PS/PSL-1500 Series Screw Sorting System

Operation Manual

Ver. 0 D \     

CHING CHAN OPTICAL TECHNOLOGY CO., LTD.

11016
Headquarter in Taiwan:
No.16, Lane 110, Chunghsiao St.,
Hunei District, Kaohsiung City,Taiwan 829
TEL+886-7-693-7937~8 FAX +886-7-693-3643
E-m
ail: sales@ccm3s.com
www.ccm3s.com

Table of Contents
1.

Introduction ------------------------------------------------------------------------- 1-5

1.1 Introduction of Camera and Charge Coupled Device (CCD)
1.2 Introduction of vision measuring terminology
1.3 Introduction of lens
1.4 Introduction of light sources
1.5 Introduction of accuracy of calculation
1.6 Introduction of control components

2.

Sorting software and sorting items----------------------------------------------- 6-16

2.1 Operating system
2.2 Code setting
2.3 Procedures for camera change over
2.4 Introduction of sorting items

3.

Mechine Setting -------------------------------------------------------------------- 17-65

3.1. About CCM Sorting System
3.2. Basic functions of the system
3.3. Mechanism Setting
3.4. Teaching work flow
3.5. Steps for Power switch on and off
3.6. Hopper operation
3.7. Vibratory feeder introduction/ selection/operation
3-8. Feed-in track
3.9. Guide of CCD Adjustment
3.10. Rotary Disc change over
3.11. Light source adjustment and Optical fiber amplifier
3.12. Adjust Plunger and strokes
3.13. Position sensor adjustment
3.14. Adjust reject mechanism
3.15. Adjust Laser Check Point
3.16. Cone Mirror Change-Over
3.17. Lift-up mechanism
3.18. Accepted/ Reject parts discharging mechanism
3.19. Hand wheel: function and operation
3.20 Machine parts description
3.21 A schematic diagram of PS 1500 Series sorting platform
3.22 Recess Depth Inspection and Rotary Socket
3.23 Inspection of wheel crack

4.

HMI Interface operation-----------------------------------------------------------66-69

4.1 Enter the page
4.2 Main page
4.3 Parameter setting
4.4 Error resume

4.5 Validity
5

Soriting items setup------------------------------------------------------------------70-98

5.1 Introduction of CCM sorting software
5.2 Software teaching steps

6.

Repair and Maintenance -------------------------------------------------------------- 99-102

6.1 Cleaning of computer
6.2 Cleaning and maintenance of sorting platform
6.3 Cleaning and maintenance of Electrical control box
6.4 Cleaning and maintenance of motor chamber

7. Troubleshooting -------------------------------------------------------------------------- 103-107

7.1 All three lights on the machine are on and flashing - reject abnormality
7.2 Red light is on and machine is stuck
7.3 Yellow light is on, and the machine is in shortage of feed.
7.4 CCD error or computer crash when software system executes an image capturing
action
7.5 Computer cannot be started up
7.6 Error in executing process or other error message or abnormal screen of software
system when software system is started
7.7 Machine omits strange noise during the machine running
7.8 Machine stops running suddenly without any action of signal light or only with a flash
of yellow light
7.9 Incorrect counting: less count, more (even much more) count
7.10 Light source flashes twice for one test object
7.11 Red light flashes for no reason, or inspection result is not correct, or light source
flashes at an instable frequency (Light source flashes only once for several inspected
objects)
7.12 Reject cylinder cannot be restored when air pressure is released after a reject failure
7.13 How could we adjust to get the image clear on screen?
7.14 Why I cant check head dimension from side view.
8.

Parts Maintenance Checklist-------------------------------------------------------108-112

9.

Maintenance and Replacement Schedule ----------------------------------------113-128

Chapter OneIntroduction
1. Introduction of Camera and Charge Coupled Device (CCD)
The term camera in genera l is f amiliar for people. T raditional optical camera disp lays the
images by the way of film sensitization, and in ve rsus, digital camera stops using film s by applying
sensitized components, either CCD (Charge
Coupled Device) or CMOS (Com
plementary
Metal-Oxide Semiconductor).
CCD and CMOS are with different structure. Due to structural reason, CMOS images easily appear
with noise, and it gets overheat by frequent application. Though CMOS is cheaper, CCD becomes the
mainstream due to the requirement of high precision and rapid image processing. CCM Vision sorting
machines are equipped with CCD.
.
CCD is the f ilm of a digital cam era. A digital cam era with 12m ega pixel represents its CCD is
consisted with 12m ega pixel. The arrangem ent of CCD is generally rectangular. W ithin same size
range, the more the pixels are, the clearer the image appears.

Following items will be considered while purchasing digital camera

1. The chip size: influences CCD display area, usually sizes are 1/2 inch, 1/3 inch, 2/3 inch. The
bigger the chip size is, the finer the images will appear.
2. Resolution: A sensor chip size long by wide, for example: 720 * 480.
3. The images range (Field of view, or FOV): the scope of images taken.
4. shutter speed: time length for image capture; such as 1/500 sec stands for an image to be taken at
1/500 sec.

2. Introduction of vision measuring terminology

Pixel: Every CCD stands for one pixel in image processing.
The color of the image differentiate each other by value of 0 to 255, a value of 0 represents black, the
value of 255 represents white, other colors have their own values instead. Corresponding to
black-and-white cameras, if the value of 0 ~ 255 represents the different degree of gray, the images
are called grayscale images. Binarization is to select a figure between 0 to 255, smaller than the
selected figure represents black, larger than this figure are all white, so you can easily convert
grayscale image to black and white one.

Exposure (shutter) Shutter: the shutter opening time. To shoot a moving object, the shorter the
shutter opening time, the clearer the image will become. Longer opening time of shutter will blur the
image

Contrast : adjust contrast without changing the shutter opening time, and the image can be bright or
dim. However, if the contrast adjustment is too huge, it will cause snowflake-like noise.
Brightness: to adjust the brightness of the images. Adjusting range is smaller than Contract, and no
snowflake-like noise occurs.
Grayscale level: very CCD value of 0~255 represents one color. This value is so called grayscale
level.

Focal length: within a certain distance, Camera through the lens makes an object clear image, this
distance (Y) is called the focus, the distance of the lens and CCD (y) is the focal length.

Depth of field: Through the Lens, the camera can only take one focal length, which means that only
one object can have clear image. If two objects exist in an image, due to different
object-locations with different focal length, there will be an object clear and the other object
vague, this is the result of the depth of field. The easiest way to increase the depth of field is to
adjust the lens aperture to be smaller, the backlight to be brighter. By doing this, the depth of
field will be increased, and two objects with different focal length can be clear in the same
camera.

Angle of Elevation: The angle above horizontal that a camera must look to see an object that is higher
than the camera. When camera focuses the edge of the object, you also see the side of the object.
Image size: the size of photos varies from the camera pixel amount. For example, pictures/images are
300,000-pixel, the camera are with 640 X 480 pixel points.
Pixel size: represents the actual distance represented by one pixel (pixel) while calculating accuracy
(mm)
Actual size: represents the sizes physically measured by measuring tools.
Teaching: means the process of editing the measured images taken from a test object.
Calibration: the process of calculating the size of measured pixel
Baseline: is the based line for measurement
AOI: Automated Optical Inspection, referred to as the AOI, high-speed high-precision optical
inspection system, which applies vision as the detection Standard, to improve the shortcomings of
traditional inspection system of human checking by applying optical instruments. The AOI is
3

applicable for wide ranges of area, such as for R&D of the high-tech industries, the field of
manufacturing quality control, as well as national defense and people's livelihood, health care,
environmental protection, electricity ... etc
Diffraction: Diffraction refers to light waves passing by the edges of opaque bodies or pores or
through slots, causing fringes of light and dark bands.
3. Introduction of lens
The function of the lens is to make the camera shoot objects clearly. Generally speaking, a lens is with
a focal length and aperture for possible adjustments. The actual adjustment range of the lens varies
from brands to brands with some slight differences. The focal length adjustment is used to make
image clear, and aperture adjustment is used to make the image darker or brighter

To choose appropriate lens is based upon the working distance, focal length, and aperture, in order to
take clear images.
4Light sources
Light source plays a very important role in image acquisition, light hits on the surface of the object
and creates reflection or refracted into the eyes, so we can clearly see every objects. The sunlight is
the most natural light. Without light, human are incapable to see any objects.
Light source will directly affect the accuracy of the measurement. In general, there are 2 types of light
source application ways:
Front light: front light places between camera and object, which enables the camera clearly capture
the object surface.

