Functional Specifications ATM18
Contents
1. ATMIS Functional Specifications 26 C9502FE1 DOC c Operational warnings NC9502F ling The operational warnings preceded on the screen by the letter W do not stand for a bad operating of the machine but they advise the operator when some events occur which can alter the machine operating or when the operator himsel The simple operator s intervention is enough to restore normal condition MESSAGE Disconnected printer or printer OFF f gives an invalid command Printer connections SOUND SIGNAL MACHINE CONDITION Function disabled Operator s error Inadmissible value Operator s error Parameter writing not enabled Parameter writing key not present I O board on MANUAL module x Start with DM526 board on manual Motor board on MANUAL module G9 Start with DM522 board on manual 3 seconds Emergency stop module x Emergency push button emergency circuit 3 seconds Box y full module x Excessive number of ampoules out of seat box Conti nuous Stop box y full module x Excessive number of ampoules ATMIS Functional Specifications 3 seconds 27 C9502FE1 DOC NC9502F ling 4 INTERFACE All the operations described are performed using the machine s two keyboards Control keyboard located on the external wall of the loading table Console keyboard All information is furnished by the computer screen b2. Container starts rotating on its axis Check correct operation of rotation mechanism Process diagram sheet 2 Is No Is the orientation OK Yes 1 turret steps Y rotation OK 6 turret steps T The container Machine stops is braked 1 turret steps The spindle Error message is orientated is displayed Station TV1 particles test see par 3 2 1 Machine stops Y Image acquisition and processing see sheet 1 Error message is displayed 5 turret steps ee S Station TV2 particles on bottom tes see par 3 2 2 Image acquisition and processing see sheet 1 e 8502pr2 cdr ATMIS Functional Specifications C9502FE1 DOC Container starts rotating again Check correct operation of rotation mechanism Is rotation OK 6 turret steps The container is braked 1 turret steps The spindle is orientated Process diagram sheet 3 Station TV3 Particle test see par 3 2 1 Image acquisition and processing see sheet 1 3 turret steps Station TV4 fill level test see par 3 2 3 Image acquisition and processing see sheet 1 Machine stops Container moves Error message to the sorting device is displayed Is the orientation OK 1 turret steps Machine stops Error mes
3. lp EN i 91 io IN 9h FOR INFORMATION FOR APPROVAL DR E RECKEU CUSTOMER L APPROVED C APPROVED AS NOTED
4. 3 4 1 Safety 24 3 4 2 Error and alarm messages 25 4 INTERFACE 28 4 1 ACCESS LEVELS 28 4 1 1 Operator 29 4 1 2 Supervisor 31 4 1 3 Maintenance technician 31 5 GLOSSARY APPENDIX B Classes of Defects and Reject Priority ENCLOSURE Enclosure1 LAY CONNAUGHT 13 rev 2 ATMIS Functional Specifications 2 C9502FE1 DOC NC9502F ling 1 INTRODUCTION This document is prepared by Brevetti C E A S p A in order to define functional criteria of ATMIS machine which must operate in line with a LTM Jupiter to inspect 0 5 1ml and 6ml ampoules The tests required by the Customer in the User Requirement Specification 1 are subdivided between the two machines as follows ATM18 is placed upstream respect to LTM Jupiter Test Ref URSS 1 TCM TVi TV2 ip 0 l1 NA TVI TV3 Particles N A ATM18 TV2 Particles on bottom N A TV4 Level and black particles N A LTM Stations 1 2 3 4 Micro holes N A This document is prepared in accordance with what foreseen in 14 15 Instruction Standard Format of Machine Documentation 2 This document is produced by the System Analysis Department and approved by Quality Assurance and then submitted to the Customer s approval as foreseen by the Quality Plan 3 1 1 REFERENCES When there is a reference to another document only the number is reported into square brackets as indicated in the following table NO REF DOCUMENT 1 N A
5. SPECIFICATIONS FOR BREVETTI AUTOMATIC INSPECTION MACHINE AND BREVETTI JUPITER LEAK DETECTOR dated June 26 1995 2 14 15 Standard Format of Machine Documentation 3 NN9501Q Quality Plan 4 NC9502U ATMIS User Manual 5 NG9502F LTM Jupiter Functional Specifications 6 NN9501F TCM Functional Specifications 7 NC9502Z SW Configuration SP programs and Parameters m ATMIS Functional Specifications C9502FE1 DOC NC9502F ling 2 GENERAL DESCRIPTION ATMIS machine is designed to be inserted in modern pharmaceutical product lines It is installed downstream from filling and freeze drying lines and upstream from labelling and packaging systems ATMIS receives the containers by the upstream machine TCM by means of a first in first out line The output of rejected containers occurs on standard stainless steel C E A boxes the accepted containers are addressed to the loading table of the downstream machine LTM Jupiter The ATM18 machine consists of Mechanical module inserted in the production line and charged with transporting the containers along the test path The mechanical module has got a double configuration two modules mechanically equal and specular but wholly independent Remote monitoring and control console it handles the mechanic module management and its interface with the production line Furthermore it permits the user s monitoring of the process 2 1 PROCESS DESCRIPTION Process control is totally
