Installation / Set-up LIS Camera Systems to DS1000/DS1200 Inserters Written By: Colin Langridge Issue: Draft Date: N/A 1 Date: N/A 2 Date: N/A 3 Date: 12 th September 2006 4 Date: 12 th July 2007 5 Date: 07 th November 2008 Page 1 of 27
1. Installation Instructions Depending on which units the cameras are to be fitted to the initial set up varies slightly. (Camera systems can be fitted to the input and / or the output of the DS inserter range) These instructions are intended as a general guide to help initial set up and running The detailed manual from Lake Image Systems (LIS) is included in the documentations directory on the inserter PC. The Approx offset is unit dependent: Hi-Cap Collate offset = 120 /110mm OMR Feeder offset = 45mm Folder OMR offset = 100 / 110mm Output reader = 175mm Set up above is shown for a hi-cap into a collate unit. The method is very similar for all other feed units; the difference is the orientation of the camera (top or bottom read) OMR feeder is always bottom read. For an output reader the full height of the adjusting bracket can be used to position the camera. The change in height can be used to give a greater or lesser field of view. After positioning the camera you will need to refocus the lens (focussing is only available on an output camera). All camera systems / cable routings are shown for illustration only. These are subject to change as the camera system evolves. Page 2 of 27
The type of bracket used to mount the camera to the DS inserter unit may vary depending on age of the system. However, the important dimensions do not change (50mm height from the camera to the paper for input reading cameras. This height has some tolerance and lens ring spacers can be fitted if required). Camera fitted to collate unit (left) and output unit (right). Shows the camera brackets and the connectors for the frame grabber and the LCU Light source for output reader is a separate unit fitted to the side frame of the output divert unit The above view shows the positioning of the camera system. For certain string/label positions a Horizontal barcode kit may need to be fitted to allow the camera to be positioned correctly. One Kit A3249A is included, others maybe ordered as required. Once the cameras are mounted in approximately the correct location fine adjustment can be made when the first form is loaded to the reader (the jobs need to be set up first) If the FOV required needs to be altered (enlarged (particularly true for output reading)) then spacers can be added / removed to the camera lenses, these will change the focal length. If these are fitted / removed then the camera will need to be re-focused. Only a trained engineer should carry out these changes. Page 3 of 27
2. Cable Routing and Electrical Installation The LIS input reader requires a separate dedicated PC to decode the images. 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, new jobs will need to be setup by a trained operator / engineer prior to running the customers jobs The camera PC boots directly to the camera application. The operator selects the desired job on the camera PC and ensures the camera is in the correct position. The inserter sets the trigger delay and the reading mode (OCR, Barcode etc) 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. (Same principle for any other feeder unit (See pictures below) (Output camera system is wired from unit 0 to the LIS PC) 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. Page 4 of 27
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 The ribbon cable from the Hi-capacity feeder supplies the exit sensor signal to the camera PCB. This signal is used for the trigger command used by the LIS camera system The ribbon cable plugs into J3 on the LIS camera PCB. This MUST be unplugged before removing the feeder Page 5 of 27
LIS PC PORTS DESCRIPTION Position Description 1 A Frame Links to LCU Grabber 1 2 B (Port 4) C (Port 3) COMMS Links to camera 2 Links to camera 3 3 D E SCM3 Links to sensors 3 Cable for camera 3 4 F G SCM2 Links to sensors 2 Cable for camera 2 5 H I SCM1 Links to sensors 1 Cable for camera 1 6 J K L M N Frame Grabber 2 Links to all SCM cards Port 3 Not Used 7 O P LCU Light source to Links to Frame each camera Grabber 1 (1A) Port 2 Links to camera 3 Port 1 Links to camera 2 Port 0 Links to camera 1 Page 6 of 27
Rear view of camera LIS PC showing the main connection ports. All ports and connectors are clearly labelled See table on previous page for description of the ports Ports subject to change depending on camera system installed The following images show how to wire the LIS PC for up to 3 cameras. LCU Light source to the camera Linking the LCU to the frame grabber This cable is used to link the SCM cards and the frame grabber to the DS inserter The inserters cabling links to the sensors out from the camera system cabling. (3 shown in this example as there are 3 cameras) Page 7 of 27
