I.

Table of Contents
I. Table of Contents ............................................................................................................. 2
II. Copyright, Disclaimer & Trademarks ................................................................................. 9
I. Copyright ........................................................................................................................................ 9
II. Disclaimer ....................................................................................................................................... 9
III. Trademarks ..................................................................................................................................... 9
III. Introduction to Technology ............................................................................................ 10
The Coherix 3D Advantage ................................................................................................................... 10
IV. Basic Principles of Operation .......................................................................................... 11
Laser Line Projection ............................................................................................................................ 11
Laser Triangulation............................................................................................................................... 11
Mounting Offset ................................................................................................................................... 11
Z-Axis Range & Calibration ................................................................................................................... 12
Tilt Determination ................................................................................................................................ 12
Tilt Angle & Measurement Compensation........................................................................................... 13
V. Tool Center Point Method vs. Spline Method.................................................................. 14
TCP Integration Overview .................................................................................................................... 14
TCP Setup Benefits ............................................................................................................................... 14
TCP Maintainability Benefits ................................................................................................................ 14
What Can’t TCPs or Splines Handle? .................................................................................................... 14
VI. Coherix File Transfer Site ................................................................................................ 15
Accessing the Site................................................................................................................................. 15
Software (current version) ................................................................................................................... 16
Software (previous versions) ............................................................................................................... 16
Firmware and FPGA.............................................................................................................................. 16
Project Updates.................................................................................................................................... 17
Documentation .................................................................................................................................... 17
Data Sheets .......................................................................................................................................... 17
Videos 17
CAD Drawings ....................................................................................................................................... 18
Communication Setup.......................................................................................................................... 18
Example/Sample Submission Instructions ........................................................................................... 18
1. Receiving the Predator3D and Predator3D Pro ............................................................... 19
Factory Calibration and Testing ............................................................................................... 19
Electrostatic Sensitive Device .................................................................................................. 19
Unpacking the Predator3D................................................................................................................... 19
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 Unpacking the Predator3D Pro ............................................................................................................ 21
Confirmation Checklist ......................................................................................................................... 22
2. Hardware Overview - Predator3D ................................................................................... 23
Sensor – Top ......................................................................................................................................... 23
Sensor – Bottom................................................................................................................................... 24
Casing & Operating Temperature ........................................................................................................ 24
3. Hardware Overview - Predator3D Pro............................................................................. 25
Sensor Head – Top ............................................................................................................................... 25
Sensor Head – Bottom ......................................................................................................................... 26
Processor – Front and Side .................................................................................................................. 26
USB – C Cable ....................................................................................................................................... 27
Casing & Operating Temperature ........................................................................................................ 27
4. Required Hardware - Predator3D ................................................................................... 28
12-Pin Power Cable (not included) ...................................................................................................... 28
Power Supply (not included) ................................................................................................................ 29
4-Pin D-Coded Ethernet Cable (Not Included) ..................................................................................... 29
Human Machine Interface – HMI PC (may be purchased from Coherix or customer supplied) ......... 30
5. Required Hardware - Predator3D Pro ............................................................................. 31
5-Pin Power Cable (Not Included) ........................................................................................................ 31
Power Supply (not included) ................................................................................................................ 32
8-Pin X-Coded Ethernet Cable (Not Included) ..................................................................................... 32
Human Machine Interface – HMI PC (may be purchased from Coherix or customer supplied) ......... 34
6. Setting up the HMI PC .................................................................................................... 35
Configure IP Address of HMI ................................................................................................................ 35
Confirmation Checklist ......................................................................................................................... 39
Setting Credentials & Shared Drives for Remote Desktop ................................................................... 40
Confirmation Checklist ......................................................................................................................... 44
7. Pre-Mounting Validation - Predator3D ........................................................................... 45
Power Connection ................................................................................................................................ 45
Ethernet Connection ............................................................................................................................ 45
Status LEDs ........................................................................................................................................... 45
Laser Safety – Predator3D.................................................................................................................... 48
Open Laser Safety Shutters (if so equipped)........................................................................................ 48
Confirmation Checklist ......................................................................................................................... 49
8. Pre-Mounting Validation - Predator3D Pro ........................................................... 50
Connecting the Processor to the Sensor Head ........................................................................ 50

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 Power Connection ................................................................................................................................ 51
Ethernet Connection ............................................................................................................................ 51
Status LEDs ........................................................................................................................................... 52
Laser Safety – Predator3D Pro ............................................................................................................. 53
Open Laser Safety Shutter (if so equipped) ......................................................................................... 54
Confirmation Checklist ......................................................................................................................... 54
9. Pre-Mounting Validation - Predator3D Pro.2 .................................................................. 55
Connecting the Processor to the Sensor Head .................................................................................... 55
Power Connection ................................................................................................................................ 56
Ethernet Connection ............................................................................................................................ 56
Status LEDs ........................................................................................................................................... 57
Laser Safety – Predator3D Pro.2 .......................................................................................................... 58
Confirmation Checklist ......................................................................................................................... 59
10. Windows Settings Validation .......................................................................................... 60
Test Remote Desktop Connection ....................................................................................................... 60
Confirm System Settings ...................................................................................................................... 62
Configure Predator3D IP Address ........................................................................................................ 63
Confirmation Checklist ......................................................................................................................... 65
11. Mounting the Predator3D/Predator3D Pro ..................................................................... 66
Bracket Considerations ........................................................................................................................ 66
Electrical Grounding Considerations .................................................................................................... 68
Collision Considerations ....................................................................................................................... 69
12. Updating the Predator3D/Predator3D Pro ...................................................................... 70
Updating Software – Predator3D ......................................................................................................... 70
Updating Software – Predator3D Pro .................................................................................................. 71
Updating Predator Project ................................................................................................................... 71
Updating Documentation..................................................................................................................... 71
13. Interacting in the Software (i-Cite).................................................................................. 72
Control Overview ................................................................................................................................. 73
User Help .............................................................................................................................................. 76
i-Cite Status Bar .................................................................................................................................... 79
User Access Levels................................................................................................................................ 80
GO: Go Online ...................................................................................................................................... 81
STOP: Go Offline................................................................................................................................... 82
PART: Changing the Active Part ............................................................................................... 83
LEARN: Setting up an Inspection .............................................................................................. 84
BACKUP: Performing a Project Backup ................................................................................................ 84
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 RESTORE: Performing a Project Restore .............................................................................................. 86
Predator3D Control Panel .................................................................................................................... 90
14. Post-Mounting Validation for Predator3D System........................................................... 91
Validate the Nozzle Position ................................................................................................................ 91
Validate the Mounting Offset .............................................................................................................. 92
Validate Electrical Grounding............................................................................................................... 93
Confirmation Checklist ......................................................................................................................... 93
15. Setting Up Communication ............................................................................................. 94
Configure Digital I/O Map .................................................................................................................... 94
Confirmation Checklist ......................................................................................................................... 97
16. Setting Imager Windows ................................................................................................ 98
Confirmation Checklist ....................................................................................................................... 104
17. Setting Imager Brightness ............................................................................................. 105
Confirmation Checklist ....................................................................................................................... 110
18. Saving TCP Data ........................................................................................................... 111
Pedestal TCP Setup (FANUC robots only) .......................................................................................... 114
Confirming Register Mapping ............................................................................................................ 116
Confirmation Checklist ....................................................................................................................... 118
19. Acquiring Image Scans .................................................................................................. 119
Preparatory Tasks............................................................................................................................... 119
Acquiring Scans .................................................................................................................................. 119
Confirmation Checklist ....................................................................................................................... 122
20. Creating a Template Image ........................................................................................... 123
Creating a Singular Template Image .................................................................................................. 123
Confirmation Checklist ....................................................................................................................... 130
Creating a Mosaic Template Image.................................................................................................... 131
Confirmation Checklist ....................................................................................................................... 138
21. Setting up the Active Part Style – Preliminary Setup ..................................................... 139
Preparatory Tasks............................................................................................................................... 139
Load a Saved Image Scan ................................................................................................................... 139
Enter Learn Mode .............................................................................................................................. 141
Confirmation Checklist ....................................................................................................................... 142
22. Setting up the Active Part – Spline Method ................................................................... 143
Setup Part Style - Splines ................................................................................................................... 143
Edit Spline Paths ..................................................................................................................... 147
Edit Tracks .............................................................................................................................. 154

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 Edit Marks .......................................................................................................................................... 157
Confirmation Checklist ....................................................................................................................... 164
23. Setting up the Active Part – TCP Method ...................................................................... 165
Setup Part Style - TCPs ....................................................................................................................... 165
Learn Template Tool Center Points.................................................................................................... 168
Confirmation Checklist ....................................................................................................................... 175
Learn Adjust Tool Center Points......................................................................................................... 176
Confirmation Checklist ....................................................................................................................... 180
24. Setting up the Active Part – Finalizing the Setup ........................................................... 181
Compute Recipes ............................................................................................................................... 181
Edit Zones ........................................................................................................................................... 182
Validate the Setup .............................................................................................................................. 186
Confirmation Checklist ....................................................................................................................... 186
25. Configuring Reporting .................................................................................................. 187
Reporting Overview ........................................................................................................................... 188
Change Frame Results Report Folder (OPTIONAL) ............................................................................ 190
Change Default Names....................................................................................................................... 193
Change Reporting Options ................................................................................................................. 194
26. Data Management ....................................................................................................... 195
Scan Save............................................................................................................................................ 195
Panel - Data Management ................................................................................................................. 195
Timed Event Map ............................................................................................................................... 201
Appendix: Maintenance for Predator3D/Predator3D Pro ...................................................... 203
Cleaning – Laser & Imager Windows ................................................................................................. 203
Appendix: Head Angle Adjustments ...................................................................................... 204
Appendix: Sync to Feature Setup .......................................................................................... 208
Preparatory Tasks............................................................................................................................... 208
Setting up Sync to Feature ................................................................................................................. 209
Confirmation Checklist ....................................................................................................................... 215
Appendix: Feature Tool Setup ............................................................................................... 216
Preparatory Tasks............................................................................................................................... 216
Interacting with Feature Tools ........................................................................................................... 217
Interacting with Feature Tools while Online ...................................................................................... 224
Validate the Setup.............................................................................................................................. 228
Confirmation Checklist ........................................................................................................... 228
Appendix: District Setup ............................................................................................. 229

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 Accessing the Edit Districts Page........................................................................................................ 229
Interacting with Districts .................................................................................................................... 232
Interacting with Districts while Online............................................................................................... 237
Appendix: Learn Surface Setup ............................................................................................. 239
Preparatory Tasks............................................................................................................................... 239
Enabling Learn Surface ....................................................................................................................... 240
Validate the Setup .............................................................................................................................. 242
Confirmation Checklist ....................................................................................................................... 242
Appendix: Robot Assist ......................................................................................................... 243
Robot Assist Interface ........................................................................................................................ 244
Z Distance ........................................................................................................................................... 245
Angle 245
Robot Tool X/Y Angles ........................................................................................................................ 245
Predator3D Coordinate Check ........................................................................................................... 245
Interacting with Robot Assist ............................................................................................................. 249
Confirmation Checklist ....................................................................................................................... 251
Appendix: Upgrade Codes ..................................................................................................... 252
Appendix: Auto Repair Setup ................................................................................................ 253
Setting up Auto Repair ....................................................................................................................... 253
Repair Troubleshooting Check List..................................................................................................... 256
Validate the Setup .............................................................................................................................. 258
Confirmation Checklist ....................................................................................................................... 258
Appendix: Shape Tools Setup ................................................................................................ 259
Preparatory Tasks............................................................................................................................... 259
Configuring Shape Tools..................................................................................................................... 259
Interacting with Shape Tools while Online ........................................................................................ 268
Validate the Setup .............................................................................................................................. 271
Confirmation Checklist ....................................................................................................................... 271
Appendix: Configuring Specific i-Cite Login Information ........................................................ 272
Confirmation Checklist ....................................................................................................................... 273
Appendix: Advanced HMI Setup............................................................................................ 274
Removing Log in Credentials on the HMI........................................................................................... 274
Confirmation Checklist ....................................................................................................................... 276
Naming/Renaming the HMI PC .......................................................................................................... 277
Confirmation Checklist ........................................................................................................... 280
“Always on Display” for the HMI............................................................................................ 281

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 Confirmation Checklist ....................................................................................................................... 282
Appendix: i-Cite Network Discovery Tool (INDT) ................................................................... 283
Downloading the Tool ........................................................................................................................ 283
INDT Information ............................................................................................................................... 283
Appendix: Possible Remote Desktop Issues ........................................................................... 284
Possible Solutions #1.......................................................................................................................... 284
Scenario #2 ......................................................................................................................................... 285
Scenario #3 ......................................................................................................................................... 287
Possible Solutions #3.......................................................................................................................... 287
Scenario #4 ......................................................................................................................................... 287
Possible Solutions #4.......................................................................................................................... 287
Appendix: Reloading Correct Calibration File ........................................................................ 288
Predator3D Pro – Getting the Calibration File ................................................................................... 288
Restoring Calibration Files – Predator3D and Predator3D Pro .......................................................... 289
Confirmation Checklist ....................................................................................................................... 292
Appendix: Troubleshooting FAQs .......................................................................................... 293
Appendix: Predator3D Hot Swap Procedure Walkthrough ..................................................... 297
Hot Swap Tool List .............................................................................................................................. 297
Confirmation Checklist ....................................................................................................................... 301
Appendix: Predator3D GlassMaster Pro Setup ...................................................................... 302
Bracket Design Considerations .......................................................................................................... 302
Confirmation Checklist ....................................................................................................................... 304
Post-Mounting Validation GLS ........................................................................................................... 304
Confirmation Checklist ....................................................................................................................... 305
Robot Program Considerations .......................................................................................................... 305
Data Tree Parameter Changes ........................................................................................................... 306
Setting Imager Brightness GLS ........................................................................................................... 308
Confirmation Checklist ....................................................................................................................... 308
Setting Imager Windows GLS ............................................................................................................. 309
Confirmation Checklist ....................................................................................................................... 309
Setting Up the Active Part GLS – Spline Method ............................................................................... 310

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II. Copyright, Disclaimer & Trademarks
The latest version of this manual and all product documentation may be found at https://filetransfer.coherix.com. Please
refer to the Coherix File Transfer Site section in this manual to access it.

I. Copyright
This document contains proprietary and privileged information of Coherix Inc. No part of this document may be
disclosed or transmitted by any means or form to any third party without the prior written consent of Coherix Inc.
No part of this document may be reproduced by any means or translated to another language without the prior
written consent of Coherix Inc.

© Copyright Coherix Inc. 2018-2022.

All rights reserved.

II. Disclaimer
Coherix, Inc. reserves the right to make changes in specifications, product or product documentation at any time and
without prior notice. The information provided in this document is believed to be accurate and reliable at the time of
print. No responsibility is assumed by Coherix Inc. for use of this document, nor for any infringements of patents or
other rights of third parties resulting from its use. No license is granted under any patents or patent rights of Coherix,
Inc.

The Predator3D bead inspection systems are not medical devices, they are not intended for any medical purposes nor
intended to meet regulations regarding medical devices in the U.S., Europe, Asia, or elsewhere in the world.

III. Trademarks
Coherix®, i-Cite™, Shark™, Predator3D™, GlassMaster™, DotMaster™, PrimerMaster™, SwirlMaster™, RobotAssist™,
VAC™, Z-Tracking™, AutoRepair™, Feature Tools™, RobotAssist™ and LocationMaster™ are trademarks of Coherix,
Inc.

All other brand names, product names, and trademarks, registered and unregistered, are property of their respective
holders.

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III. Introduction to Technology
The Predator3D family are Coherix proprietary 3D vision solutions, solving adhesive and sealant bead inspection and
process control problems. These solutions are self-contained and built from machined aluminum. They have no
moving parts and are IP65 or 67 rated. They are mounted around the dispensing nozzle, and with the self-contained
architecture and built-in processing, there is no need for an additional processor outside of the cell. They inspect the
bead width, height, and instantaneous volume 400 times per second during the dispense – with no penalty to cycle
time. Additionally, the distance between the bead and a feature within the system’s field of view can be inspected to
ensure proper bead placement. Predator3D systems support both pedestal and robot dispensing applications. They
are widely used to ensure proper dispensing of structural adhesive and sealants onto assemblies in powertrain, body-
in-white, closure panels, plastic and composite assemblies, electronics and lighting assemblies, battery/EV assemblies
as well as glass final assembly involving urethane. Predator3D allows mastery over the rapidly changing gluing and
sealing market.

The Coherix 3D Advantage

Predator3Ds are laser-based solutions that perform 3D bead measurement independent of the contrast between the
bead and the part. They are not affected by changes in part color or ambient light. The robustness of these solutions
enables successful black-on-black, grey-on-grey, and white-on-white inspections, where existing 2D techniques
consistently fail. Predator3Ds can utilize robot Tool Center Point information, allowing automatic adjustments to their
inspections to accommodate changes in the dispensing program after the initial setup. This allows floor operators to
change the speed of the dispensing path without having to update the inspection. Predator3Ds also facilitate the
automatic repair of locations on the part where the bead is missing or too small and they can check the nozzle for
adhesive build-up or for being bent or out of position. These capabilities add value to the dispensing control process.

2D image of the part 3D data from Predator3D™

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IV. Basic Principles of Operation
This chapter provides a summary of the basic principles of operation for the Predator3Ds and GlassMaster, including
explanations of the various terms associated with the inspection.

Laser Line Projection

The Predator3D projects four (4) laser lines onto the part. These surround the
nozzle and are used to inspect adhesive beads dispensed onto the part
surface. The number sign or hashtag design allows for at least one laser to
always be trailing the nozzle, eliminating the need for special 7th axis
equipment and programming during setup.

Laser Triangulation
Each of the four (4) laser lines is paired with an imager. This pairing allows 3D
profiles of the adhesive bead to be captured during dispense. The software then
utilizes the fixed Triangulation Angle between the imager and the laser to build a
point cloud of 3D data that it will use inspect for defects along the length of the
bead while measuring dimensions of the bead such as width, height, and volume.

Mounting Offset
The Mounting Offset is the optimal distance between the surface of the part and
the sensor. The optics within the sensor produce a focused laser line at any
standoff; however, the triangulation angle between the lasers and imagers
creates an optimal standoff at a specific distance from the part for each variant
of the Predator3D. Mounting a sensor too close or too far from the part surface
will cause the laser lines to fall outside the sensor’s Field of View (FOV).

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 Z-Axis Range & Calibration
Each of the four (4) imagers has a large range along the Z (nozzle) axis, enabling the system to accommodate
significant tilt of the Predator3D with respect to the part’s surface. The system still inspects the adhesive bead
even when there is a tilt, as long as the surface of the part and the entirety of the adhesive bead is within the FOV.
The Laser Profile coordinates from the imagers are digitized and converted into real-world coordinate space via
the 3D calibration carried out on the Predator3D.

FOV X Width
FOV Z Height

Tilt Determination
When the sensor is titled relative to a flat surface, 3D calibration is used to determine the intersection of the laser
on the surface that is then classified as being either higher or lower in the FOV of each image sensor. This
information is then converted to its associated Z-axis range, ensuring that the adhesive bead is always inspected
correctly.

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 Tilt Angle & Measurement Compensation
The example below illustrates how the four (4) profiles may vary depending on orientation to the surface of the
part. So, the angles to the surface of the part are determined and factored into the measurement of the bead,
ensuring it is not skewed due to tilting of the nozzle (within the constrained ±30° from normal).

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V. Tool Center Point Method vs. Spline Method
Predator3Ds can be configured to receive real-time Tool Center Point (x, y, z, roll, pitch, yaw) information from the
robot/gantry system during the dispensing process. When this information is sent to the sensor, Predator3D
inspections can be configured to adapt to speed changes and minor path changes eliminating downtime required to
re-teach the inspection after a change in the manufacturing process. Sending this information to the Predator3D
improves the end-user’s ability to maintain their systems. Additionally, this information makes setting up and re-
teaching inspections easier.

The Spline method is used when the Predator3D cannot receive the TCP data from the robot/gantry system. This
method is easy to use but is not as simple as the TCP method. The Spline method requires the end user to tell the
system the spatial relationship between the data collected and the dispensing path, and requires the timing between
the inspection and dispensing process to be consistent.

TCP Integration Overview

Coherix currently has documentation to support the setup of the TCP Method with FANUC, Kawasaki, KUKA and ABB
robots. We are continually developing interfaces with other robot brands and provide I/O maps to allow the end-user
to map the correct information to the Predator3D. TCP implementation is supported for carried applications, where
the nozzle and Predator3D are mounted to the end of the robot and surrounding the nozzle, as well as pedestal
applications where the robot carries the part under a fixed dispenser.

TCP Setup Benefits

The following are the benefits during set up from implementing the TCP Method as compared to the Spline Method:
• Significantly decreases the time to set up an inspection.
• Decreases the time required to be certified as a user.
• Improves the accuracy of the inspection results by synchronizing the spatial relationship between the
Predator3D and the bead during the dispense.

TCP Maintainability Benefits

The following are the benefits system maintenance when implementing the TCP Method as compared to the Spline
Method:
• Automatically adapts to robot program speed changes caused by increasing or decreasing point speeds or
increasing/decreasing the overall program speed.
• Automatically adapts to minor robot path changes caused by adjusting a program point from the original
program point.
• Beneficially impacts the time required and ease of reoptimizing an inspection.

What Can’t TCPs or Splines Handle?

The following are a few things that will require you to reteach the inspection when using either TCPs or Splines:
• Moving the location of the start or end of the dispensing path.
• Shifting an entire dispensing path on the part.

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VI. Coherix File Transfer Site
The Coherix file transfer site has the latest updates to existing documentation and software. An internet connection
is required to access the file transfer site. The steps below show how to access the file transfer site.

Accessing the Site

1. Go to https://filetransfer.coherix.com using an internet browser.

2. In the Authentication window, (1) key in PredatorUser for User Name: and (2) predator user for Password:

3. Click the Log In button.

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 4. Upon successful log-in, you will see the following display.

Software (current version)

1. Click on the Software (current version) link.

2. From here you can download the latest software version for the Predator3D.

3. The software to be used will be in the format of “rc#####A.coherix” where the “#’s” represent a number and
the “A” represents a letter.

Software (previous versions)

1. Click on the Software (previous versions) link.

2. From here you can download older versions of software for the Predator3D.

Firmware and FPGA

1. Click on the Firmware and FPGA link.

2. From here you can download Firmware versions and FPGA versions for the Predator3D if they cannot be
found on the system. Note that these files are automatically included in the software zip file when it is
downloaded from the file transfer site.

3. Ensure the files that are downloaded are correct for the hardware in use.

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 Project Updates
1. Click on the Project Updates link.

2. This is where you will download the latest project version for the Predator3D or Predator3D Pro.

3. The project name will be in the format of “StandardPredator3D-YYYY-MM-DD (#-#-#).mvp” or

“StandardPredator3DPro-YYYY-MM-DD (#-#-#).mvp” where “YYYY-MM-DD” represents the date and the
“(#-#-#)” represents the version number of the project.

Documentation
1. Click on the Documentation link.

2. This is where you will find the latest revision of the Predator Manual, or other useful documents and examples.

Data Sheets
1. Click on the Data Sheets link.

2. This is where you will find sales/overview documentation on features or options available to enhance the
inspection capabilities or other aspects of the Predator3D or Predator3D Pro.

Videos
1. Click on the Videos link.

2. Here you will find useful video tutorials or guides for various aspects of the Predator3D.

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 CAD Drawings
1. Click on the CAD Drawings link.

2. Here you will find “.zip” files with CAD Drawings, CAD models, and files showing the clearance and mounting
envelopes for all of the Predator3D variants. There are two folders that will contain the CAD models for the
various Predator3D models.

Communication Setup
1. Click on the Communication Setup link.

2. Here you will find guides, references, and tools relating to robot and gateway communication setup for a
Predator3D.

Example/Sample Submission Instructions

1. Click on the Example/Sample Submission Instructions link.

2. This document outlines what information must be submitted and how you must submit it to your Coherix
Representative whenever you request assistance for something related to using either the Predator3D or the
embedded i-Cite software.

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 1. Receiving the Predator3D and Predator3D Pro
Coherix ships systems in protective packaging. The following section details what to do when you receive your unit
and additional important information.

Factory Calibration and Testing

Predator3Ds and Predator3D Pros are factory calibrated and tested prior to being shipped by Coherix.

Electrostatic Sensitive Device

The Predator3D systems contain ESD (Electrostatic Discharge) sensitive components that may be damaged
if proper ESD control procedures are not followed. These are required when handling the product. Do not
expose the units to environments with strong electrostatic, electromagnetic, magnetic, or radioactive fields.
All Predator3Ds are shipped from Coherix in packaging that is customized to minimize jarring, impact, and electrostatic
buildup/discharge during shipment. The packaging consists of either pink anti-static foam or gray foam with an
additional static shielding bag. For storage and shipping, it is necessary to use proper protective and anti-static
packaging. We suggest using the original packaging in which the system was shipped. The gray foam without the static
shielding bag is insufficient. Note, pink anti-static bubble-wrap is an acceptable replacement if the original packaging
has been discarded.

Please contact Coherix if you have questions or if proper packing material is unavailable.

NOTE: Failure to comply with these guidelines may damage the product and will void the system warranty.

Unpacking the Predator3D

If there has been damage to the exterior of the box during shipping, perform a quick validation of the condition of the
hardware after unpacking the system, checking for any damage prior to moving forward.

1. Open the box; there will be a piece of protective foam that must be removed.

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 2. The ESD static bag containing the Predator3D plus its grounding wire will be secured in the bottom
protective foam.

3. Remove the Predator3D and its grounding wire.

4. If there was damage to the packaging during shipping, inspect the components for any signs of damage.

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 Unpacking the Predator3D Pro
If there has been damage to the exterior of the box during shipping, perform a quick validation of the condition of the
hardware after unpacking the system, checking for any damage prior to moving forward.

1. Open the box; you will find a piece of protective foam that must be removed.

2. Two ESD static bags containing the Predator3D Pro sensor head and processor, a bag containing the USB-C
cable and hardware to connect the unit, plus two grounding wires will be secured in the bottom protective
foam.

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 3. The five pieces of hardware that you will find are the Predator3D Pro sensor head, the Predator3D Pro
Processor, the USB-C cable plus two grounding wires.

4. If there was damage to the packaging during shipping, inspect the components for any signs of damage.

Confirmation Checklist
Tasks that were accomplished at the end of this section:
✓ Removed Predator3D system from the packaging.
✓ Ensured all hardware was received.
✓ Validated that if there was damage to the packaging that the sensor was not damaged.