There are many types of front lights for varies of applications, including ring light, coaxial light, bar
light, hemispherical light .. etc

Backlight: The object is between the camera and light source. With the backlight, the camera can
clearly capture the outline of objects

The application of backlight is simpler. Only 2 different types: diffusion backlight and parallel
backlight
5Accuracy calculation
This section is to explain how to apply images to size measurement. For example, a camera with 0.3
mega pixel, image size is 640 X 480 pixels, to shoot a 5mm diameter object. We assume the diameter
of object is 200 pixels in the image, then pixel size will be 0.025mm
i.e pixel size = actual size pixel = 5mm 200 = 0.025mm

Pixel size can be obtained 0.025mm. The tolerance of camera is 1 pixel, so the measuring
accuracy of the object is 0.025mm. With this theory, an object with actual size of 5mm,
detected through the detection software will be between 4.975 ~ 5.025mm. This calculation will
be completed by the software automatically.

6Control components
The control components of CCM superb image screening machine are composed with the Advantech
industrial dual-core computer, and PLC controller (Fatek for rotary disc type, Mitsubishi for glass-dial
and conveyor type), Delta industrial grade inverter, Japan YASKAWA servo motor control system

Chapter Two
Sorting Software/ Sorting items
1. Operating System
Window XP / XPE equipped with CCM in-house developed sorting software

2. Code setting
Every computer requires a password to enter the system, and all new computers can only be
operated by CCM default setting.

3. Procedures for camera change over

MCD flowchart ( machine equipped with Three cameras)
Step 1: Location route
Enter C:\CCM Sorter\MCD\MCD

Step 2 : Enter the screen

Enter MCD opening screen

Step 3 : Open the file

Open the MCD file of Machine Data. mcd

Step 4 : The types of cameras

Choose the CCD type: AVTBaslerIMIuEye

Step5 : Choose machine model

Choose one of the models: Glass dial, Conveyor, or Rotary disc

Step 6:

7.1.

Parameter Setting

1.
2.
3.
4.
5.
6.

Click on the camera

MCD shows the serial No. of the camera
According to the position of the camera to move up or down
The width is 640, the height is 480, and bandwidth 3000
Signal types: 3
Positioning setting A: rotary disc types
6.1.CCD1setting 4
6.2.CCD2setting 1
6.3.CCD3setting 1
remarkglass dial types(PSG)conveyor types(PSC) requires no MCD setting
7. Position setting B: Rotary disc types
head inspection: CCD setting 1
7.2. tail inspection: CCDsetting 2
remarkglass dial types(PSG)conveyor types(PSC) requires no MCD setting

Where you can find the CCD S/N

Identify CCD by the S/N of the CCD, and move up and down while setting MCD

10

Step 7 : File saving

Press the Save button to cover the original file to complete the setting, and then
open the sorting software

11

4. Sorting Items

Multi-Width
Multi-Height

Angle

Ex-, in-,chamfer dia

12

Zinc

Roundness

Concentricity

Recess Depth

13

Surface

AF / AC

Surface Feature

Wheel Crack

14

Side feature

Recess Depth

15

Oval inner- /outer perimeter

Mark / Slot / Rotating mark

Rim thickness
Nuts thread presence / Pitch distance
patch presence on thread
All dimension
Nuts 360degree thread damage checking
Customized functions

16

Chapter ThreeMachine Setting

3.1. About CCM Sorting System
3.1.1 General:
This optical sorting system is designed with high resolution camera to capture the images of an
inspected object for automatic inspection at low cost and high efficiency by comparing the
relationship between images and dimensions on industrial computer with the software system
developed by our R&D team. The application of system will reduce not only labor-consuming manual
operations, but also the errors of manual detection to improve greatly the products quality and
competitiveness of our company.
Quality monitoring of on-line products during production becomes practical if this system is
applied in the process of production control, which can not only reduce the waste of materials, but also
have a more effective control on the timing. As a result, the screw manufacture industry and the
related hardware accessories industry will be benefitted greatly from the system in reduction of
resources consumption, either labor or materials, tangible or intangible. In brief, this system is a great
tool for screw sector to reduce production cost, improve productivity and enhance their
competitiveness.
3.1.2 Software system:
The software system is an effective optical screws inspection system that provides a high speed,
high precision and high stability and user-friendly interface. The screw dimensions can be measured at
a best accuracy to below 1 pixel under normal lighting condition in the way of sub-pixel image
processing with special and simple calibration. <PS has a same user interface as PSL>
This system can inspect screws in head diameter, head recess depth, concentricity, washer
diameter and thickness, outer diameter, inner diameter, pitch, thread angle and length etc.
3.1.3 Hardware equipment:
As a safe, convenient, and labor and cost efficient automatic equipment, the optical screw sorter
is comprised of a feeding system (optional), a vibratory feeder, a feeding track, an inspection platform,
a computer system, and a conveyor system (optional) as follow,
Feeding system: optional for customers to select as proper for their inspection environment.

17

 Vibratory feeder: self-manufactured for screw only, commonly model PS 1500 attaches with
KS 520, and PSL - 1500 with KS 620. Optional models are available as required by customers
to meet their product specifications.

Inspection platform: main part of the system, equipped with high-speed industrial camera,
HD-lens from Japan, transistor PLC, solenoid valve from Japan, BIMBA cylinder from the USA,
DEX cam splitter and advanced industrial motor etc.
Computer system: industrial computer installed with authentic version of operating system, 17-in
LCD, ICP DAS data treatment interface card, and an optical screw sorting program system
developed by our company.
Automatic conveyor system: optional equipments; can be operated with the system for automatic
carton feeding, carton packing and carton discharge after sorting, with count function to prevent
error in packing.

Above are our standard provisions, and other customized demands are accepted.
3.1.4 Inspection speed:
PS - 1500 series,
Normal speed (stage 1): 600 pcs/min max;
Reject speed (stage 2): 400 pcs/min max.
PSL - 1500 series,
Normal speed (stage 1): 400 pcs/min max;
Reject speed (stage 2): 300 pcs/min max.
3.1.5 Applicable specifications
PS 1500 series,
Length 5.0 ~ 80.0 mm
Wire diameter 3.0 ~ 8.0 mm
Head diameter 5mm~ 15 mm
PSL 1500 series,
Length 15.0 ~ 115.0 mm
Wire diameter 8.0 ~ 16.0 mm
Head diameter 10~ 25.0 mm
Inspection range: within the set range.
18

3.2. Basic functions of the system

3.2.1 Head height, head diameter, washer thickness and washer diameter
Image of screw head is captured by the software system, and it pixels are converted into
dimensions of length for sorting through calculation of mathematical formulas, therefore the sorting
quality depends on the definition and size of image.

3.2.2 Outer diameter, inner diameter, pitch and thread angle

Image of screw pointed end is captured by the software system, and its pixels are converted into
dimensions of length for sorting through calculation of mathematical formulas, as the function in 2.1,
the sorting quality depends on the definition and size of the images. Thread angle is determined by
measuring the angle formed between the line across a pair of crests and the horizontal line.

3.2.3 Crest shape and broken crest

Make sorting by comparing the images. Compare all the screws with sample for their crest
shapes to determine their quality based on the similarity of the images by percent, therefore, besides
the definition and size of images, the choice of sample also has an impact on the sorting results.

19

3.2.4 Length
There are usually two ways to measure the length, one with and the other without screw head.
Generally, as the inspection point in either ways is positioned in the two images, pay special attention
to the definition of the images in setting. Also notice the matter of visual angle, which exists in any
non-tapered screw. In the case that length measurement as a critical inspection point, the camera shall
be placed at a height as the level of screw end.

3.2.5 Shank diameter and length of threaded section of the shank

The profile of the part to be inspected is captured by camera, and the shank diameter is measured
with the function of Shank Width, while the length of threaded section of shank is measured with the
function of Bottom Length for sorting. In applying the function of Bottom Length, make sure there is
explicit plane at the place to be defined for the sorting program to make determination.

3.2.6 Inspection of in-hole thread

One way to inspect if there is any thread in a hole is to apply a pin as adequate, those with
threads are considered as good parts if the pin cannot be inserted into the hole with its entire length
(and can if there is no thread in the hole); another way to make such inspection is to carry out a test of
optical fiber on the fixed base of the lighting source for camera 3, which can be done directly with the
programmable controller and sensor without going through the software system.

20

3.2.7 Pin depth inspection

Apply a presser mechanism to insert the pin as adequate into the hole of screw head to make the
test of broken pin in simulation of artificial measurement by depth gauge. For good parts, the pin will
be inserted into the hole with its entire length, otherwise, it can not be inserted into the hole with its all
length.

3.2.8 Application of head socket

In association of the adequate socket and presser mechanism, the function of Head Height and
Head Shape can be used to sort out the screws with head dislocation, head deformation, steel button
deformation and with or without steel button.