SCM cards linked to the frame grabber 3 sensor connectors (1 for each camera) Lighting cable Frame grabber cable Both cables wire directly to the rear of one of the cameras. This is repeated for each camera system fitted to the inserter Each camera fitted to the inserter is wired back to a SCM card and a COM port on the LIS PC This connector wires back to the inserters camera interface PCB This shows the wiring for camera 1. SCM 1 and COM port 1 are used Page 8 of 27
This shows the wiring for camera 2. SCM 2 and COM port 3 are used This shows the wiring for camera 3. SCM 3 and COM port 4 are used Cable 182-638 (1 per camera) Cable 182-638 (1 per camera) The connectors at the back of the camera PC are clearly labeled for any specific camera system. The connectors for each camera are:a) Camera lead Circular connector b) Light source Circular connector c) DS inserter cable (182-638) 15 Way D type (splits into 3 connectors) i) Serial 9 way D type to COM port ii) Trigger 15 way D type Sensors iii) Tacho 9 way D type to SCM card Each connector will be clearly labeled Page 9 of 27
The LIS PC is powered from the electrical panel in unit 0. This is where the inserter PC is powered. The electrical panel remains Live when the main power switch for the inserter is turned off. This allows for either PC to be used when the inserter is off. Inserter monitor powered from here LIS PC powered from here Inserter PC powered from here Mains IN to the electronics panel Electronics Panel on Unit zero of the inserter The camera PCB 180-775 and the OMR PCB 180-711 are mounted beneath the shingle feeder behind the rear track cover. The cables and PCB used are the same for any camera on any feeder. (The only difference is the fixed offset for the trigger delay) Trigger switch on 180-775 must be set to Hardware NOTE OMR feeders have to use the hardware trigger so the trigger cable must be fitted (black and orange cable from the OMR PCB to the Itrack module PCB 180-811. Page 10 of 27
3. LIS Camera Monitor and Dual Display The LIS camera PC utilizes the inserter s 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 one of the outputs from the dual VGA cable on the Inserter PC 3 A Goes to LIS PC VGA graphics port Page 11 of 27
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 12 of 27
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 13 of 27
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 14 of 27
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 15 of 27
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) The Engineer will also be responsible for setting up the other passwords for the other user levels to allow the customer/operators run the camera system. This is achieved by running the application Multicamsetup.exe and going to the users tab. Then follow the on screen instructions to define new users and assign passwords. Only the trained Engineer should use the administrator user login. (It is not necessary to set-up any logins to operate the system) 4. Engineer Initial Set Up The application Multicamsetup.exe sets up the camera system. These settings are factory set by NTL (Neopost Technologies Loughton). Below is a summary of the important settings The first screen shows the installed licenses and the registration numbers. The second screen sets the ports for the SCM cards: Port 5 for SCM1, Port 6 for SCM2, Port 9 for SCM3, Port 10 for SCM4. Port numbering for the SCM cards is subject to change. These are set by the camera manufacturer prior to delivery. The settings on the camera tab (see screen on the next page) set the frame grabber output number, the camera type/orientation as well as the SCM settings. These vary for each feed unit, as the offset is unique to each feeder unit. The conversion factor for pulses to mm is set to one, the mode is encoder, the trigger polarity is rise and the trigger input line is set for each camera. Page 16 of 27
(Camera could be referred to as HR-50)(Camera type may be different of each unit) Each camera is set up for a particular feed unit. If the camera image in the FOV is in the incorrect orientation then adjust the camera rotation until the image displayed in the desired Each serial port is set up to communicate with the inserter. The settings are the same for each output port: Format DS Port 3 (camera 1), 4 (camera 2), 7 (camera 3) 8 (camera 4) Baud rate 9600 Parity Even Data Bits 7 Stop Bits 1 Port number is dependent on what COM ports are fitted and available Page 17 of 27
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 C:\Program files\multicam Reader\SCM\SCM.exe Serial Port This configures the serial communication between the serial card and the software. Default port is 5. Outputs 1-8 This monitors the output from each trigger. (Normally output 1 for camera 1) 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. To test the SCM card is seeing the associated inserter unit, go to Engineer and start the Hybrid motor for the unit under test. Now switch to the camera system and select Read Frequency. The tacho frequency will appear at the bottom of the screen. This will be between 1,000 and 3,000 pulses per second. Page 18 of 27
