LVS 6010 OCR READER. Label Vision Systems 101 Auburn Court Peachtree City, Ga Phone: (770) Fax: (770)

Transcription

1 LVS 6010 OCR READER Label Vision Systems 101 Auburn Court Peachtree City, Ga Phone: (770) Fax: (770) MSPUB:OCRMANUAL-2001

2 Table of contents 1. Equipment List and Installation 1.1 Read head 1.2 Photo-Eye 1.3 Light Tower Interface Unit 1.4 Touch screen computer system 1.5 Cables and connections 2. OCR Software Program 2.1 Welcome Screen 2.2 Camera Set-up Screen 2.3 Job Set-up Box 2.4 Operate Screen 2.5 Reports Screen 3. Diagrams

3 Introduction The LVS-6010 is a PC based, user friendly, Optical Character Recognition (OCR) system, designed to read printed characters at high speeds. It is commonly used to verify dynamically printed variable data for readability, sequentiality, and mis-match. It can be used to verify the readability of any optical character format. The system is designed to warn the operator with audible and visual alarms when an error has been detected, then produce a full report. All reported data can be archived internally, externally or networked. Error conditions can be connected directly to any machine and cause it to stop when an error has been detected. The speed and labels per second at which this system will effectively work depends on the number of characters being read. Typically, 15 to 25 labels per second at speeds up to 250 feet per minute can be achieved. The system is based on a touch-screen operating system, and is designed to be very user friendly. Figure 1: The LVS-6010 mounted on a Rewind table fitted with an Ink Jet system designed to print OCR on the back side of a Pharmaceutical la bel.

4 1.1 Read head The read head (see Figure 2:) consists of a progressive scan video camera and a DC florescent light module. The DC light source is expected to emit at least 85% of its rated output for 30,000 hours. It has a footprint of 5 X 5 X 6. Typically, a read head is mounted to a machine via an LVS Universal Mounting Bracket (See Figure 3). This bracket allows the operator to adjust the read head to any position or angle necessary to see the OCR image. Special handles are used to lock down any position without the use of tools. Figure 2: Read head The distance from the OCR image and the front frame of the read head is called the object distance. The object distance as well as the size of the image determine the type of video camera lens required for a specific job. Different jobs may require a different lens. There is a video camera with lens (See Figure 4:) inside the read head. This lens will have an iris adjustment ring as well as a focus adjustment ring. The iris, and focus are adjusted to obtain a good image as viewed on the OCR software s Setup Screen. In order to minimize the effects of opacity, a background plate may need to be installed behind the label stock. Figure 3: Read head connected to a Universal Mounting Bracket. Iris adjustment ring. Focus adjustment ring. Figure 4: Iris and Focus adjustment DC Florescent light Module

5 (Read head Setup continued) The OCR size and font type was established at the factory. This image is centered inside a red outlined alignment box located within the field of view. (See Figure 5.) Once the image is centered within the alignment box (outlined in red), the iris, focus, and object distance are adjusted to obtain a good read rate. Software can follow a plus or minus 15% deviation in size, slant, or contrast. Figure 5: Red box located within the Field of view. 1.2 Photo-eye or Trigger A trigger signal is required to tell software when an object is in the alignment box (outlined in red) located within the field of view. Software needs to detect this trigger so that it knows when to look for the OCR image. There are three ways to accomplish this:: Method 1- Print a registration mark on the label stock and use a reflective photo-eye to detect this mark.. The LVS part number is PHO0004 Method 2- Use the print command from a print head (when available). The LVS part number for the connection cable is CAB0020. Method 3- Detect the gap between labels by using a through-beam photo-eye (See Figure 6:) to detect the gap. The LVS part number is PHO0011. The Photo-eye input port can use any of the above methods providing the signal is an active high pulse between 5 and 24 volts DC. It is connected to the computer s I/O port located on the side panel of the display. Method 1 Reflective Photo-eye: A reflective photo-eye is mechanically positioned to detect a printed registration mark. The printed registration mark must be at least.25 inches Figure 6: Universal Photo-eye bracket assembly with Through-beam photo-eye.

