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Section 1

FEAT

URES

ZFV

User’s Manual

Section 1
Part Names and Functions

Part Names and Functions

The following describes the names and functions of parts on the Amplifier Unit and Sensor
Head.

■

Amplifier Unit

(1)

OUTPUT indicator

The Output indicator lits when the OUTPUT signal turns ON.

(2)

RUN indicator

The RUN indicator turns ON in the RUN mode.

(3)

Control keys

The Control Keys are for setting measurement conditions and other information.

Displays and Key Operations p.45

(4)

Menu selector switch

This switch selects the setup menu.

STD...Standard menu. Select this when setting the minimum required items for

measurement.

EXP...Expert menu. Select this item when making a more detailed setup.

(1) OUTPUT indicator

(2) RUN indicator

(3) Control keys

(9) I/O cable

(4) Menu selector switch

(8) Coupler

(6) LCD monitor

(5) Mode selector switch

(7) Sensor Head connector

Summary of Contents for ZFV Series

Page 1: ...Cat No Z207 E1 01 USER MANUAL Smart Sensors ZFV Series...

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Page 4: ...ction 3 Section 4 INTRODUCTION SECTION 1 SECTION 2 SECTION 3 SECTION 4 User s Manual Smart Sensors with Ultra high speed CCD Camera ZFV Series APPLICATION CONSIDERATIONS Please read first FEATURES INS...

Page 5: ...NFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED STORED INSTALLED AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION ABUSE MISUSE OR INAPPROPRIATE MODIFICATION OR REPAIR SUITABILITY FOR USE OMRON shall not...

Page 6: ...ations of the product may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult w...

Page 7: ...er Supply and Wiring The supply voltage must be within the rated range DC24V 10 Reverse connection of the power supply is not allowed Open collector outputs should not be short circuited Use the power...

Page 8: ...witching regulator make sure that the FG ter minal is grounded If surge currents are present in the power lines connect surge absorbers that suit the operating environment Before turning ON the power...

Page 9: ...may cause errors 5 Optical Axis and Detection Range The center of the guide light and detection range are for reference only The center of the optical axis sometimes differs according to each Sensor...

Page 10: ...number MENU Mode SYS1 BANKSET CLEAR Setting the bank switching method Select how to switch banks MENU Mode SYS1 BANKSET SWITCH Setting Description BANK 1 BANK 8 default value BANK 1 Selects the targe...

Page 11: ...d enclosed by brackets aa Visual Aids Indicates points that are important to ensure full product performance such as operational precautions and application procedures Indicates pages where related in...

Page 12: ...Smart sensor Features 14 Basic Configuration 16 Part Names and Functions 18 SECTION 2 INSTALLATION CONNECTION 21 About Installation and Connection 22 Amplifier Unit 23 Attaching the ferrite core 23 In...

Page 13: ...witching method 58 Setting the System Environment 59 Adjusting the measurement speed 59 Selecting the measurement timing 59 Selecting the teaching mode from an external device 59 Setting canceling the...

Page 14: ...TERN SEARCH MATCH 66 BRIGHT 67 AREA 68 WIDTH 69 POSITION 70 COUNT 71 CHARA CHARA 1 CHARA 2 72 SECTION 4 APPENDIX 77 Troubleshooting 78 Error Messages and Remedies 79 Q A 80 Run Mode Display Item List...

Page 15: ...12 Introduction ZFV User s Manual Introduction CONTENTS MEMO...

Page 16: ...Section 1 FEATURES 13 ZFV User s Manual Section 1 FEATURES ZFV Smart sensor Features 14 Basic Configuration 16 Part Names and Functions 18...

Page 17: ...tection and recognition of different objects which have up till now been performed visually to be executed fast and accurately 1 Compact Sensor Head The LED light emitting section and lens are built i...

Page 18: ...installed at a wide range of sites Specifications and External Dimensions p 83 Outstanding operate ease has been achieved by a 1 8 color LCD motor an industry first icon based menu and simple key layo...

Page 19: ...ow view type ZFV SR10 Wide view type ZFV SR50 Sensor Head Used for confirming images and menus performing measurement processing and outputting the result of processing Single function type ZFV A10 A1...