Setting Correct Output Fonts This is set before the system leaves the factory. The output font required is DS. A line feed and a carriage return 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?? C:\Program files\multicam Reader\OutpFmtSetup.exe Page 19 of 27
6. Operator Instructions Setting Up Modes An individual mode will need to be set for each Run (e.g. one for 2D and one for OCR) it is possible to define multiply modes for various runs (a different mode depending on the documents being processed) OCR or 2D This allows a tool (OCR or 2D) to be assigned to a mode. This also allows access to the set up screens for OCR/2D. Set up of Fonts Area (region) of Interest: This is where the camera looks for an image. (White box in image) This can be dragged to the correct size/position. Font: A new font needs to be defined for each print type used on the document. (Direction is critical) Orientation: Depending on the document (print) and the feed direction the orientation needs to be set for each font(you must set the orientation before creating a new font) Auto Threshold: This sets the amount of light to allow the camera to distinguish between black (characters/blobs of the defined font) and white/grey (the paper) background. Adjust the threshold to the upper and lower limits to see the range that detects the correct number of blobs, then set to the mid point of this range. Check the final result by viewing the binary display. Than adjust the threshold if required (if the black area encroaches on the characters) Define a new font or select an existing one Live Image: Used to check the alignment of the string/label under the camera Binary Display: This displays the true black on white image based on the current threshold Page 20 of 27
Teaching Characters Each character has to be taught and stored in a database. So when the camera triggers a read, it can decode the image from the stored characters and produce an output. It is best to teach each character individually (or ensure the string that is being taught only contains one example of each character) this ensures the database is a manageable size and reduces the decode time. It is also recommended to use the Auto Learn function as this stores three images in the database for each character at varying threshold levels. (One low, one high and one at the set level) Fit to Database Once all the characters have been taught then using the fit to database command analyses the sizes of all the defined characters (blobs) and sets the max/min height and width, which means all blobs outside the size range in the AOI will be ignored by the camera. (This prevents marks on the page from causing bad reads) Advanced options: Format Read Allows the user to specify certain characters within the string as significant and ignore the others. The example shown ~yyyyyyyyyy uses the tilda symbol (~) this means only the last 10 characters are read. (This means there can be a variable number of characters before the significant ones) Another example: nnnnyy means only the 5 th & 6 th characters are significant. The asterisk symbol (*) specifies all characters in the AOI are significant. Using the format read ~yyyy and fitting the taught blobs to the database we get the following example: The last three characters (in green boxes) (020) have been read. The character 1 is just out side the AOI so is ignored. So the 4 th blob is now taken from part of the other label in the AOI, which is not recognised (red box). The other blob found is ignored (yellow box), as we are only interested in the last four blobs due to our format read settings. All other possible blobs from the other label are ignored as the blob sizes are outside the limits of the database. Page 21 of 27
Touching Characters If characters are too close together that the system sees them as 1 blob or not at all (due to size filtering) then enable Touching Characters set the value to one and the system will apply an algorithm to separated the two characters. (If the value is set too high then poorly printed characters will be separated into multiple blobs) Example before the Touching Character filter is applied. The 54 characters are not seen as they are too close together and the size filter has eliminated them Example of the Touching Characters filter applied. The characters 54 are now recognised as separate blobs and hence read correctly as they match the trained characters in the database Other options allow for improving the readability of the characters. Gap Filling. Poor quality print may have gaps in the printed characters. Enabling Gap filling allows for poorly printed characters to be converted to match characters already defined in the database Quality Threshold. Determines how close a Match the read character has to be to the characters in the database NOTE. Changing the above settings can cause false reading of characters. It is recommended not to change the default settings. Page 22 of 27
