Installation / Set-up of Autoread Camera System to DS1000/DS1200 Inserters

Installation / Set-up of Autoread Camera System to DS1000/DS1200 Inserters Written By: Colin Langridge Issue: Draft Date: 03 rd July 2008 1 Date: 29 th July 2008 Page 1 of 25

Installation Instructions The Autoread camera system is designed to replace the standard OMR section from a collate unit on the inserter. The instructions are intended as a general guide to help with initial setup and running the system. The detailed manual from Lake Image System (LIS) is included with the inserter documentation. There is a new supplement dedicated to OMR setup The above view shows the basic layout of the autoread camera system The camera system is set to a fixed height. The camera lens needs to be focused and the locking screws fitted prior to running the camera system Page 2 of 25

Autoread Camera fitted in the inserter. View showing 1 of the fixed LED light sources. Whole top assembly pivots as shown to allow for access to the OMR section if required View showing the Autoread camera in the inserter. The operator replaceable camera bracket is shown here as well as the disposable camera cables. (Swapping of the camera is required for some high-density 2D labels) Page 3 of 25

Cable Routing and Electrical Installation The Autoread input reader requires a separate dedicated PC to decode the image. This PC is located under a downstream feeder on the inserter. The PC is located in a secure enclosure to prevent tampering with the cables / connections. (A separate keyboard / mouse is attached to the PC to allow the camera to be installed) Once the camera system has been installed and setup by an engineer to work with the inserter, then there is no need to make any adjustments or change any settings. New jobs will need to be setup by a trained operator / engineer The camera PC boots directly to the camera application. The inserter selects the desired job, sets the trigger delay and moves the camera to the correct position for each job. The camera system utilises the standard OMR PCB (180-711). The camera has a separate interface PCB (180-775) that connects to J1 on the OMR PCB. All cables route back to the LIS PC through the collate unit. PC enclosure containing the LIS PC. (shown situated under a feeder.) All camera cables wire back to the rear of the LIS PC as shown The two short cables form the camera wire into the connectors as shown. These then wire back to the LIS PC through the collate unit. The Two short cables from the camera are designed to be replaceable (If required) Always ensure the power is OFF on the LIS PC before replacing the cables from the camera Page 4 of 25

The camera system has three fixed light sources. These LED light sources ensure that the entire FOV is well lit and the light is very uniform. The three light sources wire back to a distribution box situated in the bottom of the collate unit. A single cable then wires back to the LCU card in the LIS PC. Three light sources in position Light sources shown for the autoread camera system. Each light source contains 72 hipower white LED. These are triggered by the inserter and controlled (current & on time) by the LIS hardware Trigger from the hi-cap exit sensor. Ribbon cable picks up the signal and sends it to the camera PCB. This means the camera is triggered by the LE of the document, this gives an accurate and consistent trigger point. The trigger delay (made up from the fixed offset and the variable delay) is then applied using tacho pulses to ensure the camera system triggers at the correct point in time Page 5 of 25

Camera System Connections Explanation CAMERA PCB 180-775 Cable to LIS PC (182-662) Trigger in from the exit sensor on the hi-cap feeder Link cable between OMR PCB & Camera PCB (182-637) OMR PCB (180-711) Standard serial COMS cables to inserter control PCB Note no software trigger required for this setup. Link between OMR PCB and Collate module PCB NOT required. Switch on Camera PCB must be set to SENSOR Position Description 1 A B COMMS Port 6 Port 5 Not used Not used 2 C D COMMS Port 4 Port 3 Not used To inserter 3 E F SCM Links to Inserter Sensors cable 4 G H F/wire To camera Not used 5 LCU I To LED lights Page 6 of 25 J To camera cable 1

Camera cable 2 Camera cable 1 To light distribution box To Camera PCB Cable 182-638 Rear view showing all connections from the LIS PC Rear view of LIS camera PC. Showing all cables connected. LIS supplied camera cable Page 7 of 25

Hardware Installation of the Autoread Camera on the Inserter To use the Autoread head (camera) it needs to be selected in the hardware setup of the inserter application as shown below: Once the autoread camera is selected in the hardware then the COM port needs to be setup. Navigate to the external devices screen and select the desired COM port for the Autoread Head. The COM port number should be the same as the COM port number assigned to the USB to serial adaptor when it was installed. NOTE: Once selected in hardware and the external device port number is set it is recommended that he application is closed and re-started to ensure all the settings are initialised correctly. Page 8 of 25