NOTE: If there has been damage to the unit, please contact your Coherix representative.

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 2. Hardware Overview - Predator3D
The following section is an overview of the Predator3D hardware. The Predator3D is the entire system below that is
an IP rated, closed system that is not customer serviceable. If any person outside of Coherix opens the system, the
warranty of the system will be voided.

Sensor – Top

M
A

B L
K
J

C
F
N E G H
D
ITEM DESCRIPTION
A Laser Safety Label
B LASER Activity Indicator LED
C PWR (Power) Indicator LED
D Sensor Head
E CAM 0/1 Activity Indicator LED
F CAM 2/3 Activity Indicator LED
G 100Mb Ethernet Connector
H Network Activity Indicator LEDs
I PWR (Power) Indicator LED
J STATUS Indicator LED
K Power & I/O Connector
L Processor
M Serial Number Label
N Ground Screw Location

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 Sensor – Bottom

ITEM DESCRIPTION
O Imager Windows
P Laser Shutters (if equipped)

Casing & Operating Temperature

The Predator3D sensor is IP65 rated and is capable of operating in ambient temperatures between 0° to 45° Celsius
(32° to 113° Fahrenheit).

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 3. Hardware Overview - Predator3D Pro
The following section is an overview of the Predator3D Pro hardware. The Predator3D Pro system has three
components that are individually replaceable. When all components are correctly assembled, the system is IP67 rated.
None of the components are customer serviceable, but the individual components are customer replaceable. If any
person outside of Coherix opens the system, the warranty of the system will be voided.

Sensor Head – Top

C B
A
F

D E

ITEM DESCRIPTION
A LASER Activity Indicator LED
B POWER Indicator LED
C Sensor Ready Indicator LED
D Cable Entry
E Ground Screw Location
F Laser Safety Label
G Serial Number Label – Sensor Head

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 Sensor Head – Bottom

I H

ITEM DESCRIPTION
H Imager Windows
I Laser Shutter (if equipped)

Processor – Front and Side

P
N

J O
M L K
M
ITEM DESCRIPTION
J Power Connector
K Power Indicator LED
L Gb Ethernet Connector
M Network Activity Indicator LEDs
N Cable Entry
O Ground Screw Location
P Serial Number Label - Processor

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 USB – C Cable

The Predator3D Pro Sensor Head and Processor are connected by a USB-C 3.1 cable specified by and sourced only
from Coherix. Cables from other manufacturers may not fulfill all requirements to meet the high-flex rating, the IP 67
rating, the CE certification, or data transfer rates required for the Predator3D Pro.

R
S
ITEM DESCRIPTION
Q Molded Connection
R Circular Ferrite
S Shielded Cable

Casing & Operating Temperature

The Predator3D Pro IP67 rating requires proper assembly with the Coherix cable attached to the sensor and processor.
Prior to making the connections, the IP rating does not apply. The image below shows a Predator3D Pro when
assembled properly. The Predator3D Pro is capable of operating in ambient temperatures between 0° to 45° Celsius
(32° to 113° Fahrenheit).

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 4. Required Hardware - Predator3D
The following is a list of hardware and accessories required to integrate the Predator3D. These hardware and
accessories may not be included or shipped with the system and will have to be procured. These include:

• Power Cable with the corresponding mating plug.

• Power Supply.
• Ethernet cable with the corresponding mating plug.
• HMI (Human Machine Interface) PC to facilitate access to the Predator3D.

12-Pin Power Cable (not included)

1. The connector for the power supply on the processor of the Predator3D is a Phoenix 1441820 type.

2. An example of a suitable cable that can be used to mate with the connection above is the Phoenix Contact
Part Number 1430158.

NOTE: There is a 12-pin to 5-pin adaptor that can be used to connect to the power connector. Please contact Customer
Service of your supplier or Coherix for further information relating to this possible cabling method. CHECK THE PINS ON
ALL CABLES PRIOR TO PLUGGING THEM INTO THE PREDATOR3D SO THAT THE SYSTEM IS NOT DAMAGED AND THE
WARRANTY VOIDED.

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 3. The M12 male plug incorporates 12 pins, connected in the following order:
• Pin1: Reserved
• Pin2: Reserved
• Pin3: Reserved
• Pin4: Reserved
• Pin5: 24 V Return
• Pin6: 24 V Return
• Pin7: 24 V In
• Pin8: 24 V In
• Pin9: Reserved
• Pin10: Reserved
• Pin11: 24 V Return
• Pin12: 24 V In Male Side View

4. Coherix suggests this cable be no longer than 10 meters.

Power Supply (not included)

The power supply must provide 24 volts with a power capacity of at least 40 watts. It should be an isolated supply
with inrush current surge protection that is capable of handling a high capacitive load.

4-Pin D-Coded Ethernet Cable (Not Included)

1. The connector for the Ethernet connection on the processor of the Predator3D is a Phoenix 1424071 (M12 D-
CODED) type.

2. An example of a cable suitable to mate with the connection above is the Phoenix Contact Part Number
1407363.

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 3. The M12 female plug incorporates four (4) pins, connected in the following order:
• Pin1: SBC _Tx0+
• Pin2: SBC_Rx1+
• Pin3: SBC_Tx0-
• Pin4: SBC_Rx1-

4. Coherix suggests the cable be no longer than 10 meters. Female Side View

5. The other end of the Ethernet cable must be connected to the network via the same switch to which the HMI
PC is connected.

Human Machine Interface – HMI PC (may be purchased from Coherix or customer supplied)

An HMI – PC placed near to the Predator3D is highly recommended to store and review the inspections being carried
out by the Predator3D. The HMI must be a Windows-based PC with Windows 7 or later as the operating system. It
must be capable of establishing a Windows Remote Desktop Connection to the Predator3D. The HMI must also have
an Ethernet port to tie the system into the cell network. Coherix suggests that there be at least one USB type-A port
on the HMI PC to allow USB cables and devices to be easily used.

An HMI mounted near the Predator3D is the optimum interface between the Predator3D and the responsible operator
or engineer at the end-user’s facility. The HMI allows one to visualize the results of inspections, tweak inspection
parameters, change the displays that are active during the inspection, and much more.

NOTE: Depending on the amount data and history to be saved, it is important to size the hard drive in the HMI
appropriately. As an alternate to having a large hard drive on the HMI you can ask your I.T. department to establish a
connection to your internal network (intranet) to pull data from the HMI and store it elsewhere. Please consult with
your Coherix representative for additional information.

All data is created and saved onto the Predator3D which can then export it to the HMI at designated time intervals. If
the data is not exported, the use of FIFO buffers ensures that the Predator3D will not run out of internal storage.

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 5. Required Hardware - Predator3D Pro
The following is a list of hardware and accessories required to integrate the Predator3D. These hardware and
accessories may not be included or shipped with the system and may need to be procured. These include:

• Power Cable with the corresponding mating plug.

• Power Supply.
• Ethernet cable with the corresponding mating plug.
• HMI (Human Machine Interface) PC to connect to the Predator3D.

5-Pin Power Cable (Not Included)

1. The connector for the power supply on the processor of the Predator3D is a Phoenix 1441888 type.

2. An example of a suitable cable that can be used to mate with the connection above is Phoenix Contact Part
Number 1500758.

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 3. The M12 male plug incorporating five (5) pins, connected as shown below:

4. Coherix suggests the cable be no longer than 10 meters.

Power Supply (not included)

The power supply must provide 24 volts with a power capacity of at least 40 watts. It should be an isolated supply
with inrush current surge protection that is capable of handling a high capacitive load.

8-Pin X-Coded Ethernet Cable (Not Included)

1. The receptacle for the Ethernet connection on the processor of the Predator3D is a Phoenix 1424177 (M12 X-
CODED) type.

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 2. An example of a suitable cable that can be used to mate with the connection above is the Phoenix Contact
Part Number 1407472.

3. The M12 female plug consists of eight (8) pins, connected as shown below:

4. Coherix specifies that the cable be no longer than 10 meters.

5. The other end of the Ethernet cable must be connected to the same network switch into which the HMI PC is
connected (in order to maintain Gigabit Ethernet speeds, the network switch must support all the necessary
connections).

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 Human Machine Interface – HMI PC (may be purchased from Coherix or customer supplied)

An HMI – PC placed near to the Predator3D is highly recommended to store and review the inspections being carried
out by the Predator3D. The HMI must be a Windows-based PC with Windows 7 or later as the operating system. It
must be capable of establishing a Windows Remote Desktop Connection to the Predator3D. The HMI must also have
an Ethernet port to tie the system into the cell network. Coherix suggests that there be at least one USB type-A port
on the HMI PC to allow USB cables and devices to be easily used.

An HMI mounted near the Predator3D is the optimum interface between the Predator3D and the responsible operator
or engineer at the end-user’s facility. The HMI allows one to visualize the results of inspections, tweak inspection
parameters, change the displays that are active during the inspection, and much more.

NOTE: Depending on the amount data and history to be saved, it is important to size the hard drive in the HMI
appropriately. As an alternate to having a large hard drive on the HMI you can ask your I.T. department to establish a
connection to your internal network (intranet) to pull data from the HMI and store it elsewhere. Please consult with
your Coherix representative for additional information.

All data is created and saved onto the Predator3D which can then export it to the HMI at designated time intervals. If
the data is not exported, the use of FIFO buffers ensures that the Predator3D will not run out of internal storage.

NOTE: Predator3D Pro uses a Gigabit Ethernet connection. To maximize the data transfer rate, ensure all Ethernet
switches, cables and the HMI itself support GigE connections. Additionally, the maximum length of all Ethernet cables
in the “cable run” for Predator3D Pro cannot exceed more than 100 meters. Otherwise, GigE speeds may be lost.

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 6. Setting up the HMI PC
Every Predator3D is shipped from Coherix with a default IP Address to enable access remotely from an HMI PC via the
Remote Desktop function in Windows. For the HMI PC to successfully establish a connection via Remote Desktop,
specific steps are required to configure the PC’s Windows settings. The following will set the IP address of the HMI PC
to allow communication with the Predator3D.

NOTE: For guidance on additional configuration choices that improve the HMI PC, refer to Appendix: Advanced HMI
Setup.

Configure IP Address of HMI

1. Connect the HMI into the same Ethernet switch as the Predator3D/Predator3D Pro.

2. On the desktop of the HMI, right-click on the Windows icon and select Control Panel.

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 3. In the Control Panel window, click View network status and tasks option under Network and Internet.

4. The Network and Sharing Center window will be presented.

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 5. Click the Change adapter settings option that can be found on the left side of the window.

6. In the Network Connections window, right-click on the network port and click Properties on the pop-up menu.

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 7. In the Local Area Connection Properties window, select Internet Protocol Version 4 (TCP/IPv4) from the listing
and click on the Properties button.

8. Select Use the Following IP Address button and key in an appropriate IP address and Subnet Mask for the HMI
PC to connect to the Predator3D.

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 9. Click OK to confirm the input IP address and subnet mask and exit the Control Panel.

NOTE: The Predator3D is shipped with a preset IP Address of 192.168.20.10 and Subnet Mask of 255.255.255.0. First,
you must change the IP Address of the HMI to ensure compatibility with the IP Address of the Predator3D. Later, you
may then change the Predator3D’s IP Address to ensure compatibility with the cell. After setting the IP Address on the
HMI to ensure compatibility with the cell, then reconnect to the Predator3D’s new IP Address using Remote Desktop via
the HMI.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Configured the IP Address of the HMI PC to be compatible with the Predator3D’s IP Address.

NOTE: You may be prompted by Windows to restart the HMI PC for the changes to take place. Do so if prompted.

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 Setting Credentials & Shared Drives for Remote Desktop
1. On the desktop of the HMI PC, right-click on the Windows icon and select Run.

2. In the Run dialog, (1) key in mstsc and (2) click on the OK button.

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 3. In the Remote Desktop Connection window, input the credentials for the Predator3D for both the Computer:
(default is 192.168.20.10) and the User name: (default is predator-pc\predator).

4. Click Allow me to save credentials option.

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 5. Click Local Resources tab to open the Local Resources page.

6. Click More… to display the page for local devices and resources.

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 7. Click the Drives box and then click on OK to return to the previous window.

8. Click the General tab.

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 9. Under Connection settings, click the Save As button to save the current connection settings to a file.

10. Save the configured Remote Desktop Connection in two places: the Desktop and to C:\Users\Predator-
3D\AppData\Roaming\Microsoft\Windows\StartMenu\Programs\Startup. Note that the user Predator-3D
may not exist on the HMI; replace this with the appropriate user for the HMI. Also, note that AppData may
be a hidden folder; to view it in the File Explorer, click view and check the Hidden Items checkbox.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Setup Remote Desktop Connection to connect to the Predator3D.
✓ Saved the Remote Desktop log-in credentials in the HMI PC.

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 7. Pre-Mounting Validation - Predator3D
Before mounting a Predator3D, perform the following validation checks.

Power Connection
1. Connect the 12-Pin power cable to the connector labeled 24V/IO on the processor.

2. Turn on the power supply for the Predator3D.

Ethernet Connection
1. Connect the 4-Pin D-Coded Ethernet cable to the connector labeled ETHERNET on the processor.

Status LEDs
1. There are seven LEDs on the surface of the processor. Verify that:
i. The STATUS LED is off; this indicates normal behavior.

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 ii. The PWR LED is solid; this indicates power is being received by the processor.

iii. The ETHERNET Link LED (upper-left of the Ethernet connector) is solid; this indicates connection.

iv. The ETHERNET Activity LED (upper-right of the Ethernet connector) is blinking; this indicates data is
being transferred.

v. The MICRO LED is flashing; this indicates normal behavior.

vi. The CAM 0/1 LED is solid; this indicates normal behavior.

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 vii. The CAM 2/3 LED is solid; this indicates normal behavior.

2. There are two LEDs on the surface of the sensor. Verify that:
i. The PWR LED is solid; this indicates power is received by the sensor.

ii. The LASER LED is off when the lasers are off and it is on when the lasers are on.

NOTE: If the LEDs are not behaving as described above, first remove the power from the sensor, wait 30 seconds and
then plug back in. Repeat the check. If these LEDs are still not functional, check for damage along the cable connecting
the sensor to the processor. If damage is observed, please contact your supplier or Coherix for further instructions.

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 Laser Safety – Predator3D
The Predator3D bead inspection system is a laser-based system designed to be integrated into adhesive dispensing
cells. Proper laser safety precautions must be followed. The lasers utilized in the Predator3D are Class 3R with a
wavelength of 660 nm (+/- 5nm) and a maximum output of 4.99 mW x C6. These are generally considered as eye-safe
and no injury will be sustained when the reflected laser lines are viewed by the naked eye. The natural blink response
of the human eye is sufficient to protect the eye from bright lights like these lasers. However, it is recommended to
avoid direct eye exposure to the laser. Some earlier Predator3D sensors heads are equipped with shutters that can
be put in place as a physical barrier when people are in the cell and the system is not offline. Later editions of the
International Laser Safety regulation removed the requirement for these shutters for Class 3R lasers.

On the sensor, the LASER LED is off when the lasers are off and it is on when the lasers are on.

Open Laser Safety Shutters (if so equipped)

1. Power down the Predator3D.

2. Ensure the PWR light is off.

3. Carefully flip the sensor head over. Ensure you do not touch the glass on the imager widows.

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 4. Move the four shutters to the open position, exposing the glass beneath. There are currently two methods to
do so.

i. If the shutters are held in place by screws, you must first loosen the screws, open the shutters, then
retighten the screws to hold the shutters in the open position.

ii. If the shutters are not held in place by screws, then there are permanent magnets within the sensor
to hold the shutters in the open position.

Confirmation Checklist
Tasks that were accomplished in these sections:
✓ Powered the Predator3D.
✓ Connected the Predator3D to the Ethernet.
✓ Validated status indicator lights are normal.
✓ Opened the laser safety shutters (if so equipped).

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 8. Pre-Mounting Validation - Predator3D Pro
Connecting the Processor to the Sensor Head
Prior to performing pre-mounting validation checks, connect the processor to the sensor head. Following these
instructions explicitly will ensure the sealing necessary for the unit to maintain its IP67 rating.

1. On the sensor head, insert one cable plug into the cable entry.

2. Use the cord to press in and seat the cable plug, then secure it with the two M2.5x6 mm screws.

3. On the processor, insert the other cable plug into the cable entry and ensure proper seating. Then secure it
with two M2.5x6 mm screws.

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 Power Connection
1. Connect the 5-Pin power cable plug to the receptacle labeled 24V on the processor.

2. Turn on the power supply for the Predator3D Pro.

Ethernet Connection
1. Connect the 8-Pin X-Coded Ethernet cable plug to the receptacle labeled ETHERNET on the processor.

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 Status LEDs
1. There are three LEDs on the surface of the processor. Verify that:
i. The Power LED is solid GREEN; this indicates power is being received by the processor.

ii. The ETHERNET Link LED (lower-left of the Ethernet connector) is solid; this indicates a connection.
a. If the connection uses eight (8) wires (for possible GigE speed), it will be GREEN
b. If the connection uses four (4) wires (limiting speed to 100 Megabit), it will be ORANGE

iii. The ETHERNET Activity LED (upper-left of the Ethernet connector) is blinking; this indicates data is
being transferred.

2. There are three LEDs on the surface of the sensor. Verify that:
iii. The POWER LED is solid; this indicates power is received by the sensor.

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 iv. The LASER LED is off when the lasers are off and it is on when the lasers are on.

v. The Heartbeat LED flashes GREEN every 2.5 seconds. If the LED is BLUE, then data is not being
transferred from the sensor head to the processor.

NOTE: If the LEDs are not behaving as described above, first remove the power from the sensor, wait 30 seconds and
plug it back in. Repeat the check; if the LEDs on the surface of the sensor are not functional, check that the cable is
properly seated and then check for damage along the cable connecting the sensor with the processor. If a failure
remains, please contact your supplier or Coherix for further instructions.

Laser Safety – Predator3D Pro

The Predator3D Pro bead inspection system is a laser-based system designed to be integrated into adhesive dispensing
cells. Proper laser safety precautions must be followed. The lasers utilized in the Predator3D Pro are Class 3R with a
wavelength of 660 nm (+/- 5nm) and a maximum output of 4.99 mW x C6. These are generally considered as eye-safe
and no injury will be sustained when the reflected laser lines are viewed by the naked eye. The natural blink response
of the human eye is sufficient to protect the eye from bright lights like these lasers. However, it is recommended to
avoid direct eye exposure to the laser. Some earlier Predator3D Pro sensors heads are equipped with shutters that
can be put in place as a physical barrier when people are in the cell and the system is not offline. Later editions of the
International Laser Safety regulation removed the requirement for these shutters for Class 3R lasers.

On the sensor, the LASER LED is off when the lasers are off and it is on when the lasers are on.

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 Open Laser Safety Shutter (if so equipped)
1. Power down the Predator3D Pro.

2. Ensure the Power light is off OR disconnect the sensor head from the processor and ensure the Power light
on the sensor head is off.

3. Carefully flip the sensor head over. Ensure you do not touch the glass on the imager widows.

4. Move the circular laser shutter to the open position, exposing the glass beneath.

i. The shutter is held in place by two screws, you must first loosen the screws, open the shutters, then
retighten the screws to hold the shutter in the open position.

Confirmation Checklist
Tasks that were accomplished in these sections:
✓ Connected the Predator3D Pro sensor head and processor.
✓ Powered the Predator3D Pro.
✓ Connected the Predator3D Pro to the Ethernet.
✓ Validated status indicator lights are normal.
✓ Opened the laser safety shutter (if so equipped).

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 9. Pre-Mounting Validation - Predator3D Pro.2
Before mounting a Predator3D Pro.2, perform the following validation checks.

Connecting the Processor to the Sensor Head

Prior to performing pre-mounting validation checks, connect the processor to the sensor head. Following these
instructions explicitly will ensure the sealing necessary for the unit to maintain its IP67 rating.

1. On the sensor head, insert the cable plug into the cable entry.

2. Use the cord to press in and seat the cable plug; then secure it with two M2.5x6 mm screws.

3. On the processor, insert the cable plug into the cable entry and ensure proper seating; then secure it with
two M2.5x6 mm screws.

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 Power Connection
1. Connect the 5-Pin power cable to the connector labeled 24V on the processor.

2. Turn on the power supply for the Predator3D Pro.2.

Ethernet Connection
1. Connect the 8-Pin X-Coded Ethernet cable to the receptacle labeled ETHERNET on the processor.

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 Status LEDs
3. There are three LEDs on the surface of the processor. Verify that:
iv. The Power LED is solid GREEN; this indicates power is being received by the processor.

v. The ETHERNET Link LED (lower-left of the Ethernet connector) is solid; this indicates a connection.
a. If the connection uses all 8 wires (for possible GigE speed) it will be GREEN.
b. If the connection uses 4 wires (limiting the speed to 100 Megabit) it will be ORANGE.

vi. The ETHERNET Activity LED (upper-left of the Ethernet connector) is blinking; this indicates data is
being transferred.

4. There are three LEDs on the surface of the sensor. Verify that:
vi. The POWER LED is solid; this indicates power is received by the sensor.

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 vii. The LASER LED is off when the lasers are off and it is on when the lasers are on.

viii. The Heartbeat LED flashes GREEN every 2.5 seconds. If the LED is BLUE, then data is not being
transferred from the sensor head to the processor.

NOTE: If LEDs are not behaving as described, first disconnect power from the sensor, wait 30 seconds and reconnect.
Repeat the check. If LEDs are still not functional, ensure the cable connecting the sensor with the processor is properly
seated and not damaged. If damage is noted, please contact your supplier or Coherix for further instructions.

Laser Safety – Predator3D Pro.2

The Predator3D Pro.2 bead inspection system is a laser-based system designed to integrate into adhesive dispensing
cells. Proper laser safety precautions must be followed. The Predator3D Pro.2 is a Class 2 laser product with a
wavelength of 660 nm (+/- 5nm) and a maximum output of <1.0 mW x C6. It is eye-safe; no injury will occur when
viewing these laser lines. The blink response of the human eye protects the eye from bright lights like these lasers.

On the sensor, the LASER LED is off when the lasers are off and it is on when the lasers are on.

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Confirmation Checklist
Tasks that were accomplished in these sections:
✓ Connected the Predator3D Pro.2 sensor head and processor.
✓ Powered the Predator3D Pro.2.
✓ Connected the Predator3D Pro.2 to the Ethernet.
✓ Validated status indicator lights are normal.

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 10. Windows Settings Validation
Before mounting a Predator3D, it is highly recommended that the following validation checks are performed on the
embedded Windows operating system.

Test Remote Desktop Connection

1. On the HMI PC, right-click on the Windows icon and select Run.

2. In the Run dialog, (1) enter mstsc and (2) click the OK button.

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 3. In the Remote Desktop Connection window, check that the credentials for the Predator3D Computer: and
User name: are correct.

4. Click Connect to establish a Remote Desktop Connection to the Predator3D. When prompted for a
password, the default password is predator.

NOTE: If you cannot connect via Remote Desktop, it may be that the HMI Remote Desktop is not configured correctly.
Verify that the configuration is correct.

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 5. When the connection is successful and the Predator3D or Predator3D Pro functions properly, the i-Cite
software will be as shown. At this time, there is no need to interact with the software.

Confirm System Settings

1. On the Predator3D, set the local date, time, and time zone by right-clicking on the Windows icon on the lower
left corner of the HMI PC and selecting Control Panel or Settings. Then click Date & Time to modify settings.

2. If the date and time are off by more than a day, then the Predator3D needs to be recharged.
i. Set the correct local date, time, and time zone.
ii. Keep the Predator3D powered on for at least one hour.
iii. After one hour, turn off the power to the Predator3D.
iv. Wait 10 minutes.
v. Power the Predator3D back on.
vi. Verify the date, time, and time zone is still correct. If not, contact your Coherix representative.

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 Configure Predator3D IP Address
1. Now that you have connected to the system, you must ensure that the system is able to communicate within
the cell’s network.

2. On the Predator3D or Predator3D Pro, open the Control Panel and click on the View network status and tasks
option under Network and Internet.

3. The Network and Sharing Center window will be presented.

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 4. Click on the Change adapter settings option that can be found on the left side of the window.

5. In the Network Connections window, right-click on the network port and select Properties in the menu.

6. In the Local Area Connection Properties window, select Internet Protocol Version 4 (TCP/IPv4) from the
listing and click on the Properties button.

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 7. Select Use the Following IP Address button and key in the appropriate IP address and Subnet Mask for the
Predator3D to connect to the cell’s network (this will be determined by your controls engineers or by IT).

NOTE: You will have to change the IP Address of the HMI first to ensure compatibility with the new IP Addresses of both
the Predator3D and the cell. Then reconnect to the Predator3D’s new IP Address using Remote Desktop.

Confirmation Checklist
Tasks that were accomplished in these sections:
✓ Connected to the Predator3D via remote desktop.
✓ Ensured that the system settings were configured correctly.
✓ Changed the IP address and re-confirmed the remote desktop connection.

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 11. Mounting the Predator3D/Predator3D Pro
This chapter highlights factors to be considered when mounting the Predator3D onto a robot or pedestal. It is
important that these factors are carefully considered to ensure optimal performance of the system.

1. Go to the Coherix File Transfer Site and follow the steps described in the CAD Drawings section to download
all of the STEP files and dimensional drawings for your specific variant of the Predator3D or Predator3D Pro.
These files help you properly mount your unit.

Bracket Considerations
1. Both the Predator3D sensor head and Predator3D Pro sensor head will be mounted directly onto the robot or
pedestal via one or more brackets.

2. There are four M4 mounting holes available to affix the sensor head to the bracket. The outer and throat
diameters for specific units may differ. Refer to the Coherix File Transfer Site for more information.
i. Mounting holes for Predator3D sensor head

ii. Mounting holes for Predator3D Pro sensor head

3. The bracket securing the sensor should allow fine adjustment in both the X & Y axes. The primary purpose of
this is to ensure that the sensor will be precisely centered around the nozzle.

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 4. The bracket design can be improved by allowing the sensor to be mounted in more than one orientation.
Additional holes drilled in the bracket can allow the sensor head to be mounted at various states of rotation
about the nozzle: holes at 0, 30, and 60 degrees or 0 and 45 degrees allow greater flexibility in mounting.