3.2.9 Quality of thread (If there is any sloped thread or lack of thread)
Capture the image on the part of thread to be sorted, compare the images and determine the
thread quality based on the similarity of images by percent. The Two Threads Mode shall be selected
in setting, further more, it is favorable that the sample has more intact and fuller. The sorting can also
be made in association with the thread angle.

21

3.2.10 Trailed, twisted and slotted ends

Use presser mechanism to rotate the screw 180 around its own axis in front of the camera,
capture the motion pictures during the rotation of screw, then observe the physical shape and size of
screw from several angles to find out the difference between the good parts and the bad parts for
sorting. This function can be used to inspect the defects such as trailed, twisted and slotted ends.

3.2.11 Ineffective thread length (Unthreaded length or not threaded sufficiently)

Support the screw from its end so that the first thread under the head is not covered by index
plate, then check if there is any deficiency of outer diameter or lower position in the first thread by
defining the horizontal dimensions in this area.

3.2.12 Head-crack
Use the drawing unit in the program function library to process the images captured from the
outer edge of the head to obtain the different pictures between good parts and bad parts, then convert
the pixels of the obtained images into the dimension of area for sorting.

22

3.2.13 Displacement and eccentricity of head hole

The sorting program calculates as defined the central point of outer edge of head and the central
point of head hole, then calculate the distance between the two central points, the obtained distance is
the size of displacement; a product is determined as bad part when the size of displacement is larger
than or equal to the specified tolerance.

3.2.14 Head diameter, roundness

Use the central point of the outer edge of head as the circle center to split the head image by
equal angle degree, and measure the length of 12 diameters of the head to determine the deformation
of head. If the difference between the longest diameter and the shortest diameter is larger than the
specified tolerance of head roundness, the product is determined as defective. In defining the
inspection, a significant difference is that the longest diameter of sample head shall be entered into the
program to have a precise measurement of head diameter.

23

3.3Mechanism Setting
As this system captures images by high resolution camera for precise measurement, user should
do routine cleaning in the operating area prior to setting for new object to be inspected to avoid
unanticipated error. The cleaning areas involve the route that the object to be inspected may go
through (storage system, aligning system, inspection platform, reject system), imaging system
(camera, lenses), and even the surrounding areas. Set up step by step as follow after cleaning:
3.3.1 Main Platform

Inspection platform

Vibratory feeder

Computer

AVibratory feeder
Ching Chan manufactures vibratory feeders in-house, such as KS-520 to compliance with PS
1500 machine. Customers can choose accessories according to their own demand meeting their
products requirement

Fiber amplifier

Controller

24

BInspection platform
Main platform of this sorting system, equipped with BASLER professional high pixel CCDhigh
resolution lensPLCJapanese PISCO solenoid valveBIMBA cylinderDEX Cam Index
Industrial motor.etc.

CComputer system
Advantech industrial computer, Microsoft Windows XP professional working system19
(or17 ) monitor1394 card, ICP DAS data processing interfaceCCM programmed sorting software

25

3.4Teaching work flow

Step 1. Identify the sorting objects, sorting specification, actual measuring sizes

Step 2. Verify sorting items, and choose suitable machine model based upon actual samples
Step 3: choose suitable light sourcestart to take object images from actual samples for teaching
Step 4: Human Machine Interface
Positioning settingspeed adjustment
Step 5. Marking on NG samples for visual identification
Step 6. Static test to make sure the teaching for NG as well as for Good parts are correct.
Step 7. Running test to see if good rate is acceptable or not.
Throw the NG parts into the feeder to check if they shall be kicked out

26

3.5Steps for Power switch on and off

3-5-1 Switch on the power on the big HMI

3-5-2

Press the pointed black button to turn on the computer

3-5-3 Switch off: On the left corner on bottom on the XP screen, execute Start(S), Shutdown(U), and Shutdown(U),
then switch off the big HMI, then the system is switched off completely

27

3.6Hopper operation
3-6-1. If the feeder has plenty of parts inside, the end of swing pole will be taken away from vertical
position and incline an angle. In this situation, the light will be off.
If less parts are inside the feeder, the swing pole will swing back naturally and will be more likely a
vertical orientation. In this situation, the light will be on and send a signal to hopper to feed parts.
hopper

Swing pole

motor

Led OFF

Led On

SWING POLE
SWING POLE

(Fig1)

(Fig 2)

28

3-6-2. How to adjust the vibration amplitude of the hopper motor

symmetric adjustment on both sides is required.

Step 1

Firstly remove the four screws on both sides to take off the lid

Step 2 Loosen the column block screws to adjust the position, the vibration amplitude is divided into
three scales
1.low amplitude scale

2. medium scale

3. big scale

29

3-6-3.
Full feeding time on feeding controller (PS-888): stands for the time length of power for hopper motor .The
longer the time length is set, the more parts will be fed into feeder.
Material Empty time: stands for the sensing time length of the sensor on the swing pole. The longer the sensing
time is set, the longer feeding interval will be

Full feeding time: the bigger the figure is, the longer the
Delay time will be.
Material empty time: the bigger the figure is, the longer the
Delay time will be.

3.7Vibratory feeder introduction/ selection/operation

feeder

amplifier

Controller for feeder

30

3-7-1 feeder adjustment

Flow regulation

Adjustable width

Adjustable width
Adjustable width
Adjustable

Adjustable width

look down, left to right side, tracks get wider

Optimal adjustment position

31

3-7-2 feeder controller: to adjust the speed, Full time, empty time
Speed: the bigger the figure is, the faster the speed will be
Full: the bigger the figure is, the longer it will keep feeding.
If the time is set too long, itll cause screws jammed in feed-in track.
If the time is set too short, it might cause constantly machine stop, due to no-feed-in.
Empty: the bigger the figure is, the longer it delays before start to feed.
If the time is set too long, it might cause constantly machine stop, due to no-feed-in.
This switch on: Feeder stops
automatically when no parts
in the feeder.

3-7-3 Tips on adjusting vibratory feeder and Hopper

1. Control the quantity of screws in feeder to prevent any clashing damage of screws. The quantity
of screws in the feeder can be adjusted by the swing pole and the feeding controller;
2. If the quantity of screws in feeder is less, the swing pole will be more like in vertical oriented; if
the quantity of screws in the feeder is full, the swing pole will be more inclined.
3. The longer the full feeding time on feeding controller of hopper, the longer the feeding time.
The longer the material empty time on feeding controller of hopper, the longer the interval of
no-feeding time.
4. The gap of feeding track on the vibratory feeder shall be adjusted gradually from the vertical
height to the horizontal width, the gap shall be from narrow to wide to prevent jam of longer
screws; the gap shall not be wider than the head.
5. The smooth movement of screws and the maximum flow may be facilitated by regulating the
flow with the flow control plate, it is recommended not to increase the flow only by regulating
the speed (or even to a too high speed) on the feeding controller, which results in screws
jittering in place rather than moving forward.

Flow control plate

32

3-7-4 Optical fiber amplifier on vibratory feeder

the green LED light is on in normal condition
No parts, Orange light is off
feeder running

with parts: orange light is on

feeder no running

Fiber amplifier setting

Fiber sensitivity control

Position: both down

Signal light
Power light

Intensity knob

Signal knob
Light Shield ON
Loaded ON

Red light signal,

(Signal Yes)

delay time needed

Light Shield OFF

Red light signal, no

Loaded OFF

delay time needed

(Signal No)

33

3-8. Feed-in track

Feed-in track is to guide screws to the bore holes of rotary disc. While adjusting, make sure the
feed-in track align with the bore holes, if not, adjust the track to left or right, and make sure the screws
can enter the bore holes smoothly, if not, adjust the track forward or backward, or adjust its height or
angle of elevation.
The track end can be a bit higher (do not lower) than the Rotary disc to let the screws move smoothly
to the bore holes of rotary disc. However, too high will cause the jam of screws; the gap between the
track and rotary disc should be as small as possible only if they dont get into contact. To finish the
adjustment, adjust the fixing block and feeding-in auxiliary board to a position as proper before
fastening the screws.
Height adjusting screw

Feeding track height board

Small knob

Big knob

Left-right adjusting
Back-forth

Step 1: Loosen the Feeding track height board for track width adjustment

34

Step 2: Loosen the large knobs and nuts to adjust the track width.

Restore the Feeding track height board and loosely fasten it to an extent that the gap height can
be adjusted easily with the height adjusting screw. In adjusting the height, make sure the screws
can go smoothly through the track and fall down on rotary disc. It is recommended to keep the
inlet higher than the outlet, and finally fasten the small star knob and nut (As shown in the figure
below) (Generally, the upper track is wider than the lower track).