Page 20: ...figuration multiple Sensor heads are used to simultaneously inspect multiple locations on a workpiece When the TRIG signal is input from a single specified Amplifier Unit the connected Amplifier Unit...

Page 21: ...r turns ON in the RUN mode 3 Control keys The Control Keys are for setting measurement conditions and other information Displays and Key Operations p 45 4 Menu selector switch This switch selects the...

Page 22: ...asurement Output is performed only when the RUN mode is currently selected 6 LCD monitor The LCD monitor displays setup menus and images captured from the Sensor Head 7 Sensor Head connector This conn...

Page 23: ...fier Unit 4 Sensor Head mounting fixture This fixture is for mounting the Sensor Head This fixture can be mounted on all of the four mounting surfaces 5 Focus adjustment control This control is used f...

Page 24: ...ation and Connection 22 Amplifier Unit 23 Attaching the ferrite core 23 Installing the Amplifier Unit 23 Gang mounting 27 About the I O cable 31 Timing charts 34 Sensor Head 37 Attaching the ferrite c...

Page 25: ...of this manual and check the instal lation environment Checking the installation site Read Precautions for Correct Use at the beginning of this manual and check the installation site About the power...

Page 26: ...is turned OFF The Smart Sensor may break down if the Smart Sensor is connected or disconnected while the power is ON Attaching the ferrite core Attach the ferrite core provided with the Smart Sensor t...

Page 27: ...nto place Always hook the connector end of the Amplifier Unit on the DIN track first Hooking the I O cable end on the DIN track first may impair the mounting strength of the DIN track attachment Remov...

Page 28: ...the Amplifier Unit on a panel Panel Mount Adapters p 87 1 Push out the Amplifier Unit from the rear of the panel towards the front 2 Install the small Mount Adapters on the four holes on the Amplifier...

Page 29: ...Unit with Mount Adapters attached onto the panel from the front Take care not to pinch the I O cable 5 Hook the hooks of the mounting fixture onto the two holes of the smaller Mount Adapters and tigh...

Page 30: ...on the 35 mm DIN track Installation procedure 1 Install Amplifier Unit on the DIN track p 27 2 Open the connector cover on the Amplifier Unit Slide the cover to remove 3 Insert the Controller Link Uni...

Page 31: ...ctor on the Controller Link Unit 2 Slide the Controller Link Unit and remove from the connector on the Amplifier Unit 3 Install the cover on the coupler of the Amplifier Unit 4 Pull the hook on the I...

Page 32: ...87 1 Install the Amplifier Unit on the DIN track p 27 2 Push out the Amplifier Unit from the rear of the panel towards the front 3 Install the small Mount Adapters on the four holes on the Amplifier U...

Page 33: ...front 6 Hook the hooks of the mounting fixture onto the two holes of the smaller Mount Adapters and tighten the screws 7 Make sure that the Amplifier Units are firmly fixed on the panel Panel Mount Ad...

Page 34: ...ces Wiring them together or placing them in the same duct may cause induction resulting in malfunction or damage 2 GND The GND terminal is the 0V power supply terminal 3 OUTPUT control output This out...

Page 35: ...measurement modes synchronous measurement and continuous measurement Which mode of measurement is to be performed in is selected in the menu Selecting the measurement timing p 59 8 BANK1 bank switchin...

Page 36: ...2 Amplifier Unit 33 ZFV User s Manual PNP output type ZFV A15 A25 Brown Blue Black Orange Light blue Load Power supply 24VDC OUTPUT ENABLE ERROR GND 0V 24VDC Yellow Pink Gray Green TEACH TRIG BANK1 BA...

Page 37: ...nt Measurement is performed only once in synchronous with the change in TRIG signal state from OFF to ON and the result is output The minimum ON width of the TRIG signal is 1 ms The OUTPUT signal is h...

Page 38: ...t the workpiece to be taught is in the teaching area 4 Input the TRIG signal from the outside 5 The ENABLE signal turns ON after teaching is completed At this timing check the state of the ERROR signa...