6. 1 05 OK OK OK OK OK Rel 2 010 Battery OK Rel 2 010 Battery OK Flash cleared Fig 3 5 Typical Self Test Screen ATMIS Functional Specifications 25 C9502FE1 DOC b Operating errors NC9502F ling The error messages are displayed in order to signal the wrong operation of fundamental parts of the machine that would not allow to correctly test the product The error messages listed here below preceded on the screen by the letter E are always associated with an automatic and immediate stop and a 3 second sound signal Consider them as serious alarms which require the intervention of technical personnel MESSAGE Lack of electronics 12VDC supply module x Power section MACHINE CONDITION Lack of Telecamera 12VDC supply module x Power section Lack of Services 24VDC supply module x Power section Motor breakdown y module x Motor inverter belts encoder DM522 motor board Transmission error MP SP y Connections SP board Receive error MP lt SP y Motor speed too high Programme too long Phase error module x Encoder DM526 board Out of phase star wheels module x A star wheel is out of phase Photocell error y module x Connections optical fibers amplifier for optical fiber DM526 board Reject error y module x DM526 board DM532 board actuator sensor on actuator
7. Print outs Change one or more parameters associated with the product To perform this operation it is necessary to own the parameter writing enable key and to insert it on the front panel of the DM503 board The change is possible only on the parameters of the active product To make the product active follow the instructions described previously To make modifications refer to the User Manual It is enough to select the desired page and press the lt Prt Scr function key 4 1 3 Maintenance technician The maintenance technician has a key for safety exclusion which actuates a switch to disable the safety switches mounted on the machine covers This permits the machine operating with open covers in order to perform maintenance or repairing operations The condition of disabled safety is signalled by the lighting up of a yellow lamp on the panel of the operating keyboard Each of the two modules has got its own key switch and its own yellow signal lamp ATMIS Functional Specifications 31 C9502FE1 DOC NC9502F ling 5 GLOSSARY Analog Quantity or signal which can continuously change The video signal supplied by the telecamera is analog because it changes in a continuous way analog to the variations of the luminosity of the framed object Binarization Image processing consisting in the conversion of the value of luminosity of each pixel into a binary value that is 0 or 1 based on a threshold This permits to o
8. automatic Each container undergoes a series of tests performed by telecameras It is enough that only one of the tests results negative for the container to be rejected Containers are transported along the test path including the tests which are listed here below Particles Particles on bottom Particles Level and black The specifications of the different test stations and of the image processing method are present in Chapter 3 Functions of this document The process diagram is shown in the next pages Sheet 1 shows the process flow chart for all inspection stations if inspection is enabled the images are processed and the result is stored as an active reject or accept flag in the shift register The acquired scans are processed while the machine is carrying the container to the next station The diagram shows from the functional point of view the main functions performed by the system during operation A more detailed explanation of the routines the software executes to test the various sections of the machine is given in the Software Design Specification Fig 2 1 shows the layout of the stations to which we refer in the process diagram ATMIS Functional Specifications 4 C9502FEI DOC NC9502F ling ts tation rejected ampoule accepted C9502f21 cdr Fig 2 1 Test station layout ATMIS Functional Specifications C9502FE1 DOC 2 1 1 Process Diagram Sheets
9. complete line D End of production batch GOAL Record the data relative to the inspected batch It corresponds to print the data referring to the counters and the parameters with which the inspection was carried out PROCEDURE To print the counters the selection path is lt F7 gt lt Prt Scr gt To print the parameters the selection path is test parameters lt F7 gt F3 F5 Prt Scr gt motor speed F7 lt F3 gt F5 lt Prt Scr gt ATMIS Functional Specifications 30 C9502FE1 DOC NC9502F ling E Changing the active product GOAL PROCEDURE 4 1 2 Supervisor Change the type of product being tested The following parameters are associated with each type of product Name of product Sensitivity parameters Programs of the different SP sub systems Motor speed Parameters for timing the output boxes Changing the active product automatically changes all the parameters associated with that product Selection path lt F3 gt lt F1 gt Position the arrow located in the left part of the display on the row regarding the product to be activated using the up and down arrow keys lt gt and lt b gt Press the F2 key to select the product Note that to confirm acceptance of this command the name of the chosen product appears on the heading of the video screen To create and record a new product refer to the User Manual A Changing a parameter GOAL PROCEDURE B