Small knob

Height adjusting
screw

35

Step 3: Loosen the fixing block and screw feeding-in auxiliary board
Feed-in fixing block
Feed-in auxiliary board

Rotary Disc

Step 4: back-forth, left-right adjustment

Left-right adjustment( 4 screws)

Back-forth adjustment( 4 screws)

Align the right track firstly to the holes on the

right side, and tighten after adjustment
Feed-in track adjustment, and tighten after adjustment.
(before)

(After)

36

Step: 5 Aligned the track and disc to allow the screws smoothly feed into the disc borehole
Test if screws stuck. Feed-in fixing block and
screw feed-in auxiliary board should be affixed to
the track and tightened.

Step 6: put down the exit plate over the screw head. The height should be slightly higher than the head,
and causes no jam.
Exit plate for screw height

37

3.9 Guide of CCD Adjustment

The Base of CCD allows adjusting vertically and horizontally. CCD position is decided by the
size of images.

Up/down
adjustment

Front/back
adjustment

Tips: How to adjust the CCD Image:

Adjust the aperture roughly to get a blur image. Then adjust the focus to get a clear and sharp image. If
the image is not satisfying, we can add or reduce the extension rings between the lens and camera. As
well, adjust the CCD position to get a bigger and clearer image. Please note that an aperture with a big
value will cause over exposure and distortion, which is called diffraction phenomenon.
We can also adjust the CCD as well as the light-house control box, to get the best images. Clear and
sharp images are beneficial to the stability of sorting work; while large images are beneficial to reduce
error.
a. Too dark

d. Rightwards

b. Too bright

c. Fuzzy image

e. Best Image

Light-house control box ; to adjust light magnitude.

38

3.10 Rotary Disc change over

Step 1: clear off the space over the rotary disc.
Before

Remove the light source

Push back the NG parts

pull-mechanism

Move the exit plate to

lower position

Move the Accepted parts

plateplate
removing

After

39

Step 2. loosen screws which tighten the disc

Step 3: remove the disc

40

Step 4: place another disc on to the machine

Step 5: press Jog to get the right positioning( press 3~5 times)

Tips: Selecting suitable rotary disc.

Standard rotary disc will have 24 bore holes for hanging screws.
If bore hole is much larger than the shank width, the screw will have big swing and displacement
during rotation which might influence the accuracy of inspection.
If bore hole is too close to the shank width, screw might have difficulty to get in the hole or have
difficulty to discharge it.
Optimal rotary disc should have bore holes that is slight larger than the shank width and will not
interference the discharge.

41

Step 6: Observe the adjusted positioning of feed-in track as well as rotary disc
Improper positioning: offset in the wrong place.

Well adjusted positioning

42

3.11 Light source adjustment and Optical fiber amplifier

3-11-1. Apply the knob to regulate light brightness.
Adjust the brightness till get the clearest image

2nd light source

Lightsourceswitc

1st light source

3rd light source

Counting

Optical fiber for track

3-11-2 Optical fiber amplifier

Counting sensor

Array optical fiber

( parts
sensoring)
()

43

Full sensor: same as for feed-in track sensor

position

up-down

down-up

44

3.12. Adjust Plunger and strokes

screw head dia must be smaller than plunger dia.
correct

wrong

Plunger bigger than screw

Plunger smaller than
screw head

Screw head

Screw head

Adjust the Plunger Stroke

The plunger stroke can be long stroke or normal stroke. The height of stroke is controlled by a
cam in the motor housing. On the cam there are two screw holes, for center hole, its for normal
stroke; for the hole away from the shaft center, its for long stroke.
Long stroke is for higher head screw or to combine a rotary recess-pin to inspect the recess depth
by mechanical action.
However normal stroke has higher speed. User can select according to the sorted items.

3.13. Position sensor adjustment

Loosen screw for

up-down move

Trigger sensor
blocked, red
light off

Trigger plate

Correct

Correct

Wrong

The positioning sensor is a photo interrupter sensor (As shown in the Figure above) Light-off is a
signal to capture image; while light-on is a signal to stop capturing image. All movement of
machine is guided by the trigger of sensor, so it is called a position sensor. All stroke
mechanisms should associate with position sensor. Standard machine equips with a 24-index,
while rotate the hand wheel a circle, itll be a complete inspection cycle..

45

3.14 Adjust reject mechanism

PS 1500
There are two parts in the reject mechanism, one for reject of good parts and the other for bad parts
(As shown in the figure below).

Bad Parts Chute

Good Parts
Chute

Blow pipe and discharge cylinder (For PS only)

While reject parts comes, cylinder will be activated and withdrawed, in the meantime, the blow pipe will
blow rejected screws into the chute of NG parts;

Discharge
Cylinder

blow pipe

46

 Reject picker (For PSL only)

Bigger screws (Length: 20.0 ~ 115.0 mm, outer diameter 6.0 ~ 16.0 mm) shall be sorted by PSL series.
However, rejected bigger screws may not be able to discharge to NG chutes by using a air-blower
mechanism. Thus all the models of PSL utilize Cylinder picker to discharge NG parts into NG chute. (As
shown in the figure below). While NG parts comes, cylinder will be activated and withdrawing to push parts
into the chute.

Cylinder
picker

47

3.15 Adjust Laser Check Point

3-15-1 If defective NG parts is not discharged, all warning lights flash. This is a foolproof mechanism to
prevent NG parts sorted to OK parts, in case of any error occurs. User must check its normal per every
inspection.
When locating the rotary disc, the red spot of laser check point shall be projected at the hole of index plate,
otherwise, please make adjustment. In case the screws are black or the other colors that do not reflect laser
well, or are contaminated by oil dirt or become rusty on the surface, that will result in poor reflection of laser
and cause incorrect determination or stop operation. To solve this problem, raise the intensity of sensor to
improve the sensitivity.

laser optical
fiber detector

Intensity
knob

Projected
spot

48

3.15.2 Adjust the sensing intensity

Use the small slotted drive in the toolbox to turn the knob of laser optical fiber sensor. Both indicators are on
when the red spot under the reject inspection plate is projected at the screw or index plate, (As shown in the
figure above), and the green indicator is on when projected at the cavity of index plate.

Yellow light off: no parts

Laser spot position

Yellow light on w/ parts

Laser spot position

slot

49

3.17. Lift-up mechanism

Step 1: Loosen the screw

screw
Step 2: Turn the metal ring to the end

Turn to the end

Step 3: Disassemble plunger, place the spring into the tool box (as for lift-up, spring is not applied), then
assemble the set as below
disassemble

distance depending
upon the screw head

50

Step 4: Tighten the fixing plunger onto the top view light source

Tighten the fixing plunger on the top of light

Step 5: tighten the fixing block on the detection pole and then tighten the fixing block on to the fixing
base

Fixing
block

Step 6: Check the lift-up performance by jog movement.

Check under-head
area

51

3.18. Accepted/ Reject parts discharging mechanism

Rejected exit

Adjust the position by screw size

Adjust speed of cylinder

Adjust the distance based upon parts

Accepted exit

3.19. Hand wheel: function and operation

Manual lever

Manual lever
holding plate

Hand wheel

52

Step 1: Remove the fixing plate from the manual lever.

Step 2: push in the hand wheel, now it can rotate the rotary disc.

53

3.20 Machine parts description

54

3.21 A schematic diagram of PS 1500 Series sorting platform

55

3.22 Recess Depth Inspection and Rotary Socket

The setting of hardware needs the inspection unit of rotating head (As shown in the figure below), the
proper punch socket and proper punch (It is recommended that user uses the used formed punch
still compliant).
Connecting rod
Rotating head

for rotating head

Spring
Inspection
drive

Inspection rod
weight

Combine the three items above and form into recess-check mechanism (As shown in the figure below)
Recess-check
mechanism

Inspection
unit

56

To inspect recess depth effectively, user shall be cautious here that the recess-check mechanism will be
lowered and shall touch the screws in inspection, while the front end of punch shall enter the recess
pin-hole in the screw head (As shown in the figure below).

Therefore, in adjusting the hardware mechanism in this part, user shall make sure that the central point of
punch shall be right against the central point of bore hole of rotary disc as possible (May also be just the
central point of screw head) when the recess-check mechanism is lowered to touch the screw. (As shown
in the figure below)

57

Here is the general faulty setting, and user shall pay special attention to them.

Much the punch is positioned inside the index plate

Much the punch is positioned to the right side of screw punch hole of index plate

58

Generally, it is recommended to change the inspection stroke to long stroke when using
recess-check mechanism. In inspecting the broken-pin, plugged-hole, recess-depth or other
similarities, the recess-check mechanism shall not be lowered to a height that is too low, i.e.
when the mechanism is lowered to the lowest point of stroke, that spring will not over-compress
and it can rotate smoothly down into the punch hole (As shown in the figure below).
Refer to this notch for the rotating

Spring compressing

The setting for software has no difference from general setting, in which the recess depth is
calculated on the basis of the distance between the central point of tune-up area for head position
and the lower edge of head compressor, as a result, the tune-up of head position is relatively
important.