Page 39: ...e seventh time onwards are ignored 5 The ENABLE signal turns ON after teaching is completed Check the state of the ERROR signal at this timing 6 When teaching has been completed successfully the ERROR...

Page 40: ...xture Attach the mounting fixture provided with the Smart Sensor to the side of the Sensor Head Installation procedure The mounting fixture can be installed on all of the four mounting surfaces 1 Alig...

Page 41: ...uide light Install so that the part to be inspected is inside the frame formed by the guide light Installation distance The following graphs show the relationship between detection range and setting d...

Page 42: ...of Sensor Head becomes 95mm About installation for reflective workpieces Install the Sensor Head at an angle to prevent mirror reflection light from being picked up by the sensor Detection range H mm...

Page 43: ...tment control is a multi turn variable resistor However the control stops turning at the upper or lower limit positions Do not exert unnecessary force to turn the control at the upper or lower limit p...

Page 44: ...easurement speed 59 Selecting the measurement timing 59 Selecting the teaching mode from an external device 59 Setting canceling the Eco mode 60 Initializing setup data 60 Checking the version 60 Chan...

Page 45: ...ching and register the judgement criteria Settings in an application extended connection Set the processing details for each Amplifier Units Applying Settings Performing Measurement Set how to output...

Page 46: ...itions Additional Functions Changing the display image Clearing all data Use multiple banks for changeover Change the details to display on the LCD monitor during measurement Initialize the Amplifier...

Page 47: ...Switch the menu according to your specific requirements To switch the menu use the menu selector switch Mode Description MENU mode This mode is for executing teaching or setting up the measurement con...

Page 48: ...ode Changes the display details type of measurement value UP key DOWN key The function of these keys differs according to the operating mode In MENU mode Moves between menus selects parameters and set...

Page 49: ...BINARY METHOD AVERAGE AVERAGE DEVIATION COPY CLEAR SWITCH KEY I O KEY IMAGE RATE FINE NORMAL HIGH SPEED NORMAL MEAS TYPE TRIG CONTINUE TRIG TEACH TYPE STATIONARY MOVING STATIONARY ECO MODE ON OFF ON...

Page 50: ...K WHITE WHITE COLOR DIRECTION BLACK WHITE WHITE COLOR DIRECTION NONE MODEL EDGE MODE MODEL COLOR BLACK BLACK WHITE DIRECTION SEARCH AREA NONE MODEL EDGE MODE 1LINE SHORT 1LINE NORMAL 1LINE LONG 2LINE...

Page 51: ...s the details set in teaching are used as the reference in judgment Teaching Flow There are two ways of executing teaching by key operation and by external signals The following shows a procedure for...

Page 52: ...NT p 51 Characters CHARA CHARA 1 CHARA 2 p 52 Item Description Example of Application PATTERN SEARCH Select this item to detect the presence of a workpiece This item supports workpieces tilted to an a...

Page 53: ...ition of differ ent kind of instruction sheet BRIGHT Select this item to detect brightness density or scratches dirt on plain workpieces Set the teaching area to the desired part of the workpiece to d...

Page 54: ...of the workpiece is detected and judgment is per formed by comparing those edge coordinates against refer ence coordinates Example Set so that there is one change in brightness in the detection area...

Page 55: ...ground Judgment is performed by comparing the changes in density brightness of a regis tered character string Omission of characters errors miss ing dots etc cannot be detected Detection of presence o...

Page 56: ...udged as OK Setting item Range Details of Adjustment Average density value 0 to 255 This is the range of the average density inside the teaching area Density deviation value 0 to 127 This is the range...

Page 57: ...t is unstable Adjustment of area value Binary image LEFT RIGHT keys Select upper limit lower limit UP DOWN keys Change values Contrast image Can be set on either image Switch to ADJ Mode Measured valu...

Page 58: ...etails of Adjustment Number 0 to 128 This is the number of times that counting is to be performed Adjustment of edge position Measured value Adjustment of edge level Amount of shift Amount of shift Ed...

Page 59: ...ring teaching is taken to be 100 Setting item Range Details of Adjustment Correlation value 0 to 100 This is the lower limit of the correlation value with the teaching model This value or above is jud...