10. distribution shown the mean and standard deviation are displayed Furthermore a zoom function is available to expand the graph on the x axis to make it more readable 4e possibility of displaying a list of the last 256 alarms occurred during a production lot 4f 5 features Each alarm is displayed complete with date and time Only the alarms with codes 1 1999 Operating errors are listed These alarms usually involve intervention of a technician to be recovered see par 3 4 2 The user can browse the alarm list using lt Pg Up and Pg Dn Keys The contents of the screen can be sent to the printer using lt Prt Sc key When the counters are reset at the beginning of a new lot the alarm list is cleared possibility of entering product and batch data two 80 character lines available which is displayed in the Home screen lt F7 gt key If the machine is switched off this data remain stored in a sionsvolatile memory some test functions useful for performing trials on each single test station and on the total efficiency of the machine such as 5a utility for Knapp test execution with print out of graphical and numerical report KNAPP menu 5b possibility of acquiring an image from any station and immediately execute with the machine stopped any processing program for testing purposes PROGRAM menu It is possible to change parameters and instructions to check their effect without original programs
11. for goods sends it into the in line connection channel with the LTM which is placed downstream 3 3 4 Protections a All parts in contact with the product are made of stainless steel or of plastic material which does not produce dust and can be removed to permit cleaning b The transportation zone of the containers is separated from the mechanical and electrical parts so that the product residues can not reach them c The parts in movement are protected by covers made in plastic material d Access panels to parts that require maintenance can be opened only using a proper tool 3 4 SAFETY ERROR AND ALARM MESSAGES 3 4 1 Safety a The cover of the loading star wheel is equipped with a device which in case of opening stops the machine in emergency b Mushroom shaped emergency push buttons are located around the machine in easily accessible positions The machine stops in emergency for the following reasons 1 a mushroom shaped push button was pressed 2 one of the covers was opened 3 a spindle is not oriented one of the devices to orient the spindles could be malfunctioning When an emergency stop occurs all parts of the machine stop After an emergency stop the operator must press the emergency reset push button to start the machine again c Access panels to parts that require maintenance can be opened only using a proper tool d Parts directly in contact with mains voltage are shielded by insulating panels in
12. four consecutive rejects occur for lack of light the machine stops and displays the message Station breakdown The first processing the image undergoes is the binarization the user defines a threshold between 0 and 255 so that the system assignes the value 0 to all the elements of the digitized image which have a value below this threshold and assignes the value 1 to the ones which have a value above the threshold Just to make an example if the object monitored has a middle grey colour the image will be a table full of 127 values corresponding thus to the middle of the range 0 255 If the binarization threshold is set at 128 the resulting binarized image will be a table full of 0 values if the threshold is set at 126 the table will be full of 1 values In this way we obtain one or more binarized images consisting only of 0 and 1 values If we test a vial and succeed in lighting it up so that the defects to be detected look darker than the vial glass we will set the binarization threshold at such a value that in the resulting binarized image the defect becomes a completely black spot on a completely white background that is a group of 0 values surrounded by 1 values The system can be programmed to look for defects in definite zones of the image to detect bigger defects than the ones whose dimensions was preset by the user to make measurements to detect presence or absence of particulars ATMIS Functional S
13. square with 70 jum side DIFFUSION FILTER NEON LAMP TELECAMERA 9502133 cdr Fig 3 3 Station TV4 Level and particle test ATMIS Functional Specifications 22 C9502FE1 DOC NC9502F ling 3 3 MECHANICS 3 3 1 Loading The containers coming from the upstream machine by means of an in line connection are moved to the loading star wheel by means of a worm screw The star wheel which rotates with continuous motion moves the containers to the turret in the moment the spindle which is still is in the condition of receiving the ampoule when the moving wing is open 3 3 2 Gripping system The container is inserted in a spindle consisting of a fixed and a moving part The moving part permits the loading and the unloading of the ampoule from the spindle Fig 3 4 The opening and closing occurs by means of a cam which is fastened to the machine in correspondance with the input and output of the ampoules from the turret The two parts are removable and change according to the dimensions of the ampoules to be tested cavas con ide lai fixed wing Fig 3 4 Spindle ATMIS Functional Specifications 23 C9502FE1 DOC NC9502F ling 3 3 3 Output At the turret output if the container must be rejected a proper actuator hooks a pull out device in order to send the ampoule into the rejects box in case of a good container it proceeds just for a step and the pull out device