5. There are six M4 mounting holes to affix the processor to the bracket. Refer to the Coherix File Transfer Site
for information regarding specific models (the dimensions for these holes are the same between the
Predator3D and Predator3D Pro).
i. Mounting holes for Predator3D processor

ii. Mounting holes for Predator3D Pro processor

6. The Mounting Offset and the Clearance Standoff are critical distances that must be considered when mounting
the unit. Each variant of the Predator3D functions in the same manner, but from one to the next, there are
critical dimensions that differ. Therefore, refer to the Coherix File Transfer Site for information regarding
specific models.

i. Important dimensions for mounting Predator3D

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 ii. Important dimensions for mounting Predator3D Pro

Electrical Grounding Considerations

All Predator3D and Predator3D Pros are electrostatic sensitive devices and, thus, both the sensor head and controller
must be connected to earth ground. With the aid of a multi-meter, the continuity readout between both modules and
the earth ground must be less than 50 ohms. Failure to properly ground the sensor can lead to permanent hardware
damage, which can result in the loss of inspection capability, and will void the warranty of the unit.

1. The unit must be grounded with green/yellow strap and star washers at all locations shown below.
i. Ground location for Predator3D

ii. First ground location for a Predator3D Pro – sensor head

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 iii. Second ground location for a Predator3D Pro – processor

Collision Considerations
After bolting the Predator3D system to the bracketry, it is important to ensure there will no collisions with the system.
Such collisions are possible if the motion programs used in the cell are not verified prior to running production.

1. Practice proper cable management; use cable management systems or zip ties as necessary.

2. Check all dispensing programs to ensure the sensor, cables, etc. will not suffer collisions or become snagged,
torn, or damaged.

3. Check all programs that bring parts into and out of the dispensing area for potential collisions.

4. Check all other motion programs used in the cell for potential collisions.

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 12. Updating the Predator3D/Predator3D Pro
At the time of manufacture, the latest versions of firmware and software are installed in the Predator. However, there
may be a long period between then and installation. The i-Cite software is constantly being improved and new features
are added on a regular basis. Therefore, you should always update the system to the most recent versions prior to the
initial installation and prior to configuring anything in the i-Cite software.

1. Go to the Coherix File Transfer site as directed in Coherix File Transfer Site.

2. Download a copy of the newest software onto a USB drive. Follow the steps in Software (Current Version) to
find the newest software; it will be in a .zip folder.

3. Download a copy of the latest Predator Project onto a USB drive. Follow the steps in Project Updates to find
the newest project; it will be named StandardPredator3D-YYYY-MM-DD (#-#-#).mvp (for a Predator3D Pro,
it will be named StandardPredator3DPro-YYYY-MM-DD (#-#-#).mvp).

4. Download copies of the newest documentation onto a USB drive. Follow the steps in Documentation to find
these; these .pdf files are at the top level of the documentation folder.

5. Plug the USB drive into the HMI and open the remote desktop connection with the system.

Updating Software – Predator3D

After this initial setup, DO NOT update the system if everything functions as desired. Upgrading the software should
only occur when a feature in a release is desired or if there is an issue that is affecting the inspections.

NOTE: If you are upgrading software from a version prior to 2.16.00A to version 2.16.00A or later you must FIRST run
the Microsoft Visual C++ 2017 Redistributable, referenced in Upgrade.txt located in the software .zip file.

1. Make a copy of C:\Program Files (x86)\i-cite NxT (delete any copies of the folder older than this one).

2. Copy the .coherix file with the newest software to C:\Program Files (x86)\i-cite NxT\Upgrade.

3. Extract the files to C:\Program Files (x86)\i-cite NxT.

i. The password is coherix.
ii. Replace the files in the destination.
iii. Merge the folders in the destination.

4. Open i-Cite and go to Window→ Status and ensure no FPGA and Firmware errors appear. If errors do
appear, go to…
i. C:\Program Files (x86)\i-cite NxT\Support\PREDATOR_FW_FPGA_Update_MM_DD_YEAR. (For
software version 2.17.01A or later, go to C:\Program Files (x86)\i-cite NxT\Support\
P3dFirmwareFpgaUpdate)
ii. Follow the procedure in UPGRADE FPGA AND FIRMWARE.TXT.

5. The software can now be used.

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 Updating Software – Predator3D Pro
After this initial setup, DO NOT update the system if everything functions as desired. Upgrading the software should
only occur when a feature in a release is desired or if there is an issue that is affecting the inspections.

NOTE: Support for Predator3D Pro does not exist in software prior to 2.17.00A. If both Predator3D Pros and
Predator3Ds exist in the plant, to maintain software consistency across all hardware, contact Coherix for assistance
upgrading the software on all units. This can be done remotely via VPN if supported by the plant IT group.

1. Make a copy of C:\Program Files (x86)\i-cite NxT (delete any copies of the folder older than this one).

2. Copy the .coherix file with the newest software to the Desktop.

3. Extract the files in a folder on the Desktop.

i. The password is coherix.
ii. Copy the files from the folder into C:\Program Files (x86)\i-cite NxT.
iii. Give administrator permission to copy and replace the files in the destination.
iv. Merge the folders in the destination.

4. Open i-Cite and go to Window→ Status and ensure no FPGA and Firmware errors appear. If errors do
appear, go to…
i. C:\Program Files (x86)\i-cite NxT\Support\ P3dFirmwareFpgaUpdate)
ii. Follow the procedure in UPGRADE FPGA AND FIRMWARE.TXT.

5. The software can now be used.

Updating Predator Project

After this initial setup, DO NOT update the project unless directed and guided by your Coherix representative. The
project is a backup that contains settings, panels, etc.; when restored this will overwrite all current inspections.
Additionally, anything unique to your system will be lost if this is done incorrectly after the initial setup.

1. Copy the .mvp file that contains the newest project to D:\Project Backups.

2. Open i-Cite and complete the steps in RESTORE: Performing a Project Restore, select the .mvp file as the file
to restore from.

3. Re-open i-Cite when this process is complete.

Updating Documentation
After updating the software and the project, the version of the user manual and other documentation on your system
may be out of date. To ensure you have the most up to date version of the documentation, follow the steps below.

1. Copy the .pdf files that contain the newest documentation to D:\Documentation.

2. If the file(s) already exist, overwrite the file(s) that are there.

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 13. Interacting in the Software (i-Cite)
The software embedded in the Predator3D is called i-Cite, a machine vision software platform that has been developed
by Coherix over the past 20+ years. The Predator3D solution is used for adhesive bead inspections, ensuring that the
end-user is placing the correct quantity of adhesive along their dispensing paths while ensuring that there are no
defects along the path. When using Predator3D, i-Cite provide a highly customizable interface to create powerful but
user-friendly vision solutions.

There are numerous displays that can be selected to be active during the inspection. These are all configurable by the
user and can show a large number of statistics and other information about the dispense. The above image shows five
common i-Cite displays. An end-user can have as many or as few displays open as they desire.

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 Control Overview
Most of the interaction with the software is done via mouse clicks. There is minimal use of the keyboard as an input
device for the software. The controls within the software are slightly different from typical interactions in a Microsoft
Windows-based system. Therefore, they are briefly described in this section.

1. Shown is a sample of a typical display in the software.

2. Interacting with a Dialog Box: left-click in the box before entering the appropriate information.

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 3. Interacting with an Integer Edit: move the mouse cursor to the position of the digit and:
• Every left-click made at a specific column within the value increments the value by 1.

vvvvvvvvvvvvvvv

• Every right-click made at a specific column within the value decrements the value by 1.

vvvvvvvvvvvvvvv

4. Interacting with a Float Edit: to manipulate the entry within the float edit boxes:
• Every left-click made at a specific column within the value increments the value at the column
selected by 1.

vvvvvvvvvvvvvvv

• Every right-click made at a specific column within the value decrements the value at the column
selected by 1.

vvvvvvvvvvvvvvv

• Left-click on the push button on the top-left corner places the cursor to the 1st position in the value
for manual entry via the keyboard.

vvvvvvvvvvvvvvv

• Left-click on the push button on the bottom-left corner resets the current value in the box to zero.

vvvvvvvvvvvvvvv

5. Interacting with a Combo Box: left-click on the downward pointing arrow on the right side of the box to
expand; then select one of the options available within.

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 6. Interacting with a Button: left-click on the button to activate the button’s function. Functions that a button
can do include opening/closing a panel or display, activating/deactivating something, or doing whatever else
is described by the button.

NOTE: Buttons that are greyed out are disabled and not accessible at the current access level. Also, not all controls may
be available at all access levels since i-Cite is an access level-controlled software.

7. Interacting with a Help button: left-click on the button to show/hide the descriptions for the parameters
visible in the current window or panel.

NOTE: The Help button is available on various windows, panels, or dialogs both when online or offline. See User Help
for more information

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 User Help
There are numerous help buttons throughout i-Cite. The two primary locations where help can be found is in LEARN
mode when you are attempting to set up an inspection and on panels when you are online. Below are examples of
each of the primary help types.

Learn Mode Help: Each step of the learn process has a help dialog associated with it. The process will walk you step-
by-step through the process of setting up a part. If you are unable to remember what exactly you need to do when
setting up a part, you can open the dialog, follow the steps, and complete the process.

1. There is help for Tool Center Points on its tab below and help for Spline Setup on the Page tab below.

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 Online Panel Help: Each panel or tab that can be opened has its own unique help dialog as seen in the examples
below.

Example 1: Setup Panel Help – Imager Window Tab

Red Heading Text: describes the primary purpose of the panel.

Pink Heading Text: describes the primary purpose of the tab.
Bulleted Text: describes what to do step-by-step if applicable or other information useful to the panel or tab.
Blue Heading Text: describes a specific parameter on the panel or tab, listing the default value of that parameter and
how to change it to potentially improve the inspection of the dispense.

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 Example 2: Parameter Panel Help – Curved Tab

Red Heading Text: describes the primary purpose of the panel.

Pink Heading Text: describes the primary purpose of the tab.
Green Heading Text: describes the primary purpose of the group of parameters.
Bulleted Text: describes what to do step-by-step, if applicable, or other information useful to the panel or tab.
Blue Heading Text: describes a specific parameter on the panel or tab, listing the default value of that parameter and
how to change it to potentially improve the inspection of the dispense.

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 i-Cite Status Bar
At the bottom of the software there is a status bar that displays some important information for the user:

This is the name of the current project.

This shows if you are ON LINE or OFF LINE,

the current Access Level of the system and
This is the name of the current PART*. the IP Address of the system.

*PART and Part Style are different. PART refers to a set of programs in an i-Cite project. Part Style refers to the identifier
for the physical part on which the bead is dispensed. An i-Cite project PART could contain taught programs for multiple
Part Styles.

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 User Access Levels
Although the i-Cite software offers four distinctive access levels, Predator3D uses only three. These access levels
control what can be done within the software. The accessibility at each level is:

• Basic (1): Same as Operator (below). When user types in the wrong password in the Change Access
Level window, i-Cite will downgrade access to Basic (1) level.

• Operator (2): Users assigned to this level can only review results. When the software is open to an
access level that is higher than Operator (2), it will revert to Operator (2) after 10 minutes of inactivity.

• Maintenance (3): Users assigned to this level can use all functions assigned to access levels 1 & 2. They
can also teach and re-optimize parts, adjust inspection criteria, and perform Backups or Restores of
project files.

• Engineer (4): Users assigned to this level can perform all functions documented in this manual. They
can fully set up a Predator3D system out of the box.

NOTE: The current Access Level is shown in the bottom right corner of the Status Bar.

To change to a different user access level:

1. On the drop-down menu, click i-Cite -> Access Level… and input the appropriate password into the dialog
presented.

2. In the Change Access Level window, type the password for the access level to which you wish to gain access
in the Enter Password dialog; then click the OK button.
3.

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 4. When the correct password is entered, the Confirm Access Level Change window will indicate the New
Access Level. Click OK to confirm the change in access level.

NOTE: If either no password or an incorrect password is entered, the New Access Level indicated in the window will
revert to “1”. Click Cancel & relog in to set the desired access level.

GO: Go Online
To run inspections, the system must be online.

1. The vision system will automatically begin online after a power cycle or whenever the i-Cite software is
opened.

2. If you are offline, click the GO button.

3. The online interface is as shown.

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 STOP: Go Offline
To setup inspections, edit the digital IO map, setup timed event maps, etc., the system must be offline.

1. Change your Access Level to Maintenance (3) or Engineer (4).

2. If you are online, click the STOP button.

3. The offline interface is as shown.

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 PART: Changing the Active Part
When offline, you can browse and select existing part files that have already been created. To change the active part
file, follow the steps below.

1. When offline, click the PART button.

2. In the window that is presented, click the dropdown arrow on the right side of Select Part.

3. Left click to select the desired part file.

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 4. Click on OK to confirm the selection.

LEARN: Setting up an Inspection

When offline, you can set up Part Style inspections. To enter LEARN, follow the steps below. Detailed instructions for
LEARN can be found in Setting up the Active Part – Preliminary Setup.

1. Click the LEARN button on the Program Bar.

2. This will bring you to the first window in the LEARN process. However, the specific portion of the learn process
that you enter is access-level dependent.

BACKUP: Performing a Project Backup

The Backup button on the Program Bar provides a convenient way to copy the part files and settings already in place.
With a backup file created, it will allow you to restore the system to a known working state. To create a backup file:

1. Change your Access Level to Maintenance (3) or Engineer (4).

2. Bring the program Offline by clicking the STOP button.

3. Click the BACKUP button on the Program Bar.

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 4. In the Select Project Backup File window, select the (D:) > ProjectBackups drive in the drop down.

NOTE: You may wish to use the Machine ID plus Date as a possible filename (e.g., Plant2Cell1_2018-08-03.mvp). Files
are saved with a “*.mvp” file extension.

5. Click on the Save button to confirm.

6. In the Enter Project Backup File Comment window that appears, add comments about the project file.

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 7. Click on the OK button to enable the software to start creating the backup file.

RESTORE: Performing a Project Restore

The Restore button on the Program Bar is used to load a project restore file that was previously saved using the Backup
function. It is advisable to perform a backup of the current project file prior to performing the restore operation. This
ensures you will be able to revert back to this project should the file that you restore not be what you expected. To
perform a restore:

1. Change your Access Level to Maintenance (3) or Engineer (4).

2. Bring the program Offline, by clicking the STOP button.

3. Click the Restore button on the Program Bar.

4. On the prompt window that appears, it is recommended to select YES and make a backup before moving to
step 5. Selecting No will directly move you to Step 5 without making a backup.

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 1. In the window that appears, enabled or disabled are the restore options selectable by clicking the checkbox
associated with each option. Typically, the default settings (shown below) should be used whenever restoring
a project, unless otherwise directed by your Coherix representative.

Options are defined as follows:

• Project Files - Refers to everything displayed in the Project Window, including panels, reports, circuits,
links, companion documents, etc. - essentially everything that is part of the GUI.
• Camera Calibrations – Refers to the calibration files.
• Digital I/O Map – Refers to the communication map between the sensor and the PLC, robot, etc.
• DataTree System Information – Refers to the settings & parameters in the file.
• User IDs & Passwords – Refers to the Access Level passwords and any User IDs and associated
passwords.
• Project MRU list – Refers to the Most Recently Used list of circuits in the project.
• Everything Else – Refers to everything else stored in the .ini file.

NOTE: The Camera Calibration contains the calibration information specific to the Predator3D on which the backup was
created. DO NOT enable the Camera Calibration as part of the Restore Options because you may overwrite your
system’s calibration data with the wrong data.

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 2. Click OK to continue.

3. Choose the backup file you would like to restore and click Open.

4. The Select Project Restore Destination dialog will default to the directory from which the project restore file
was made. This destination should be changed to New Volume (D:) > Projects > StandardPredator3D.
5. Click Save to continue.

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 6. If a dialog appears stating the file already exists, click Yes to override the existing project file.

7. Click OK to close i-Cite.

8. Re-open i-Cite by double-clicking the shortcut on the Windows desktop. This completes a project Restore.

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 Predator3D Control Panel
When online in Auto, the user will interact with the Control Panel.

1. You must be online in Auto to view/interact with this panel.

2. When at the Operator (2) access level, the user will only see the green Auto button as shown.

3. Users who are able to log in at Maintenance (3) or Engineer (4) access levels will be able to see the Manual
button and can click this to switch the system to Manual mode.

The selections are defined as follows:

• Auto – The Predator3D is able to inspect parts. The Predator3D will communicate with the
robot/PLC/dispenser and will be in one of three scan save modes (Save Disabled, Save All, or Save
Failures)..
• Manual – Only available for Maintenance (3) and Engineer (4) level users. First, the communication
with the robot/PLC/dispenser is disabled. Users can then load scans and configure the inspection.
Lasers can be manually turned on by clicking Acquire. Users can access the secondary panels such as
Setup, Parameters and Data Management in the top menu bar. Engineer (4) level users can also
search for Defect positions and Feature Tool positions and can open a DataTree view at certain nodes.
Note that a Maintenance (3) user will have fewer options than an Engineer (4) user.

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 14. Post-Mounting Validation for Predator3D System
After mounting the Predator3D to the bracketry, a few additional steps will confirm it is mounted correctly. This
ensures the system is placed at the optimal mounting offset for which it was designed, and that the system is mounted
to place the nozzle as centered as possible within the # laser pattern. These steps require the system to be powered
on and connected to an HMI.

Validate the Nozzle Position

1. Move the part under the nozzle such that all four lasers appear on the surface. Use the robot to make the
nozzle as normal to the part as possible. The distance between the nozzle and the part should be the height
of the bead.

2. If you are offline, click the GO button.

3. Change your access level to Maintenance (3) or Engineer (4).

4. On the Predator Control Panel, click Manual.

5. Change the image mode to Acquire.

NOTE: You may need to perform some mechanical adjustments to the bracket to center the nozzle within the # laser
pattern to achieve optimal alignment. The lasers CANNOT be obstructed in any way.

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 6. With the lasers on, look at the part surface and the laser alignment around the nozzle. Ensure the nozzle is
centered in the # laser pattern. If it is visibly off-center, adjust the mounting of the sensor to better center the
nozzle in the pattern (it may be necessary to move the part and repeat the process until centered).

7. Ensure that the nozzle is centered in all directions.

Validate the Mounting Offset

1. Move the part under the nozzle such that all four lasers appear on the surface and make the part as normal
to the nozzle as possible.

2. Ensure that the part is at the proper dispensing distance from the tip of the nozzle. This is typically the height
of the bead.

3. At a dispensing location normal to the part, measure distance from the part to the bottom blue surface of the
sensor (the Mounting Offset) to ensure that it is correct for the specific version of Predator3D you are using.
You can find information specific to each sensor on the file transfer site under CAD Drawings.

Predator3D Predator3D Pro

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 4. If the distance is not within the tolerance specified on the CAD drawings, adjust the mounting appropriately.
You may need to perform some mechanical modifications to the bracket to ensure a proper Mounting Offset.

5. Step through the robot program(s) and ensure that the distance between the nozzle and the part is consistent
throughout the dispense. This will improve the inspection and will also improve the quality and consistency
of the bead as dispensed.

6. If you made any changes to the Mounting Offset, ensure that the Nozzle Position is still centered in the pattern.

Validate Electrical Grounding

Failure to properly ground the Predator3D system can lead to permanent hardware damage, which can result in the
loss of inspection capability and will void the unit’s warranty.

1. Check the grounding of the unit as described in Electrical Grounding Considerations.

2. If the unit is improperly grounded, comply with the instructions in Electrical Grounding Considerations.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Validated that the nozzle is centered in the laser # pattern.
✓ Validated that the sensor’s mounting offset is correct
✓ Validated that the sensor is grounded properly.

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 15. Setting Up Communication
Predator3Ds receive inputs from either the robot, PLC, and/or dispenser. The communication between these systems
is via Ethernet cabling. The communication can be routed via a gateway if the robot, PLC, or dispenser do not natively
communicate with the protocols that the system uses. This section discusses setting the communication on the sensor
using Modbus TCP. It will not go into detail about routing the communication through a gateway or setting it up on a
robot, PLC, or dispenser. Please reference the file transfer site’s Communication Setup folder for additional
information on these topics. By default, Predator3Ds are shipped with Modbus TCP enabled as the active
communication protocol.

NOTE: The Predator3D natively support Modbus TCP and Ethernet IP protocols. However, Ethernet IP is an add-on
option that is not part of the standard Predator3D configuration. Please contact Coherix or your System Integrator for
information on procuring/enabling the Ethernet IP protocol.

Predator3D Pro can natively support PROFINET. However, this add-on option must be selected prior to purchasing the
system because it requires the installation of additional hardware within the unit.

Configure Digital I/O Map

1. Change your access level to Engineer (4).

2. If the system is online, click STOP to bring it offline.

3. Select i-Cite > Configuration > Predator3D(TM) Sensor Auto Config to bring up the Auto Configuration Option
window.

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 4. In the Auto-Configuration option window, click the Digital I/O button.

5. In the Digital I/O Auto Configuration window, enter the starting address to be used for the communication
to the Predator3D under the Base Address.

6. Enter the IP Address of the system communicating with the Predator3D in the Base Robot IP Address field.

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 7. Enter the number of systems that communicate with the Predator3D in the Number of Robots field. If this
value is greater than 1, the IP address of the second system is set to be 1 greater than the previously entered
IP address. If this is not how your IP addresses are structured, you must manually change this later.

8. Under the Type drop-down menu, click the option for the communication as defined by the setup on the
system that must communicate with the Predator3D.

The options in the drop-down box are:

• Predator3D Standard Control: This provides the minimum communication the system needs and is
configured as the default. This selection uses Splines.
• Predator3D Speed & Head Angle Block Data: This option is reserved for possible future
development. Currently, i-Cite does not use the Head Angle Data in this selection.
• Predator3D Standard Speed Block Data: This option supports the real-time speed of the robot. It
auto-adjusts to minor speed changes in the dispensing path. If the frequency
the speed data is sent is too low, it may not adapt to speed changes in the
dispensing path as expected. This selection uses Splines.

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 • Predator3D Standard TCP Block Data: This option is the recommended configuration. It exploits the
real-time TCP (x, y, z, roll, pitch and yaw) data sent from the robot/gantry to simplify the setup of the
inspection and to better adapt to minor speed and path changes throughout the dispense. If the
frequency the TCP data is too low, it may not adapt to speed changes in the dispensing path as
expected. This selection uses TCPs (however, splines can still be implemented if TCP data is received).
• Predator3D TCP With 7th Axis Block Data: This option was designed for applications using a 7th axis.
It combines the Predator3D Standard TCP Block Data with additional rotation data from the 7th axis
control. It is primarily used in pedestal-mounted GlassMaster applications where the nozzle and
sensor head rotate around a 7th axis that is coordinated with the robot movements.

9. Click on the OK button to exit out from the Digital I/O Auto Configuration window.

10. Click the OK button on the prompt to acknowledge the need to restart the program.

11. Manually close i-Cite by clicking the X in the upper-right corner.

12. On the desktop, double-click the i-Cite icon to re-launch the program.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Defined the Base Address for the system communicating with the Predator3D.
✓ Defined the IP Address for the system communicating with the Predator3D.
✓ Defined the number of robots that will be communicating with Predator3D.
✓ Selected the communication configuration to be used.

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 16. Setting Imager Windows
With the Predator3D system mounted and powered up, you must next set the imager windows. These steps are done
before setting the imager brightness and acquire scans. This ensures that when scans of the parts are captured, the
bead is located within the system’s FOV throughout the dispensing process. Your access level must be set to Engineer
(4). It is important to note that these settings will apply to all inspections for which the Predator3D is configured
(unless Districts are used to change these settings by part style; see Appendix: District Setup for more information).

1. If the system is offline, click the GO button.

2. On the Predator Control Panel, click Manual.

3. Click Panel and then Setup… to open the Setup Panel.

4. In the Setup Panel, click the Imager Windows tab.

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 5. Click Display Icon; this opens the Outliner Overlays (All Imagers) display on the screen.

6. With the mouse, move the cursor to the edges of the Outliner Overlays (All Imagers) display and drag the
edges of the window to make it as large as possible.

7. Place a sample part with a pre-dispensed bead under the sensor and ensure that the nozzle is the proper
distance from the part that will be used for dispensing.

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 8. In the Imager Windows tab, click Acquire Test. The background of the button will turn GREEN, indicating the
system is acquiring images (the system will only acquire images for 3 seconds).

9. Clicking Acquire Test causes the Predator3D to acquire and display the laser lines that are projected onto the
part surface and bead as seen by the imagers in the Outliner Overlays (All Imagers) display.

10. The Outliner Overlay (All Imagers) display shows the last image of the laser line from each imager.

NOTE: The laser lines displayed may not be perfectly aligned on the center of their respective imager window that is
indicated by the BRIGHT GREEN line. This is normal and does not indicate that there is an error.

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 11. If the laser lines appear in the lower half of the imager window, increase the values in the dialogs on the
Imager Windows tab. If the laser lines appear in the upper half of the imager window, decrease the value.
Click the Acquire Test button each time you make a change to update the Outliner Overlay (All Imagers)
display.
i. First, adjust the Imager Center (Global) value (this adjusts all four imagers).

ii. Then adjust the individual Imager # Center (pix) value (this adjusts a single imager).

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 12. Adjust the values to move the RED laser line onto the BRIGHT GREEN line (center of imager window) for all
four imagers. This will center each laser line in their respective imager windows. See below for an example of
a well-aligned imager window.

13. Repeat the above steps for Imagers 1, 2 & 3. The laser lines for all of the imagers should be as close to centered
as possible within each of the imager windows.

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 14. Click Save Changes to save the adjustments made to the imagers. The background of the button will turn
BLUE once the button is clicked & the adjustment is saved.

15. Close the Outliner Overlays (All Imagers) display; click the X in the upper-right.

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 16. Close the Setup panel; click the X at the upper-right.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Configured Imager Windows to center the laser lines for all imagers.
✓ Saved the changes.

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 17. Setting Imager Brightness
With the Predator3D system mounted and powered up & the imager windows set, you must now set each imager
brightness before attempting to acquire scans. This ensures the image is not too saturated/bright that negatively
impact the inspection results. Ensure your access level is set to Engineering (4). Note that these settings apply to all
inspections for which the Predator3D is configured (unless Districts are used to change these settings by part style,
see Appendix: District Setup for more information).

NOTE: This initial setup is typically carried out in one or two locations of the part. But this process may need fine-tuning
after running a full part. Therefore, it is highly recommended to fine-tune the process after a full dispense on a part.

1. If the system is offline, click the GO button.

2. On the Predator Control Panel, click Manual.

3. Click Panel and then Setup… to open the Setup Panel.

4. In the Setup Panel, click the Imager Brightness tab.

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 5. Then click the Display Icon; this opens the Imager Brightness display.