59

There are many similar applications, and only the application of socket is described here. For some
screws used for outer wall construction (As shown in the figure below), their heads are shielded
with stainless steel cap to prevent the rusting of screws.

Correct angle with

even opposite side

However, as it is hard to control the occurrence of bad parts in the process of cap fabricating (As
shown in the figure below), there may be significant impact on the construction and screw life.

Incorrect angle with budge

here on a side plane

With the above setting, if the punch is removed and its socket is replaced by head socket, then the
bad parts can be sorted out by defining the head height function as above.

60

3.23 Inspection of wheel crack

Corn Mirror is developed by CCM (Ref. No.: LS 1501). This module is used to inspect the crack in
the round periphery of screw head, which is completely invisible when looking down from above
by standard lens.

Regulating screw
for Corn Mirror
height

Setting of wheel crack set

Select Corn Mirror set
The principle to select Corn Mirror (Ref. No. LS-1502) is generally the same as the Rotary
Disc. As required for imaging, the height of imaging end in Corn Mirror (As shown in the
figure below) may be attached on Rotary Disc, i.e. the inspected screw head may be
completely covered inside the lens.
Imaging end

Therefore, the diameter of Corn Mirror opening at the imaging end (We defined this diameter
as the specification of Corn Mirror) shall be a bit larger (but not too larger) than the outer
diameter of screw head, an opening diameter much larger than the outer diameter of screw head
may affect the authenticity. Specification of Corn Mirror is proportional to the outer diameter of
screw head captured image and consequently affect the accuracy of inspection. It is
recommended that the dimension of Corn Mirror is proportional to the outer edge of screw head
by 1:1.2, but the Corn Mirror of larger dimension may be selected to prevent the possible
damage on it if there is significant variation of screw head diameter.

61

 Setting of Corn Mirror

Generally, the height of Corn Mirror set is set at a lower height to meet the requirement of
imaging, the gap between imaging end and index plate is usually smaller than 1.0mm, but the
height of Corn Mirror is adjustable depending on the shape of screw head and crack.
The lens set can be set as the light source of camera 3 in two positions, i.e. the inspection unit and
the light source positioning lever of camera 3 (As shown in the figure below). Usually, it is set
on the inspection unit, where the height of the entire Corn Mirror set is adjusted with the
height regulating screw of Corn Mirror.

Camera 3 light source

positioning lever
Inspection Unit

62

 Cone Mirror Change-Over

Detection
lever

Fixing pole for light source

Step 1: tighten the fixing block onto the detection pole

Fixing block

63

Step 2: Make sure to keep distance of 3~5mm between the bumper and the cone mirror

Step 3: Fix the cone mirror onto the holder

Wrong!! Bumper is not removed, it will crash cone mirror

Correct: Remove the bumper

bumper

64

Step 4: Tighten the position for holding cone mirror

Color plate

Cone mirror hole

65

Chapter Four : HMI Interface Operation

Man-machine interface(HMI) has been integrated into this sorting system in order to enhance the control
efficiency and the convenience of machine operation and design. In the HMI, thousands of virtual buttons
can be programmed to replace the physical wiring buttons. On the HMI, all machine running status can be
displayed by text, and graphics. No matter how complex the machine might be, control panel can
performing all status displaying, and greatly reduce costs for development and assembly.

HMI operation interface

I.

Enter the page : after the power is switched on, this page automatically shows,
meaning it is ready for operation.

II. Main page

Press Enter and it comes to the main page of the system.
The top gray column displays the condition of the machine.

66

System can run under Manual and Auto. Manual is applied for machine setting as well as trouble
shooting, and Auto is applied after setting or after problems solved. By touching the panel, you can switch
the 2 functions easily.

Manual: The following functions can only run by Manual mode.

rotary disc continuously runs clockwise.

Rotary disc moves by single-cell movement, once one press makes the disc rotate one grip.

Execute parts discharging.

Start or stop the Cylinder function on the Feeding track
Turn on or off of the power of the feeder
System records qty during inspection, and by pressing this bottom, the qty can be reset.

optional functions, switch on/off the vacuum for dust suction

After error is removed, press this bottom to clear the error message.
Press on this button to change to other pages for other function setting.

67

Auto: the following buttons run on Auto model

Once stepping into Auto mode, Operator can only press Start or Stop.
Press Start to run the machine automatically. Press Stop to stop the machine.

This window is to show the status of connection between camera and software. If connection
failed, it shows CCD OFF.

This window is to show the rpm and pieces per min.

III. Parameter setting

This page offers operator the function to do the qty setting. On the HMI, it will show total qty
reaches as set qty. Low speed setting enables machine to run at lower speed before qty is reaching,
to ensure the accuracy of qty counting. (If operator found the machine run only at a very low
speed and unable to speed it up, maybe the set quantity is set too low.)
Continuous NG setting is to remind the operator that NG parts are defected continuously, and
that might be caused by error setting, or due to exceptionally too many defective parts. This
function can be applied while its needed.

68

IV. Error resume

This function is to record all error messages happened in the machine. Operator can learn about all
errors that were happened to the machine and gather relative information.

V. Validity is due.
This info shows when the validity is due. Please contact the supplier for further processing.

69

Chapter 5: Sorting items setup

I.

Start the software

Software of CCM Vision sorting system can run under Window XP. On desktop, double click
to enter the software. You will be led to choose to open old files, and new file

While choosing open old files, software will offload the file automatically. Old files can be found with
route C:\CCM Sorter\Config. Teaching data can be set in computer A, and be utilized in computer B.
This can facilitate operator continue the teaching work in different computers even it is not finished.

70

After opening an old file, software displays a screen as below:

Below are the commands provided by software, their description listed as below:
File : to open old files, save files, and open new files
Image : to open files saved. Images shot in one computer can be opened and utilized in different
computers.
Open Image : To open past image, image file is saved as bmp file with 640*480 resolution.
Open Fail Image : To find failure image, which are saved under the route of C:\FailImages
Save Image :To save the images
Set Offline Image Folder :Can be utilized for off-line simulation. It can serve for internal staffs practice
and training.
Save Teach Images : for images storage and for later application.
Show Error Image : Displaying fail images while its at automatic
sorting. User can turn it on or off, because this
function will load the computer and prolong
calculating time.
System : Click this icon to display language, images saving, or SPC
report.
User Control : Enter to change language. English, Simplified
Chinese and Traditional Chinese, Japanese, German are available.
User can also set the limit of images saving. Because Software saves
both NG and OK images automatically, you can change it to avoid
out-of-memory error, if Software takes too much images..
71

Report : to set up SPC report. This is an optional function

Exit To close the sorting software
About Displaying the current software version.

Teaching, after image taking, enter this icon to set up the measuring positioning.
Click this icon Image to continuously take images manually.

Click this icon to get into automatic sorting status.

Static inspection. After teaching, click this icon to make sure all teaching has been
successfully set.

Click this icon to save files.

II. Software Operation steps

Place the test object on the position, and select Manual mode on big HMI to move the object to
the pre-set CCD position. Click image, start to adjust lens and light source to get optimal image, which
means the most clear image within the inspection area.. Close the image after all adjustment is done. Click
teach to enter the key steps:

There are 6 sorts of main sorting items.

Sort 1: Measuring setup
This is to inspect distance between any 2 parallel lines and 2 horizontal lines, the
angle of oblique straight lines. In one screen, 30 different sizes can be inspected by
side-view CCD.
Sort 2: Head inspection
All images taken vertically from top to bottom or from bottom to top are being taught
By this inspection item.
Sort 3: Inner thread
To inspect the presence of inner thread. This item is applied by 45 degree CCDs,
from the upper or from the lower level. In the case of plated nuts, which are clean
and dry, the pitch distance of inner thread might be inspected, sorting of big or
72

fine threads might also be possible..

Sort

4: Outer Thread
This is the full sorting function of screw sorting, incl. Head height, head width, under
head length, thread major diameter, thread minor diameter, pitch distance, thread
quality, bevel angel, head shape, tail shape. These are inspected by side-view CCD.

Sort

5: 360 thread
This is an advanced function of inner thread. The 360 thread image is taken by
special lens. It can inspect thread damage or thread presence.

Sort

6: Octagonal lens
This is an optional function for twisted hex of nuts.

I.

Side-View inspection: Multi Height, Multi width, Angle

Enter the teaching screen,

A.

Choose the sorting items.

B.