14. the image or in order to eliminate little disturbances present in the image ATMIS Functional Specifications 19 C9502FE1 DOC NC9502F ling 3 2 TESTS What follows is a description of all test stations installed in the machine 3 2 1 PARTICLE TEST Station TV1 A telecamera horizontally placed in front of the ampoules frames the Station TV3 ampoule s content which was previously rotated and abruptly braked in order Fig 3 1 that the possible particles present in the liquid are in movement in front of the telecamera The container is lighted up from underneath by an halogen lamp with collimator The inspection method used is the one for differences In area 1 indicated in the figure the test is performed The mask placed between the ampoule and the telecamera is necessary to cover possible reflections coming from the meniscus which could cause the reject of the good containers The minimum detectable defect is a particle which has a visible area equivalent to a square with a 54um side TELECAMERA mask position for different COLLIMATOR filling level HALOGEN BULB ca502t91 cdr Fig 3 1 Stations TV1 3 Particle test ATM18 Functional Specifications 20 C9502FE1 DOC NC9502F ling 3 2 2 PARTICLE TEST ON THE BOTTOM Station TV2 A telecamera horizontally placed in front of the ampoules frames by means of Fig 3 2 a 45 inclined mirror the ampoul
15. video signal This signal is sent by means of a cable to the SP acquisition and processing board This board samples the signal at a sampling rate of 8MHz that is it measures the signal level each 125ns then it converts the detected value into a number from 0 to 255 i e 0 black 127 gray 50 255 white A table is created in memory and it is filled with the numbers coming from the conversion stage Each one of these numbers represents the quantity of light present in a definite point of the image at the moment of sampling This method is called analog to digital conversion or digitizing At this moment there is a 144 x 416 table whose cells contain all information necessary to understand if the object acquired as an image presents some defects This map therefore can be called image or more precisely digitized image The present system permits to acquire up to 8 images while the container stands in front of the telecamera The container can be monitored 8 times while it is rotating around its own axis covering thus the whole lateral surface In case of flip off or bottom test a unique image is sufficient 3 1 2 PROCESSING SYSTEM In all the application programs both using the difference method or the binarized one a test is pesrformed in order to check if the quantity of light is enough for the correct execution of the program itself In the negative the container is rejected termining the program execution Moreover if
16. 1 4 NC9502F ling Start Acquire images Process Images ls inspection enabled Is processing No Process diagram sheet 1 acquisition routine Each station assigns its Good reject flag to the container to be inspected If the station is disabled the flag always assumes the Good value If the station is enabled and it did not detect defects beyond the tolerance allowed the flag assumes the Good value The container is accepted if the flags of all stations have the Good value at the moment when it reaches the machine output N B The aim of this diagram is to show the process from a functional point of view Actually the functions shown here are performed by different processors complete allowable limits The acceptlreject flag in set to reject The accept reject flag in set to reject The acceptreject flag in set to accept SUR ine mecha The accept reject flag in set to accept Display error message KBS02prt odr ATMIS Functional Specifications C9502FEI DOC NC9502F ling Container comes from TCM Y Container is picked up by first star wheel Y Container is detected by proximity sensor C RR Shift register is updated with container present flag Container is inserted into turret
17. C9502FEI DOC Brevetti C E A S p A Via del Commercio 28 36050 Sovizzo VI ITALY Tel 0444 551988 Fax 0444 536241 NC9502F ling COPY N 3 Functional Specifications ATM18 Order C9502 Customer Connaught Canada Reference NC9502F Version 1 Date January 30 1996 This document contains 32 pages one page of Appenidx B and one Enclosure Author V Maruzzo LEGER He fon Name Position Review Signorelli Project Responsible Approval D Dal Bello Q A Manager Customer s review Customer s approval Signature Date Ada 2 2 0 U3 2 Wu ATMIS Functional Specifications 1 C9502FE1 DOC NC9502F ling TABLE OF CONTENTS 1 INTRODUCTION 1 1 REFERENCES 2 GENERAL DESCRIPTION 2 1 PROCESS DESCRIPTION 2 1 1 Process Diagram Sheets 1 4 2 1 2 Mechanics layout 2 2 COMPUTER DESCRIPTION 2 2 1 Hardware architecture 2 2 2 Software architecture 2 3 MACHINE DESCRIPTION 2 4 TECHNICAL NOTES 2 4 1 Performances 2 4 2 Services required 24 3 Limits 2 4 4 Working environment 2 4 5 Expandability interface options 3 FUNCTIONS 3 1 ACQUISITION SYSTEM L SSSSoR RWW a 3 2 1 Station TV1 Station TV3 3 2 2 Station TV2 3 2 3 Station TV4 3 3 MECHANICS 3 3 1 Loading 3 3 3 2 Gripping system 23 3 3 3 Output 24 3 3 4 Protections 24 3 4 SAFETY ERROR AND ALARM MESSAGE 24
18. and keys F7 F6 F2 lt F2 gt to temporarily disable all functions To access them again a password must be re entered ATMIS Functional Specifications 28 C9502FE1 DOC NC9502F ling 4 1 1 Operator 4 1 1 1 Machine operations A Starting and stopping Machine START green and STOP red commands are given by illuminated push buttons present on the control keyboard Command activation and acceptance are signalled when the push button lights up These commands only permit start up and stop with the machine in phase Each of the two modules has got its own control push buttons B Emergency stop Immediate machine stop is obtained by pressing one of the self retaining EMERGENCY push buttons red mushroom shaped push buttons located around the machine in easily accessible positions Pressing one mushroom shaped push button makes both the modules stop in emergency mode When the EMERGENCY RESET push button is illuminated it signals the condition of emergency stop Each of the two modules has got its own emergency reset push button At power up the machine is set in emergency for safety reasons C Reset after an emergency stop To restore normal operation you must release the emergency push button which caused the machine stoppage and press the interested EMERGENCY RESET push button This sequence of operations Release emergency button press Reset press Start guarantees and protects the machine operator against