6. Move the cursor to the edges of the Imager Brightness display and drag the edges of the window to make it
as large as possible.

7. Place a sample part with a pre-dispensed bead under the sensor and ensure that the nozzle is the distance
from the part that would be used for dispensing.

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 8. In the Imager Brightness tab, click the Acquire Test button. The background of the button will turn GREEN
to indicate the system is acquiring images (the system only acquires images for 3 seconds).

9. As the system acquires images, the Imager Brightness display depicts the brightness of each of the four
laser as sensed by each of the four imagers.

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 10. First, adjust the Duration value and click the Acquire Test button. Repeat this until the least bright imager
has an AVG value of 128±10 (if this is not possible with the maximum duration, move to the next step).

11. Second, adjust the Imager # Gain value for each individual imager and click the Acquire Test button to see
the effects of the changes. Repeat until all four imagers have an AVG value of 128±10 (increase the gain to
increase the brightness). If this is not possible with a maximized gain, move to the next step.

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 12. Click Save Changes to save the adjustments made to all of the imagers. The background of the button will
turn BLUE once the adjustments are saved.

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 13. Click the X at the upper-right corner of the Imager Brightness display to close it.

14. Click the X at the top-right corner of the Setup panel to close it.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Set Imager Brightness to ensure proper image saturation.
✓ Saved the changes.
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 18. Saving TCP Data
This section covers saving TCP data in a text file (if Predator3D Standard TCP Block Data was selected when the Digital
I/O Map was configured). Prior to saving Acquiring Image Scans, it is necessary to configure the Predator3D to save
TCP data being sent from the robot/gantry system. This should have already been configured by following the
documentation found under Communication Setup on the file transfer site. Ensure your access level is set to the
Engineer (4). Explicitly follow the instructions below to correctly configure the system. Afterward, whenever a scan is
saved, a text file containing TCP data will be generated. This must be validated before proceeding.

1. If the system is offline, click the GO button.

2. On the Predator Control Panel, click Manual.

3. Click Panel and then Setup… to open the Setup Panel.

4. Click TCP on the Setup Panel.

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 5. Click the proper Block Data Format. It should be TCP Block Data Standard (Version 1) unless specified by your
Coherix representative. If required, please consult with them for more information.

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 5. Change the Block Data Register to the appropriate value on the TCP tab of the Setup Panel (below Block
Data Register is set to 5).

6. When finished, click the Save Changes button; the button will turn Blue when saving is complete.

7. If there are two robots configured, repeat this process for the additional robot.

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 Pedestal TCP Setup (FANUC robots only)
For FANUC robot pedestal applications, information for the remote nozzle tip user frame has to be input. This is
accessed through the FANUC’s teach pendant by selecting Menu->Frame->Detail (F2) where the user frame of the
nozzle tip (X, Y, Z, W, P, and R) is input as directed. This does not apply to ABB, Kawasaki or KUKA robots. Those brands
handle this transformation internally.

1. Click the Advanced… button for the appropriate robot.

2. On the TCP Advanced Setup panel, set the TCP Transform to be Pedestal.

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 3. Input the Remote User Frame information, i.e., X, Y, Z Point coordinates, plus Slope (rotations about X, Y and
Z) also known as roll, pitch, and yaw.

4. Click Save Changes. When saving is complete, the button will turn Blue.

5. When finished, close the TCP Advanced Setup panel by clicking the X in the upper right.

6. If there are two FANUC robots carrying parts under the same dispensing nozzle, repeat this process for the
second robot.

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 Confirming Register Mapping
This section facilitates confirmation that I/O registers are correctly mapped. This ensures proper synchronization with
the TCP data.

1. Change your access level to Engineer (4).

2. Bring the program Offline by clicking the STOP button.

3. Click the LEARN button and select References Map.

4. You will see the P3D References: Map. It is necessary to ensure the In Bits, In Registers, Out Bits, and Out
Registers are all properly mapped after any IO changes.

NOTE: All entries in Lines tab and Regs tab begin counting from 0.

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 5. Click i-Cite and then click Digital I/O…

6. Use the Lines tab to check the mapping for the In Bits and Out Bits. If you are using Auto-Repair you can also
map the signals associated with that at this time.

7. Use the Regs tab to check the mapping for the In Registers and the Out Registers. For example, ensure that
Part Style and Control Timestamp are mapped correctly for In Registers and that Failure Code is mapped
correctly on the Out Registers.

8. When finished, click Done.

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 9. Click GO to go Online and click Yes to save changes.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ If Speed or TCP data is being received, configured the saving of said data.
✓ If FANUC robots are being used with Pedestal dispensing, configured the frame transformation.
✓ Confirmed Register Mapping.
✓ Saved the changes.

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 19. Acquiring Image Scans
Collecting an image scan is necessary for both the Learn process and the Setting up the Active Part – Preliminary Setup
or fine-tuning a part style that is already setup. There are two possible formats in which scans can be saved. The
default 3D Scan format saves the post-processed 3D data in a reduced file size while Full Scan saves the raw laser line
data in a much larger file size. The Full Scan is useful for in-depth analysis but should not be used for normal production
operation.

NOTE: Some of the buttons and menu selections explained below may not be visible / available on your screen. These
options are configurable such that their availability is determined by the access level you are currently assigned.

Preparatory Tasks
Before beginning, make sure that you have:

• A sample of the part onto which the bead will be dispensed during the acquisition.
• The robot operating at production speeds during the process.
• The robot program is complete and the Predator3D is repeatably receiving the following signals with the
proper timing:
i. Part Style: signal for indicating which part is to be inspected.
ii. Run ON: signal for beginning the image acquisition.
iii. Gun ON: signal for the start of each track/bead dispensed.
iv. Gun OFF: signal for the end of each track/bead dispensed.
v. Run OFF: signal to stop the image acquisition once all dispensing is complete.

If the Predator3D was configured to save TCP data, ensure the data is being received by clicking File then selecting
Digital I/O… then clicking the Regs tab to validate the incoming data.

NOTE: On a part which has already been dispensed, you will run the robot program without dispensing and ensure that
the nozzle is not ploughing into the bead and creating a trough bead.

to.

Acquiring Scans
The following steps are required to acquire an image scan of the desired part.

1. If you are offline, click GO to bring the system online.

2. Prepare the part for dispense. Fixture it in the same way that it would be for normal production. If the part
already has adhesive dispensed on it, ensure that the dispenser will not dispense onto it again. However, the
Predator3D will still need to receive all IO signals.

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 3. Make sure AUTO button is green. Otherwise click the AUTO button.

4. Ensure Scan Save is set to Save All.

5. Set the Scan index to a value that has not yet been used to save an image scan. Refer to the default scan
directory (D:) > Scans if necessary.

6. Run the dispense program and take note of the Part Style number associated with that part and the saved
scan. This value is set by the robot/PLC and needs to be unique for each inspection.

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 7. The saved image scan can be found in the directory New Volume (D:) > Scans.

8. The filenames of the saved scan will contain the index value that was set above, followed by the description
of the file, e.g., Scan0660Imager0.bmp or Scan0660Events.txt.

9. There will be a number of files from the Scan found in the directory. The exact number depends on how the
system was configured. Every file with the same index belongs to the same scan.

10. If you saved TCP data, open the text file and ensure the values are populated. The file below is
Scan0000Tcps.txt and shows an example of saved TCP data.

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 Confirmation Checklist
Tasks that were accomplished in this section:
✓ Acquired & saved a scan of the part.
✓ Validated the scan was saved in D:\Scans.
✓ Validated the TCP data was correctly saved.

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 20. Creating a Template Image
A template image is very useful to setup a new part style. A template image can be a digital photo of the part with the
adhesive dispensed on it. A steel ruler or two datums a known distance apart should be included the image. The
template image may also be a screenshot of a CAD drawing that shows the adhesive path. The beads on a template
image are overlaid with the actual 3D results from the bead inspection. This combination provides an effective visual
reference to help identify any portions of the bead that are out of tolerance.

Creating a Singular Template Image

1. Begin with a production part that has the adhesive beads dispensed on its surface and ensure that the beads
are an accurate representation of the production beads.

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 2. Place a ruler on the surface of the part. Alternatively, you can skip this step if you know the distance between
any two points visible on the part.

3. Take a digital photo of the part in a standard image format (JPEG, PNG, etc.).

NOTE: If you intend to use two points visible on the part surface, ensure that the distance between the points represents
at least 1/4 of the longest measurement on the part, e.g., do not use a 6 mm diameter hole when dispensing a lengthy
bead like that on the side of a vehicle from the A-pillar to the C-pillar.

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 4. Make sure the digital photo shows the entire part with all of the beads clearly visible in the image.

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 NOTE: If there are multiple surfaces at varying angles on which the bead is dispensed, the template image should be a
mosaic of multiple digital images of the part, taken at appropriate angles. Refer to the section on Mosaic Template
Images for further information.

5. Load the digital image into Paint.

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 6. Click Resize and then ensure Maintain aspect ratio is checked and that Pixels is selected. Then click OK.

7. If the size of the image is not between 640 x 480 and 5000 x 5000 pixels, resize it appropriately within those
limits. After resizing the image, ensure each bead is visible with resolution that is not too low.

NOTE: You want to size the image appropriately. If you are dispensing a single small bead, feel free to use a lower
resolution template image. If you are dispensing beads across an entire car body, use a higher resolution template
image.

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 8. Using Paint, annotate the image with:
i. The Part Style number of the part: this is the number the robot will send to the Predator3D to identify
the part (if desired, the addition of a more descriptive identifier can be added for later use in the
software).
ii. For each track, indicate its track number to set the order of bead dispensing (tracks start at index 0).
iii. For each track, indicate the direction in which the bead is dispensed.

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 9. To save the changes made to the image, click on File -> Save as -> JPEG picture from the drop-down menu.

10. In the File name: dialog box, type the Part Style number (e.g., Part Style 0) as the filename for this image &
click JPEG as the option for the Saves as Type:

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 11. Make certain the template image is saved in the D:\Projects\StandardPredator3D folder.

12. Click Save to save the modified template image.

NOTE: The changes to the digital image can be carried out on a different PC and upon completion, transferred into the
Project directory (D:\Projects\StandardPredator3D) within the Predator3D via the Remote Desktop connection.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Acquired a photo of the part.
✓ Included additional information (dispense direction, track number, etc.).
✓ Saved the edited image in the Project folder.

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 Creating a Mosaic Template Image
A mosaic template image must be created when a single photo of the part cannot show the entire dispense path or
when a single picture distorts the true shape of the dispensing path. For instance, a part that has surfaces at right
angles to one another will require two photos to create a mosaic template image. The image below shows an example
of such a part. It has two beads dispensed, but one bead is dispensed onto two surfaces at right angles to each other.

1. Choose a production part that has the adhesive beads dispensed and ensure the beads are an accurate
representation of normal production (see above).

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 2. Place a ruler on/near the surface of the part.

3. Take a photo of the part in a standard image format (JPEG, PNG, etc.).

4. Ensure the digital image of the part shows the entire surface of the part and that all of the beads are clearly
visible.

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 5. Rotate or re-orientate the part such that the other surface is now clearly visible. Place a ruler near that surface.

6. Take a photo of the new surface of the part in the same standard image format (JPEG, PNG, etc.).

7. Repeat the above steps if there are more than two surfaces on which the bead is dispensed.

8. Load the digital images taken into the same window of Paint if the images need to be rotated at non-right-
angles or resized as described below.

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 9. Ensure the scaling between every image is the same.

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 10. Click Resize; ensure Maintain aspect ratio is checked and that Pixels is selected; ensure the entire image is
resized.

11. If the size of the image is not between 640 x 480 and 5000 x 5000 pixels, resize it appropriately within those
limits. After resizing the image, ensure each bead is visible on the part and is not too low in resolution.

NOTE: It is good to size the image appropriately: if you are dispensing a small bead, use a lower resolution for the
template image; if you are dispensing beads across an entire car body, use a higher resolution for the template image.

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 12. On the image annotate:

1. The Part Style number of the part: this is the number the robot will send to the Predator3D to identify
the part (if desired, a more descriptive identifier can be added for later use in the software).
2. For each track, indicate its track number to set the order of bead dispensing (tracks start at index 0).
3. For each track, indicate the direction in which the bead is dispensed.

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 13. To save the changed image, click on File -> Save as -> JPEG picture from the drop-down menu in Paint.

14. In the File name: dialog, enter the Part Style number (e.g., PartStyle-1) as the filename for this image. Click
JPEG as the option for the Saves as Type:

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 15. Ensure the template image is saved in the D:\Projects\StandardPredator3D folder.

16. Click Save to save the latest template image.

NOTE: The changes to the digital image can be carried out on a different PC and upon completion, transferred to the
Project directory (D:\Projects\StandardPredator3D) within the Predator3D via the Remote Desktop connection.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Acquired a photo of each surface of the part.
✓ Merged the pictures into a single mosaic image keeping the same scale.
✓ Included additional information (dispense direction, track number, etc.).
✓ Saved the edited image(s) in the Project folder.

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 21. Setting up the Active Part Style – Preliminary Setup
In Learn mode, setting up an inspection of a specific dispense accesses a number of main pages, and on each page,
there are required steps. This process covers the standard interface for Engineer (4) access level and guides a user
when setting up a part style. Maintenance (3) access level can also be used to setup a part style but shows fewer
Learn options. For a video tutorial of this process, see the Videos section of the Coherix File Transfer Site.

NOTE: Some of the buttons and menu selections explained below may not be visible / available on your screen. These
options are configurable such that their availability can be determined by the access level you are currently assigned
to.

Preparatory Tasks
Before beginning the learn process, ensure all steps from prior sections are completed, including:

• Completed Setting Imager Windows.

• Completed Setting Imager Brightness.
• Configured Saving TCP Data and the Pedestal TCP Setup (FANUC robots only), as applicable.
• Completed Acquire Image Scans of the part with the adhesive beads applied (recommended to be a live
dispense).
• Completed Creating a Template Image of the part, and if necessary, created a Mosaic Template Image (note:
when using TCPs, a template image is optional but highly recommended).

Load a Saved Image Scan

The following steps are required to successfully configure a Part Style inspection.

1. Sign in to Engineer (4) access level and click GO if you are offline.

2. In the Predator Control Panel, click Manual.

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 3. When in Manual Mode, the control panel will appear as follows:

4. Click the Load button to load the scan for further use:

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 Enter Learn Mode
You can set up Active Part Style inspections in Learn.

1. Click LEARN.

2. This is the Main view for Learn. Ensure that the proper part style you wish to learn is entered under Active
Part Style.

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 3. Click Learn… to begin setting up an inspection.

4. Proceed to the Setting up the Active Part – Spline Method chapter or the Setting up the Active Part – TCP
Method chapter depending on how the system was configured.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Loaded a saved scan.
✓ Entered Learn mode.

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 22. Setting up the Active Part – Spline Method
This chapter covers using Splines to setup the Active Part. If you are using Speed data or if you are not using TCP data,
use the following steps to setup an inspection.

Setup Part Style - Splines

1. The text in red acts as a prompt to indicate what has not been configured yet in this process.

2. Step-by-step instructions for setting up a part style are available in Help.

3. For Part Style Identifier, type a descriptive part name.

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 4. Click the button to the right the box labeled Template File: to opens the file explorer. Navigate to and click
an appropriate Template Image for the part. The template image that was previously created should have
been stored in the Project Directory.

5. If the template image orientation is not desired, click on the Template Orientation (deg) drop-down box to
refine the proper orientation in which the image is to be presented on the left side of the screen.

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 6. On the template image, drag the red and green crosshairs on either end of the yellow line to a scale or a
part feature with a known dimension.

NOTE: If the tool is not visible, it is likely located along the edge of the template image (e.g., bottom-right corner).

7. To place the tool accurately it may be necessary to zoom in on the image. There are a few ways to do this.
i. Right-click on the image and click Zoom > and then set the desired zoom.
ii. Click on the image; then hold Ctrl and scroll with the mouse wheel to change the zoom.
iii. Double-click on the image to change the zoom if the resolution of the image allows. This also scales
the image to fit the screen if it is currently zoomed in.

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 8. Input the distance between the red and green crosshairs into the Millimeters Between Crosses (mm).

9. Input Typical Application Speed (mm/sec), Typical Bead Height (mm) and Typical Bead Width (mm).

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 10. When all inputs have been configured, the text on the template will turn green and show Part Setup Valid:
Learn Using Splines.

11. Click the Next > button to finish.

Edit Spline Paths

In this section, you will learn to draw splines on the template image for each dispensed bead. Splines are lines and
arcs which follow the bead path enabling the proper overlay of results onto the template image. Splines also help the
operator identify the bead on the part during a visual inspection.

1. Set Track to 0 if it is not already that. This ensures the first spline drawn is on the first bead dispensed.

2. Click Begin Cursor Path; a warning will appear.

3. Click OK to acknowledge.

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 4. It is possible to toggle between Add Curved Segment and Add Line Segment by clicking the button below.

5. Begin by clicking a point approximately 20 millimeters before the start of the first dispensed track.

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 6. Click along the center of the track to roughly trace the bead path. Cutting the corners is acceptable because
the path will be changed later. End by clicking a point approximately 20 millimeters after the end of the track.

NOTE: The Start and End points of the splines are based on the dispensing direction of the robot. Ensure they extend at least 20mm
from the actual start and end of the beads. This allow i-Cite to depict 3D data as far out as the spline extends.

7. Once finished, click End Cursor Path.

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 8. The spline starts with a green square; at every clicked location there is a red circle. These mark the end of a
line segment. The yellow circles between two ends of a line segment are used to curve that segment.

9. Double-clicking on a drawn segment of the spline will bring up the following dialog.

The dialog’s options are:

• Convert to Line: Converts a curved segment to a straight segment and deletes the yellow circle on
the curved segment where the double-click was performed.
• Convert to Circle: Adds a yellow circle to the center of a straight segment.
• Divide Section: Separates the segment where the double-click was performed into two segments.
• Delete Section: Removes the segment after the location where the action was performed.

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 10. Drag the yellow circle to place the red line along the center of the bead. You must drag from the center.

NOTE: When adjusting the yellow circles, the transition from one line segment to the next should be as smooth as
possible.

11. Once you have the red line centered in the bead for the entire track, it should look something like this.

12. To define subsequent splines, increment Track by 1 and click Begin Cursor Path… to start the next one.

NOTE: If there is more than one track on the part, each track MUST be defined as a separate track, each with its own
GUN ON and GUN OFF signals. There is only one spline definable per track.

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 13. Below, the three stitches are treated as a single track to demonstrate the Track Type option that can be
used for stitch beads.

14. Repeat this process until all splines are drawn for your specific part.

15. Click Reference All Paths… to compute the paths from the drawn splines.

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 16. Click Yes to confirm.

17. Click Next >.

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 Edit Tracks
In this section, you will learn to define the actual start and endpoints of the beads.
1. Ensure Track is set to 0.

2. Click on the first track and drag the first red-green transition to the center of the start of the bead and then
click and drag the second red-green transition to the center of the end of the bead.

3. Click the proper Track Type for the bead.

The Track Type options are:

• Standard Continuous: The default selection, choose this when the dispensed bead is
continuous, with Gun ON and Gun OFF signals indicating the start and end of the bead.
• Stitched Track with Single Gun: This is for stitch beads that have a single Gun ON for the start of
the first stitch and a single Gun OFF. The assumption made for this choice is that the stitched
bead has equally sized and spaced stitches.
• Stitched Track with Gun per Stitch: Separates the segment where the double-click was
performed into two segments.

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NOTE: The stitch selection is used with the Spline Method but not often used with the TCP Method. This is because the TCP method
will, by default, populate tracks for each dispensed bead as long as the system receives all IO signals.

4. For subsequent tracks, increment Track by 1 or click on the spline to switch to that track and repeat the
process.

5. If you select either type of Stitched Track, select the appropriate number of Stitches for the track.

NOTE: For any track that has a stitched Track Type, line up the beginning of the green section to the center of the start
of the FIRST bead and then click and drag the end of the green section to the center of the end of the LAST bead.

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 6. Repeat this process for each Track on the part.

7. Click the drop-down arrow to the right of Robot Concurrency and select None.

The Robot Concurrency options are:

• None: With the default selection, the robot/PLC only transmits the IO signals for the inspection. This
selection must be selected if neither Speed Data nor TCP data is received by the system.
• Speeds Only: This makes us of the configured, real-time speed of the robot. It auto-adjusts to minor
speed changes in the dispensing path. This may be selected with the Spline Method if the system is
receiving the Speed Data from the robot/gantry.
• Speeds Then TCPs: This option is reserved for possible future development.
• TCPs Only: This makes use of the configured, real-time TCP data (x, y, z, roll, pitch, and yaw) sent from
the robot/gantry to adapt to minor speed and path changes throughout the dispense. This may be
selected with the Spline Method if the system is receiving the TCP data from the robot/gantry.
• TCPs Then Speeds: This option is reserved for possible future development.

NOTE: Please consult Customer Service of your supplier or Coherix if you are unsure of this setting. If you are unsure
which selection may be implemented, select None. The system will automatically downgrade your selection if it is not
receiving all the necessary data, but it will not downgrade if wrong information is being received.

8. Click Next >.

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 Edit Marks
This section teaches you to line up each drawn spline with the 3D data that corresponds to the location on the spline.
This aids the operator in identifying a gap and/or other flaw in the bead by overlaying the 3D data in the correct
location on the template image.

1. Click the drop-down arrow and select Setup Crossings (All Imagers).

The options available in the drop-down are:

• Learn Edit Marks (Path Marks by Position): This shows locations of Gun ON/OFF signals along with
the location of every anchor that you place. In addition, it shows the orientation of the lasers at a
location you click based on the currently selected Track Head Angle option.
• Setup Crossings (All Imagers): This shows 3D data from the point of view of each of the four imagers
during acquisition. Each imager corresponds to a specific column of data: the 1st column is Imager 0,
the 2nd column is Imager 1, and so on.
• Setup Sections and Crossings (All Imagers): This also shows 3D data from the point of view of each of
the four imagers during acquisition. Each imager corresponds to a specific column of data: the 1st
column is Imager 0, the 2nd column is Imager 1, and so on. It also attempts to highlight a potential
bead in green and shows the center of the potential bead with a red line.
• Measure Sections (Recipe): This does not show any information until the learn process is completed
for the first time. This shows where on the part each imager is used; this can be used to fine-tune
anchors after the initial inspection is set up.

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 2. Click Initialize All Tracks….

3. Click Yes to confirm.

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 4. After Initializing the tracks, the drawn spline will be shown unwrapped across the four columns. A column
shows the data collected from a single imager; it is now possible to lineup the spline with the bead.

NOTE: Due to this scan being saved during live dispense, the bead is usually seen by only the trailing imager.
Occasionally it is seen in two imagers when a transition between imagers occurs. The bead is depicted in light grey
because it is taller than the part surface that is darker grey.

To show which laser was identified as trailing, i.e., behind the nozzle at a certain point in time, the spline path will be
BOLDED, while the laser in front of the nozzle at that time will be thinner. The orientation of the spline will be modified
in later steps.

5. Next to Track Head Angle (deg) click the C to direct the software compute the Track Head Angle. (This
calculated value may require some adjustment. When you click this button, an additional display will pop up
which you can close.) The Track Head Angle is used to identify the orientation of the sensor relative to the
nozzle and part. A constant head angle assumes the part is only translating relative to the nozzle.

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 6. Click at the start of the spline, then switch back and forth between the current display, Crossings (All Imagers),
and Learn Edit Marks (Path Marks By Position) to observe the Track Head Angle. This value identifies the
orientation of the sensor relative to the part along the dispensing path.

NOTE: If the inspection was done on a pre-dispensed part, the bead will be seen in both the leading and trailing imagers.
Special attention is required to determine the trailing laser/imager when setting the Track Head Angle (deg). The trailing
imager will show the start of the bead slightly below the start of the bead in the leading imager.

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 7. If the track head angle is 180 degrees off, click Mirror to adjust the track head angle by 180 degrees. Below,
Imager 3 sees the beginning of the bead but the spline is not bolded at the beginning of the bead. After
Mirroring the spline and adjusting the Track Head Angle, the bolded spline lines up laterally with the bead.

8. Now adjust Track Offset (Seconds) to align the spline with the start of the bead. Track Offset (Seconds) sets
the offset between the Gun ON IO signal and the actual start of dispense. The Pink to RGBY transition aligns
with the center of the beginning of the bead. Making this value more positive moves the spline down on the
display while a more negative value moves it up.

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 9. The use of Anchors allows the spline to be aligned with the bead. Click a location on the display where you
wish to add an anchor. A horizontal dark green line will appear where you clicked. Then click Add Anchor. A
horizontal flashing blue line will appear. This is the anchor.

NOTE: Anchors are designed to hold in place any part of the spline above the anchor. They are typically added at or
near transitions from one imager to the another or at changes in direction of the bead. To allow the spline to be aligned
with bead data, click on the bead in the display, then add an anchor, then adjust the spline to the bead (do not attempt
to adjust the bead to the spline).

10. To adjust the vertical position, click and hold on the Anchor. If you then drag your mouse up the page, the
spline will move up; if you drag down the page, the spline will move down.

Spline Adjusted too High Spline Aligned with Bead Spline Adjusted too Low

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 11. Select the next location on the Track that requires the spline to be adjusted and repeat this process. The
previous anchor will turn pink to show that it is not currently selected. It is most logical to work from the top
of the Track to the bottom of the Track. It may be necessary to go back and add additional Anchors if the
spline above moves due to the adjustment Anchors that follow.

12. To improve the performance of the system, see Appendix: Head Angle Adjustments. This appendix details how
the spline can be adjusted locally left and right by using the Head Angle Adjustment (deg) to adjust the spline
at every anchor location and at each Gun ON or Gun OFF location. For a video tutorial, see the Videos section
of the Coherix File Transfer Site.

NOTE: If the part rotates and translates relative to the sensor, it is required to change the Head Angle Adjustments drop
down from None to one of the other available options. Reference the Appendix: Head Angle Adjustments for more
information. Head Angle Adjustments can improve the alignment of the spline with the bead for all spline setups.

13. Now set Gun Off Offset (Seconds) to align the spline with the end of the bead. This sets the offset between
the Gun OFF IO signal and the actual end of the dispense. The Pink to RGBY transition will be lined up with
the center of the end of the bead. Making this value more positive moves the spline down on the display while
more a negative value moves it up.

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 14. Increment Track by 1 and repeat all of the above steps for the remaining Tracks.

