the image displays a dropdown to select the
level of magnification for the entire image area (2X, 4X, or 6X)
3. When a level of magnification is selected the image is
1 displayed using that level of magnification. You can move the
image by clicking on the green arrows in the upper left-hand
corner.
2
3
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Image Analysis –
This tool places a movable red line
or circle on the image and displays:
1. position of markers on the line
2. gradient between marker
locations
3. grayscale of the pixels where
the markers are located
4. graphic of grayscale value for
all pixels on the line or circle
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Sensor Menu –
NOTE: The Lane must be offline to access the
top 5 Items in the Sensor Menu.
Right-click on the sensor window to display
this menu with the following choices:
• Camera Gain and Offset
• Part Tracking
• Offline Imaging
• Image Analysis
• Lighting
------------------------------
• Options
• Inspection Change Log
Sensor Manu choices are displayed on the
following pages.
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Camera Gain and Offset –

• These parameters are normally set during installation by the Pressco installer
and should not be adjusted without confirmation from Pressco. Improper
adjustment of these parameters could cause a distortion of the image.
• Camera Gain is the amplification of the video signal
• Offset adjusts the grayscale reference values
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Part Tracking –
• This opens the part timing software that
allows for calibrating the Part Present Delay,
the Reject Time Delay, the Reject Dwell, and
the Part Width.
• Each of these parameters will be defined and
Part Timing will be discussed in the “System
Timing / Part Tracking” section.
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OFFLINE IMAGING allows the user to snap images when the Lane is offline.
• Continuous – using input from the part detect (PD) sensor, pictures are taken continuously at the
rate that parts are being presented under the camera.
• Single Snap – using the PD sensor, an individual picture is taken every time the button is clicked
and a part goes by.
• Immediate – NOT using the PD sensor, an individual picture is taken immediately every time the
button is clicked.
• Continuous Snap – camera and light array take continuous pictures at the rate determined by
where you set the Image Update Interval
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Image Analysis –
Allows user to determine the exact grayscale value for any pixel in the image.
User can place a red line/circle anywhere on the image, then the graphic displays the
grayscale for every pixel on the line as well as the difference in grayscale (i.e. the
gradient) between any two pixels.
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Lighting –
• Opens either the Basic or
Advanced Lighting
software.
• Lighting is discussed later
in the “Chromapulse
Lighting” section.
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Options –
• With this the user can select what is displayed in the inspection tree, can display
• Icons
• Symbols
• Pressco inspection names vice inspection names as they were renamed by plant
personnel
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Inspection Change Log –
• This log displays changes that have been made to
inspection parameters.
• Log entry details can be displayed by clicking on an entry
and then “Details”
• “Filter” button allows filtering of displayed log entries
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TOPIC NOTES
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SECTION 4
DISCOVERY SOFTWARE
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What is Discovery?
“Discovery” is software installed on the Intellispec hard drive that automatically looks for
and then identifies certain components installed on each lane. Specifically, this software
identifies any Cameras, Lighting Drivers, Part Trackers, and if used, Intellimass Drivers that
are attached to the system. Each one of these devices communicates with the Intellispec
software via Cat-6 cabling and is assigned a unique MAC address.
It is anticipated that end-users of our system will rarely need to use this software; however,
if a new component (i.e. camera) is installed on the system this software would be used to
configure the new camera with the Intellispec software.
Additionally, during system start-up if a previously configured component fails to
communicate with the Intellispec software, the Discovery Software screen will
automatically appear on the user interface, alerting you of the problem.
The following slides will familiarize you with the Discovery screen and then show you how
to access and use this software.
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Discovery Software Screen

1. The tree on the left side of the
page shows the system
1 configuration including the
3
lanes and the name and MAC
address of each component in
that lane.
a. Unassigned hardware
devices are shown in red.
b. Missing hardware devices
are shown in orange.
2 2. This menu allows the user to
perform specific actions, such
as add or edit lanes or sensors,
by clicking on the designated
button.
3. On the top right corner is the
menu toolbar, which allows
the user to perform additional
actions. These actions are
described on the next slide.
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Discovery Menu Toolbar