Open Item page

Click to enter the measuring setup. Only 6 steps will be taken.

Measurem ent is done by gray scale image..

73

Step 1: Selecting the sorting item

Horizontal: from left to right. Click the horizontal, and green
column appears. Place the green column on the inspection
area, and 2 red lines shows the measuring distance.

Vertical : from top to bottom

Click vertical and see one green column. Place the green
column on the inspection area and see 2 red lines. Distance
between 2 red lines is the distance to measure.

Angle: An oblique straight line seen as baseline. By the way

of contract % inspecting the angle, the sorting accuracy is
about +/- 1 degree
Click on the angle, a green column will appear. Place the
column on the oblique straight line to be inspected. One line
will show, and after teaching, this line will catch the oblique
straight line automatically.

2R: considering the realistic demand, 2 different measuring positions can be selected by 2different
columns.

74

Horizontal neck width, vertical head height: this is

to inspect smaller area.

Positioning: as images may vary slightly, positioning line is to make contrast of teaching area
and distance between test objects, and move the teaching column following object.
In other words, teaching area may move following the test object to get more
accurate inspection function.
Position X for horizontal movement
Position
Y for vertical movement

Baseline: special features, no baseline for objects shot from top-down, then select part of
the object to measure the distance between the horizontal and vertical

75

Binary: when images are shot too bright or too dark, binary can change the effect of the image.

Measurem
ent sensitivity: come to black and white boundaries, divided into six levels of
sensitivity, very high, high, high, low, low, and very low. The higher the more sensitive, and when black
and white are vague, it requires high sensitivity.
Save fail image: fail images can be saved on to C: \ path Failimages while inspection running.
If more sorting items are needed, click Add to add more items. Currently, there are 8 functions available.

Step 2: After completion of the sorting items settings, press the teach bottom, the software will
execute all set sorting items. The sorting result is shown in pixels.

76

Step 3: Key in the maxi and min value according to the print, and the actual value by physically
measuring the sizes.

Step 4: Click calibrate and software will calculate the pixel size.

Step 5:

Click Inspection, to check all setting are done.

77

Step 6: Save all settings.

II. Head inspection

S teps are as above mentioned. On the main page, enter teaching and select head sorting items,
screen will enter head inspection page.
6 steps to complete the teaching.

78

Step 1:
A. Select head setting. There are 4 head shapes:
round, hexagonal, quadrilateral, slotted. Here
we take round shape as example, so we
choose round, the outer diameter of the head
on the image is black, so we chose Dark,
If the outside diameter is displayed in White,
then choose Bright.
B. Select the sorting items, depending upon the requirement to select the items, such as head
diameter, electroplating, roundness, pinhole concentric, broken pins, recess. While selecting
sorting items, Advanced Settings will show as below:

Step 2: Teaching
After finishing sorting items selection, start to do teaching

Software wizard will lead the operator step by step to follow

instructions to take actions.

Click Next, if theres no need to do any setting.

While setting head detecting area, there are 2 concentric circles:

Big one circles the outer diameter, and small one circles inside of
outer diameter.

79

While doing binary, adjust the blue area to be fully round. This
step will influence the roundness checking.

Different plating shows different effect under CCD.

Computer will calculate the average value from the selected
area based upon the detected gray scale value.

Roundness checking will find the central point first, and get
the smallest radius and biggest radius. Roundness is the
difference of the 2 radius. During sorting, Red= oversize,
Blue=undersize, Yellow=error, Green=OK

80

Pinhole concentricity setting requires a closed curve to find the

center of the pinhole and the center offset.

The checking result is shown in pixels.

Step 3: enter the Actual values

Step 4: convert the pixels value.

Click Calibrate to get pixel size.

81

Step 5:

Click

to test if teaching steps are done correctly.

Step 6: Save teaching setting

82

III. Side View: Outer thread

The outer thread is the easiest sorting item to set up. It applies backlight, and the operator needs to avoid
diffraction phenomenon occurs on images. For rotary discs type machines, it requires 2 CCDs to take
images, one from the head area, and the other from the thread area, as shown below:

After teaching of head area is done, continue to do the teaching of tail area. Steps are as above mentioned:
6 steps to complete teaching.

83

Step 1: Select teaching items

Select teaching items from the
listed sorting items. From the
image shown, this image can
only be measured its head
height, head width, so only
select these 2 items.

In the Main setting, no thread means on the shaft, there is no thread to be detected. However, Head area
still requires as this is going to be a baseline for some calculation based on parameters set, such as the
screw datum is skewed, then the head must be applied as the baseline to increase the inspecting accuracy.
As long as threads are with 2 different sizes, this function is required.
Main Setting:
Measuring sensitivity: If the difference of brightness between background and object is low, select higher
sensitivity. In the contrary, if difference is high, select low sensitivity. There are six levels of sensitivity,
very high, high, high, low, low, and very low.
Note: If backlight is too light, it would cause diffraction and cause trouble for computers judgment.
Adjust the brightness of light as a solution.
With Head: If the image of thread has head.
No Thread: No thread means on the shaft, there is no thread to be detected.
Bright: If the inspecting area is brighter than background, turn on this function.
Screw Alignment: specify the screw is orientated in vertical or horizontal.
Used Head Bottom as Reference Line: If screw is inclined, set head bottom as reference line might
increase the inspection accuracy.
Auto Teach: For standard 60 thread, turn on auto teach function.
High Low Thread: If thread has 2 different sizes, turn on this function.
Save Fail Images: Fail Images will be saved automatically, while machine is running. This would
increase the loading of computer. The limit of image can be adjusted from the system command.
Save Success Images: Save success images, while machine is running. This would increase the loading of
computer. The limit of image can be adjusted from the system command.

84

Step 2: Teaching. After selecting teaching area, start to do the

teaching steps.
Adjust binary to make the object clearly seen, then the next setting.

Select inspecting head area, then click next to complete the

teaching.

When teaching is finished, it displays the qty of pixels

.

Step 3: Enter the values of the pixels.

Step 4: Calibration. Convert the pixels into actual sizes.

85

Step 5: Click inspect to make sure teaching is done successfully.

Step 6: Save the teaching file.

86

After Head teaching is done, continue the tail teaching. All steps are the same.

Step 1: Select sorting items

From the image taken as example, total length, major diameter, tail shape, and also thread
presence.

Step 2: teaching. After sorting items are selected, start to teach.

Adjust binary to get clear image. Click next.

87

Teach Thread Region:

The program will guide user to place column on suitable area.
If there has no thread, itll measure the major diameter.
If there are threads, itll measure major diameter, minor diameter, pitch,
thread angleetc.
While teach the thread area, at least 3 good threads will be required, but
1st thread and the last thread should be avoided.

Tail area teaching to inspect the total length

as well as tail shape.

Continue the next, teaching finishes. The tails shape will be recorded for contrast.

Step 3: Enter the values

88

Step 4: Click Calibrate. Convert pixels into sizes.

Step 5: Click Inspect. Make sure all steps are correct.

Step 6: Save, this is the most important step.

89

Teaching steps are completed. Click Exit to return to the main page.

Click Static Inspection to check if there is any problem. By Static Inspection, software can take 50 images
per min.

If theres no setting error, click Run

, the machine will start to sort automatically.

IV. Bending (Optional Function)

Bending checking is an optional function which required 2 additional CCDs to confirm the
presence of bending. The 2 off CCDs cant carry out other function simultaneously, and mainly
aim at bending checking. The maximum limit of PS series is 4 off CCDs, whereas that of PSL is 6
off CCDs. Due to this reason, bending checking is recommended to used on PSL series for larger
space to install the additional CCDs.

90

Illustration of bending checking.

2 Lens as a foolproof, in case the screw rotates to a degree and cheat the CCD no bending.

The bending result of CCM

Screw

90 degree angle

Using a measuring device to check the bending, the bending degree will be double of the result of
CCM measured.

The CCD setting of bending checking will be set by CCM before ex-factory, however, if this
function is purchased after-sales, then user can change CCD setting at users premise.
Following is the procedure of CCD setting.

91

 Procedure of CCD setting or exchange

Open MCD File and select Bent inspection and set Bent CCD1 and Bent CCD2,

Bent signal should be the same point!

Teaching of bending
Select outer thread function, then process teaching.

Step 1: Select sorting items

Screw alignment is horizontal, so we select horizontal. The region of no-thread is much larger than
thread region, so we select no thread. Select Max. Diameter, then select bent.
Please be noted that bent function can be selected when Max. Diameter is selected.

92

Step 2: teaching. After sorting items are selected, start to teach.

Adjust binary to get clear image.

Teach thread region, place cross center at the center of screw.

93

Teach shift region. While screw shifts in the defined region, inspection column will shift accordingly.