NOTE: For straight tracks, Anchors are often not needed. Merely adjust the Track Head Angle (deg), the Track Offset
(Seconds) and the Gun Off Offset (Seconds) to align the spline with the bead.

15. Once this process has been done for every Track, click Next >.

16. Proceed to Setting Up the Active Part – Finalizing the Setup.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Selected a template image and defined typical bead measurements and robot speed.
✓ Drew splines for every track and specified the start and end of each track on the template image.
✓ Initialized the inspection and added anchors to align the spline with the bead.

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 23. Setting up the Active Part – TCP Method
Here you will use TCP data to setup the Active Part for inspection. Though it is possible to still use the Spline Method
when receiving the TCP data, this section covers full incorporation of TCP data into the inspection process.

Setup Part Style - TCPs

This page is where you begin setting up a part style inspection.

1. The text in red acts as a prompt to indicate what has not been configured yet in this process.

2. Note - step-by-step instructions for setting us a part style are available in Help.

3. For Part Style Identifier: type in the descriptive name used for the template image.

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 4. Click the drop-down button to the right of the box under Template File: to open the file explorer. Navigate to
and select an appropriate Template Image for the part. The template image that was created should have
been stored in the Project Directory.

5. If the orientation of the template image is incorrect, click Template Orientation (deg) drop-down box and
input the proper orientation in which the image is to be presented on the left side of the screen.

6. The text in red will indicate what remains to be configured.

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 7. Input Typical Bead Height (mm), and Typical Bead Width (mm).

8. When all inputs have been configured the text on the template will turn green and show Part Setup Valid:
Learn Using Tool Center Points.

9. Once finished, click on the Next >.

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 Learn Template Tool Center Points
Here, TCP points are aligned on the template image for each dispensed bead. This aids the visual interpretation of
inspection results by an operator. The large green circle on the TCP paths indicates Gun On and the large red circle
indicates Gun Off. It is best for a track’s TCP paths to be aligned with the corresponding bead on the template image.

1. Prior to interacting with the primary controls, note their purpose and how to use them:
i. Zoom To Fit is a single-click button; it seeks to scale the TCP data to fit onto the template image.
ii. Restore From Reference is a single-click button if a TCP path has been previously referenced (i.e., if
Reference All Robot Paths has been clicked, it will reset to previously referenced paths).
iii. Scale, Translate and Rotate are each clicked to activate. Then click and hold on the template image
and drag the cursor to manually adjust the TCP paths instead of using direct numeric inputs.
iv. Edit Track allows the user to make changes to a single track by selecting the track number or all tracks
by selecting ALL. When individually changing a track, the numeric values next to Scale, Translation,
and Rotation are offsets from the values set for ALL tracks.
v. Scale, Translate and Rotate numeric values are used for direct inputs to change the TCP paths on the
template image instead of using the manual adjustments via the buttons.
vi. Compute Rotations button directs the software to calculate the rotation of the TCP paths to minimize
the Nozzle Vector: Length %.
vii. Gun On/Off (Seconds) numeric values are used to offset the timing of the IO signals within the TCP
paths. These values are rarely changed through these controls.
viii. Reference All Robot Paths is a single-click button that acknowledges that the user has finished editing
the TCP paths on the template image and is ready for the next step.
ix. Reset All Paths/Tracks reset the referenced robot paths and tracks in a single click.

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 2. Use Compute Rotations to minimize the nozzle vector for the TCP paths. The resulting screen image should
appear like below.

3. When first viewing this page, it is possible that not all Tracks will be visible on the display. Click Zoom To Fit to
direct i-Cite to attempt to bring all Tracks into view.

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 4. After clicking Zoom To Fit, the screen should appear as follows.

5. Click Edit Track and set value to “0”.

6. Move the mouse cursor onto the P3D Tools::Learn Template Tool Center Points display; left click anywhere on
the display and drag Track 0 down.

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 7. Use the third numeric input for Rotation to rotate TCP path around the Z axis to align the path with the bead
in the Template Image.

8. Move the mouse cursor onto the P3D Tools::Learn Template Tool Center Points display, left click anywhere on
the display and translate Track 0 to match the Template Image as shown below.

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 9. Adjust Scale to better align the TCP path to the Template Image.
Rotation and Translation might need to be fine-tuned match the TCP path with the Template Image as shown.

10. Use Edit Track to set track name from 0 → All.

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 11. Adjust Gun Off Offset so the end of Track 0’s TCP path is aligned with the Template Image.

12. Adjust Gun On Offset so the start of Track 0’s TCP path is aligned with the Template Image.

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 13. Go to each track by changing the track number in Edit Track and then adjust the Scale, Translation and
Rotation to match each track to the Template Image. When the TCP path is properly matched with the
Template Image, the display will look like the following screenshot.

14. Another display useful/interesting when changing Gun On/Off (Seconds) settings is accessed by right clicking
on the template image and selecting Display->Tool Center Points->3D View (All Points).

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 15. The blue trace shows the TCP robot path data the system recorded between the Run On and Run Off signals.
Green points along the trace indicate Gun On locations in the TCP data while red points indicate Gun Off
locations. The blue trace should resemble the robot path. If it does not, the TCP data (or the FANUC pedestal
transformation) may be incorrect. Verify the TCP configuration is correct for both the robot and i-Cite.

16. Click Next >.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Aligned TCP path with the Template Image.
✓ Used i-Cite to compute rotations.
✓ Used scale, rotate & translate the refine the path alignment with the image.
✓ Refined the Gun On & Gun Off offsets.

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 Learn Adjust Tool Center Points
Here you will learn to line up the TCP data with the 3D data that corresponds to the bead physical location. This aids
the operator in identifying the failure on the part because it will be projected onto the template image in the correct
location.

1. The TCP path from the template image is shown unwrapped across the four columns. Each column shows the
data collected from a single imager. It is now possible to lineup the TCP data with the bead data.

NOTE: When the scan is saved from a live dispense, the bead is usually seen in only the trailing imager. Occasionally it
is seen in two imagers when a transition between imagers occurs. The bead is depicted in light grey because it is higher
than the part surface which is darker grey.

To identify which laser is trailing (behind the nozzle at a certain point in time on TCP path), its path is BOLDED while the
laser in front of the nozzle at that time will be thin. The orientation of the path will be changed in later steps.

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 2. Prior to interacting with the primary controls, it is important their purpose and how to use them.

i. Display Track show the imager data and TCP path for the currently selected track (if Edit Track is
selected to be ALL).
ii. Edit Track allows the user to make changes to a single track by selecting the track number, or ALL
tracks by selecting All. When changing an individual track, the numeric values next to Scale,
Translation, and Rotation are offsets from the values set for ALL tracks.
iii. Head Angle (Degrees) show the orientation of the sensor relative to the nozzle and the TCPs to
illustrate how the part or robot are rotating relative to each other.
iv. Nozzle (Seconds) is used to determine the offset between the nozzle and when the sensor scanned
the bead.
v. Gun On/Off (Seconds) values offset the timing of the IO signals within the TCP paths. These values are
able to be finetuned since the bead data is available with which to align the TCP paths.
vi. Initialize System Offsets… and Reset System Offsets… are used to set offsets for all part styles or reset
all offsets, respectively. This should only be done on the first part style being set up. Changing these
values later will affect all other part styles. These buttons simultaneously impact the Head Angle
(Degrees), the Nozzle (Seconds) and the Gun On/Off (Seconds) because they are typically similar
across all part styles. Current values can be readily checked by clicking either button.
vii. Robot Concurrency selects the method used to synchronize the inspection, if applicable.

3. With Edit Track selected to ALL, click the C button next to Head Angle (Degrees) to direct the software to
calculate the correct Head Angle. This calculated value may require some adjustment. When you click this
button, an additional display will pop up, which you can close.

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 4. The TCP path now aligns fairly well with the bead data but requires additional tuning. Close the extra display
that appeared.

5. In this example, Imager 3 sees the beginning of the bead, but the spline is not bolded at the beginning of the
bead. This is because the Head Angle is 180 degrees off. Click M to mirror the track head angle. After Mirroring
the spline and adjusting the Track Head Angle, the bolded spline lines up laterally with the bead.

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 6. With Edit Track selected to ALL, click the C next to Nozzle (Seconds) to have the software calculate the correct
the Nozzle Offset. This calculated value may require some adjustment. When you click this button, an
additional display will pop up, which you can close. The TCP path now lines up well vertically.

7. At the beginning of the track, use “Gun On (Seconds)” to line the Pink to RGBY transition up with the center
of the beginning of the bead. Making this more positive moves the beginning down, and more negative moves
it up.

8. At the end of the track, use the “Gun Off (Seconds)” parameter to line the Pink to RGBY transition up with the
center of the end of the bead. Making this more positive moves the beginning down, and more negative moves
it up on the display.

9. Change the Edit Track value to 0, then 1, then, etc. and use the Head Angle (Degrees), Nozzle (Seconds) and
Gun On/Off (Seconds) values to individually fine tune each track.

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 10. Once this has been done for every Track, click Back and ensure the TCP paths still line up on the template as
desired. The TCP paths may need minor adjustment to their Scale, Translation, and Rotation values due to
changes made to the Gun On/Off (Seconds) parameters.

11. Click Next to get back to the Learn Adjust Tool Center Points page.

12. Next to the Robot Concurrency, there is a drop-down arrow. Click this and select the appropriate concurrency
(the method used to synchronize the inspection).

The options for Robot Concurrency are:

• None: The default selection: the robot/PLC only transmits the IO signals for the inspection. This must
be selected if neither Speed Data nor TCP data is being received by the system.
• Speeds Only: This option is used for implementing the configured real-time speed of the robot. It is
meant to auto-adjust to minor speed changes in the dispensing path. This may be selected with the
Spline Method only if the system is receiving the Speed data from the robot/gantry. This cannot be
selected with the TCP Method.
• Speeds Then TCPs: This option is reserved for possible future development.
• TCPs Only: This option is used for implementing the configured real-time TCP (x, y, z, roll, pitch, and
yaw) data sent from the robot/gantry to adapt to minor speed and path changes throughout the
dispense. This is the recommended selection for the TCP Method.
• TCPs Then Speeds: This option is reserved for possible future development.

NOTE: Please consult Customer Service of your supplier or Coherix if you are unsure of what this should be set to. If you
are unsure, select None. The system will automatically downgrade your selection if it is not receiving all the information
necessary, but it will not downgrade if wrong information is being received.

13. Click Next to move forward and proceed to Setting Up the Active Part – Finalizing the Setup.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Selected a template image and defined the initial criteria for the inspection.
✓ Adjusted TCP paths for every track on the template image.
✓ Adjusted the TCP paths to line up within the bead data.

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 24. Setting up the Active Part – Finalizing the Setup
This chapter covers the portion of setting up the active part that is shared between both the Spline Method and the
TCP method, along with the validation of the setup once back online.

Compute Recipes
The purpose of this section is to have the software compute and determine which imager is used for the inspection at
what point during the dispensing process, either by time or by location on the part if the TCP Method was used.

1. Click Process All Tracks.

2. Click Yes to confirm and begin computing.

3. Click Next> to depict.

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 Edit Zones
The purpose of this section is to configure the inspection criteria for the part, i.e., what the minimums and maximums
are for width, height, and/or volume along with what the maximum defect length is and what the maximum failure
percent is. It is possible to configure up to 99 unique inspection zones on a part, Zone 1 to Zone 99. Zone 0 is reserved
as a Do Not Inspect zone and will allow everything in that zone to pass, even if there is no bead dispensed in that area.
This section was written using images from the Spline Method but is also applicable to the TCP Method.

1. If this is the first-time configuring Zones on the part, click Reset All Zones.

2. Click Yes on the pop-up that appears, this will set the Min/Max criteria in all Zones to be +/- 50% of the
typical bead width and height values previously configured. This is used as an initial estimate of appropriate
criteria but should be fine-tuned further on.

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 3. The flashing spline shows the currently-selected zone. Edit the Max Allowable Failure % that specifies the
percentage of measurements inside an individual zone that are able to be outside of the tolerances
configured before the zone fails. This parameter is often left at the default.

4. Edit the Max Allowable Defect Length (mm). This parameter specifies the length of measurements in a row
that can be out of tolerances before the zone fails. Resist setting this value below 3mm. Otherwise, there
may be an increase in nuisance inspection failures.

5. Set the Minimum and Maximum value for each of the criteria that are to be used for the inspection. Enable
the Volume criteria by checking the box next to it, or disable Width or Height as criteria for the inspection
by unchecking the boxes next to them.

NOTE: The Volume inspection criteria is the volumetric flow rate (i.e., instantaneous volume) for the dispense. The
volume is approximated as the instantaneous volume of the bead (the area of the bead) at a specific location by the
width of the laser. If the flow rate and the dispensing speed were constant across a section, then the volume of the
bead in that section would be the volume reported by Predator3D.

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 6. To change the inspection for all Zones, first, change the setting below in the active Zone then click Copy To All
Zones. This will change the….. for all Zones on the part.
i. Max Allowable Failure %
ii. Max Allowable Defect Length (Count)
iii. Max Allowable Feature Failures (Count) and whether it is enabled/disabled
iv. Min/Max Width (mm) and whether it is enabled/disabled
v. Min/Max Height (mm) and whether it is enabled/disabled
vi. Min/Max Volume (mm^3) and whether it is enabled/disabled

7. Click Yes to confirm.

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 8. To set a portion of the bead to a different zone, change Edit Zone to an unused Zone, i.e., the zone will NOT
be flashing on the template image.

9. Click and drag a box around the section of bead that needs to be a new Zone and then click Set Window to
Zone, then customize the criteria for that Zone. Multiple areas on the part can be set to the same Zone.

10. Once all Zones have been configured/added to specific areas of the part click Learn Done.

11. Click Done to exit Learn Mode.

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 Validate the Setup
1. Change the Scan number to the scan used to Learn.

2. Click Load to begin loading the scan.

3. Validate the result of the inspection. All tracks should pass the inspection. If they do not, either edit the
criteria for the beads when on line or go back to the Edit Zones portion of Learn Mode if additional zones need to
be added to the part, or the placement of zones on the part needs to be tweaked.

4. It is highly recommended that, once the inspection has been validated, create a Backup of the project.

5. To further validate the robustness of the inspection, watch the inspection results across multiple production
parts and investigate any areas that are marginal or fail.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Computed and depicted the recipe for the inspection.
✓ Created and configured the zones and corresponding inspection criteria.
✓ Validated the setup by loading the scan used to setup the inspection.

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 25. Configuring Reporting
This section overviews the default reporting capabilities of the Predator3D and Predator3D Pro. To ensure that proper
reports are created for the end-user, complete the steps below as part of the initial setup. This also ensures the
process has the desired traceability. Discussed below are the default reports. These reports may be customized to
show additional information that is required by the end-user. Reports are one of the primary values created by the
system. It is important to note that if reports are being generated and the Data Management chapter has not been
properly followed, then the system may run out of memory. Failure to properly manage the saving, storage and/or
transfer of data is the responsibility of the end-user.

1. Sign in to Engineering (4) access level.

2. If i-Cite is not online, click the GO button.

3. On the Predator Control Panel, click Manual.

4. Click Panel and then Setup.

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 5. Click the Reporting… button.

6. Click “?” for assistance when configuring the system’s reporting.

Reporting Overview
1. In the Reporting panel, there are two types of reports that can be saved. They are the…
i. Frame Log Report – Appends a single line to a text file with basic information (date, time, part style,
pass or fail, a status string, the scan number, Image Control, and the name of the report created or
not created).

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 ii. Frame Results Report – Shows the results display with the areas of the bead that pass the inspection
criteria highlighted in green and those areas that fail the inspection criteria highlighted in red, along
with additional information (Date, Time, Cell Name, Part Style, etc.).

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 Change Frame Results Report Folder (OPTIONAL)
The default location can be changed by editing the fields in the Data Management Panel.

1. Click Panel and then Data Management to open the Data Management panel.

2. In the Data Management panel, click the Reports tab and then click the … button to change the directory in
which the Frame Results Report will be saved.

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 3. Select the directory in which reports will be saved. The (D:) > Reports directory is selected as default.

4. Click Save to confirm the new save directory (it is not recommended to change the directory).

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 5. The new directory will then be updated and listed under Local Directory.

6. When finished, click the Save Changes button; the button will turn Blue when saving is complete.

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Change Default Names
The default names can be changed by editing the fields below.

1. Click Panel then Setup to open the Setup panel.

2. The Add Cell to Name text box shows the generic name used in reports. If you want to add a more meaningful
Cell Name to the report file name, type it in this text box.

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 Change Reporting Options
The default options for when/what to report can be changed by editing the fields below.

1. If you do not wish to generate reports when parts pass the inspection, leave the box adjacent to Generate
Report on Pass in the Disabled mode.

2. If you do not wish to generate reports when you load scans, leave the box adjacent to Generate Report When
Loading Scans in the Disabled mode.

3. If you want to save the frame report in RTF format, set the Generate RTF Report to Enabled. If the Generate
JPG Image of Results View is Enabled, then only the resultant view will be saved in the report folder in JPG
format. If both options are Disabled, no reports will be generated.

4. If you wish to save more information in the report (including both RTF and JPG) file Name, you can choose to
add Part Style, Part Serial Number, Pass/Fail and Scan Number information using the following checkboxes.

5. Click the Save Changes button. The background of the button will turn BLUE once the button is clicked and
the changes are saved.

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 26. Data Management
This is an overview of the data management capabilities of the Predator3D. To ensure that the system will not fill its
hard drive, it is necessary to do the following steps during initial setup. This ensures the process has the desired
traceability while preventing the running out of internal storage. This may be customized to meet end-user
requirements. First, Scan Save and Data Management Panel modes will be discussed. Then the Timed Event Map
will be discussed. Managing the saving, storage and/or transfer of data is the responsibility of the end user.

Scan Save
This section is the primary driver for the creation of data on the system and is influenced by the traceability required
of the system. Saved Scans produce a large amount of data. To prevent running out of memory, either Timed Events
or FIFO Buffers must be set up. Managing saving, storage and/or transfer of data is the responsibility of the end user.

1. Sign in to Engineering (4) access level.

2. If i-Cite is not online, click the GO button.

3. On the Predator Control Panel, click Scan Save. And choose the desired save mode.

Panel - Data Management

This panel is allows configuring the process for managing created data. Properly managing the saving, storage and/or
transfer of data is the responsibility of the end user.

1. Sign in to Engineering (4) access level.

2. If i-Cite is not online, click the GO button.

3. On the Predator Control Panel, click Manual.

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 4. Click Panel and then Data Management.

5. The first selection on the left is Disk Drive. Note that the Free Space remaining on the disk is shown along
with the Percentage (%) of available space that this represents.

6. By changing the entry in the Show System Message, the end user can direct the system to issue a System
Message when the Percentage (%) of the remaining disk space reaches a specified critical level.

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 7. If the critical % of disk space is reached when the system is in Auto mode, a System Message will be shown.
Help troubleshooting the System Message can be accessed by clicking “?”.

8. The next selection on the left is Project Backups. The Upload Directory for a Timed Event is where Project
Backups are uploaded; this location can be selected or changed by clicking ….

9. A local copy of the most recent project backup is stored on the system when this button is Enabled.

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 10. The next selection on the left is Reports. To ensure the hard drive does not fill up, set the FIFO Buffer to hold
one week of Reports before being deleted or moved by Timed Events. For example, if 1000 parts are run in a
day and generate 5Gb of reports (approximately 5% of the D: drive), set the FIFO Buffer to be at least 25%.

11. Check the size of the reports generated by going to D:\Reports\. Ensure the size of the reports multiplied by
the number of reports to be saved will not fill up the hard drive. This step is critical to ensure the system does
not run out of disk space and lose data.

12. Alternatively, all reports can be uploaded after an inspection by establishing a Timed Event Map in i-Cite →
Configuration. To not impact the sensor's ability to inspect, there must be enough cycle time between the
end of one inspection and the beginning of the next to complete the Timed Event upload.

13. The Upload Directory to which Timed Event Reports will be moved can be selected or changed by clicking ….

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 14. Select the directory in which reports will be saved. The (D:) > Reports directory is selected as default.

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 15. The last selection on the left is “Scans”. The local directory where scans are saved can be changed by clicking
the … button.

16. Image Scan Format is generally set to 3D Scan. Select Full Scan only when there is a need to save a full scan
for advanced tuning or troubleshooting. Full Scan saves all raw laser line data in a much larger file and should
not be used for normal operation.

17. To ensure the hard drive does not fill up, set the FIFO Buffer to hold one week of Scans before being deleted
or moved by timed events. For example, if 1000 parts are run daily and generate 5Gb of scans (approximately
5% of the D: drive), set the FIFO Buffer to 25%.

18. Check the size of the scans generated from each part style by going to D:\Scans\. Ensure that the typical scan
size times the number of scans to be saved will not cause the system does not run out of disk space.

19. Alternatively, all scans can be uploaded after an inspection by establishing a Timed Event Map in i-Cite →
Configuration. To not impact the sensor's ability to inspect, there must be enough cycle time between the
end of one inspection and the beginning of the next to complete the Timed Event upload.

20. Click … to modify the destination in the Upload Directory to which Timed Event Scans will be moved.

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 21. Once complete click the Save Changes button. The button will turn Blue when the save is complete.

Timed Event Map

Timed Events are setup to occur at specific times of day. They enable the Predator3D to move data from its hard drive
to the HMI PC or a specified location on the customer’s network to maintain the desired system traceability. If events
are not configured, then FIFO buffers above and/or manual intervention will be required to not fill up the system’s
hard drive. Managing the saving, storage and/or transfer of data is the responsibility of the end-user.

NOTE: For the Timed Events to export data to the HMI PC, the Remote Desktop Connection must be open. Additionally,
the Remote Desktop Connection must have been configured as described in the manual. See Setting Credentials &
Shared Drives for Remote Desktop to ensure the connection is configured correctly.

1. Sign in to Engineer (4) access level.

2. If i-Cite is online, click the STOP button.

3. Click File → Configuration → Timed Event Map.

4. The Index of the preconfigured events is in the first column, the Name of the event is in the second column,
the Scrip File that is used to run the event is listed in the third column and whether the event is Enabled or
Disabled is shown in the fourth column.

5. Click on the event to select it, then click the Edit… button.

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 6. The Edit Timed Event display will appear. To enable the event, check the box next to Enabled.

7. Change the Time the event will occur, the Start Date and how often the event will Repeat.

8. Select if the event fails to execute whether it will Retry on Failure or not.

9. Repeat this process for all Timed Events. It is recommended to make a Backup of the system once finished.

10. Click the OK button when complete.

NOTE: The directories configured on the Data Management Panel are the directories to which the Predator3D will move
data from Timed Events. Timed Events should be scheduled during downtime; between shifts is the ideal time. If there
is not enough time for the transfer to occur during downtime, the transfer will still be in progress when downtime is
over; this may cause inspection issues until it is complete.

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 Appendix: Maintenance for Predator3D/Predator3D Pro
Before performing maintenance on the system, ensure the system is powered down and that none of the LEDs are
illuminated. It is recommended that the work-cell be in a lockout state. The procedure below is to be applied to optical
surfaces on the bottom of the sensor.

NOTE: None of the internal components of the sensor require periodic maintenance. The precision-aligned optics and
lasers within the sensor MUST NOT BE DISTURBED. Opening the sensor may cause damage and WILL VOID ITS
WARRANTY.

Cleaning – Laser & Imager Windows

1. Use finger cots to avoid depositing oil from bare hands onto the windows.

2. Blow loose dirt and particles from the surface of the filters & windows using a puffer. DO NOT blow with your
mouth; such action may deposit particles onto optical surfaces.

3. Apply isopropyl alcohol to a lint-free cotton swab and rub the surface of the filters & windows in a circular
motion, working from the center to the edge. Apply pressure gently and avoid rapid side-to-side motion.

4. Use a puffer to evaporate excess alcohol from the surface of the windows.

5. Repeat steps 3 and 4 using a clean, lint-free cotton swab as necessary.

6. To finish, wipe the surface of the laser and imager windows with lens paper, gently applying pressure.

LASER WINDOWS
(Under Laser Safety Shutters)

IMAGER WINDOWS

Predator3D Predator3D Pro

NOTE: DO NOT USE water, detergents or any other non-optical cleaning material. DO NOT USE an unfiltered or
compressed air supply that may contain traces of oil or other contaminants.

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 Appendix: Head Angle Adjustments
In the Edit Marks section of Setting up the Active Part – Spline Method, the parameter Track Head Angle applies to
the entire spline within each Track. Having a constant head angle is not always possible during a dispensing process;
the robot may need to rotate to avoid collisions or joint limits. When the Predator3D rotates, the track head angle
must be adjusted along the spline to ensure that the spline is aligned with the center of the bead. The Head Angle
Adjustments selection allows the local track head angle to be adjusted at any Anchor and at the Gun ON/OFF
locations. The following steps describe adjusting the head angle.

NOTE: Using Head Angle Adjustments can improve the inspection in a number of cases including if the spline was drawn
poorly or if the nozzle is not centered in the # laser pattern.

1. If possible, before using Head Angle Adjustments to align the spline left and right in the bead data, complete
the vertical alignment of the spline in the bead data by following the Edit Marks section. In the example, at
the locations where the Predator3D rotates, the spline does not line up left and right in the bead data. The
highlighted areas below are where the Predator3D was rotating, causing the misalignment of the spline.

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 2. Where the local head angle needs to be adjusted, click on the Anchor already there or add an Anchor as
necessary.

3. Select the Head Angle Adjustments type. You will see the parameter Track Head Angle (deg) appear (if an
Anchor is currently selected, it will flash blue).

The Head Angle Adjustment options in the drop-down are:

• Polynomial: This selection seeks to keep the spline smooth between anchors and prevent sharp corners
when doing adjustments.
• Linear: This selection was developed for GlassMaster applications but may be used with other inspections.
It can create sharp corners in the inspection because each anchor acts to break the spline into line
segments.

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 4. Use the Head Angle Adjustment to move the spline left or right at the selected anchor. Note that i-Cite will
use a 4th order polynomial to attempt to keep the spline transition smooth. This can cause the behavior seen
below where the spline bubbles out as the head angle is adjusted.

5. To eliminate the bubble, add additional Anchors to the spline and re-apply the Head Angle Adjustments to
shift the spline back into the center of the bead path.

NOTE: When using the Head Angle Adjustment, the spline points may look scattered because of the polynomial fit.
When this happens, try setting the head angle adjustment to 0 degrees, adding an anchor where the spline scatters
and setting that to 0 degrees. You may also try deleting existing anchors or adjusting the existing Head Angle settings.