Page 60: ...y display 33 ms 1 In the case of BRIGHT the display can be switched average density value density distribution value by the LEFT RIGHT keys In the case of AREA the display can be switched to binary im...

Page 61: ...s Clearing deletes the settings of the currently selected bank number MENU Mode SYS1 BANKSET CLEAR Setting the bank switching method Select how to switch banks MENU Mode SYS1 BANKSET SWITCH Setting De...

Page 62: ...ision image Note how ever that it takes longer to perform measurements NORMAL default value Standard HIGH SPEED Select this to perform high speed measurement Note however that images are rougher Setti...

Page 63: ...and system settings to their factory settings MENU Mode SYS2 ALL CLEAR Checking the version Displays the type of Sensor Head type of Amplifier Unit and version information of the software MENU Mode SY...

Page 64: ...PUT ON STATUS One shot output OUTPUT turns ON for only the preset output time from when the OUTPUT signal turns ON Synchronous measurement Continuous measurement Setting Description OK ON Turns the OU...

Page 65: ...ME Setting the ON delay time Set this item to delay the timing that the OUTPUT signal turns ON MENU Mode SYS2 OUTPUT ON DELAY Setting Description OFF default value One shot output is not performed ON...

Page 66: ...ang mounted Set to the all gang mounted Amplifier Units Setting Description 0 to 255 default value 0 Set the time ms to delay turning OFF of the OUTPUT signal MENU AMP1 AMP2 TRIG LINK I O HEAD NOTUSE...

Page 67: ...plifier Unit to which the TRIG signal is to be input LINK Synchronizes to the TRIG signal from the Amplifier Unit gang mounted on the right side Setting Description USE default value Select this for A...

Page 68: ...4 digit number Adjust the light intensity by the UP DOWN keys MENU Mode CUSTM LIGHT 1 Switch the light intensity by the UP DOWN keys When performing partial adjustment LEFT RIGHT keys Select the adju...

Page 69: ...nd increase detection accuracy Specify the top left and bottom right of the search area MENU Mode CUSTM SEARCH AREA Setting the rotation range of a workpiece This item is displayed only when SEARCH is...

Page 70: ...erage density value Whether or not an object is lighter or darker is detected by referring to the den sity during teaching DEVIATION Performs detection using sudden changes density deviation in densit...

Page 71: ...on level Set the level for converting 256 tone contrast image captured from Sensor Head to a binary image MENU Mode CUSTM BINARY Setting Description WHITE default value Select which part of the measur...

Page 72: ...edge to be detected MENU Mode CUSTM COLOR Selecting the edge detection direction Select the direction in which edges are searched MENU Mode CUSTM DIRECTION Setting Description WHITE default value A c...

Page 73: ...change for the edge to be detected MENU Mode CUSTM COLOR Selecting the edge detection direction Select the direction in which edges are searched MENU Mode CUSTM DIRECTION Setting Description WHITE de...

Page 74: ...nsity change for the edge to be detecte MENU Mode CUSTM COLOR Selecting the edge detection Select the direction in which edges are searched MENU Mode CUSTM DIRECTION Setting Description WHITE default...

Page 75: ...here are more characters than the number of reference characters in the selected item measurement accuracy drops Setting Description 1LINE SHORT Select this when the character string is 6 characters o...

Page 76: ...ering models Set this when MODEL is selected to MODE Specify the top left coordinate and bottom left coordinate of the model MENU Mode CUSTM MODE DTL MODEL Setting Description NONE The position is not...

Page 77: ...e detected MENU Mode CUSTM MODE DTL COLOR Selecting the edge detection direction Select the direction in which edges are searched MENU Mode CUSTM MODE DTL DIRECTION Setting Description WHITE A change...

Page 78: ...l in Specify the top left coordinate and bottom left coordinate of the area MENU Mode CUSTM MODE DTL SEARCH AREA When searching edges Measurement can be performed only when the search area contains an...

Page 79: ...76 Section 3 SETUP ZFV User s Manual Section 3 Customizing Measurement conditions MEMO...

Page 80: ...Section 4 APPENDIX 77 ZFV User s Manual Section 4 APPENDIX Troubleshooting 78 Error Messages and Remedies 79 Q A 80 Run Mode Display Item List 81 Specifications and External Dimensions 83 INDEX 89...