Teach Bent Screw 1st Region, then press the next.

A window will pop out and ask whether the region is with thread or without thread.
If With thread, click Yes, if without thread, click No.

Yes

No

94

Teach Bent Screw 2nd Region, then press the next.

A window will pop out and ask whether the region is with thread or without thread.
If With thread, click Yes, if without thread, click No.

Yes

No

95

Step 3: Enter the actual size, min and max sizes.

Step 4: Click Calibrate. Get the size of max. diameter and bending degree and pixel size.

96

Check the result of detected threads. If the detected crests of thread are incorrect, adjust the number of
thread height. If all thread are found, yet the detected crests are not correct or more crests are found or less
crests are found, please lower the setting of thread height.

Ifsoftwaredoesnt
findALLthreads,
decreasethesetting
ofThreadHeight.

Enter the Acceptable Max. bending value

97

Step 5: Click Inspect. Make sure all steps are correct.

Step 6: Save, this is the most important step.

98

Chapter Seven:

Troubleshooting

After years development and te st, and further field test in our so rting center, Chin Chang
Vision Sorting system has becom e mature and we ll-developed vision inspection system . With
more than three years refinement by continual im provement and complying with custom ers
demand, Chin Chang new digital system has become more user friendly and optimal for application.
Considering it might still be som ewhat complicated for beginners, below listing points are for the
purpose for beginner to get acquainted with the system within short period of time.
Question 1.: All the three warning lights are on and flashing: This is because an error on ejection of
NG parts
Troubleshooting: two possible reasons
Ejection failure of NG parts. Reasons could be short of air pressure, cylinder problem ,
and jammed issue.
Incorrect setting on the check-point sensor at
ejection gate, or the sensor should be
cleaned.
CheckpointsensorpositionedaftertherejectedcylinderanditwillstopthemachineiftheNGpartisnot
ejectedandcometothenextpositionduringindexing. GatesensorwillensurethatNGpartshouldnotgo
totheAcceptedbin.
Thesequenceofcheckpointsensorshouldbetwolightson(GreenandOrange)whenlightbeamsonindex
plateorheadofparts.Anditshouldbeonlygreenlightonwhenlightbeamsonhole.Ifthesequenceisnot
correct,adjusttheheightofsensororturnthecrosstoadjustthestrengthofbeam.

Thisrelatedtologicsequence.Be
alwaysatD.

Thecrossistoadjustthestrengthofbeam.
Betternottoadjustittoostrong,otherwise
whenreddotbeamsonthehole,itwill
alsohavebothlighton,whichwillcause
problem.

Question 2.: The Red light is on. Objects are stuck somewhere or other abnormity.
Troubleshooting: several positions to check the root cause
A. Parts might be stuck at the following positions
End of the feeding tr ack where the screws enter th e index plate to adjust the track
alignment with the bore hole of index.
Station 1( Top view) where the parts are held by V clamp under the top view station.
Jammed or stuck at head plunger
Jammed or stuck at any of chutes
103

Ejection failure at Rejection

PSL-1500 series)

chute, Retest chute, o r Restart area (Applicable for

B. Errors or Abnormity
The location of check-point sensor might be too low, causing ejection failure.
The problem of ejection cylinder, might due to lack of air, or cylinder is down.
The solenoid valve is contaminated
Reed switch is damaged
When the machine is stuck during the operation, operator can check the positions mentioned
above and remove the problem.

Question 3: The yellow light is on: feeding shortage

Troubleshooting: feeding shortage; the output speed of vibrating f eeder is slower than the sorting
speed, the reasons may be as follow:
The vibrating feeder is stuck due to the cr ossed screws, defor med screws, or foreign
objects. Or the setting of loading period is too long.
The feeding track is stuck
The speed o f vibrating f eeder becomes slow, which m ight be caused by changed m ain
voltage or overfed hopper
The setting of empty time for feeder is too long
Question 4: CCD error or computer crash when the software executes an image capturing action
Troubleshooting: CCD1 error , the problem might be the cable of camera 1 or cam era 2 or the
cable of I/O card. One of them might connect improperly or is disconnected.
CCD3 error, camera 3 is connected improperly or disconnected.

Question 5: Computer cannot be started up

Troubleshooting: the RAM or graphic card can not be found in the computers BIOS system. Most
of the time, it is due to bad connection caused by dust on the slot which impair the
connection.
For industrial com puter, please contact CCM when such problem happens. We
will contact the PC su pplier to deal with it if it s on warranty period. Any
disassembling of the computer will lead to the invalidity of warranty.
For general computer, users only need to ask computer personnel to open the case
and carefully rem ove the RAM, graphic card, image capture cards or I/O card,
and after cleaning dust on all cards a nd the mother board by air gun. Then
re-assemble them on t he computer. When cleaning with air gun, keep an
adequate distance to prevent dam aging of the precision com ponents in the
computer.

Question 6: Error message or screen in executing process, when software system is started
104

Troubleshooting: the RAM or graphic card can not be found in the computers BIOS system. Most
of the time, it is due to the bad connection caused by dust that blocks the PCI slot
and impairs its connection.
For general computer, users only need to ask computer personnel to open the case
and remove the RAM, graphic card, im age capture card or I/O c ard, and after
cleaning all these parts and the m ain board by blowing the dust, reinstall them
back to the com puter. When clean ing with air blow gun, k eep an adequate
distance from the com puter to p revent the over air pressure from damaging the
precision components in the computer.
For industrial com puter, please contact with Chin Chang when such problem
happens, and we will contact the m anufacturer who prov ides warranty to deal
with it. Any disassembling of the computer will lead to the invalidity of warranty.
Question 7: Machine emits strange noises while running
Troubleshooting: Following reasons might cause such noises:
Lack of lubrication on the rod bearings in motor chamber, for maintenance please refer to
Chapter 6 - 4.Motor chamber.
Either the index plate is too low or the acry l plate for source light scattering of camera 1
is too high, which results in noise from their mutual friction. User may take adjustment as
adequate.
Either the index plate is too high or the acryl plate for source light scattering of camera 2
is too low, which results in noise from their mutual friction. Users may make adjustment
as adequate.
Either the index plate is too low or the end of feeing tr ack is too high, w hich result in
noise from their mutual frication. User may make adjustment as adequate
Question 8: Machine stops running suddenly, no warning light is on, or yellow light flashes once.
Troubleshooting: this fault usually occurs when the pressure is insufficient. It may be caused by the
over air blow of alignment on the vibrator y feeder or the over air blow on the
feeding track, or there is leakage of pipeline. U ser may switch off the vibratory
feeder and feeding track in turn to see if any improvement is made, then check if
there is any leakage of pipeline that causes the insufficient air pressure.

Question 9: Incorrect count, qty insufficient, even a lot less

Troubleshooting: the counting sensor beside the good parts exit chute may be contaminated by oil,
dirt or dust, which results bad reflection. To prevent this fault, clean this area prior
to setting. As cleaning this area, users must remove the entire base of optical fiber
and align its head with the outlet of the beams using air blower to blow off the dirt
on the optical fiber head before cleaning it with paper tissue; adjust the optical
fiber head to a position (general as 0.5~4.0mm) as proper (m ay vary with th e
object to be inspected) before restoring the seat of optical fiber.

105

Question 10: Light source flashes twice for one test object
Troubleshooting: Incorrect setting on inspection point. The interceptor optical sensor is intercepted
twice for a same inspected object. Rotate forwards the hand wheel slowly to find
the cause of the fault, and adjust the sensor or interceptor to a height as adequate.

Question 11: The red light flashes for no reason, in spection result is not correct, or light source
flashes at an instable frequency (Light source flashes only one for several inspected objects)
Troubleshooting: The interception optical sensor b ecomes less sensitive in reflection due to the
contamination or is defined incorrectly , or there may be short circuit of signal in
programmable controller. When this fault occurs, check the interceptio n optical
sensor at th e inspection point first, check if the height of sensor related to the
interceptor is adequate, then clean th e control cham ber with air blow gun and
eliminate the short circuit if any.
Question 12: Rejection cylinder cannot be restored when air pre ssure is released after a re jection
failure
Troubleshooting: This problem often happens when the cleaning work is not done properly during
machine setup. Nor mally, rejection error signal occurs, th en cylinder will b e
sucked, in the end, m achine can not be started, these are caused due to wrong
setting on the solenoid valves.
To fix the wrong setting needs to restore th e solenoid valve first. User presses the
manual button of the solenoid valve in
motor chamber with unreleased air
pressure, wie shown in the photo below . Press both the up and down buttons to
restore the positioning of solenoid valve.

Backgauge
cylinder

NG

MANUAL
RETEST

Then clean the m achine properly, especially to remove the oil dirt, ink and the lens of laser
sensor for abnorm al rejection under the inspecti on point of abnor mal reject, now the m achine
should be able to run properly.

