OMRON ZFV Intelligent Sensor Practical Guide

2.4 Rules for Parallel Installation

Up to 5 amplifier units.

The image data is transmitted from the right unit to the left, and the TRIG signal is also transmitted from the right to the left.

Host Device: A unit that receives TRIG/TEACH signals and outputs comprehensive judgment results, usually the rightmost unit.

Client Device: Other units that do not receive external TRIG/TEACH.

Comprehensive judgment output (ALL mode): If any unit is NG, the total output is NG.

The new and old versions of amplifier units (distinguished by serial numbers) cannot be mixed (see page 94 for details).

Basic operations and mode switching

3.1 Three working modes

Mode switch position, mode purpose

MENU menu mode sets measurement conditions and executes teaching

ADJ adjustment mode adjustment judgment threshold

RUN mode performs actual measurements and outputs results

3.2 Two menu levels

STD menu (standard menu): Set the most basic measurement conditions.

EXP menu (expert menu): Detailed settings, including output conditions, communication environment, I/O monitoring, etc.

Switch through the menu selection switch at the top of the amplifier unit.

3.3 Key Functions

←/→: Move menu in MENU mode; Select the threshold type (upper/lower limit) in ADJ mode.

↑/↓: Change values or select parameters.

TEACH/VIEW: Teaching in MENU mode; Switch screen display in RUN/ADJ mode.

SET: Select/apply settings.

ESC: Return to the previous menu.

Teaching Practice

Teaching is the process of registering the image features of qualified products as reference templates. ZFV supports two teaching methods: button teaching and external signal teaching.

4.1 Selection of Teaching Types

Select from MENU mode → [ITEM] based on the detection content:

Testing content, teaching type, applicable scenarios

Pattern/Shape/PATTERN/SEARCH recognition of product direction, with or without markings (supports ± 45 ° tilt)

Pattern matching PATTERN/MATCH recognizes different objects (does not support tilting, but is more refined)

Brightness/scratches/dirt BRIGHT detects surface defects and indicator lights on/off

Area Area: Check for screws and missing materials

WIDTH width detection for lead spacing and label offset

Position POSITION detects label offset and edge position

Count COUNT, count the number of pins and cables

Character (whole string) CHARA 1 detects whether there is a print date

Character (missing) CHARA 2 detects missing single characters

4.2 Button Teaching Process

Mode switch → MENU, move the cursor to [TEACH] → SET.

Adjust the position of the workpiece so that the part to be inspected is within the frame.

Select [1. ITEM] → SET, choose the teaching type.

Press the TEACH key to perform teaching.

After successful teaching, switch to mode → ADJ and adjust the threshold.

Mode switch → RUN, start measuring.

Key point: After teaching, it is necessary to switch to ADJ mode to adjust the threshold, otherwise the judgment may be inaccurate.

4.3 External Signal Teaching

Shutdownary teaching for workpieces:

Set [SYS1] → [TEACH TYPE] to [STATIONARY].

External TEACH signal ON → ENABLE OFF → Input TRIG → ENABLE ON, confirm the status of the ERROR signal.

Moving teaching of workpieces:

Suitable for workpieces that cannot be stopped (such as assembly lines).

It is necessary to continuously input the TRIG signal 6 times, each time corresponding to a position of the workpiece.

TRIG interval should be at least 200ms (when installed side by side).

Threshold adjustment techniques

Adjust the threshold according to the measurement type in ADJ mode. The following are the key thresholds for each type:

5.1 PATTERN/SEARCH、MATCH、CHARA2

Correlation value: 0~100, set the lower limit of OK. The higher the value, the stricter the requirements.

5.2 BRIGHT

Average concentration value: 0~255, set the OK brightness range (upper and lower limits).

Concentration deviation value: 0~127, used for detecting scratches/dirt (large deviation indicates unevenness).

5.3 AREA

Area value: 0~999, set the percentage range of OK based on the teaching area of 100%.

5.4 WIDTH

Edge width: Set the OK range based on the teaching width of 100%.

Edge level: 0~100, set the threshold for determining the concentration change at the edge. Adjust this value when the measurement is unstable.

5.5 POSITION

Position: Display offset (in pixels), set OK range.

Edge level: Same as above.

5.6 COUNT

Quantity: Set the OK counting range (0~255).

Edge level: Same as above.

5.7 CHARA 1

Concentration distribution value: Set the OK lower limit based on a teaching concentration of 100%.

System environment settings

6.1 Balance between measurement speed and accuracy

MENU mode → [SYS1] → [IMAGE RATE]:

FINE: High precision, long measurement time.

NORMAL: Standard (default).

HIGH SPEED: High speed, rough image, reduced accuracy.

6.2 Measurement Timing

TRIG (Synchronous Measurement): The rising edge of the TRIG signal triggers one measurement.

Continuation: Repeated measurements during TRIG ON.

6.3 Output Condition Configuration (EXP Menu)

Menu Item Options Description

[ON STATUS] OK ON/NG ON conditions for output signal ON

[ONE SHOT] OFF/ON is a single pulse output

[OUT TIME] 0~255ms single pulse width

[ON DELAY] 0~255ms output ON delay

[OFF DELAY] 0~255ms output OFF delay