Page 81: ...ight is short ened So we recommend setting the Eco mode p 60 Images are not displayed Is the Sensor Head connector connected correctly Is the brightness of the LED light set to a dark value p 40 p 65...

Page 82: ...recognize Amplifier Unit Failed to load data from flash memory Faulty hardware operation Faulty software operation Faulty Amplifier Unit Contact your OMRON representative TEACHING FAILED The workpiec...

Page 83: ...ops p 59 Switch the screen display during measurement to Display only image The measurement time can be reduced proportionate to the reduction in display time p 57 Teaching is not going well What shou...

Page 84: ...x value JG Judgment result OK NG MCONT Measurement count 1 to 9999999 NG NG occurrence ratio NG count measurement count TH Judgment threshold value In the case of the upper lower limits XX YY lower li...

Page 85: ...splay Item List COUNT CHARA 1 Display Characters Meaning COUNT CNT Count Display Characters Meaning MES Area value value obtained by normalizing with area value during teaching taken as 100 DENAVE DAV...

Page 86: ...mensions Sensor Head ZFV SR10 SR50 33 6 30 6 36 30 6 36 4 20 32 4 5 4 5 67 9 17 9 5 6 32 12 8 dia 4 5 4 5 20 0 1 2 M4 34 17 9 Mounting fixture can be attached on each side 23 3 Mounting hole dimension...

Page 87: ...ielectric strength 1 000 VAC 50 60 Hz for 1 min Vibration resistance destruction 10 to 150 Hz 0 35 mm single amplitude 10 times each in X Y and Z directions for 8 min Shock resistance destruction 150...

Page 88: ...Section 4 Specifications and External Dimensions 85 ZFV User s Manual Amplifier Unit ZFV A 52 5 90 90 3 9 4 6 60 23 4 23 2 14 8 4 2 18 Heat resistant PVC shielded cable 5 2 mm dia standard length 2 m...

Page 89: ...Bank selection inputs BANK1 to BANK3 3 Workpiece still teaching TEACH or Workpiece moving teaching TEACH Switched by using menu Sensor Head interface Digital interface Image display Compact TFT 1 8 in...

Page 90: ...50 Hz 0 7 mm double amplitude 80 min each in X Y and Z directions Shock resistance destructive 300 m s2 3 times each in six directions up down left right forward backward Materials Polycarbonate PC et...

Page 91: ...no icing or condensation Ambient humidity Operating and storage 35 to 85 with no condensation Vibration resistance destructive 10 to 150 Hz 0 7 mm double amplitude 80 min each in X Y and Z directions...

Page 92: ...COLOR 68 70 71 74 COPY 58 Correlation value 53 56 Coupler 19 D Density deviation value 53 Density distribution value 56 Detection content 49 Brightness scratches dirt 49 Characters 49 Number 49 Patte...

Page 93: ...hronous measurement 61 Operating modes 44 OUTPUT 64 OUTPUT TIME 62 P Part Names and Functions 18 Amplifier Unit 18 Sensor Head 20 Position 55 Power supply 16 R ROTATION 66 Rotation range 66 RUN mode 4...

Page 94: ...tion 4 INDEX 91 ZFV User s Manual CHARA 1 56 CHARA 2 56 COUNT 55 MATCH 53 POSITION 55 SEARCH 53 WIDTH 54 Timing charts 34 Continuous measurement 34 Synchronous measurement 34 TRIG 64 V VERSION 60 Vers...

Page 95: ...ion History Revision History A manual revision code appears as a suffix to the catalog number at the bottom of the front and back covers of this manual Revision code Date Revised contents 01 August 20...

Page 96: ...ility or the results from the use of Goods in combination with any electrical or electronic components circuits system assemblies or any other materials or substances or environments Any advice recomm...

Page 97: ......

Page 98: ...ve Schaumburg IL 60173 847 843 7900 For US technical support or other inquiries 800 556 6766 OMRON CANADA INC 885 Milner Avenue Toronto Ontario M1B 5V8 416 286 6465 OMRON ON LINE Global http www omron...

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