19. and parameters which are stored in a non volatile memory being changed 5c possibility of activating the Manual mode MANUAL menu this is useful for instance for format changeover it permits to disable lamps and motors without the machine diagnosing operating errors 5d possibility of acquiring an image from any station and immediately execute different processing for testing purposes TEST SP menu the gray scale image and the binarized one are shown in separate windows The user can change the binarization threshold and see the effects on the binarized image Furthermore it is possible to copy the image in a new window and process it using algorithms as subtraction between two images or convolution 5e possibility of activating an oscilloscope function OSCIL menu a window sf complete with a reference grid shows a real time oscilloscope like display of the light intensity along a row or a column of the image The user can examine the desired row or column simply by using the four arrow keys A red line indicates the level of binarization by changing this level with the lt gt lt gt keys the red row moves and gives a help to look for the more appropriate binarization threshold possibility of testing the inputs and outputs with the machine stopped TEST HW menu ATM18 Functional Specifications 13 C9502FE1 DOC NC9502F ling 6 includes a complete programming environment reserved to techn
20. as picked up by one of the photosensors contained in the CCD sensor Sampling Acquisition process of an analog signal a circuit measures at regular intervals the analog signal applied at its input and at output it gives a sequence of istantaneous values picked up in the different moments of sampling SP Signal Processor acquisition and processing circuit which processes the images coming from the telecameras and communicates the test result to the Machine Processor Video Terminal Processor it is the computer section which handles the user interface screen and keyboard This permits the operator to program the SP processors to set and store the test parameters and to get the results of the production carried out ATMIS Functional Specifications 32 COSO2FEI DOC NC9502F ling APPENDIX B Classes of Defects and Reject Priority C L Fill level Particles Tv1 E ee je ie Particles inthe bottom x T A E A P Fill level Black Particles Each defect is assigned to a class if the corresponding cell is crossed Each defect must belong only to one class Classes are numbered in descending priority order Note since TV1 TV2 and TV3 perform the same inspection they should be assigned to the same class ATMIS Functional Specifications Appendix B Page 1 e d Le zx d z y 1000 T ml p miu 3 N o 9 E ES
21. btain an image composed of black and white colours only CCD Charge coupled device it is a solid state photosensor where the received luminous energy produces a variation of the electric charge which is picked up and amplified by the telecamera circuits CCIR International Radio Consultative Committee It stands for a standard format of the video signal Digitizing or analog to digital conversion Conversion of an analog signal into a series of numbers At first the analog signal is sampled in order to have istantaneous values later converted into a number sequence describing the signal amplitude step by step The accuracy of the signal translation into numbers depends on the sampling and conversion frequency and on the resolution of the converter circuit The higher is the frequency the higher is the resolution and thus the accuracy Image Image stands for the whole numbers resulting from the analog to digital conversion it is a table of numbers each of them representing the luminosity value in a definite point of the field focused by the telecamera Machine processor it is the processor which controls the machine movements and the correct operating of all parts After receiving the results of the SP boards tests it actuates the reject device if the container is considered defected Pixel Contraction of Picture Element each element composing the image In the telecamera image a pixel corresponds to what w
22. e s bottom The test is performed in instantaneous way acquiring only an image while the container is at a stop The container is lighted up from underneath by an annular optical fiber and an halogen lamp in this way the possible defects will result black on light background In figure 3 2 area 1 represents the framed field while area 2 represents the test zone The minimum detectable defect is a particle with a visible area equivalent to a square with 220um side in case the contrast between object and background is equal to 100 mpoule ampolule with particle ANNULAR FIBER OPTICS LIGHTING DEVICE TELECAMERA LJ 69502132 cdr MIRROR Fig 3 2 Station TV2 Particle test on the bottom ATMIS Functional Specifications 21 C9502FEI DOC NC9502F ling 3 2 3 LEVEL AND PARTICLE TEST Station TV4 A telecamera horizontally placed frames the ampoule A lighting unit with a Fig 3 3 neon lamp and a diffuser filter lights up the ampoule sideways making the ampoule outlines and meniscus appear black on white background The program executes two different tests first of all it finds in instantaneous way the meniscus position 1 then uses line 1 as reference line below which to perform the particle test with the difference method zone A The precision for the level check is about 0 5mm while for the particle test it is a particle with a visible area equivalent to a