Setting up Communication Ports The inserter communicates via its PC to the LIS PC. The port needs to be configured within the Inserter and Windows. Follow the provided instructions to install the hardware (USB to Serial Adaptor). To set up the USB to serial adaptor navigate to: Control Panel System Hardware Device Manager Ports (Com & LPT) right click for Properties. Please ensure that the settings for the comm. Port are as follows: COM port settings Baud Rate 57600 Parity EVEN Data Bits 8 Stop Bits 1 Flow Control NONE The COM port number defined within the inserter application can vary, just ensure that the settings are correct and that the com port number defined within the application is the same as the com port number assigned to that USB to serial adaptor The COM port number of the USB to serial adaptor can be changed to any unused port number if required. (Select advanced options and select an unused port number from the list) COM PORT NUMBERS SHOWN ARE FOR ILLUSTRATION ONLY The LIS PC always uses com. port 1 for communications with the inserter. Page 9 of 25

LIS Camera Monitor and Dual Display The LIS camera PC utilizes the inserters second display. This second display is used to display the camera application Multicam. The second monitor can also be used to display the inserters run screen. The second display is set to clone the inserter display. (This can be very useful if fitted to an inserter with a large number of units as the run screen can be seen from the far end of the inserter (also allows for the run screen to be seen from various viewing angles)) A manual switch box is used to swap between the two inputs on the second display. The switch box is mounted underneath the divert / collate unit on the prime station (directly next to the second display) The connections for the switch box are as follows 1 I/O goes to the 2 nd Monitor 2 B Goes to Inserter PC 3 A Goes to LIS PC Page 10 of 25

Rear view of the switch box Front view of the switch box Note. Always ensure that the switch box is set to the main inserter display when the inserter PC is powered on. Otherwise the second display may not be detected The video signal from the inserter PC is split so that it can be used on a dual display setup. This is achieved by using the following cable This cable plugs into the graphics card output and provides 2-off VGA outputs. This is used to send the signal to two analogue displays. All new inserters are fitted with this cable as standard. VGA splitter cable Simple Block Diagram showing the Dual display connections / cable routings MAIN INSERTER DISPLAY VGA SPLTTER CABLE INSERTER PC Mains Panel B SWITCH BOX A LIS CAMERA PC I/O Mains SECOND DISPLAY Page 11 of 25

Clone Display Instructions To display the inserter PC display (run screen) it is necessary to setup the second display and then set it to clone the main display. To do this following these instructions: Right click on the desktop and select Properties Navigate to the Settings tab and select the advanced. This will display the monitor setup screen. Select the Catalyst control center tab and run the application (the application may vary due to the manufacturer of the graphics display card fitted to the inserter PC but the basic principles are common) Select the BASIC option and select Next to proceed The following screen is then shown. Select Go and proceed to the next screen Page 12 of 25

The following screen is now supplied. This shows the monitors that are currently available. Only the main display is currently active Select the second display as shown. Then press Next to proceed The following screen is now displayed. Select the Clone option. This will copy the display from the main monitor onto the second display monitor. Press Next to proceed. Select YES when prompted to accept the changes Page 13 of 25

The following screen is now displayed. Select Finish to proceed. Both displays should now be able to show the inserter run screen. After completing all of the steps above. It may be necessary to select a different screen display resolution. Right click on the desktop select Properties. Then select the Settings tab. Select the desired display (1 or 2) the adjust the screen resolution as required (the inserter application is designed to be used on a display set to a resolution of 1024 x 768) select apply when finished Clone Display Warning For correct functionality on power up you must ensure that the switch box is set to B (inserter) to make sure the dual display works correctly and the display is cloned Picture showing the inserter run screen on the second display Page 14 of 25

Passwords and Access For all set up, the engineer must log in as an administrator. This gives full access to all the functions required to set the camera systems up. (The Administrator Password If not known can be obtained from AM5Support (AM5SUPPORT@PFE.CO.UK) Setting Correct Output Fonts This is set before the system leaves the factory. The output font required is Automailer. A carriage return and line feed follow each camera read. The advance settings determine what is sent by the camera to the inserter when a no read or a misread occurs, in both instances this should be?? Page 15 of 25