TOOLS MENU
• Hardware Web Pages – This is software used by
Pressco Engineers to access component information
for troubleshooting.
• Rediscover New Hardware – When this command is
initiated the software will perform another search of
all hardware communicating with the Intellispec and
display it in the tree on the left side of the screen.
• Add Simulated Devices for Testing – This is software
used by Pressco Engineers to assign devices on an
Intellitrainer.
• Inspection Module Preset Editor – This is software
used by Pressco Engineers to assign data for new
components as they become available.
WIZARDS MENU – Lists the same choices as those listed
in the green buttons in the center of the screen.
LANGUAGE MENU – Displays language choices that can
be displayed.
HELP – Provides software assistance for users.
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Accessing and Use of Discovery
• The initial configuration of all hardware devices will be performed by the Pressco installer, and it
is not anticipated that plant personnel will normally need to utilize Discovery software.
• The Discovery screen is automatically displayed during system start-up anytime a hardware
device that was previously configured is not communicating with the Intellispec software.
• An example of a situation where plant personnel may use the Discovery software and actions to
be taken follows:
o During system start-up a camera does not communicate with the Intellispec software.
o The Discovery software sees this as a missing piece of hardware and automatically displays
the Discovery screen. The configuration tree shows the camera in the expected location
but displayed in orange, indicating that this hardware device is missing.
o As a first step the user should open the Tools Menu Icon (the wrench) and select
“Rediscover New Hardware”, this will trigger the software to initiate a search for the
missing camera.
o If the camera re-establishes communication, as seen by the camera name changing to
black, the user can close the Discovery software and resume normal operation.
o If the camera does not re-establish communication this indicates a hardware problem and
the camera will most likely need to be replaced.
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TOPIC NOTES
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SECTION 5
CHROMAPULSE LIGHTING
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Accessing the Lighting Software
The easiest way to access the Chromapulse Lighting software is to right-click on the desired
sensor window, and select Lighting. Normally you will select the Basic Lighting selection.
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Basic Lighting Software Upper right corner displays each zone. A zone is selected for
adjustment by left-clicking on it. A single zone or multiple
zones can be selected at any one time. As lighting is changed
the zone and the button next to it change color.
Separate slider bars for

each color (red, green,
blue, and infrared)
allow individual
adjustment.
Incremental Mode
If “proportional %” is
checked, moving the
slider bar adjusts all
colors but maintains the
current percentage of
each color.
If “Equal %” is checked,
moving the slider adjusts
all colors an equal
amount.
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Advanced Lighting Software

Opens a color palette and Pixel Smear
By Section allows changing lighting allows user to choose Evaluates the amount of
by each individual section. pre-selected colors. pixel smear based on
By Color allows changing lighting lighting, image size, and
for multiple sections at once. part rate. (Setup Req’d.)
Should be kept below 1.
On-Screen Keypad (OSK)

When a slidebar is
selected, this keypad
allows user to type in the
desired number which is
shown in the window
above the keypad.
A – B Buttons
Allow user to set up two
different lighting settings
for the same part so you
can view each and
compare.
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TOPIC NOTES
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SECTION 6
SYSTEM TIMING /
PART TRACKING
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Sequence of Events
Part Detected Image Processed

Reject Decision
Image Acquired
Part Movement
Part Width
Reject Position
Camera 1 Position
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Part Timing Terminology

Part Width –
The number of encoder pulses that the part detect sensor “sees” the part.
Part Present Delay –
The distance (in encoder pulses) from the part detect sensor to the camera
centerline. When this circuitry is met two independent signals are generated to:
1) have the lights strobe on, and 2) have the camera snap an image.
Reject Time Delay –
The distance (in encoder pulses) from the part detect sensor to the rejecter. This
signal ensures the correct part is rejected.
Reject Dwell or Reject Pulsewidth –
The duration (in milliseconds) of the reject signal. This signal must be long
enough to ensure the part is efficiently rejected, and short enough to ensure that
only one part is rejected for each reject pulse.
Reject Confirm (if used) –