23. ical personnel this permits to write the image processing programs and change the existent ones These operations are performed by using an integrated editor the programs can be saved on non volatile memory and on removable memory card 2 2 2 2 Application software The application software consists of the image processing programs or SP programs The programs are written using a language developed by Brevetti C E A which has specific functions for image processing Each program is assigned to one or more SP systems and executes on the acquired images the sequence of operations and measures required by the inspection to be performed SP Program listings are included in the document 7 ATMIS Functional Specifications 14 C9502FE1 DOC NC9502F ling 2 3 MACHINE DESCRIPTION The machine consists of the following main parts 1 Control console 2 Machine body 3 Loading line 4 Unloading line The containers are moved from the upstream machine by means of a first in first out line and they are loaded into the turret by means of a worm screw and a loading star wheel Inside the turret the containers rotate on their own axis when this is required by the kind of test to be performed The motion of the turrets is intermittent and the containers test occurs during the pause from one traverse and the following one At turret output the containers are addressed towards the good or rejected channels by means of two proper
24. ideo Terminal Processor or VTP 2 amachine handling unit Machine Processor or MP 3 various signal processing sub systems for the inspection stations Signal Processor or SP The power section provides the power supply to control electronics to the motors and to the various lighting systems The telecameras are equipped with a CCD matrix sensor and use standard TV lenses Operating VTP manages the user interface programmes the SP sub systems sends test parameters to the SP sub systems stores production data MP manages movements collects the results of SP sub system tests synchronizes movements and tests checks the correct operating of all parts and stops the machine in case of malfunction SPs process the images coming from telecameras and communicate the results of the tests performed to the Machine Processor ATMIS Functional Specifications 10 C9502FE1 DOC NC9502F ling 2 2 2 Software architecture The software of different processing units is stored on solid state components instead of magnetic media to avoid the risk of accidental erasure or modification A program editor with copy and modify functions and a powerful set of macro instructions makes Signal Processor programming easier a special test page permits to acquire an image and to execute the program in order to check it The control software of the machine is logically subdivided in 1 Machine handling software 2 Programmi
25. independent devices There is a box for the reject collection The transportation method guarantees a uniform movement of the containers without sudden shifts This mechanism is built with materials which cannot damage or dirty the containers Materials in contact with the containers 304 Stainless Steel 304 Stainless Steel chromium plated Delrin ATMIS Functional Specifications 15 C9502FE1 DOC 2 4 TECHNICAL NOTES 2 4 1 Performances Tested containers Dimensions of tested containers Machine speed Rotation speed Inspection stations Loading Unloading 2 4 2 Services required Electric supply Power NC9502F ling Ampoules 0 5ml 10 5mm tot h 50mm ampoules 1ml 10 5mm tot h 5 0mm ampoules 6ml 16 5mm tot h 67mm ampoules continuous regulation from 33 up to 150 pcs min continuous regulation from 300 up to 3000 rpm 4 stations for each module 3 for particles test and 1 for level black particle test with first in first out line with TCM accepted in first in first out line with LTM Jupiter rejected standard CEA steel boxes 130x500x50mm WxDxH 208V 5 60Hz 1Ph 6KW ATMIS Functional Specifications 16 C9502FE1 DOC 2 4 3 Limits Module console connection cables Dimensions WxDxH Weight Loading unloading height Minimum height above floor Noise acoustic pressure level continuous equivalent A weighted Protection level 2 4 4 Wo
26. ng software 2 2 2 1 Machine handling software The machine handling software executes the functions typically used by the product manager and the operator that is 1 provides the machine normal operation 2 provides production data operating warnings and error messages The rejects are counted according to a structure consisting of four elements 1 Defects 2 Stations 3 Classes of Defects 4 Reject Priority Each Station can detect up to four Defects for example the station x can detect at the same time cracks on the glass and uncorrect filling level Defects can be grouped in Classes A class can include both the defects detected by the same station and the defects detected by different stations for example the Cracks class can include cracks on the sidewall and on the bottom which are defects detected by separate stations In this case a container presenting one or both the defects will be counted as reject under the Cracks class A class however can consist of a single defect as well Each inspection or defect must belong only to one class The number of available classes is 16 Classes are arranged according to a Reject Priority order for example if the Cracks class is a priority respect to the Fill Level class the container with both defects will be counted only as reject for cracks Fig 2 2 In the HOME page the number of rejects for each class is displayed If ENTER is pressed when