2D Data Matrix Live Image When the document is under the camera (use the AM5 load to reader function) activate live image to insure the label is in the centre of the AOI. (Dragging a box around the label with the mouse sets the AOI) Testing label read When the label is correctly positioned under the camera use this function to check the Label is read successfully. (If you can not get a successful read check the correct label type is selected and an AOI as been defined around the label) Setting Label Type Select Data Matrix from the list of label types. (Deselect all other types) Setting Direction Select the direction as any Advanced options Types and Format of 2D Data Matrix Select the correct format and type for the 2D label being processed. The above example shows the settings for the 2D label on the PFE test document (this is included in the documentation section of the latest AM5 upgrade) Note that this screen may change slightly with newer versions of software Page 23 of 27
7. Run Screen Controls The trigger delay (made up from the fixed offset and the variable delay) is applied using tacho pulses to ensure the camera system triggers at the correct point in time The operator can make fine adjustments to the trigger delay from the LIS PC run screen (this allows print movement to be catered for) Start/Stop This turns the camera reading on/off for the mode that is running Changing from One Camera to the Next To swap from camera one to camera 2 use the mouse to select the corresponding blue square. The red/green coloured circle in the bottom RHS of the camera selection button indicates if the last read on that particular camera was successful or not.(red means the read was a no read or misread) Ending current mode / Changing to a new mode Select End to stop the current mode (OCR) to select another defined mode (2D) just pick from the displayed list Serial data sent to DS Inserter The log table displays the data sent via the serial port to the inserter for the selected camera. Display Window This shows the documents as they pass under the camera the image updates each time there is a trigger. The display window 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 label/string relative to the AOI and adjust the trigger delay if necessary or make adjustments to the font database/format to eliminate false blobs if the printing is poor Trigger Delay Adjustment This is used to move the string/label 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 string to the left and decreasing the trigger delay will move the string 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 24 of 27
8. DS Inserter Hardware Setup to use a LIS Camera The LIS camera system can be fitted to different hardware configurations. Each unit that is going to have a camera system fitted to it requires the hardware settings to be set correctly Collator OMR Feeder Page 25 of 27
OMR Folder Output Camera Page 26 of 27
9. DS Inserter Configuration Set up to Run LIS Camera Systems The DS inserter needs to be configured to run a label document. The label is defined as before depending on the required Label Machine Control. The number of characters, the customer ID start/length, the data logging start/length and all other parameters are set up as for any label. When the defined label as been assigned to a document and the document selected to run in the configuration, the read type is always OC/2D/Barcode Label (Camera System) for the Lake Image Camera system. Set the rest of the configuration as required (including the reader number and bad read destination.) All items to be read by a camera system must have a label defined to them. This applies for documents and envelopes. Then select the defined job on the run screen and press clear and re-start. Using the mechanical VDU switch box change to the camera system run screen and check the correct mode is selected. Then press start. This sets the camera application running (waiting for a trigger from the inserter). (System will display running in a green dialog box) Also check that the required camera is selected (applies to systems where more than one camera is fitted) Now press go on the inserter remote, and the camera will trigger when requested and send the data to the inserter to process. Use VDU switch box to select the IMOS application or the LIS camera system programme. The trigger delay (made up from the fixed offset and the variable delay) is applied using tacho pulses to ensure the camera system triggers at the correct point in time The operator can make fine adjustments to the trigger delay from the LIS PC run screen (this allows print movement to be catered for) Page 27 of 27