The distance in encoder pulses from the rejecter to the reject confirm sensor.
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Accessing the Part Timing Software
The easiest way to access the Part Timing software is to right-click on the desired
sensor window, and select Part Tracking. The Part Width must be calibrated first.
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Calibrating the Part Width
To perform the calibration you must be After enough parts have gone by, click on
running parts past the part detect sensor. “Stop Calibration” and the calibration data is
Left-click on “Start Calibration”, and as displayed. Ensure the minimum and maximum
parts go by the software gathers readings are within ~10 encoder ticks of the
information, and displays the part width (in mean value. If you agree with the calibration
encoder pulses) of each part in the data, click on the green check mark, if not,
“Encoder Ticks” window. click on the red X and re-calibrate.
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Calibrating the Part Present Delay
To calibrate the part present delay:

• Select the same screens as before but this time you
select ‘Part Present Delay Calibration”.
• Select “Start Calibration”
• Run a part by the part detect sensor. It will trigger the
part detect sensor, count out the number of encoder
ticks displayed on the screen and take a picture.
• Repeat this adjusting the part present delay until the
image is centered every time a part is run through the
system.
• When completed, select “Stop Calibration”.
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Calibrating the Reject Time Delay and Dwell
Calibrating the Reject Delay and Dwell:

• Select “Reject Delay Calibration”
• Run a part through the system. After the
number of encoder ticks shown on “Reject
Delay” the rejecter will be activated.
• Repeat this adjusting the reject delay until
the part is rejected every time.
• Adjust the Reject Dwell so it’s long enough
to completely reject the part, and short
enough that only one part is rejected for
each reject pulse.
• When completed, select “Stop Calibration”.
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Calibrating the Reject Confirm (if used)
Calibrating the Reject Confirm:

• Select “Reject Confirm Calibration”
• Ensure the Reject Confirm has been enabled
• Run a part through the system
• When completed, select “Stop Calibration”
• The circuitry will determine the number of
encoder pulses from the part detect sensor
to the reject confirm sensor
• The value for the reject delay is subtracted
from the value established above, and this
number is established for the reject confirm
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TOPIC NOTES
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SECTION 7
COMMONLY PERFORMED
TASKS
• System Power-up and Power-down
• Part Changeover
• Report Setup
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System Power-Up and Power-Down

NOTE:
• The host PC and each of the integrated camera/sensor modules have their own power
on/off switches.
• Since the user interface and inspection modules are independent the sequence of which
unit to power on first is unimportant.
POWER-UP:
1. To power up the user interface and the vision processor, turn on the switch on the side of
the system cabinet.
2. To power up each of the camera/sensor modules that will be used:
a. Turn on the switch on the top of the camera/sensor module, or
b. If a cluster box is being used turn on the rotary switch on the side of the cluster box.
1 2a 2b
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System Power-Up and Power-Down
POWER-DOWN:
1. Individual camera/sensor assemblies can be powered down while the rest of the
system continues to run, (i.e. for individual camera/sensor maintenance). To power
down an individual camera/sensor, turn off the switch on the top of the
camera/sensor assembly.
2. To power down the whole system:
a. Turn off the switch on the top of all camera/sensor assemblies, or
b. If a cluster box is being used, turn off the rotary switch on the side of the cluster
box, then
c. Turn off the switch on the side of the system cabinet
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Part Changeover
Part Changeover –
• Go to the applicable Lane Overview
screen
• Left-click on the window that
displays the part list
• Select the desired part that you are
going to run
• The system will re-align to assign
the proper inspection parameters
and lighting for the selected part
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Report Set-up
• Go to the Lane Overview screen
• Left-click on the Wrench icon
• Select “Reporting” then select
“Schedule Reports”
• Click on the checkbox “Enable
Scheduled Report”
• Select the location where you
want the report to be sent and
name the file
• Determine whether you want the
report to keep the same name
• Determine if you want the
statistics reset when the report is
generated
• Select the time you want the
reports to be printed and the time
in between prints
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TOPIC NOTES
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SECTION 8
SERIES 5 HARDWARE
AND MAINTENANCE
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HARDWARE OVERVIEW
INTELLISPEC CABINET AND USER INTERFACE