27. order to avoid accidental contacts The equipment features protections against overloads and earth leakage ATMIS Functional Specifications 24 C9502FE1 DOC 3 4 2 Error and alarm messages a Start up diagnostic test NC9502F ling At power up the machine control system performs a series of self diagnostic tests in order to check the operating condition of the boards and of the printer The test results are shown on the screen until the user does not make any selection from the keyboard The tests performed are in this order Memory test Parameter test Back up battery test Board test Printer test The following information is displayed for each test Test description Result Note where result corresponds to OK if the test passed FAIL if the test failed According to the kind of test there can be an additional note in particular for the electronic boards equipped with software the note reports the software release if the test of the program checksum is negative the note reports FAIL or Rel 000 The typical self test screen is shown in figure 3 5 gt gt TEST lt lt Test Video Terminal Processor Test Machine Processor Test Flash Memory Test Flash Memory Test Parametri Card 7 DIGITAL I O OK Test Printer OK Press any key to continue Card 0 SIGN PR OK Rel Card 1 SIGN PR OK Rel Card 46 MOTORS OK Rel 2 010 2 010
28. pecifications 18 C9502FE1 DOC NC9502F ling A second technique is the one based on the differences that is used for the search of particles inside the fluid The container rotates and then abruptly stops so that the particles move inside the fluid while the container stays in front of the telecamera The SP system is designed to detect only the particles set in movement so it acquires the first image that is the one with a value between 0 and 255 for each pixel then acquires the following ones comparing at every new acquisition the value of each pixel with the one it had in the first image In memory a new table called map of differences is built in this table is inserted a value 1 when in any image a pixel presents a variation respect to the first image equal or above the threshold difference threshold preset by the user In this way only the particles set in movement are marked parts of the image such as the silk Screen on an ampoule even though they are very bright or reflecting they do not produce luminosity variations in time and so they are not detected The difference method is used also for the alu cap inspection and the one concerning the lateral surface of the container This permits to detect while the container is rotating little differences of light due to the presence of cracks or dents The Signal Processor can be programmed to process the map of differences in order to look for defects in certain zones of
29. rking environment Operating temperature Relative humidity Electromagnetic compatibility Pressure NC9502F ling 15m lenght mechanic module 1910 x 860 x 1340mm console 1200 x 600 x 2100mm mechanic module 900Kg console 350Kg 900mm 50mm mechanic module 150mm console 50mm 70dB A mechanic module within the CEI standard IP22 console within the CEI standard IP54 435 435 C max 90 no condensation emission within the CEI EN50081 1 standard limits 0 5 2 bar 2 4 5 Expandability interface options Software reserve space Cabling reserve space Interface Options Prearrangements 20 10 spare terminals RS232C baud printer in line connection with external stop not applicable ATMIS Functional Specifications 17 C9502FE1 DOC NC9502F ling 3 FUNCTIONS 3 1 ACQUISITION SYSTEM The system of image acquisition and processing is explained into detail in the User Manual This chapter sums up its operating in order to give an overall view of the techniques used and facilitate the understanding of the tests performed by the machine The telecamera has a CCD type matrix sensor Charge Coupled Device The sensor consists of thousands of single elements each of them supplies a quantity of electric energy proportional to the quantity of luminous power it receives The circuits of the telecamera measure all voltage values supplied by the single elements of the sensor and build a standard CCIR
30. sage is displayed 1050203 car ATMIS Functional Specifications NC9502F ling C9502FE1 DOC NC9502F ling Process diagram sheet 4 Has reject box activated limit switch Must the container be rejected Yes Reject device is not energized It remains Reject device is ener gized It disengages A message is engaged to a cam itself from the cam and x displayed with the container proceeds ain makes Kpah an audible alarm to the accept device Rp Reject device position is checked Is reject device operating correctly Machine stops Error message is displayed The accept device pushes the container on the JUPITER connection line Reject box position is checked xoso2prt car ATMIS Functional Specifications 9 C9502FEI DOC NC9502F ling 2 1 2 Mechanics layout See enclosure 1 2 2 COMPUTER DESCRIPTION The computer is housed in a double standard 19 inches per 40 units rack enclosure containing the computer hardware the monitor the keyboard the power supply section the power section and the signal processors for the telecameras 2 2 1 Hardware architecture The control system is multiprocessor architecture based with high speed serial connection among the different processors to assure real time process control It is composed of 1 visual display terminal interface V