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 6. Go to the next location where the Head Angle Adjustment is needed. Repeat the above process until the
spline for the trailing laser lines up in the center of the bead.

7. Head Angle Adjustment can also be applied to Gun On and Gun Off. If needed, click on the Green or Red
horizontal line which represents the Gun On or Gun Off points respectively; it will flash. Then use the Head
Angle Adjustment to align it in the bead path.

8. Finish the remaining steps found in the Edit Marks section.

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 Appendix: Sync to Feature Setup
Predator3D’s inspection with the simplest setup is based on the timing of IO signals between the Predator3D and the
robot or other systems. If the variation in the communication between the Predator3D and the robot or PLC is very
inconsistent, the inspection may be negatively impacted. This appendix details the initial setup process that allows
the inspection to be synchronized to a 3D feature or an edge on the part that falls within the field of view of the
Predator3D at the beginning of the dispensing process. This synchronization allows the inspection to work around
inconsistent IO communication while assuming the timing of the robot program itself is consistent.

NOTE: Sync to Feature does not exist in software versions prior to 2.15.30A. There may be features in this appendix
related to Sync to Feature that are not available to you unless you upgrade to the latest software version.

Preparatory Tasks
Before beginning this process, ensure you have done the following:

• Ensure your software version is 2.15.30A or higher. If not, you must upgrade to a newer version before Sync
to Feature can be used.
• Complete all chapters of the manual up to and including Setting up the Active Part – Finalizing the Setup
until the very last step of the Edit Zones section where it says to exit Learn Mode by clicking Done.
• Note: Adding Sync to Feature after an inspection has been setup is also an option, but a scan must be
loaded to accomplish this prior to entering Learn Mode.

NOTE: If the robot path for the part changes, it is necessary to re-learn the inspection and reconfigure the Sync to
Feature option to ensure that the feature attempting to be synced to is still visible in the inspection and the timing of
the dispense has not been changed. If this is not done after the robot program is changed, false rejects may occur.

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 Setting up Sync to Feature
With the inspection initially setup, it is now possible to use the Sync to Feature option. First, you must be in Learn
Mode and signed into Engineer (4) access level.

1. Instead of clicking Done at the end of the Edit Zones section, when the following panel is visible. Click
Configure Sync to Feature… to begin the setup process for this option. This selection can also be found by
going into Learn Mode while signed into Engineer (4) access level.

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 1. When opening the Sync to Feature setup, the view may be hard to understand. The view that is shown is called
the Linear Height Map that is specific for each Imager. Unlike Learn Mode, it is not broken into segments by
Track. But note that there is Help available.

NOTE: You may need to click the Page tab after clicking Help to view the help text for Sync to Feature.

2. Click the Display at First Gun On button so that the Linear Height Map will automatically zoom into the Gun
On position. Then click Position at Display Index to move the red/green tool to that location. This will
automatically check the Display Range box and change the Display Index to the index of Gun On signals.

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 3. Use the Imager selection to cycle through the four imagers and look for a well-defined feature with a crisp
edge(s). Once identified, this will be the feature to which the inspection will sync.

Example: Feature
without crisp edge(s)
visible in Imager 0.

Example: Feature
with crisp edge(s)
visible in Imager 1.

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 4. Once a proper feature is identified, move the red-green tool over the sync feature and then configure what
the tool is looking for. Click and drag each end of the tool so it remains vertical and that it spans the feature,
similar to what is shown below. When an edge is identified a horizontal line will mark the location of the edge.

5. Set the Track Sync Source to Sync to Feature and choose the appropriate Edge Polarity.

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 6. If the feature is not being identified correctly, or if there is a lot of noise around the feature, there are
parameters that can be changed to influence how a feature is detected and identified. These include the Edge
Algorithm, the Edge Excerpts, the Edge Filter Size and the Edge Position Weight.

The options in the Edge Algorithm drop-down box are:

• Standard: finds positions of individual edges where the first order grayscale derivative is at a local
maximum.
• Peaks: finds average positions of pairs of opposing polarity edges.
• Normalize Dark: Same as "Standard", but the grayscale derivative calculation is modified to be biased
toward darker, hard-to-see edges.
• Normalize Bright: Same as "Standard", but the grayscale derivative calculation is modified to be
biased toward brighter, easy-to-see edges.

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 7. Use the current display and the SyncToFeature::Edge Feature::Profile Plot option to edit inspection criteria
for the tool to ensure that the correct edge is detected. To eliminate the possibility of secondary features
creating an identified edge, increase the Edge Threshold such that it excludes any secondary features.

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 8. Switch the display back to Learn Sync to Feature, click Reference and then click Yes to apply the Sync to
Feature setup to the inspection.

9. The Sync to Feature has been setup, click Learn Done to exit.

10. To validate the robustness of Sync to Feature, watch the inspection across multiple production parts and
investigate any areas that are marginal or fail.

11. If Sync to Feature is not functioning as desired, it can be disabled by switching the Track Sync Source back to
Zero.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Setup Sync to Feature.
✓ Validated Sync to Feature setup.

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 Appendix: Feature Tool Setup
Feature tools are used to evaluate the bead location relative to a 3D feature within the FOV of the Predator. These
tools measure the distance from the bead edge or center to 3D features across a measurement profile at a specific
location. These tools are most commonly applied to measure the distance from the inner/outer edge on a powertrain
part or the distance from a hemming flange for a body panel to ensure the bead is placed in the correct location
relative to that feature. This appendix details the process to set up one or more feature tools. To classify as an
adequate feature against which to measure the bead, it must have a consistent shape/orientation and position on the
part and must be visible in the field of view of Predator so that it can produce a transition region in measurement
profile.

Outer Edge Outer Edge

Inner Edge

Inner Edge

NOTE: In theory, feature tools may be added at every measurement profile. But in practice, they are most useful at
regions where bead quality is consistent and the features do not change from part to part. With these tools, the system
can detect shifts in the bead caused by inconsistency in pallet/part positioning or from the nozzle being
bent/contaminated. Feature tools are evaluated after the bead is evaluated, and so, the addition of feature tools
incrementally increases the time it takes the system to produce its inspection results.

Preparatory Tasks
Prior to enabling this option, ensure you have done the following:

• Verify the software version is at least 2.15.16A to ensure that you are able to use the Feature Tool option.
You may need to upgrade your software.
• Complete all chapters of the manual up to and including Setting up the Active Part – Finalizing the Setup.

NOTE: Feature Tools do not exist in software versions prior to 2.15.16A. There may be features in this appendix related
to Feature tools that are not available to you unless you upgrade to the latest software version.

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 Interacting with Feature Tools
With the inspection setup and validated, it is now possible to add Feature Tools to the inspection or to confirm the
setup of Feature Tools after reteaching an inspection. To get started, sign into Engineer (4) access level, load a part
scan, and enter Learn Mode.

1. In the Main display of LEARN mode, click the Configure Feature Tools… button.

2. The screen will look like the following. On the right-hand side of the screen is the interface for adding and
configuring Feature Tools. The control portion of the screen shows the currently selected display.

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 3. Click the drop-down next to View Selection. This lets you switch between useful views during the
configuration process.

The choices in the drop-down are:

• Configure Feature Tools (tools on template): This shows the locations of Feature Tools on the
template image. This display is useful to show where the tools are being applied on the physical part
but it is not often used for configuring the setup of the tools.
• Configure Feature Tools (tools on part height map): This shows the greyscale view of the bead and
part surface in the same layout at the template. This display is used when deciding where to place the
Feature Tools on the part. The location of the Feature Tools should not have secondary reflections
and should have the 3D feature on the part within the Predator’s FOV as it profiles the bead.
• Configure Feature Tools (tool statistics): This shows the various statistics for the Feature Tools,
including the number of edges identified across the profile, the distance and elevation of each edge,
and the distance and elevation of each edge inspection measure to the bead. This display is useful
when setting criteria for evaluating the bead placement.
• Configure Feature Tools (tool profile): This will show the cross-section of the bead and part at the
currently selected Feature Tool or of the current iteration of the Feature Tool selected. This display is
useful when trying to eliminate potential secondary edges.

4. Click the Add Feature Tool button to add a Feature Tool.

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 5. This will place the Feature Tool somewhere on the part. Switch to the Configure Feature Tools (tools on part
height map) display and then use the Track: and Recipe Position: selections to move the Feature Tool to the
desired location on the part.

6. In some locations, Feature Tools are able to inspect the distance from the bead to the feature either to the
left or right of the bead (where “left” and “right” are relative to the direction of dispensing). In others
locations, both inspections may be applied. Change your display to Configure Feature Tools (tool statistics)
after you have moved the tool.

NOTE: Use the Graphics Size Up/Down Buttons at the top of the screen to increase/decrease the size of the feature tools
to make them more visible.

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 7. Not all Feature Tool inspections can be selected. In this example, any selection with an Edge Index of -1 was
not identified. Only Edge 0 and 3 were identified as not being a part of the bead.

8. After selecting a feature inspection, the display will change to show if the Feature Tool passes or fails the
currently configured criteria. To appropriately pass or fail the placement of the bead relative to a feature, click
Next to set the criteria.

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 9. The criteria include the distance to the feature. If the feature is something like a hem flange that sticks above
the dispensing surface, the Feature Tool can be configured to check for the elevation of the feature to ensure
it is not damaged or bent relative to the part surface. To tune the criteria, scans from multiple parts are
required to capture the variation in the dispensing process and/or location of the dispense.

10. After tuning the criteria for the current Feature Tool, additional feature tools may be added onto the part.

11. Click Back to return to the previous page of controls.

12. Switch the view back to Configure Feature Tools (tools on part height map).

13. Click the Add Feature Tool button. This Feature Tool will be a copy of the first tool added. The next few steps
will demonstrate how to apply a Feature Tool across a segment of the part.

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 14. Use the Track: and Recipe Position: selections to move the Feature Tool to the desired location on the part.
This tool will be applied across a range of locations on the part, therefore when placing the tool, the distance
between the bead and the feature should be consistent across the range to be able to narrow the criteria as
much as possible.

15. Check the box for Position Range and then change the Min/Max Range and Position Interval values to space
the Feature Tools across the desired area.

16. There are now seven instances of the single Feature Tools applied across this area.

17. For this position only, the Right (red side) Feature Type will be used to check the position of the bead because
the bolt hole has some secondary reflections that could cause inspection anomalies.

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 18. Switch the view to Configure Feature Tools (tool profile). To eliminate potential secondary inclines or declines,
the Excerpts Threshold (%) and Filter Size can be used to filter out noise that may interfere with the Feature
Tool.

19. If you increment or decrement the Recipe position by one, the value will increment by the value selected for
Position interval allowing you to see the profile of each instance of the Feature Tool. (Available since 2.16.06.)

20. Change the display to Configure Feature Tools (tool statistics) and click Next to tune the criteria.

21. When tuning criteria, ensure you increment and decrement the Recipe position to account for the variation
across all of the instances of the Feature Tool. This will require clicking Back and Next multiple times to switch
the Recipe position.

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 22. The distance from the bead center to the edge of the part, for this dispense, is between 3.52 – 5.33 mm across
the area where the Feature Tool is applied. Tighter tolerances are often able to be set by using multiple single
Feature Tools instead of a single tool with multiple instances.

23. Once all desired feature tools are added onto the part, click Learn Done. Then click Done

24. Click GO to go online and Yes to save your changes.

Interacting with Feature Tools while Online

There is sometimes the need to edit Feature Tool inspection criteria while online to manage how a feature tool
impacts the passing/failing results. To do so, follow the steps below. The first two steps allow Feature Tools to be
visible on the results image...

1. Ensure you are online and at Engineer (4) access level.

2. Open the Results Display, right-click and select Edit Viewer Params… Then change the following two
parameters to see where the zone and Feature Tools are on the Results Display.

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 3. With the above settings, zones and feature tools information is now available in result view。

The Feature Tool Criteria panel is available when the project is online. This panel allows you to make minor
adjustments to feature tool criteria without going offline and affecting production. However, you cannot add,
delete or change feature tool positions while online.

4. At Level 4, click the Manual button on Predator3D Control Panel;

5. Click Advanced Options >>;

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 6. Click Feature Tool Criteria…

7. Feature Tool Criteria panel will pop up on the screen. Use this panel to change criteria for different feature
tools.

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 Steps so far will only guarantee the feature tools you configured can properly measure the positions of the bead.
This will not necessarily report a failure for the entire part when an inspection is completed. To determine if a part
is acceptable, feature tool criteria in zones also need to be correctly configured.

8. If feature tools exist in a zone, you need to make sure the Max Allowable Feature Failures (Count) is checked
in this zone on the Zone Criteria panel. Adjust the count accordingly.

9. Right-click on a view and select Display>>Statistics>>Feature Details. You will see the following window that
shows all the feature tools you have configured with their results.

The Zone Index column will show where each feature tool profile is located. This can help you adjust the number
for Max Allowable Feature Failures (Count).

On the above image, a green entry indicates this feature tool passes the inspection. A yellow entry indicates this
feature failed the inspection but the total number of failed feature tools in the current zone is below the Max
Allowable Feature Failures (Count). A red entry indicates this feature failed the inspection and the total number
of failed feature tools in the current zone is above the Max Allowable Feature Failures (Count).

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 Validate the Setup
Whenever a Feature Tool configuration is completed, it is highly recommended to validate the robustness of the
Feature Tools. Watch the inspection across multiple production parts and investigate any areas that are marginal or
fail. Since it is configured based on a scan for a good part, tests for bad parts need to be performed. You may need to
fine-tune feature tool positions, Processing Parameters and Feature Tool Criteria to get better results.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Setup Feature Tools.
✓ Validate Feature Tool setup.

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 Appendix: District Setup
When setting up inspections on Predator3D, the algorithm parameters and many other parameters are global
parameters and will work for the majority of all parts. However, there are occasions when there is a unique part, track,
or subsection of a track for which these parameters are not ideal. In instances such as these, we apply districts to
overwrite algorithms and certain other parameters to increase the robustness and quality of the inspection across
such areas. Any number of districts may be added to the part, but they are a processing-intensive tool. Districts are
defined at the level of the part, the track, or a polygon. Each district has its own list of parameter overrides. The
following is a list of parameter groups that can be overridden by Districts.

• Imager parameters control how the Predator acquires data. They may only be overridden for the part-level district
and include parameters for Imager Windows, Imager Brightness and a few others.
• Outliner parameters control how i-Cite generates a heightmap from raw data. They can only be overridden for
the part-level district. These include various filtering parameters and a few other parameters applied to the laser-
light return from both the bead and the part.
• Repair parameters control the criteria of automatic repair along with the timing offset for repair Gun signals. They
can only be overridden for the part-level district. This is to allow more or less overlap of the repair for certain parts.
• Surface Type determines which inspection algorithm is going to be used during the inspection, e.g., the Curved,
Planar, Basic and Glass. This can be overridden for both the part-level district and/or by track.
• Measure parameters control how i-Cite measures the bead from a heightmap. They can be separately overridden
for each part, track or within a polygon. These parameters include those used by the inspection algorithms, e.g.,
the Curved, Planar, Basic and Glass.

NOTE: This is an advanced operation and should be used with caution. A large number of districts may increase the
time that it takes to process the results of an inspection.

Accessing the Edit Districts Page

Districts are created and modified in configuration mode on the Edit Districts page. This page is accessed from the
Edit Districts… button on the main page. You can follow these steps to access this page:

1. Change your access level to Engineer (4).

2. Click the STOP button. Once offline, click the LEARN button.

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 3. In the main display for Learn mode, go to the desired part style, then click the Edit Districts… button.

NOTE: This button may not be available at the current access level or in the current version of software that is running.
If you wish to use this feature and cannot, it will be necessary to upgrade the software to a newer version.

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 4. The Edit Districts page shows a tree-view list of all Districts and their overridden parameters. This is referred
to as the District Tree. This image shows an example of what you might see.

5. The Display Overlay is typically set to None. In this case, no additional graphic overlays are shown over the
template image. In some cases, it may be helpful to show additional graphics overlaid onto the template image.
This selection can show the results of the last inspection or the measured width/height/volume of the beads.

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 Interacting with Districts
There are three types of districts. They can cover the entire part, an entire bead or an area of a part (each can include
a portion of a track or even multiple tracks). If your desired district is a subsection of a Track, it must be defined with
a Polygon region. You will be able to add certain parameters from the data tree to be used within each district.

• To view all districts that are currently created, left-click anywhere in the display. This will display them
while the left mouse button is held down.

• To create a polygon district, use your mouse to click and drag around an area on the part.

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 • To select a previously created Polygon District, click on the Polygon N node in the District Tree.

• To change the shape of the currently selected Polygon District:

o Left-click and drag any of the vertices (the small blue dots).
o Double-click anywhere on a side of the Polygon and select Add or Delete Vertex.

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 • To move the currently selected Polygon District, Right-click on the Polygon and drag it.

1. Click the Main…, Outliner… or Measure… button. This will open a DataTree view and expand the tree to the
appropriate node.

2. Open the DataTree and find the desired parameter to override.

3. Left-click and drag the desired parameter from the DataTree into the display.
• If you are overriding the parameter in the Part Style, a green box will flash around the entire display
perimeter.

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 • If you are overriding the parameter in a Track, the Track graphics will flash in light green.

• If you are overriding the parameter in a Polygon, the polygon graphic will flash in green.

4. When the desired graphic (Part Style, Track, or Polygon) is flashing, release the left mouse button to drop the
parameter into the District. The newly-overridden parameter will be displayed in the District Tree.

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 5. Override the value by editing it in the District Tree.

To perform other optional operations, select a parameter in the District Tree and:
• Click the Clone… button to make a copy of the currently selected District (must be a Polygon District). You
may then move that polygon to a new location.
• Click the Delete… button to delete the currently selected parameter or parameter group from its
District.
• Click the Delete All… button to delete all the Districts and their parameters.

NOTE: You should double check the Districts settings after reteaching a Part Style to ensure the Districts are still at the
desired location after a path change.

6. When you finish, click Learn Done and then click Done again to exit.

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 Interacting with Districts while Online
There is sometimes the need to edit Districts while online. To do so, follow the steps below.

1. Ensure you are online and at Engineer (4) access level.

2. Open the Results Display then right-click and select Edit Viewer Params…

3. This opens the viewer parameters for the Results Display. Select m_eInfoOverlay and change the selection
from None to District Windows to see where on the part style districts have been applied.

4. Now, right-click on the Results Display and select Edit DataTree Params…

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 5. This will open the DataTree directly to the district subsection for the active part style. If there are no districts
for this part style, there will NOT be a small + symbol next to the m_dtDistricts

6. The other method to find district parameters is to open the data tree and then…
• Identify the active part style.
• Open the correct m_dtParts[#] branch.
• Open the m_dtParams branch.
The m_dtDistrict branch will be listed towards the bottom.

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 Appendix: Learn Surface Setup
Learn Surface can be applied to potentially improve the identification and measurement of the bead. This can be used
when the bead is dispensed into a complex geometry, i.e., in a trough or a recess on the part, or when the part or
features on the part appear similar to the bead. To set up Learn Surface for a specific part style, both a part with no
bead and a part with a bead are required. Learn Surface uses the empty surface geometry as a reference to subtract
the profile of the surface from the inspection. This allows the geometric differentiation between the part with no bead
and the part with the bead.

NOTE: Learn Surface can be selectively edited through the use of Districts; see Appendix: District Setup for more
information regarding the use of Districts.

Preparatory Tasks
Before beginning ensure you have done the following before enabling this selection, including:
• Check your software version to ensure that you are able to use the Learn Surface option. If you wish to use

NOTE: Learn Surface does not exist in software versions prior to 2.16.00A. There may be features in this appendix related
to Learn Surface that are not available to you unless you upgrade to the latest software version.

this feature and cannot, it will be necessary to upgrade the software to a newer version.
• Using the scan with the bead dispensed on it, complete all chapters of the manual up to and including Setting
up the Active Part – Finalizing the Setup.
• Fixture a part with no bead and ensure that dispensing is turned off. A scan of the part with no bead must be
saved. A Full scan is recommended.

NOTE: The robot path for the part with no bead must be exactly the same as the robot path for the dispense, including
the speed of the robot and the timing for all IO signals. Any time that the robot program changes or any changes are
made between the Run On and the Run Off signal, it is necessary to re-teach the inspection and re-do the Learn Surface.

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 Enabling Learn Surface
With the inspection initially setup, it is now possible to apply the Learn Surface selection. To do so you must be Online
and signed into Engineer (4) access level.

1. Click the Add/Show/Hide DataTree Views button.

2. Navigate to Chip Data::Predator3D::m_dtP3dMain::m_dtParts[20] and go the corresponding PartStyle. Click

Reset Learn Surface. Confirm by clicking OK in the pop-up window. This is to ensure that there is not a surface
already being referenced by the inspection.

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 3. Go to Predator Control Panel and click Manual. Load the scan of the empty part.

4. Go back to the DataTree location in Step 3. Click Learn Surface. Confirm the learn by clicking OK in the pop-
up window.

5. The Learn Surface setup is complete.

6. To validate that the surface has been learned correctly, re-load the scan of the empty part. This should cause
the entire part to fail; verify this is the case.

7. To see a visual of Learn Surface, right-click on any display and go to Display → Measure → Extract

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 8. Load the scan of the part that was used to setup the inspection, verify that the inspection works as expected.

9. There are data tree parameters that can be used to change the methods used to apply the Learn Surface to
the inspection. They are identified below; these can be used to improve the quality of the inspection.

• m_eLearnedSurface: This parameter allows the software to search and fit the data being subtracted to the
data for the specific part being inspected to account for minor variations in the fixturing or part.
• Only offset X: May account for left/right shifts of the part.
• Only offset Z: May account for parts sitting at different heights in the fixture.
• Offset X and Z: May account for both left/right shifts and for shifts of the part closer or further from the nozzle.

NOTE: The robot path for the part with no bead must be exactly the same as the robot path for the dispense, including
the speed of the robot and the timing for all IO signals. Any time that the robot program changes or there is any change
between the Run On signal and the Run Off signal, it is necessary to re-teach the inspection and re-do the Learn Surface.

Validate the Setup

Once Learn Surface is configured, it is highly recommended to validate the robustness of the Learn Surface. Watch
the inspection across multiple production parts and investigate any areas that are marginal or fail.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Reset Learn Surface.
✓ Setup Learn Surface.
✓ Validate Learn Surface setup.

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 Appendix: Robot Assist
Robot Assist is a tool that gives the user live feedback on the changing distance and angle between a Predator3D and
part surface. This function helps users program a good dispense path in a shorter period of time. To use Robot Assist,
users need to have i-Cite version 2.06.03A or higher, and project version 2.5.0 or higher. If you wish to use this feature
and cannot, it will be necessary to upgrade the software or project to a newer version. Contact your Coherix
representative for more information.

1. Sign in to Engineer (4) access level.

2. If i-Cite is not offline, click the STOP button.

3. Click PART.

4. Scroll down and select the Tools button.

5. Click OK and select Robot Assist.

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 6. Click OK and click GO to go online. The Robot Assist interface is as shown.

Robot Assist Interface

In the Robot Assist interface, there are four display windows that correspond to the four imagers. When a part surface
is within Predator’s FOV and one or more laser lines are on the part surface, raw data image line(s) (white profiles)
will appear on the display windows. The RGBY lines are the surface fit lines used to find the part surface. The position
of the surface fit lines will be used to calculate Z Distance, Angle, and Robot Tool X/Y Angles.

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 Z Distance
Z Distance is the distance between Predator3D and the part surface. This can help users keep consistent nozzle height
during robot programming. The default Z Distance value is the Predator3D standoff

Angle
Angle is the overall angle measurement between the ideal perpendicular nozzle position to the actual nozzle position.
Zero in this value means the nozzle is perpendicular to the part surface. Angle is calculated based on the Robot Tool
X/Y Angles.

Robot Tool X/Y Angles

Robot Tool X/Y Angles are the angles between the robot tool axis and part surface. The first column is for the x-axis,
and the second column is for the y-axis. Same as the Angle, zero in both values means the nozzle is perpendicular to
the part surface

Predator3D Coordinate Check

To properly use Robot Assist, the robot tool coordinate, and the Predator3D coordinate needs to match. If there is a
mismatch, the Angle and Robot Tool X/Y Angles will not reflect the correct angle change. To check this:

1. Move the nozzle perpendicular to a flat surface.

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 2. Make sure surface fit lines overlap with raw data image lines in all displays. If there is no reading, proceed
to Step 3. If there is one, go to Step 6.

3. Open ChipData::CCP3dRobotAssist::m_dtP3dRobotAssist::m_dtParams::m_fLineAndPlaneFitError

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 4. Change the value to 1.500

5. The Robot Assist Interface should output values; if it does not, further increase the above parameter.

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 6. In the robot’s tool coordinate, rotate the nozzle in the positive X direction.

7. Check the Robot Tool X/Y Angles. There are four situations that may occur:
i. Robot X Angle shows positive value, and Robot Y Angle value does not change.
ii. Robot X Angle shows a negative value, and Robot Y Angle value does not change.
iii. Robot Y Angle value changes (either positive or negative), and Robot X Angle value does not change.
iv. Both Robot X/Y Angle value changes.

Situation i means the two coordinates are matched. The other situations indicate they do not match. To match
the two coordinates, change the Predator3D coordinate Angle Offset.

NOTE: Users must realign the two coordinates whenever the robot tool frame is changed. ALWAYS check the alignment
before using Robot Assist.

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 Interacting with Robot Assist
In order to have an optimal measurement, the surface fit lines should line up and overlap with the raw data image
lines that are close to the bead. This can be done by moving the persuasion point onto the raw data image line.

1. Make sure the raw data image line is in the display

2. Adjust the Camera Gain/Camera Offset/Camera Duration if the raw data image line is too bright/dark

3. Click any place on the raw data image line, the persuasion point will move to that place.

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 4. If one persuasion point is not able to fit the surface fit line onto the raw data image line, an additional
persuasion point can be added by changing the Persuasion Points control on panel (max 2).

5. After moving the nozzle to the correct distance from the part, click the Compute button. This will zero the Z-
distance between the sensor and the part to more easily identify the error in the robot program.

6. Check if the surface fit line fits the raw data image line that is close to the bead. If not, try moving the
persuasion point to other places on the raw data image line.

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 7. Repeat for all imager displays.

NOTE: If one or more imager’s measurement is too far off from that of other imagers, the overall measurement will be
inaccurate and no results will be shown. An imager can be turned off by unchecking its checkbox.