• External Connections
• Process Computer
• Ethernet Switches
CAMERA MODULES
• External view
• 8-Port Box
• Internal Wiring Connections
• Power Supply Panel
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Series 5 User Interface
Main Power
Panel
PC Power Monitor
Connector Power
Connector
Main CB
Switch
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Top View of PC
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User Interface PC
Side Cable
Entry Route cables behind
the PC mounting panel
and thru the cable
entry at the back of
Ethernet Switches the PC
are located in the
upper
compartment
(None Shown in
this drawing) Side Cable
Entry
PC
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Ethernet Switch
Connections
NOTE: The Cat-6 Ethernet cabling is divided into two groups. The
green cabling goes to/from the cameras and lighting circuitry. The blue
cabling goes to/from the part tracking circuitry.
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Typical Inspection Module
Power
Panel
8-Port I/O
Box
(See next page)
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8-Port I/O Box – MB1
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Typical Inspection Module Internal Wiring
ON/OFF Switch &

Power Available
LEDs
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Power Supply Panel Power In
ON/OFF
Switch
PS1 provides 12vDC to all logic boards and

camera power
PS2 provides 24vDC to all sensors (part
detect, encoder, rejector, correlation
sensors)
PS3 provides 48vDC to all light array LED’s
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MAINTENANCE OVERVIEW
• SUGGESTED PERIODIC MAINTENANCE

• GLASS CLEANING
• PLASTIC CLEANING
• PART DETECT CLEANING
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Intellispec Processor Cabinet and General Components

Item Description Daily Once / Once /
Week Month
Observe proper Verify defective parts are being rejected by inserting a
X
inspection known defective part thru system.
Observe proper Verify no stray parts are stuck in or near the inspection
X
inspection module or reject station
Observe proper Verify no buildup of dirt or contaminants on inspection
X
inspection module or part detector. Clean if necessary.
Observe proper Verify each channel’s image is centered and properly lit.
X
inspection
Vision Processor Rinse in clean water; use mild soap and water solution if
X
Filter oily.
Cluster Box Filters Rinse in clean water; use mild soap and water solution if
X
(if applicable) oily.
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Inspection Modules Chromapulse

Item Description Daily Once / Once /
Week Month
Part Detect Clean with soft, clean, oil-free cloth dampened w/mild
X
sensor/ reflector soap and water solution. Wipe dry.
Camera Lens Clean only w/lens tissue & lens cleaner. Do not to alter
X
focus or aperture.
Glass Surfaces: Clean w/soft, clean, oil-free cloth dampened w/lens
Beam Splitter and cleaning solution. X
Secondary lens
Ellipsoidal Mirror Normally does not need cleaning. If dirty, blow off dust As
w/clean compressed air. Needed
Plastic Surfaces: Clean with soft, clean, oil-free cloth dampened w/mild
Dome light or Ring soap and water solution. Wipe dry. X
light diffusers
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Optical Surface Cleaning

NOTE: Debris and contamination can build up on both glass and plastic surfaces, appearing
in the inspection window and causing false rejects. Clean glass and plastic surfaces often
and anytime dirt becomes visible in the inspection window to avoid false rejects.
Glass Cleaning
• Blow off dust with canned compressed air
• Use a clean non-abrasive cloth dampened with a lens cleaning solution
• Use a lens tissue and lens cleaning solution on camera lenses
• If surface has compound on it, clean w/alcohol, then with lens cleaning solution
Camera Lens Cleaning
• Clean all camera lenses once per month with lens tissue and lens cleaning solution
• Be careful not to alter position of the focus or aperture on the camera
Plastic Cleaning
• Use canned compressed air to blow away dust, DO NOT wipe away dirt as plastic
coating may be scratched
• Use a clean non-abrasive cloth dampened with a mild soap and water solution.
Saturate surface completely to let particles wash away. DO NOT use paper towels or
paper napkins as these may scratch surfaces.
• Dry the surface with clean, compressed air.
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Optical Surface Cleaning