Question 13: How could we adjust to get the image clear on screen?

106

1. Camera adjustment (front and back , up and down ) and lens adjustment (focus and aperture).
2. Light source up and down adjustment.
3. Gain and exposure option at computer.
4. Light source brightness option and upper/lower lighting turns on/off.

TherearetworingsoflightingonCCD1,sometimesupperringlighting
offorlowerringlightingoffwillhavedifferenteffectontheimage.

Question

14: W hy I cant check head dimension from side view.

The diameter of plunger should be lar ger than the head

diameter, otherwise sof tware will n ot be able to f ind the
datum and cause error.
User can make plungers by themselves. The ratio of plunger
OD and head OD should be appropriate.
For better result, the parts are suggested to posit center of
the plunger.

107

Chapter Eight: Parts maintenance checklist

Content

maintenance content

date

record

staff

Part
Counting sensor

Regular cleaning on the light exit to

ensure the counting result

Laser check point

Regular Cleaning on the light exit to

prevent exit from being blocked and
affects the machine running
performance

108

Exit cylinder

Regular cleaning on cylinder rod

and its outer, and prevent

debris

from entering and thus the cylinder

stuck.

Positioning Sensor

Outlook cleaning to ensure the

machine working performance.

Compressed air filters: daily

checking on the allowed the degree
of condensation of the water to
prevent any condensed water from
Air Units

flowing into the compressed air

piping. Spin out of the water screw
to enable emptying stagnant water
in the filter container
(Cartridge in the filter shall be
removed and washed on a regular
basis. During cleaning, no
application of Trichloroethylene on
the plastic filtration and oil cup.)
Pressure switch: add a filter in front
of the filter is sufficient. No extra
maintenance is required.
Oil + air dosing unit: regular
checking on the oil level, lubricant
from hydrant

109

Air pressure gauge

External and internal cleaning to

ensure no dust and dirt affect
machine performance.

Optical fiber: eliminating parts

Regular cleaning on optical in- and

out ports to prevent from affecting
the performance by dirt.

Optical fiber: full parts

Regular cleaning on optical in- and
out ports to prevent from affecting
the performance by dirt.

Optical Fiber amplifier

Regular cleaning by wiping and
dust blowing with air blow gun.
Repair or Replacement is required
when it works abnormally.

110

Index

Regular checking on the oil, make

sure it is sufficient.

Motor

Regular cleaning and dust removing

by air blow gun to avoid possible
stuck and damage.

111

Solenoid Valve set

Pay attention on the compressed air

to be dry! Regular external cleaning

Feeder

Outlook cleaning and avoid

collision while running

Controller

Wipe the appearance, clear foreign

stuffs around the controller to
prevent a short circuit

Clean the machine after one batch

Machine wiping

of products sorting, or do regular

cleaning to keep the machine in
good condition.

112

Chaper 9. : Maintenance and Replacement Schedule

(Working Hours or Months Used,
Replace Component Whenever Working Hours or Months Used Reaches the Suggested Time)
Working Hours
Items for Replacement

Driver
components

Bearing
components

Fiber
components

Computer
components

Lighting
components

Machine Type

V-Belt
Timing Belt
Conveyor Motor
Seamless Belt

PS.PSL
PS.PSL
PSC.PSG
PSC.PSG

Glass Dial

PSG

Roller Hub
PSC.PSG
Fish-Eye Beraing
PS.PSL
Liner Bearing
PS.PSL
General Bearing
PS.PSL.PSC.PSG
Check Point
PS.PSL
Feeding positioning fiber
PSC.PSG
Laser-Inspection
PS.PSL
Laser-feed out
PS.PSL
check sensor
Fiber Amplifier
PS.PSL.PSC.PSG
Main Unit
PS.PSL.PSC.PSG
Hard Drive

PS.PSL.PSC.PSG

Memory Battery
Power Supply
Backlight Panel
Ring Light
Third Light

PS.PSL.PSC.PSG
PS.PSL.PSC.PSG
PSC.PSG
PSC.PSG
PS.PSL

6000 9000 12000 15000 18000 21000 24000 27000 30000

replace when oil or dirt affect inspection

replace when damaged or
seriously sratched (affcting inspection)

36
36
48

36
36
48
48
36
36
36

36

36
36

Months

data back-up once in 6 months,

replace every 3 years

36
24
36
36
36

113

Chaper 9. : Maintenance and Replacement Schedule

(Working Hours or Months Used,
Replace Component Whenever Working Hours or Months Used Reaches the Suggested Time)
Working Hours
Items for Replacement

Machine Type

6000 9000 12000 15000 18000 21000 24000 27000 30000

Months

NOTE
1. ReplacementCleaning
2. All the parts mentioned above are consumables, and shall have repsective product life spans.
3. The working hours mentioned above is on the base of 400-500 PCS/M sorting speed, 8 hours of machine running, and 365 days of
work. The life span of parts shall be adjusted by actual sorting speed and machine running time.
4. Machine check for at least once a year is recommended to keep standard performance. Sorting machine check may be done by
CCM professional technicians during the regular customer service.

Controller
components

Material feed-out
components

Light Source Control

PS.PSL.PSC.PSG
Box
777 Controller (for
PS.PSL
feeder) (for
888 Controller
PS.PSL
hopper)
Feed-in Track Controller PS.PSL.PSC.PSG
Air Hose

PS.PSL.PSC.PSG

High Speed Solenoid

Valve (For feed-out)

PSC.PSG

Solenoid Valve (For Air

Pressure Allocation)
PS- Cylinder For
Rejection Exit
PSL-Cylinder For
Rejection Exit

36

36
36

36

PS.PSL.PSC.PSG

PS
PSL

48

12

48

24

12

114

Chaper 9. : Maintenance and Replacement Schedule

(Working Hours or Months Used,
Replace Component Whenever Working Hours or Months Used Reaches the Suggested Time)
Working Hours
Items for Replacement

Electrical control
box
Components

Man-machine Interface

PS.PSL.PSC.PSG

PLC Memory Battery

PS.PSL.PSC.PSG

Electric Control PanelPower Supply

Fan Filter
Vibration Steel Plate

Feeder components

Machine Type

Steel Plate Screw

Surface PU

PS.PSL.PSC.PSG
PS.PSL.PSC.PSG

6000 9000 12000 15000 18000 21000 24000 27000 30000

replace when man-machine interface cracks

or respond poorly (affecting operation)
replace once in three years

Self-Cleaning

Months

48
6

48

replace when the plate is serioulsy damaged

(affecting material flow)

48
36

NOTE
1. ReplacementCleaning
2. All the parts mentioned above are consumables, and shall have repsective product life spans.
3. The working hours mentioned above is on the base of 400-500 PCS/M sorting speed, 8 hours of machine running, and 365 days of
work. The life span of parts shall be adjusted by actual sorting speed and machine running time.
4. Machine check for at least once a year is recommended to keep standard performance. Sorting machine check may be done by
CCM professional technicians during the regular customer service.
2013 Mar

115

Driver components- V-Belt

Driver components- Timing Belt

Driver components- Conveyor Motor

116

Driver components- Seamless Belt

Driver components- Glass Dial

Bearing components- Roller Hub

117

Bearing components- Fish-Eye Bearing

Bearing components- Liner Bearing

Bearing components- General Bearing

118

Fiber components-Check Point

Fiber components- Feeding Positioning Fiber

- Fiber components- Laser-Inspection

119

 - Fiber components- Laser-feed out check

sensor

Fiber components- Fiber Amplifier

Computer components- Main Unit

120

 - Computer components- Hard Drive

- Computer components- Memory Battery

-Computer components- Power Supply

121

Lighting components- Backlight Panel

Lighting components- Ring Light

Lighting components- Third Light

122

Controller components-Light Source Control Box

777 Controller components- 777 Controller (for feeder)

888 Controller components- 888 Controller (for hopper)

123

Controller components- Feed-in Track Controller

Material feed-out components- Air Hose

124

 ()
Material feed-out components- High Speed Solenoid Valve (For feed-out)

()
Material feed-out components- Solenoid Valve (For Air Pressure Allocation)

PS
Material feed-out components-PS Cylinder For Rejection Exit

125

PSL
Material feed-out components-PSL Cylinder For Rejection Exit

Electrical Control Box Components-Man-machine Interface

PLC
Electrical Control Box Components-PLC Memory Battery

126

-
Electrical Control Box Components-Electric Control Panel-Power Supply

Electrical Control Box Components- Fan Filter

Feeder Components- Vibration Steel Plate

127

Feeder Components- Steel Plate Screw

PUFeeder Components- Surface PU

128