8. Use Robot Assist when programming dispensing paths.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Setup Robot Assist.
✓ Used Robot Assist when programming a dispensing path.

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 Appendix: Upgrade Codes
Upgrade codes can be obtained from your Coherix sales representative. For any solution Coherix provides, updates to
the i-Cite software are available on the file transfer site. Upgrade codes allow access to certain features that have
been developed and are not provided by default. A few examples of such features include Ethernet IP communication,
automatic repair and Z-Axis Tracking for glass dispensing. There may be other features already released or soon to be
released about which your Coherix representative can provide additional information. See the Data Sheets section of
the File Transfer site for more information on the options that have been developed and documented.

1. First, contact your Coherix sales representative and discuss with them what features can be obtained,
whether they are applicable to your process along with the steps required to obtain the necessary upgrade
codes.

2. Go to the sensor(s) that you wish to be upgraded. In i-Cite change your access level to Engineer (4).

3. Click the STOP button.

4. Go to File → Configuration > → Upgrade Dongle and record the serial number. Do this for all sensors that
you wish to upgrade.

5. Once the serial numbers are provided to the Coherix representative, a code or codes associated with each
sensor will be provided.

6. Enter the code(s) associated with the sensor in the Upgrade Dongle field found in steps 2 – 4 above.

7. Once successful, a message will pop up asking you to restart your i-Cite software so the changes can be
applied. Do so when directed.

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 Appendix: Auto Repair Setup
The Auto Repair option automatically repairs a defective bead after inspection by the system. This is done by re-
running the robot dispense path and using a signal from the Predator3D to trigger dispense Gun On/Off rather than
the signal from the robot. One or many defects can be repaired during this second path.

During the initial inspection pass, if a repairable defect is found, the sensor will set Status Repairable bit. The robot’s
logic must be configured to handle this situation when it receives an enabled Status Repairable bit. If the robot decides
to execute a repair path, it will set the Control Repair Mode bit before sending Run On. The robot must then repeat
the same exact path (at the same speed) used to dispense the bead. However, during this repair path, the robot will
not control the dispenser gun. Instead, the dispenser gun will be controlled by the Status Repair Gun On bit from the
Predator. The robot and/or PLC must implement this logic and any other logic necessary to properly handle other
elements in the cell such as conveyors, part handlers, indicator lights, etc. The sensor will re-inspect the bead during
the repair and will re-evaluate the status of the bead post-repair. Depending on how the criteria are configured,
overlap areas from the repair may fail due to exceeding the maximum width and/or height of the bead.

Normal Inspection Cycle Repair Cycle

Setting up Auto Repair

1. When i-Cite is online, click the Manual button (after signing into Level 4).

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 2. Click Advanced Options.

3. Click the Setup button.

4. Go to the Repair tab.

5. Check Enable Result Repairable checkbox.

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 6. Dispensing failure examples and effect of Repair Parameters
o Defect Deficiency Threshold (%) is the percentage of a continuous defect that falls under the
minimum criteria is considered repairable. (e.g., if 75% of a continuous defect is deficient in height
and the threshold is set to 50%, then the defect will be considered repairable). Usually, this value is
left at the default of 50%.

• Minimum Repairable Length (mm) is the minimum length of a repairable defect. The minimum defect
length that can be inspected is limited by Maximum Allowable Failure Length (counts) in the Zone
setting. Minimum Repairable Length should be larger than the above and is typically set to no smaller
than 3 mm.

• Repairable Failures Threshold (%). The percentage of repairable defects must be greater than this
threshold among all identified defects to be considered repairable. This value is usually set to 25%.

• Repair Position Offset (sec) and Repair Length Offset (sec). Position Offset determines the start point
of the repair bead while the Length Offset determines the length of the Repair Gun On signal. These
offsets need to be tested on actual repair runs to ensure the repair bead is dispensed correctly.

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 Repair Troubleshooting Check List
If all the steps to required enable Auto Repair were completed but the repair pass the repair did not commence, then
the following must be validated as a part of the troubleshooting process. If, after ensuring that all items below are
configured correctly, the repair functionality still does not work, please contact your Coherix representative.

1. Ensure Repair is enabled on the Predator3D

i. Open the DataTree and then open the m_dtP3DInfo branch

ii. Scroll to the bottom of this branch and open m_dtP3dDonglePacs

iii. True indicates the repair feature is enabled. False indicates it is not enabled and an Upgrade Codes
must be acquired from your Coherix Representative to enable this feature.

iv. If it is False, first acquire your code and then follow the steps in the Upgrade Codes appendix to
upgrade your system. Then, repeat this process to confirm the repair is enabled.

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 2. Check the P3D References: Map to ensure the repair is referencing the correct Input/Output IO bits
i. Sign in to Engineer (4) access level.

ii. If Online click Stop then Learn, otherwise click Learn immediately.

iii. Also, click File->Digital I/O to open the Digital I/O Control.

iv. On the P3D References: Map, click the Input Bits tab and ensure that the number next to Control
Repair Mode matches the Digital I/O Control location.

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 v. Switch to the Output Bits tab and ensure that the number next to Status Repairable matches the
Digital I/O Control location. Then ensure that the number next to Status Repair Gun On matches the
Digital I/O Control location.

3. Once the troubleshooting steps have been completed and all appropriate changes have been made, re-run
Auto Repair. If the repair still does not work, confirm the robot/PLC IO map/logic is correctly configured. If
this is the case, then Contact your Coherix Representative for further assistance.

Validate the Setup

Once Auto Repair is configured, it is highly recommended to validate the robustness of the Auto Repair. Watch the
repair process across multiple production parts and investigate any areas that are marginal or fail.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Setup Auto Repair.
✓ Validated Auto Repair setup.

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 Appendix: Shape Tools Setup
Shape Tools are used to inspect a bead or part feature that is of a known shape. In i-Cite, this option is typically used
to find and inspect a round dollop of sealant (mastic dot). Inspections that can be done on this type of dispense include
minimum and maximum width, surface area through a slice at a specified height plus total height. In this appendix, a
mastic dot inspection will be used as an example for setting up Shape Tools.

Preparatory Tasks
Before setting up Shape Tools to inspect dots, ensure the following steps are completed:

When inspecting dots, maximize the quality of the data collected by adjusting the robot program to…
• Ensure the trailing laser is perpendicular to the path, maximizing the field of view.
• Ensure the trailing laser sees the entire dot. This may require a step backward in the robot path before going
forwards if the dot was so large that it entered the lasers while being dispensed.
• Ensure the movement speed and Z-height are consistent when the trailing laser is scanning across the dot.

1. Acquire a scan. Refer to Acquiring Image Scans for detailed instructions.

2. Create a template image. Refer to Creating a Template Image for detailed instructions.

Configuring Shape Tools

To add or use Shape Tools to inspect dots, use the following example as a guide. To do so you must be in Learn Mode
and signed into Engineer (4) access level.

1. Set up the Part Style. Refer to Setting up the Active Part – Preliminary Setup for detailed instructions. Complete
the Preparatory Tasks, load a Saved Image Scan, Enter Learn Mode and Setup Part Style.

2. Edit Spline Paths. Refer to Setting up the Active Part – Spline Method for detailed instructions. Spline Paths
usually represent bead paths. For mastic dots, the Spline Paths should match the robot inspection path. The
following are a few notes about Spline Path for Dots:
• Gun On and a Gun Off identify a track in the software. If the sensor receives a Gun On and Off for each
dot then there will be one dot per track.
• Multiple Shape Tools used to inspect individual dots may be put on one Track if the sensor does NOT
receive a Gun On and Gun Off for each dot.
• In the robot program, one set of Gun On/Off should be assigned to each Track.
• When dots are much wider and taller than a regular bead, leave more margin before the first dot and
after the last dot on each track so the 3D scanner captures the entire dot.

3. Add a spline for each track as described above.

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 4. Once all splines have been drawn, click Next >.

5. On each Track, click and drag the First Path Position and the Last Path Position to the edges of the dot. Then
click Next > button to go to the next page, Edit Marks.

NOTE: As mentioned in Step 2, make sure enough space is left before Gun On and after Gun Off so 3D data can be
captured for each dot.

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 6. In the Edit Marks page, click the Initialize All Tracks… button.

7. Next to Track Head Angle, click the C to have the software compute the Track Head Angle. This calculated
value may require some adjustment so the trailing imager’s spline is centered on all the Dots.

NOTE: If the inspection was done after the dot is dispensed, special attention is required to determine the trailing
laser/imager when setting the “Track Head Angle (deg)”. The dots in the trailing imager are lower (later) than the dots
in the leading imager. Trailing imager’s spline is thicker than others. In the image above, the first small dot appears
later in red imager than in blue imager. Therefore, head angle should be adjusted so that red imager is used as the
trailing imager.

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 8. Adjust the Track Offset (Seconds) parameter to align the Pink to RGBY transition with the beginning of the
dot. Making this more positive moves the spline down, and more negative moves it up on the display. Adjust
the Gun Offset (Seconds) parameter to align the RGBY to Pink transition with the end of the dot.

9. Increment Track by one for the next dot or set of dots to be inspected. Repeat the above steps for all Tracks.

10. Once this process has been done click Next > to go to P3D Tools: Compute Recipes.

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 11. Click Process All Tracks….

12. After the process is complete, click Next > to depict the recipes and go to Edit Zones.

13. Click Set Zones by Track.

14. Uncheck all the checkboxes so the dots won’t be inspected as a regular bead. Instead, the software will use
the criteria in Shape Tools for inspection and evaluation. Then, click Copy to All Zones…

15. Click Learn Done. Then click Done.

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 16. Go Online, save the changes, load a saved image scan (refer to Load a Saved Image Scan in Setting up the
Active Part – Preliminary Setup), go Offline, click the Learn button. Click Next to go to page P3D Tools: Main.

17. Click Configure Shape Tools….

18. In View Selection, select Configure Shape Tools (tools on part height map) and check the part height map to
assess if the dots are right. Adjust the Display Shift to make the part height map brighter or darker.

NOTE: If the dots look tilted, go to Edit Marks to reteach and adjust the head angle of the spline to make the trailing
imager spline more centered in the field of view. Double check the robot program to verify the inspection path has the
dots inspected right beneath the nozzle/Predator3D. Load the scan again, go online and then return to this page to
verify if the dots look better. If they do not, an iterative process of changing the splines for the dots may be needed.

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 19. Click Add Shape Tool.

20. In Shape Type, select Dot. A circle representing a dot’s perimeter will flash on the Part Height Map.

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 21. Adjust Track and Recipe Position so the circle is centered on the first dot to be inspected.

22. Adjust Diameter (mm), Surrounding Margin Size (mm), Base Height (mm), and Contact Height (mm)
according to the dot’s nominal size. The dot’s diameter and surface area can be measured at the Contact
Height from the part surface. Descriptions for these parameters can be found by clicking Help and going to
the Page tab.

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 23. Click Add Shape Tool, change the Shape Tool Index, repeat the above steps until all shape tools are configured.

24. Click Next.

25. Adjust the criteria for each dot. Starting from Shape Tool Index 0 until all dots are set up. Change the View
Selection to Statistics :: Shape Details to read all the measurements.

26. Click Learn Done.

NOTE: If the dots are not fitted correctly, the measurement will either be 0 or show a large difference Min to Max. The
following DataTree parameters might be adjusted to improve the inspection. These parameters can be found under:
ChipData::Predator3D::m_dtP3dMain::m_dtParts::m_dtParts[X]::m_dtShapeParams::m_dtShapeParams[Y]::m_dtDot
ShapeParams:: …
• If dots are dispensed on a curved surface, make sure the DataTree parameter m_eReferenceSurface = “Curved
Lowest” or “Curved Average” as appropriate.
If inspection still doesn’t work well after the above parameters are adjusted, try other Shape parameters in the Data
Tree that have units of millimeter first, before changing any parameters with units of pixels.

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 27. Click Done then click GO to go online. Click Yes when asked whether to save the changes.

Interacting with Shape Tools while Online

There is sometimes the need to edit Shape Tools inspection criteria or how Shape Tools impact the passing/failing of
an inspection while online. To do so, follow the steps below. The first two steps allow Shape Tools to be visible on the
results image.

1. Right-click on the Results Display and left-click Edit Viewer Params… in the drop-down menu.

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 2. In Viewers Panel, set m_eResultsOverlay to None as long as there are only dots being inspected. Set
m_eDisplayIndexOverlay to None. This is to hide the results display of a continuous bead inspection.

3. Load a saved image scan (refer to Load a Saved Image Scan in Setting up the Active Part – Preliminary Setup).
Shape Tools inspection results will show on the Results Display. GREEN represents PASS, RED represents FAIL,
and YELLOW means the tool fails locally but the zone passed.

NOTE: By default, any Shape failure leads to fail of the zone and the part. To change the maximum allowable Shape
failures for Part Style X Zone Y, go to DataTree parameter –
ChipData::Predator3D::m_dtP3dMain::m_dtParts::m_dtParts[X]::m_dtZones[100]::m_dtZones[Y]::m_iMaximumShap
eFailures

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 4. To open the 3D view of a dot, drag a window around it in the Results Display.

5. A 3D Viewer showing the dot will pop up. Click and drag in the viewer to Pan or Rotate the view.

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 6. To read the measurements of each dot, right-click on the display and select Display – Statistics – Shape
Details.

7. Other displays for Shape Tools can also be accessed through right-clicking on the display. For example, 3D
Views for Contact Height can be accessed through Display – Shapes – Contact Height – 3D View. Red points
in the view are points on the surface. The dark yellow square is the base plane. The green square is the plane
at Contact Height. The yellow circle is the cross-section of the dot at Contact Height. Click and drag the 3D
View to rotate the view.

Validate the Setup

Once Shape Tools is configured, it is highly recommended to validate the robustness of the Shape Tools, watch the
inspection across multiple production parts and investigate any areas that are marginal or fail.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Setup Shape Tools for each dot dispensed.
✓ Validated Shape Tool inspections.

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 Appendix: Configuring Specific i-Cite Login Information
The standard project for the Predator3D allows users at certain access levels to add unique login information. This
allows the system to keep track of who has signed in and at what times, allowing the system to track what changes
have been made and by whom. This disables the default login configuration that allows all users to access the system
with the same password at each access level. For example, if there is an entry-level engineer and a higher-level
engineer, the higher-level engineer may add a lower-level unique login for the entry-level person.

NOTE: This appendix assumes that there are no unique logins currently configured on the system. If there are unique
logins, then step one must be done by signing in to a unique login that has access to level 4.

1. Sign in to Engineer (4) access level and click STOP.

2. From the menu select File then Access Level.

3. Click OK to dismiss the Change Access Level window.

4. On the Confirm Access, Level Change window click the Edit Access Levels button.

5. Select and enter a unique User ID and click Add User. If other users exist, they can be edited by finding them
in the drop-down box.

6. Modify the Passwords for each level and click Save.

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 7. If you wish to add another unique user, type a new User ID and click the Add User button.

8. Repeat steps 6 and 7 until all users are configured.

9. If a user is added accidentally or you wish to remove their login information, switch to their User ID click
Delete User and click Save.

10. Click the Close button when finished.

11. Now, when selecting File and Access Level, users will be required to provide both a User ID and a Password
to log in.

12. Record the login information so it will not be lost (do not record the information in a public location).

NOTE: If there are unique logins configured, the default passwords will no longer allow you to login or edit logins. If
nobody remembers their unique passwords, please contact your Coherix representative and they will be able to assist
you. The default passwords will no longer allow you to login or edit logins.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Configured unique, user-specific log in information.
✓ Recorded the user names and passwords so they will not be lost.

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 Appendix: Advanced HMI Setup
A Predator HMI PC may be further configured to either simplify its use for an operator or for an engineer. For instance,
the HMI can be configured to not require a user name or password when initializing. Additionally, the HMI can be
renamed to better reflect that it is the HMI computer communicating with the Predator3D module.

Removing Log in Credentials on the HMI

This section shows how to remove the need for a user name and password on the HMI. This is useful because it
eliminates the need to remember rarely-used information. After this change is made, there will be no need to input a
user name or password if the HMI ever loses power and has to reboot. The user can proceed directly to the home
screen of the HMI.

1. On the desktop of the HMI PC, right-click on the Windows icon and select Run.

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 2. In the Run dialog, (1) key in netplwiz and (2) click on the OK button once done.

3. In the User Accounts window, select the Predator-3D user name.

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 4. Uncheck the User must enter a user name and password to use this computer option.

5. Click on the (1) Apply button and then (2) the OK button to save the changes made.

2 1

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Removed the need for a user name and password to access the HMI.

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 Naming/Renaming the HMI PC
A Predator HMI PC should be renamed to better reflect that it is the HMI computer talking to the Predator3D system.
To avoid confusion, it should not be named “Predator-PC”, which is the default name for the computer in the
Predator3D system. The following steps are required to rename the HMI computer.

1. On the desktop of the HMI PC, right-click on the Windows icon and select System.

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 2. The System window will be launched.

3. Under the “Computer name, domain…” section, click the Change settings link.

4. This will launch the System Properties window.

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 5. Click on the Change… button to open the Computer Name/Domain Changes window.

6. Enter (1) predator-HMI as the new name in the Computer Name box and (2) click on the OK button.

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 7. Click the OK button in the dialog prompting that a restart is required to apply the changes.

8. Back on the System Properties window, click the OK button.

9. Click on the Restart Now button to complete the naming/renaming of the HMI computer.

10. Wait for Windows to restart successfully before attempting to configure the IP Address.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Provided a Suitable Name for HMI PC.
✓ Restarted the HMI PC.

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 “Always on Display” for the HMI
A Predator HMI PC should never go to sleep even when inactive. This ensures that an operator is always able to view
the results on the HMI and can observe where on a part a failure occurs. And, anyone observing the production process
will benefit from the feedback provided by the Predator3D’s graphical display. Additionally, by preventing the HMI
from going to sleep, the automatic back up of data from the Predator3D to the HMI will be unhindered.

1. On the desktop of the HMI PC, right-click on the Windows icon and select Settings.

2. In Settings select System.

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 3. In System select Power & sleep.

4. Set all Power & sleep settings for Sleep and Screen to Never.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Configured the HMI to never go to sleep or shut off the screen.

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 Appendix: i-Cite Network Discovery Tool (INDT)
INDT is a tool that can be run on a laptop or HMI that will scan the network to which the system is connected and
display the IP addresses of any Predator3D sensor on which i-Cite is configured correctly and running. There may be
multiple sensors listed. The newer versions of software that are installed on the Predator3D will also identify the serial
number of each. This helps eliminate confusion when there are multiple sensors connected in a single cell.

Downloading the Tool

1. Follow the steps to log into the Coherix File Transfer Site as directed in Accessing the Site.

2. The INDT executable is found under the Communication Setup portion of the File Transfer Site and is in a
directory titled INDT.

3. Download the tool and connect whichever computer is going to run it in the cell network.

4. Double click on the INDT.exe to run the tool. The tool is able to scan the router domain, so it will find sensors
that are on different subnet masks from the computer’s subnet mask.

INDT Information

1. INDT will not run if i-Cite is already running on the host computer. (i.e., your laptop or the cell HMI).

2. INDT will not (likely) find anything if you are running it on a virtual machine due to permission settings.

3. Each Predator3D must be powered on and be connected via an ethernet cable to the cell network.

4. On each Predator3D, i-Cite must be at least version 2.15.30B for all information to be displayed.

5. i-Cite must be running on the Predator3D. If no sensors are detected it is recommended to power cycle each
Predator3D, and to check all physical connections: between the Predator3D and the cell, between the host
computer and the cell.

NOTE: The Predator3D’s IP Address is set to 192.168.20.10 when it is manufactured; this is the default until it is changed.

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 Appendix: Possible Remote Desktop Issues
This section details a list of known errors that may be encountered when trying to establish a Remote Desktop
connection to the Predator3D. Each of the errors is accompanied by several possible root causes and recommended
corrective actions.

Scenario #1
• Connecting from a client, you click connect, and the next window displayed is Remote Desktop can’t find the
computer Predator-PC.

• Connecting from a client, you click connect, and the next window displayed is Remote Desktop can’t find the
computer 192.168.20.10.

Possible Solutions #1
• Confirm you have entered the correct IP address into Remote Desktop. (The default IP address for a Predator3D
is 192.168.20.10.)
• Attempt to connect to the Predator3D via Remote Desktop.
• If the same message appears, use INDT.exe to determine the IP Address of the Predator3D.
• If INDT.exe provides a different IP address for the Predator3D, use this IP address and attempt to re-connect to
the Predator3D via Remote Desktop.
• If INDT.exe does not provide an IP address for the Predator3D, or if connecting fails using the IP address provided
by INDT.exe:
o Disconnect the network cable connected to the controller.
o Reconnect the network cable connected to the controller.
o Attempt to connect to the Predator3D via Remote Desktop.
• If the same message appears, verify that the Predator-PC network lights are showing activity.
• If the Predator-PC network lights are not showing activity and the Predator-PC network cable is accessible:
o Disconnect the network cable connected to the controller.
o Reconnect the network cable connected to the controller.
o Attempt to connect the Predator3D via Remote Desktop.
• If the same message appears or if the Predator-PC network cable is inaccessible:
o Use a different PC to attempt to connect to the Predator3D via Remote Desktop.
• If a different PC will not connect to the Predator3D, attach a keyboard, mouse, and monitor to the Predator3D to
troubleshoot.

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 Scenario #2
• Connecting from Windows 7: click connect, enter your credentials, click OK. If you immediately get This computer
can’t connect to the remote computer, try connecting again. If the problem continues, contact the owner of the
remote computer or your network administrator.

• Connecting from XP: click connect. If you immediately get An authentication error has occurred. The specified data
could not be decrypted.
• Open a Remote Desktop Connection window.
• Click on the Options button to display the tab pages.
• Click the Advanced page.
• Set the “If server authentication fails” list to Connect and don’t warn me.

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 • Attempt to connect the Predator3D via Remote Desktop.
• If the same message appears, edit the Documents\Default.RDP file in Notepad.
• Add the line “enablecredsspsupport:i:0”
• Save the Default.rdp file.
• Close any Remote Desktop Connection windows that are open.
• Open a new Remote Desktop Connection window.
• Click on the Options button to display the tab pages.
• Click the Advanced page.
• Set the “Choose the authentication method” to apply when connecting to the remote computer list to “Do not
attempt authentication.”

• Attempt to connect to the Predator via Remote Desktop.

• If the same message appears, use a different PC to attempt to connect to the Predator via Remote Desktop.
• If different PC will not connect to the Predator, attach a keyboard, mouse, and monitor to the Predator to
troubleshoot.
• If a different message appears, please consult the list of troubleshooting techniques for different messages.

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 Scenario #3
• Connecting from a client, you get the message Remote Desktop cannot connect to the remote computer because
the authentication certificate received from the remote computer is expired or invalid.

Possible Solutions #3
• The same instructions should be followed as troubleshooting the message: This computer can’t connect to the
remote computer.
• Try connecting again.
• If the problem continues, contact the owner of the remote computer or your network administrator.

Scenario #4
• Connecting from a client, you get the message The remote computer requires Network Level Authentication which
your computer does not support.

Possible Solutions #4
• Use a different PC to attempt to connect to the Predator3D via Remote Desktop.
• If a different PC connects to the Predator3D, in the System Properties window, set the Remote Desktop setting to
Allow Connections from computers running any version of Remote Desktop (less secure). Attempt to connect to
the Predator3D via Remote Desktop from the original PC that would not connect.
• If different PC will not connect to the Predator3D, attach a keyboard, mouse, and monitor to the Predator3D to
troubleshoot.

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 Appendix: Reloading Correct Calibration File
All Predator3D sensors are shipped with factory-calibration. Under normal circumstances, there is no need for
updated calibration parameters to be installed.

Predator3D Pro – Getting the Calibration File

The sensor head for Predator3D Pro is not tied to a specific processor. If the calibration is ever lost or corrupted, reach
out to Coherix with the serial number of the sensor head that needs to have the calibration restored. Coherix will
provide the calibration file for that sensor head and then the following instructions must be followed:

1. Identify the Serial Number of the sensor head. See Sensor Head – Top for the location of the Serial Number.

2. Contact your Coherix representative and provide that Serial Number.

3. Copy that file onto the Predator3D Pro processor under D:\CalFiles. The file will be named Predator3D(TM)
Sensor 1 – SNXXXXX-Static-YYYY-MM-DD. Ensure the Serial Number matches that of the sensor head.

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 Restoring Calibration Files – Predator3D and Predator3D Pro
The following steps are required to reload the correct calibration. This section is for both for Predator3D and for
Predator3D Pro (if the above Predator3D Pro instructions have been followed).

1. Change your access level to Engineer (4).

2. Click the STOP button. Once offline, click the LEARN button.

3. In the main display for LEARN mode, click the Advanced… button.

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 4. In the Advanced window, click the Import Calibrations… button to browse to and select the correct calibration
file for this Predator3D.

5. In the Import Calibrations window, browse to D:\CalFiles. This is the default directory where the calibration
file is saved.

6. Select the most recent calibration file (based on the Date modified) having the same
Serial Number as the Predator3D.

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 NOTE: The calibration file comes in a *.XFF file extension and are listed in the D:\CalFiles directory. If they have been
deleted from this directory, please contact your Coherix Representative with the Serial Number of the sensor. They will
provide the calibration files for that sensor.

7. Click the Open button to confirm.

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 8. A popup message Import Calibrations Success! will appear. Click OK to return to the Advanced window.

9. In the Advanced window, click the Return button to return to the Main window.

10. In the Main window, click the Done button to exit out of LEARN mode.

11. Make a Backup of the project, see Performing a Project Backup to save the calibration with the inspections.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Reloaded the correct Calibration File for the Predator3D system
✓ Performed a BACKUP to save the changes made

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 Appendix: Troubleshooting FAQs
This section lists known errors that may occur when using the Predator3D including possible errors within i-Cite. Each
of the common errors is accompanied by several possible root causes and recommended actions to correct them.

Remote Desktop
Connecting from a client, you click Connect and the next window displayed is “Remote Desktop can’t find
the computer Predator-PC.”
✓ Verify the computer name and domain to which you
→ Predator PC does not belong to the specified network
are trying to connect

Connecting from a client, you click connect, and the next window displayed is “Remote Desktop can’t find
the computer 192.168.20.10.”
✓ Verify the IP address of the HMI and use INDT to
→ The IP address 192.168.20.10 does not belong to the
ensure that the IP address of the system is correct in
specified network
the remote desktop field

Connecting from Windows 7, you click Connect, enter your credentials, click OK, and you immediately get
“This computer can’t connect to the remote computer.”
✓ Retry to establish a connection
→ Failure to establish a connection ✓ Contact the owner of the remote computer or your
network administrator.