Beam Splitter Cleaning (Only on some inspection modules)
• Remove Beam Splitter to access the bottom side, may need to raise camera to access
the Beam Splitter (be sure to note camera position before moving it)
• Blow off dust with canned compressed air
• Clean glass on Beam Splitter as described earlier in Glass Cleaning
• If equipped with a diffuser inside the Beam Splitter, this must be cleaned as well as
described earlier in Plastic Cleaning
• Replace the Beam Splitter assembly
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Part Detect Cleaning
• Depending on the product, the part detect sensor is normally either a

proximity sensor (metals) or a fiber optic sensor (plastic).
• The part detect sensor must remain clean in order to properly detect parts. The
surface of these sensors must be cleaned regularly to prevent dirt and oil build-
up.
• Clean the part detect sensor surfaces with a soft, clean, lint free cloth
dampened with a mild soap and water solution. Clean the sensors on both
sides of the conveyor (if applicable).
• Do not use glass cleaning solution or strong solvents on plastic surfaces as they
might be damaged.
• The frequency of cleaning will depend on plant and process conditions.
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TOPIC NOTES
133

Intellispec Training Guide: The Vision To Innovate, The Technology To Excel™

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the vision to innovate, the technology to excel™

1 INTELLISPEC SYSTEM OVERVIEW 3-8

2 VISION INSPECTION THEORY & CONCEPTS 9-18

3 INSPECTION SYSTEM USER INTERFACE 19-84

4 DISCOVERY SOFTWARE 85-92

5 CHROMAPULSE LIGHTING 93-98

6 SYSTEM TIMING / PART TRACKING 99-108

7 COMMONLY PERFORMED TASKS 109-116

8 SERIES 5 HARDWARE AND MAINTENANCE 117-133

Intellispec Cabinet and User Interface

Trackball with two Vision

Typical Chromapulse Module

Part Present Delay

Reject Time Delay

 Each pixel is assigned a

Gray Level Distribution

190 190 187

186 190 192 185 188

189 191 193 191 190

185 115 112 105 115 183 189

180 105 10 10 107 180 185

185 103 10 10 106 182 188

186 115 112 105 115 185 187

188 185 188 184 185 186 188

188 189 188 190 189

190 188 192 191 190

191 190 190

0 5 95 110 5 100 105 0 5 10

240 235 241 240 180 65 62 68 65 190 235 240

0 55 176 178 112 0 125 167 175

240 235 241 240 180 65 62 68 65 190 235 240

Gradient = 12.7 Gradient = 8.7

(13 + 8 + 6) / 3 = 9 (18 + 25 + 22) / 3 = 21.7 (42 + 57 + 51) / 3 = 52 (31 + 45 + 54) / 3 = 43.3

USER INTERFACE DISPLAY

Lane System Overview Screen Favorites

Lane Overview Screen

Double click to Sensor View Screen Switch to System

Log-In / Log-Out Icon

Log-In / Log-Out Icon

Once logged in, if the

Log-In / Log-Out Icon

YOUR LOG-IN ACCESS LEVEL MUST BE GIVEN PERMISSION TO:

ALARMS – Clicking on this icon displays a different window

UPS Shutdown Time – the

CPU Temperature – displays

ALARMS – From the Lane or Sensor View screens, when this

View/Clear Alarms – Selecting this

To view the sensor alarms select

ALARMS – From the Lane or Sensor view screens (continued)

Lane/Sensor Alarm Configuration –

SYSTEM SETTINGS – Clicking on this icon displays a different

SYSTEM SETTINGS - From the Lane Overview screen, you

The following pages will describe

SYSTEM SETTINGS - Lane Overview – Tools Menu - Reporting

• Lane Summary Report sends report

SYSTEM SETTINGS - Lane Overview – Tools Menu - Reporting

Sensor Missed Statistics displays the number of:

SYSTEM SETTINGS - Lane Overview – Tools Menu – Part Setup