Engineer Initial Set Up The application Multicamsetup is used to setup the autoread camera. These settings are factory set and should only be adjusted by a trained engineer. The following screen dumps show the most important settings and can be used for future reference These are the settings for the SCM card in the LIS PC These are the settings for the high resolution camera. They setup the frame grabber output, the camera type/orientation. The conversion factor for pulses to mm is set to one, (this is unique for LIS camera units and different from other readers, which use 4 pulses/mm) the mode is encoder, the trigger polarity is rise and the trigger input line is set to one Page 16 of 25

Advanced settings for the camera are shown below. Format is the output font (this is explained in a previous section of the documentation) The output comms are the settings used to send the camera read data to the inserter. Format Automailer Port 3 Baud Rate 115200 Parity Even Data Bits 7 Stop Bits 1 Input comms settings Port 1 Baud Rate 57600 Parity None Data Bits 8 Stop Bits 1 The input comms are the settings used to communicate with the inserter PC. The LIS PC always uses com port 1. The Function LIS Remote Control defines the protocol for the communication between the inserter PC and the LIS PC Page 17 of 25

Multicam Run Screen Navigation Below is an example of a typical Multicam run screen. The Field of view (FOV) is shown in the top right hand corner. The region of interest (ROI) is shown by the blue box around the OMR marks. Start/Stop This turns the camera reading on/off for the mode that is running Ending current mode / Changing to a new mode Select End to stop the current mode. The inserter selects the new modes automatically. When the setup data (trigger delay etc) is sent to the LIS camera PC Serial data sent to the inserter The log table displays the data sent via the serial port to the inserter Display Window This shows the documents as they pass under the camera, the image updates each time there is a trigger. The display window (FOV) is a useful tool as it allows the operator to see the last read (Bad read action for a collate must be Stop in Collate ) this stops the error document as soon as possible and the display window will show the last/error doc. From this display you can see the OMR marks relative to the AOI and adjust the trigger delay if necessary or make adjustments to the AOI, if necessary to compensate for print movement Trigger Delay Adjustment This is used to move the OMR marks to the centre of the AOI. If the Paper travel is from right to left on the screen then increasing the trigger delay will move the OMR marks to the left and decreasing the trigger delay will move the OMR marks to the right. If no image is found get an engineer to check the correct offset is set for the feed unit and the conversion for pulses to mm is correct. Page 18 of 25

Diagnostics for an Engineer The application Step Counter Module (SCM) Diagnostic allows the engineer to test the camera set up to ensure the encoder, trigger and communications works correctly Serial Port This configures the serial communication between the serial card and the software. Default port is 5. Dual Input camera system also uses port serial port 6 for the second camera Outputs 1-8 This monitors the output from each trigger. (Normally output 1 for camera one and output 2 for camera two) Clear Errors This is used to reset any errors. Accuracy, Reverse and Comms are highlighted with green. This indicates no problems exist. If a fault does exist, the fault status color will change to red. See Manual for an example if required Check Errors Displays a message at the bottom of the screen and/or one of the green highlights changes to red. Count Counts the encoder pulses for each trigger output. Read Frequency Displays the number of pulses per 0.1 second. This is used to determine rpm s of the encoder. Read Outputs Activates all the trigger outputs Test Settings Turns the outputs ON Version Detects the SCM firmware version. Page 19 of 25

Operator Instructions for using OMR with an Autoread Camera The OMR marks need to be setup (functions defined to each mark) as per normal using the OMR setup screen in the inserter application. The camera system only sends the marks (ones and zeros) to the inserter. The decoding of the marks is performed by the inserter firmware. The OMR marks should always be programmed from the Gate mark onwards (i.e. the gate mark will always be in position one for any mark set. The mark direction field has no functionality (as the direction of the read (position of the Gate mark) is defined in the multicam application) The first mark position field is not required as the position of the OMR marks on the page are defined when setting up the document. The figures used are converted into the trigger delay (to ensure the OMR marks are in the centre of the FOV and in the ROI) The defined OMR mark set needs to be assigned to the document. The positional coordinates of the OMR marks are then defined. The X and Y values are used to determine the position of the OMR marks on the document. The dimensions are in mm and start from the datum point, which is always the top left hand corner of the document. For a vertical set of OMR marks: Value X is measured from the top left hand corner of the document across the page to the centre of an OMR mark. (This value is used to position the camera) The Y value is measured from the to top left hand corner of the document down the page to the middle OMR mark set (Example Total OMR marks is 9 so measure down the to the 5 th mark)(this value is used with the fixed offset to calculate the trigger delay) Similar principle is applied if the OMR mark set is horizontal. Page 20 of 25