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 Initialization
Cannot establish Remote Desktop Connection from HMI PC. Windows prompts “connection error/time-out”
after trying to establish a connection for sometime
✓ Unplug the power cable from the system, wait for 10
→ The system is not switched ON
seconds and plug the cable back in
✓ Check the incoming AC supply
→ No AC supply to the system
✓ Check the power cord for damage
✓ Verify that pins within power cable plug are mating
→ Power cable to the system not securely connected to
into the socket; rotate plug clockwise to tighten the
the socket
plug in the socket

→ Broken pins within power cable/socket ✓ Contact Customer Service of your supplier

Cannot start i-Cite. Message prompt: ERROR: CMainApp:: InitInstance, Valid dongle not found!

✓ Restart i-Cite on the system

→ Hard lock key not detected by i-Cite
✓ Power cycle the system if the above fails

→ A faulty internal port within the Predator3D PC ✓ Contact Customer Service of your supplier

All cameras failed to be detected when starting i-Cite. Content of Initialization Errors window:
The following digitizers or camera map entries are invalid: (Predator3D or Predator3D Pro)
Hib 400 0 or Chp Flex P3D 0
Hib 400 1 or Chp Flex P3D 1
Hib 400 2 or Chp Flex P3D 2
Hib 400 3… or Chp Flex P3D 3
→ The active project file comes from a different
Predator3D or Predator3D Pro. Serial Number of ✓ Restore an older backup created on the current
cameras connected does not match that stored in system
Camera Map

→ Internal component failure ✓ Contact Customer Service of your supplier

✓ Restore an older backup created on the current

→ Malicious deletion of the Camera Map on the system Predator3D module
✓ Contact Customer Service of your supplier

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 i-Cite Environment

→ Hand-shake between i-Cite and camera/cameras ✓ Restart i-Cite

is/are broken ✓ Power cycle the system if the above failed

→ Camera/cameras failure ✓ Contact Customer Service of your supplier

Error Message: DTP3dMain::StartDigitizerAcquisition: Calibration serial number <XXXXX> does not match
hardware serial number <YYYYY> for Imager <N>e
✓ Reload correct calibration file; refer to Appendix:
→ Incorrect Calibration file loaded
Reloading Correct Calibration File for further details

Backup & Restore

Failure to Restore MVP file. Error Message: ERROR: [DATE & TIME] CPrjItem SerializeItem: Unsupported file
version <5>.
→ MVP file to be restored was created in a software ✓ Open the .mvp file in Notepad to identify the i-Cite
version later than that of the current i-Cite version on version used to create the backup and update the
the Predator3D software to at least that version of software
→ Library file not registered during the upgrading of i- ✓ Go to the i-Cite installation directory and register the
Cite software SysCtrls.ocx file

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 Online in i-Cite

You see a Black Screen when Online

→ Part Style selected by robot/controller is not a valid ✓ Check the correct Part Style number that
Part Style robot/controller should be calling from within i-Cite
✓ Check the template image directory for the image
→ A template file for selected part style has been ✓ Check the Recycle Bin and recover the template
moved or deleted image if it has been accidentally deleted and is still
accessible
✓ Check if current project file contains the latest
→ Part Style has not been set up in the current project updates to the Part Style
file ✓ Restore the last saved backup if Part Style cannot be
found in the current project

Template Image not being updated as robot arm is dispensing adhesive on the part

→ The Predator3D is not selected to Acquire, Acquire ✓ Ensure i-Cite is online and that the Predator3D
and Save All, or Acquire and Save Failures Control Panel has an acquisition mode selected
✓ Check trigger signals from the robot/controller to
→ The robot/controller fails to send Run ON signal or
ascertain why run mode was not activated or if the
fail. to send a new Part Style Number
Part Style was not changed
✓ Check the content of the XFF file to see if RUN ON
→ Fail to receive RUN ON signal from robot/controller
signal is transmitted by robot/controller
✓ Click STOP, wait for 5 secs and click GO on the main
→ i-Cite stopped responding toolbar
✓ Close and restart i-Cite

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 Appendix: Predator3D Hot Swap Procedure Walkthrough
If a Predator3D suffers catastrophic damage such that it is no longer able to properly inspect, then a sensor can be
Hot Swapped to replace the damaged Predator3D. The steps below highlight the proper procedure for conducting a
Hot Swap. Read the entire document prior to beginning the process to ensure it can be successfully completed. This
procedure is only for a Predator3D, NOT for a Predator3D Pro.

NOTE: It is recommended to place the dispense inspection system into Bypass Mode on the PLC until you can follow this
procedure.

Hot Swap Tool List

Below is a list of general tools that will be useful during a hot swap procedure. Use Step 1 to determine which tools
are needed.

Required tools
• 1 set Allen wrenches or keys (Predator3D uses metric form factor bolts to connect to the bracket)
• 1 cell phone – to take photos
• 1 USB storage device or portable hard drive

Additional tools for Step 1 A

• A laptop or HMI with a connection to the same network to which the Predator3D is connected

Additional tools for Step 1 B

• 1 mouse and keyboard
• 1 HDMI compatible monitor
• 1 HDMI cable
• 1 male Micro-USB B hub or male USB 3.0 Micro B hub

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 1. Determine if the Predator3D is still accessible through the Remote Desktop Connection on the HMI. Open the
Remote Desktop Connection and click Connect ensure that the appropriate IP Address is populated in the
Computer: entry.

A. If it is, follow the procedure in BACKUP: Performing a Project Backup, then copy this backup first to
the HMI and then to a flash drive.

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 B. If the Predator3D is not accessible through the HMI, it is possible to directly connect to the Predator3D
using an HDMI monitor and either a male Micro-USB B hub or a male USB 3.0 Micro B hub to power
a mouse and keyboard.
o First, remove the two M3 screws and the highlighted cover on the processor.

o Now connect the USB Hub and the HDMI Monitor.

o Follow the procedure for BACKUP: Performing a Project Backup and copy this to a flash drive.

C. If the Predator3D is too damaged for a direct connection, check the HMI for the most recent backup
saved there. If the script to send a backup at a set interval to the HMI was running, there will be at
least one backup saved. Copy the most recent backup to a flash drive.
o The default location for a project backup on the HMI is C:\Coherix Backups\projectbackups\. If
the backups are not located here, search the C: Drive on the HMI to find files with a .mvp
extension. Use the most recent one of these.

D. If there is no backup available, then you must follow the proper steps in the User Manual to set up a
new system instead of following the directions in this appendix. Begin at Receiving the Predator3D or
Predator3D Pro.

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 2. There is additional information required prior to proceeding…
A. Review the internal controls group to identify the IP address of the unit. Leave it the way it is.

B. Obtain the software version being used on the damaged Predator3D. Check the software version that
made the backup by opening the .mvp file in notepad. In the first line, there will be #.##.##A where
the hash tags are numbers and the A is a letter.

C. It is recommended to take a series of photos of the current mounting configuration of the damaged
unit in order to replicate with the Hot Swap. Marking reference locations on the mounting brackets is
also helpful to aid in placing the Hot Swapped unit into a similar position and orientation.

3. Remove the damaged unit and replace it with the Hot Swap unit keeping the same mounting position and
orientation using the photos and reference marks from Step 2C. Connect the power and Ethernet cables.

4. There are two routes to configure the Hot Swap unit...

A. Directly connect the new Predator3D unit using an HDMI monitor and either a male Micro-USB B hub
or a male USB 3.0 Micro B hub for a mouse and keyboard. See Step 1B in this appendix for help.
o Set the IP address to be the same as the damaged unit.
o Load the software version being used on the damaged unit if it is newer than the version on the
Hot Swap unit.
▪ Check the status window on i-Cite by opening it and going to Window → Status to ensure
that there are no errors pertaining to the FPGA and Firmware. If there are errors, follow the
upgrade procedure to update them. This procedure is found in the most recent C:\Program
Files (x86)\i-cite NxT\Support\PREDATOR_FW_FPGA_Update_MM_DD_YEAR. (For
software version 2.17.01A or later, go to C:\Program Files (x86)\i-cite NxT\Support\) and is
titled UPGRADE FPGA AND FIRMWARE.TXT. Complete the steps listed in the document.
o Restore the backup from the damaged unit onto the new unit. See Section 12 in the User Manual
RESTORE: Performing a Project Restore for help.

B. If an HDMI monitor and either a male Micro-USB B hub or a male USB 3.0 Micro B hub are
unavailable…
o Check the HMI for a file called INDT#.zip where the hash tag is a number.
▪ If the file is not there, go to the Coherix file transfer site as detailed in Coherix File Transfer
Site then select Communication Setup and download the most recent version of INDT and
copy it to the HMI.

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 o Unzip INDT and run the .exe. See Appendix: i-Cite Network Discovery Tool (INDT) for more
information. Change the IP address of the HMI to allow a remote desktop connection to be
formed with the Hot Swap unit.
o Remote desktop to the Hot Swap unit.
o Load the software version being used on the damaged unit if it is newer than the one on the new
unit.
o Check the status window on i-Cite by opening it and going to Window → Status to ensure that
there are no errors pertaining to the FPGA and Firmware. If there are errors, follow the upgrade
procedure to update them. This procedure is found in the most recent C:\Program Files (x86)\i-
cite NxT\Support\PREDATOR_FW_FPGA_Update_MM_DD_YEAR and is titled UPGRADE FPGA
AND FIRMWARE.TXT. Complete the steps listed in the document. (For software version 2.17.01A
or later, go to C:\Program Files (x86)\i-cite NxT\Support\.) Restore the backup from the damaged
unit onto the new unit. See BACKUP: Performing a Project Backup for help.
o Set the IP address to be the same as the damaged unit and confirm your selection. (You will lose
your remote connection.)
o Change the IP address of the HMI back to what it was to allow a Remote Desktop connection to
be formed with the Hot Swap unit.
o Remote Desktop to the unit.

C. Ensure that you are able to connect using Remote Desktop to the Predator3D from the HMI. See
Setting up the HMI PC in the User Manual for more in-depth directions. If you are unable to connect
to the Predator3D using Remote Desktop, see Appendix: Remote Desktop Specific Issues in the User
Manual.

5. Run all inspections and ensure that the inspection for each active part style operates as expected.
A. If they do not, re-do Setting Imager Windows, Setting Imager Brightness, Acquiring Image Scans, and
all of the Setting up the Active Part chapters of the Manual.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Removed the damaged Predator3D.
✓ Installed and configured the Hot Swap unit.
✓ Ensured inspections function normally.

Note: Disable Z-Tracking prior to running parts after completing a hot swap. You must open the data tree and go to…
1) ChipData::Predator3D::m_dtP3dMain::m_dtParams::m_dtTrackingParams: :m_eTrackerMode → Disabled
2) Chip Data::Predator3D::m_dtP3dMain::m_dtParams::m_dtTrackingParams:
:m_bEnableAllTrackingDataOutput → False

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 Appendix: Predator3D GlassMaster Pro Setup
This section details the setup a Predator3D GlassMaster Pro. The majority of the setup is the same as a standard
Predator3D yet there are certain key differences, including the bracket design & robot programming to ensure the
bead can be properly inspected. In the i-Cite software, there are certain parameters that must be changed from their
default and there are also changes to the process of setting up an inspection. Prior to setting up a Predator3D
GlassMaster Pro first go through all introductory and core chapters of this User’s Manual to ensure a well-developed
knowledge base before continuing. This appendix was written under the assumption of this prior knowledge.

Bracket Design Considerations

The bracket design must align the crossing of two of the lasers with the notch in the nozzle from which the high-profile
bead is extruded. Additionally, the entire sensor must rotate with the nozzle to ensure the trailing lasers are always
over the peak of the bead being dispensed onto the part surface. Around corners, only one laser may be used if the
robot program does not allow for both trailing lasers to be used. Read Mounting the Predator3D/Predator3D Pro for
an initial overview before continuing.

1. Go to the CAD Drawings section of the Coherix File Transfer Site and select the Predator3D Pro directory to
find the files specific to the Predator3D GlassMaster Pro unit.

2. A file will be named P3D###S-GLS.CUSTOMER FILES.MM-DD-YY.zip with the ###’s representing the specific
Clearance Standoff for the unit. Ensure the correct one is downloaded.

3. Unzip the files. When designing the bracket, it is recommended to use the file …WITH CONES.MM-DD-YY.STEP
file that show how the lasers are projected from the sensor. This should ensure that the bracket is designed
with the proper orientation of the sensor as a primary goal.

4. Go through all the downloaded files to ensure understanding of all constraints.

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 5. The notch in the nozzle where the bead is extruded must be in line with the center of one of the X patterns
projected by the lasers. The bracket must be designed accordingly.
Direction of Travel & Dispense

Nozzle Location

Direction of
Travel &
Dispense
Direction of
Travel &
Dispense

Direction of Travel & Dispense

Notch in the Nozzle

Laser Intersection
on Bead’s Peak

Direction of Travel & Dispense

6. Ensure the processor module of the Predator3D GlassMaster Pro is located within the limits of the High-Flex
Cable that connects the sensor head and processor, providing more flexibility for fixture design. If this is not
true, the design of the bracket must be changed accordingly.

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 Confirmation Checklist
The bracket has been designed and meets the following requirements:
✓ The notch in the nozzle where the bead is extruded is lined up with one of the X patterns from the lasers.
✓ The bracket ensures that the Predator3D GlassMaster Pro rotates in line with the nozzle during the dispensing
process.
✓ The Predator3D GlassMaster Pro processor is mounted to the bracket within the limits of the High-Flex Cable
and the cable is properly managed.
✓ The trailing lasers will always be with the apex of the dispensed bead.

Post-Mounting Validation GLS

Once the bracket has been designed and the Predator3D GlassMaster Pro has been mounted, it is necessary to validate
the mounting. Otherwise, the inspection cannot be properly setup. Read Post-Mounting Validation before continuing.

NOTE: You may need to perform some mechanical adjustments to the bracket in order to get the nozzle centered in the
laser profile, achieving proper alignment. The lasers CANNOT be obstructed in any way.

1. Complete the initial steps in Validate the Nozzle Position to turn on the lasers.

2. With the lasers on, look at the part surface and the laser alignment around the nozzle. Ensure that the nozzle
is centered in the laser profile. If it is off-center, adjust the mounting of the sensor to better align the nozzle
with the laser profiles (it may be necessary to move the part and repeat the process until centered).

3. Make sure that the nozzle is aligned in all directions. If it is not possible, modify the bracket accordingly.

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 4. Validate the Mounting Offset Follow the steps in the linked location. Measure the Mounting Offset as shown
below. It is imperative that this value is within the specified range or the inspection may not be feasible. See
P3D###S-GLS Installation.MM-DD-YY.PDF from the downloaded files.

Predator3D GlassMaster Pro Bottom Surface

Part Surface

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Validated that the nozzle is correctly centered.
✓ Validated that the sensor’s mounting offset is correct.

Robot Program Considerations

To maximize the inspection integrity of the high-profile bead around corners and along the dispensing path, the
following robot program consideration should be taken into account during the initial setup of the dispense. These
considerations may be different from the current method for dispensing high-profile beads but they are intended to
maximize the quality of the inspection.

1. Ensure that the robot program keeps the Mounting Offset as constant as possible. If the distance varies, the
bead may not be dispensed properly and the quality of the inspection may degrade. Ensuring that the
Mounting Offset is constant will not only improve the quality of the inspection, it will also improve the
consistency of the dispensed bead.
i. Check this by stepping through the robot program and measuring the variation of the distance
between the nozzle and the part surface.

2. Around the corners of the glass where the nozzle is rotating, ensure that the peak of the bead is able to be
seen in at least one of the trailing imagers at all times. If the radius of the corner is too small or the rotation
of the nozzle is such that the bead apex cannot be seen by either the trailing imagers, then there may be a
small area of the dispensed bead that cannot be inspected.
i. To minimize the length of the bead that cannot be inspected, adjust each teach-point about the nozzle
to bring the cross of the trailing lasers closer to the peak of the bead. However, if the rotation is too
much, it may negatively affect the quality of the bead. Therefore, only rotate as far as possible without
impacting the bead quality.

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 Data Tree Parameter Changes
The parameters in the data tree that are different from the default relate to the filtering of the laser line. Unless these
parameters are set properly, the inspection will not be effective. Ensure that these are set correctly, as detailed below.

NOTE: The following parameter changes will be handled automatically when you select Glass as Surface Type under the
Setup panel in Standard Project version 2.5.0 or later. If using TCP data, the parameter found at
ChipData::Predator3D::m_dtP3dMain::m_dtP3dTcps::m_dtParams:: m_fTrackPathMargin must be changed from 25
mm, to 45 mm.

1. Sign in to Engineer (4) access level and click GO if you are offline.

2. In the top-left corner of i-Cite click the highlighted button to open the DataTree. (It is possible to move this
button selection around so it may be located elsewhere on the screen.)

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 3. To access the location in the data tree that needs to be accessed click the + sign next to the following
directories… Chip Data, Predator3D, m_dtP3DMain, m_dtP3dOutliners[4], m_dtP3dOutliners[0], and lastly
m_dtParams.

4. The parameters that need to be changed from their defaults are highlighted below. Use the values shown in
the right-hand image for the specified parameters.

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 Setting Imager Brightness GLS
Setting imager brightness for a Predator3D GlassMaster Pro is slightly different than setting it for a non-GlassMaster
Predator3D. Follow the steps below to properly setup imager brightness. This is done prior to Setting Imager Windows
for a Predator3D GlassMaster Pro so that the bead visible in the imager windows.

1. Follow the initial steps in Setting Imager Brightness but set the following as shown.

2. Set the Duration and Imager Gain (Global) to the maximum as shown below.

3. Click on the Save Changes button to save the adjustments made to all of the imagers. The background of the
button will turn GREY once the button is clicked & the adjustment is saved.

4. Complete remaining steps in Setting Imager Brightness.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Set Imager Brightness as directed.
✓ Saved the changes.

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 Setting Imager Windows GLS
Setting the imager windows for a Predator3D GlassMaster Pro is slightly different than setting the imager windows
for a non-GlassMaster Predator3D. Follow the steps below to properly setup the imager windows.

1. Follow the initial steps in Setting Imager Windows but set the following as shown.

2. Instead of aligning the laser line from the part surface in the Imager Window as described in Setting Imager
Windows, align the laser line in the bottom 1/3 of the Imager Window as shown below. It may be helpful to
view a sample of the bead in the trailing lasers to verify the entire bead fits within the imager windows.

NOTE: The portion of the laser line to be aligned is the laser returned from the part surface. In the leading lasers’ views,
there may be moldings along the part surface. In the trailing lasers the bead and the moldings may both be visible. It is
imperative that during the dispense, the apex of the bead does not go outside of the top of the imager window and that
the part surface does not go outside of the bottom of the imager window.

3. Repeat for Imagers 1, 2 & 3. The laser lines for all of the imagers should be as close to the bottom third of the
Imager Window as possible.

4. Complete remaining steps in Setting Imager Windows to ensure that all of the changes are saved.

Confirmation Checklist
Tasks that were accomplished in this section:
✓ Configured Imager Windows to align all of the laser lines in the bottom 1/3 of the imager window.
✓ Saved the changes.

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 Setting Up the Active Part GLS – Spline Method
The steps found in the Setting Up the Active Part chapter in Learn are slightly different for a Predator3D GlassMaster
Pro are slightly different than a non-GlassMaster Predator3D. Follow the steps below to set up the Active Part and
Part Style. The process described below covers the standard interface for Engineer (4) access level and is meant to
guide a user when setting up a part style while using the Spline Method for the inspections. For a video tutorial of
setting up an inspection see the Videos section of the Coherix File Transfer Site.

NOTE: The TCP Method can also be used for setting up inspections with a Predator3D GlassMaster Pro. There is not
actually any difference in the setup process for the active part when using TCPs with a GlassMaster Pro versus a non-
GlassMaster sensor.

This section of the manual was written using a slightly older version of software for the screenshots. Reference Setting
Up the Active Part – Spline Method for updated photos of the GUI and for additional information on selections that can
be made during this process.

1. Complete the Preparatory Tasks section of Setting Up the Active Part – Preliminary Setup. Ensure that the
Setting Imager Brightness GLS and the Setting Imager Window GLS were followed.

2. Complete the Load a Saved Image Scan section of Setting Up the Active Part – Preliminary Setup.

3. Complete the Enter Learn Mode section of Setting Up the Active Part – Preliminary Setup.

4. Complete the Setup Part Style section of Setting Up the Active Part – Spline Method.

5. Complete the Edit Spline Paths section of Setting Up the Active Part – Spline Method.

6. Complete the Edit Tracks section of Setting Up the Active Part – Spline Method.

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 7. Follow the initial steps in the Edit Marks section of Setting Up the Active Part – Spline Method. Then follow
the steps below for setup instructions specific to Predator3D GlassMaster Pro.

8. Next to Style Head Angle Mode, select Dual Perpendicular by Style. This selection indicates to the software
that two trailing imagers will both be used during the inspection.

9. In the new selection that appears, identify the two trailing imagers in the Style Perpendicular Laser dialog.
For example, below there is bead visible in imager 2 and imager 3 but not in imager 0 or imager 1. The system
will take a moment to compute the Spline when these selections are changed.

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 10. Adjust the Track Offset (Seconds) parameter to line the pink-to-RGBY transition with the center of the
beginning of the bead. Making this more positive moves the spline down while more negative moves it up on
the display.

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 11. At the end of the Track adjust the Gun Off Offset (Seconds) parameter to line the RGBY-to-pink transition with
the center of the end of the bead. Making this more positive moves the spline down while more negative
moves it up on the display.

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 12. To better setup Anchors, it is recommended below to adjust the Track Head Angle (deg) to 5° or -5° to better
align the spline in the bead and cause the corners of the part to be more prominent. The angle you choose
should cause the spline in one trailing laser to be on one half of the bead and the spline in the other trailing
laser to be on the other half.

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 13. Anchors allow the spline to be aligned with the bead. Click a location on the display where you wish to add an
anchor. A horizontal dark green line will appear where you clicked. Next click Add Anchor; a horizontal flashing
blue line will appear. This is the anchor.

NOTE: For a Predator3D GlassMaster Pro, anchors are typically added at or near features on the piece of glass. These
include corners, features such as spacers, mirrors or other items visible in the Setup Crossings (All Imagers) display. The
purpose of anchors is to allow the spline to be lined up with bead data. Because of this, click on the bead in the image
and adjust the spline to the bead. Do not attempt to adjust the bead to the spline.

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 14. To properly anchor, it is recommended to use three anchors per corner and at least one anchor per other
physical feature visible in the data. First place an anchor in the center of a corner as shown above. Then adjust
the spline to line the center of the corner in the center of the data from the first corner.

15. Now add an anchor above and below the current one. These should be aligned with the transitions due to the
corner; the spline should be aligned similarly to what is shown below.

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 16. Repeat this process for the other corners on the piece of glass. Below is a rear window, so there are three
additional corners.

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 17. After adding anchors at each corner, the next step is to anchor any locations where there are physical features
on the part. Below shows a twist of the nozzle around a small spacer on the part. For this example, the anchors
are added in a similar fashion to the way they are added for corners. The spline is also aligned similarly.

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Appendix: Predator3D GlassMaster Pro Setup - Page 319 Coherix Confidential
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 18. Below is a spacer on the part. For this example, a single anchor is added and the spline is adjusted. This aligns
the data for the spacer in the Setup Crossings (All Imagers) display to the spacer in the template image on
the Learn Edit Marks (Path Marks by Position) display.
i. First change to the Learn Edit Marks (Path Marks by Position) display.

ii. Click on the location where the physical feature is in the template image.

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 iii. Switch back to the Setup Crossings (All Imagers) display and add an anchor.

iv. From the location of the anchor, click and drag the cursor to the location of the data in the display.

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 v. Click on the location of the data in the Setup Crossings (All Imagers) display and then switch back to
the Learn Edit Marks (Path Marks by Position) display and confirm the alignment of the data onto
the template image.

vi. To precisely align data onto the template image, an iterative process may be required. Repeat the
process as necessary.

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 20. Repeat this process for any other physical features that the Predator3D GlassMaster Pro sees during a
dispense. Once all anchors have been added, it may look something like below.

NOTE: To further improve the inspection, one can change the Head Angle Adjustments drop down from “None” to one
of the other available options. Reference the Appendix: Head Angle Adjustments for more information. Head Angle
Adjustments might improve the alignment of the spline with the bead for all spline setups.

21. If there are any additional tracks, it will be necessary to increment Track by 1 and repeat the process. Typically
for dispensing on glass, there is only a single track.

22. Click Next> to proceed.

23. Complete the Compute Recipes_Edit_Tracks section of Setting Up the Active Part – Finalizing the Setup. This
step is not unique to the Predator3D GlassMaster Pro.

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 24. Complete the Edit Zones section of Setting Up the Active Part – Finalizing the Setup. This step is also not
unique. The note below discusses an example of setting Zones for rear glass and explains why the Zones were
setup that way.

NOTE: For a Predator3D GlassMaster Pro, it is recommended to setup the inspection to use the height criteria. Width
and Volume inspections are supported but are not as accurate as the height inspection. For any areas where neither of
the trailing imagers has the bead within its FOV, it will be necessary to set those areas to “Zone 0” which is the “Do Not
Inspect” zone.

The image below shows where the zones were configured for this rear window. At the beginning of the bead, Zone 2
(blue) was used to account for the variation in the beginning of the bead. Along the top of the glass there is a molding
touching the bead, so Zone 6 (orange) was setup to account for the change in width. This was also used near the spacers
at the bottom of the glass. At the center-top, there is a physical feature on the part where Zone 3 (yellow) was added
to compensate for the change in height of the bead in this area. The sides and bottom of the part use mostly Zone 1
(green) because the bead was most consistent in these areas. Zone 4 (pink) was used to account for the increase in
height of the bead due to the robot slowing down around the corners and at the end of the dispense. Lastly, there are
two small segments of Zone 0 (red in top left and bottom right corners) due to the bead falling outside of the FOV of
the system when the robot is manipulating the glass.

It is possible to configure the inspection as one Zone that uses the same criteria across the part (except where there is
a Zone 0). However, by building separate zones, inspection tolerances may be narrowed to ensure higher quality.

25. Complete the Validate the Setup_Edit_Tracks section of Setting Up the Active Part – Finalizing the Setup. This
step is not unique to the Predator3D GlassMaster Pro.

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