31. tainer was or was not rejected by the other stations 4b comprehensive on line graphical display of the inspection result of all stations HISTORY menu a map of the positions the container fills while it is transported from input to output is displayed in correspondence to each inspection station a small square appears If it is green it will indicate that the station accepted the container if it is red it will indicate that the station rejected the container in case it appears light blue it will indicate that the station is disabled and did not perform any inspection 4c graphical and numerical display of the amount of rejects for each turret spindle SPINDLES menu the reject percentage of each spindle is shown with a histogram By selecting a spindle it is possible to obtain the total containers which it loaded the total rejected and their percentage These data is useful to point out possible malfunction of the spindles ATMIS Functional Specifications 12 C9502FEI DOC NC9502F ling 4d graphical and numerical display of the distribution of the values measured by each station on the last 1000 inspections performed GAUSS menu once a station has been selected four quadrants appear Each quadrant shows the values distribution of one of the quantities analyzed by the program on a max of 1000 samples the samples are the last inspections performed by the station the number of samples can be preset by the user For each
32. the cursor is positioned on a class a window pops up which displays the number of rejects for each defect belonging to that class this display also includes the indication of which stations have detected the defects The subdivision into classes of defects can be configured according to different types and priority of defects For the Classes of Defects and Reject Priority configuration see Appendix B ATMIS Functional Specifications 11 C9502FE1 DOC NC9502F ling Station 1 Def H Def incdus naa CERE Priority 2 Priority 3 Cessa Priority 4 Priority 5 ciass 6 Priority 6 Fig 2 2 A separate window displays the following data Rejects for Machine Stop Total Rejected Total Accepted Total Inspected 3 permits to store and recall the inspection parameters for the products 4 features some display and print functions useful for monitoring the production and for system operation such as 4a on line that is in real time detailed display of the inspection result for each station ON LINE menu while the machine is operating the screen displays up to four values of measures performed on the container by the selected station together with the time taken by the inspection program for processing the image s Furthermore some symbols appear which indicate the presence or absence of the container and whether the con
33. the possibility of accidental machine start up after an emergency stop ATMIS Functional Specifications 29 C9502FE1 DOC NC9502F ling 4 1 1 2 Operations on the console keyboard The operations here described can be carried out in an independent way on the two modules In order to select the operating module press lt F11 gt key A Display of motor speed GOAL Display the speed of the machine motors for the active product This speed is expressed in pieces hour for the main motor in RPM for the rotation motors and in cm second for the belt motor PROCEDURE Selection path lt F7 gt F1 F3 B Display of production data Counters GOAL Display of the following data number of tested containers number of rejects E number of rejects divided by test station percentages PROCEDURE Selection path lt F7 gt Press the Print Screen key to get a print out of the video page C Start of production batch GOAL Set the machine up to test a new production batch This corresponds to zero the counters and if necessary put in the name or the code of a new batch PROCEDURE To zero the counters press the following keys lt F7 gt F2 F1 lt F1 gt and when required confirm with lt Y gt Two lines with 80 alpha numeric characters each one are available to enter batch name batch number or comments by pressing the keys lt F7 gt lt F2 gt lt F1 gt and lt F5 gt INFO The Esc key deletes a
34. y the telecamera monitor and by an optional printer 4 1 ACCESS LEVELS Operational Functions are accessed via passwords The system has two access levels 1 Operator 2 Supervisor Two passwords are available for each level A two character field which is constantly displayed in the video screen heading shows the current level code The level codes which can be displayed are listed below no level is active therefore no operational function can be accessed Operator level is active under password No 1 Operator level is active under password No 2 Supervisor level is active under password No 1 Supervisor level is active under password No 2 When Operator Level is active access is restricted to the following operational functions 1 Start and Stop 2 Counter Reset 3 Active Product Selection When Supervisor Level is active access to operational functions is extended and includes 1 Access to Operator Level Functions 2 Inspection Parameter and Program Modification 3 Password Modification When the machine is switched on no level is active therefore no operational function is enabled By pressing keys F7 F6 F2 Fl the Login command is selected and the system requests the user to enter a password After a password is entered the user accesses the functions reserved to that password and the video screen heading displays the corresponding level code The user can select the Logout comm
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