Configuration Settings The Mark Reading mode is OMR Marks (CAMERA) It is recommended (at least for setup) that the Bad Read Groups action is set to stop in collate. This ensures that if an error occurs, the image displayed on the Multicam run screen is of the error document. This makes the process of determining why the error occurred possible (able to see if the ROI, the trigger and the printing are correct) The camera job name defined in the inserter config screen must be the same as the mode/job name defined in the Multicam application for the OMR mark set / document to be read. This allows the inserter to automatically select the correct camera mode/job for the job run. The Autoread Head camera num should always be 1 if only one camera is installed. Page 21 of 25

Operator Instructions for Multicam (LIS PC Application) The following instructions explain how to setup the LIS camera system (multicam) to read OMR. The existing documentation for setting up LIS cameras for input and output reading explain how to setup for barcode (2D) and OCR reading Please refer to the LIS supplied documentation for more information on setting up multicam to read OMR, Barcode (2D) and OCR This shows the main run screen of the multicam application To set up a new job/mode follow these instructions. Stop any active mode and select End. This will terminate the current job. Select new and name the job/mode as desired. Then from the run screen select Setup Then define a new area selecting the required tool (for Optical Mark Reading it is OMR). Once defined the area needs to be setup for the OMR marks. Page 22 of 25

Select modify and a new screen is displayed showing the settings for the selected area. Make sure a document is under the camera when completing this part of the setup. Either manually place a document under the camera in the reading section or use load to reader function. (To do this you must have completed the LIS setup as far as this point and gone back to the main run screen of multicam. So that the inserter can select the correct mode (This also means that the config of the inserter must be complete) the inserter will load a document from the feeder under the camera and position the camera based on the X co-ordinate programmed for the current document) The Read direction must be set first. This sets the position of the Gate mark in the OMR set. The direction is defined as the direction of travel. If East is selected then in the example shown the Gate is on the far left hand side and the marks travel towards the right (EAST) Next we calibrate the system. To achieve this at least two marks are required. (We recommend using at least 4 successive marks, although it is possible to use less marks and them not to be successive) Calibration Technique Using the mouse draw a narrow ROI over the marks. Then enter the number of marks displayed using 1 and 0. For our example it should be 1111. Then set the length to 4 and select Learn Pitch. This will calculate the mark pitch. Then set the length to the total number of marks (17 in our example) Delete the displayed marks (this is only used for learning the pitch) Select Live image and then select Read Mark (the read will be incorrect as the correct full size ROI has not been defined) Page 23 of 25

Again use the mouse to draw a ROI around all of the OMR marks (make sure this covers the entire mark set. The read will then become correct. The ROI can be bigger than the mark set to allow for print movement etc. but there are limits to its size in the FOV ROI in the FOV Setting final ROI based on the OMR marks size (approx 2-2.5 times bigger than the marks) It depends on the mark size and the mark thickness / density as the OMR read is based on a contrast between the marks and the background. If the ROI is too big compared to the size of the OMR marks then you will get partial (wrong) reads (see below) The system can cope with some of the OMR marks not being in the ROI as the example shows above Always select read marks before leaving the setup screen to ensure that the marks in the ROI can be statically read Page 24 of 25

How to Adjust the ROI and trigger position in a job run During a job run it may be necessary to adjust the ROI or the trigger delay due to print movement of the OMR marks Trigger delay here is incorrect for the particular print run (marks are in a different position on the page since the original job was setup) Adjust the trigger delay on the screen (units are in mm) Increasing the trigger delay will move the OMR marks to the right and decreasing the trigger delay will move the marks to the left. If modifications made to ROI or trigger delay during a run, then the job/mode may need to be manually started before running the inserter again (check the status is running and the box is green) Page 25 of 25 Trigger delay has been adjusted to move the OMR marks into the ROI. (Trigger delay was decreased so the image was captured earlier (moved the OMR marks to the left) If the trigger delay is altered in a job run the changes are not saved. Next time the job is run from scratch the trigger delay will be sent from the inserter to the camera (based on the coordinates programmed for the Y dimension in document setup) Print movement may occur in the X direction. This is corrected by stopping the job and going to setup. Then select modify. Use the mouse to drag the ROI to the desired location around the OMR marks. Select read marks to check the setting before exiting. (DO not select LIVE VIEW, as this will loose the image on the screen) Return to the RUN screen and start the job