6 (Photo-eye or trigger continued) wide and.5 inches long. The photo-eye needs to be mounted so that it is easy to adjust to various label lengths. The LVS Universal Photo-eye bracket can be used. (See Figure 6.) Photo-eye Set at angle Label Direction of motion.25 x.5 Figure 7: Method 1: Reflective photo-eye BLACK MARK A reflective photo-eye used with this system has an LVS part number of PHO0004. It is factory set to see a black mark on a white background. The photo-eye should be placed 1.6 inches away from the black mark and at some angle. Method 2- External signal registration mark generation.: When the LVS-6010 is being used with an on-demand printer, the signal used to command the print-head to print might be used for a registration mark signal. Call the company who made the print-head and find out if this electronic signal is externally available and if it is an active high signal. The print command signal is used to tell software the position of the OCR image. The position of the read head will need to be aligned so that the OCR image is located within the alignment box (outlined in red) on the Setup Screen when the print command signal is present.

7 (Photo-eye or trigger continued) Method 3- Through-beam photo-eye or Gap sensing: This method of generating a registration mark should be used for all high-speed applications. It can also be used for most other applications and is the most common way of generating a registration mark. Basically, when bar code labels are made, there is a gap created between labels. This gap can be detected by using a through-beam photo-eye. The LVS part number PHO0011 is used for this purpose. The PHO-0011 is designed to work with the LVS-6010 series. There is a special button located on the rear panel of the 6010 series which is used to train the photo-eye to see the gap. Since all gaps do not have the same opacity (the ability to see through the web material) the photo-eye needs to learn what is considered a gap and what is considered to be the label stock. Use the following steps to train the photo-eye. Model PE-1031 GAP PHOTO-EYE (Setup) STEP 1 = Place the photo-eye so that it is sensing the gap between labels. Then press the photo-eye learn button once. The red LED on the photo-eye housing will blink red. STEP 2 = Place the photo-eye so that it is seeing through a label. Press the photo-eye learn button once again. The red LED on the photo-eye housing will turn off and the green LED will turn on. The green light indicates the photo-eye has been set correctly. The setup is complete.

8 1.3 Light Tower Interface Unit This unit interfaces the computer to the operating machine (press, rewinder, folder, etc.). It is designed to give the operator an audible and visual indication of good read and error conditions. It also incorporates a stop motion relay used to stop the motion of a machine when an error is detected. Power to run the LED based Light Tower system is supplied by an external ma power source. 1.4 Touch Screen Computer System The LVS-6010 uses a touch-screen LCD monitor with a computer system built into it. The physical keyboard has been replaced with a software keyboard. Clicking on the keyboard icon causes a keyboard screen to appear. Data is entered by touching the correct character on the LCD monitor. Figure 8: Light Tower There is a 3.5 floppy drive as well as a read / write CD drive. The hard disk is capable of storing well over 100 gigabytes of Run Reports data. The computer system is also capable of being networked. A frame-grabber video card has been added to collect OCR video data from up to eight separate read head stations. The LCD monitor / computer is mounted on a swivel base articulating arm. This allows the operator to place the monitor wherever it is needed. Figure 9: CD Drive on the side of the LCD display. Figure 10: Swivel arm with table mounting clamp.

9 1.5 Cable Connections Here is a block diagram of how the LVS-6010 is cabled. Light Tower Machine Read head Computer and LCD Display LVS-6010 Photo - eye Figure 11: Systems Block Diagram The LCD / Computer counsel is connected to the Read head, Photo-eye, and Light Tower Interface Unit. The Light Tower Interface Unit is connected to the operating machine when STOP MOTION is required. LVS Part Number CAB0103 CAB0104 CAB0069 SI0404 Description Read head Interface Cable External Trigger Cable Light Tower Interface Cable Light Tower Stop Motion Cable

10 (Cable connections continued) The rear of the LCD Monitor / Computer has some additional connection for other applications.

11 2. O.C.R. Reader System Software 2.1 The Welcome Screen When first beginning the LVS OCR Reader System, the operator will be brought to the Welcome Screen. On this screen is the version number, phone number, website address, and the index tabs. Select an index tab at the top of the page to access another screen. The following pages will describe the functions of each screen.

12 2.2 The Camera Setup Screen This screen is used to align the OCR image to the Photo-eye trigger pulse and to verify the data is read correctly. STEP 1: Touch the Camera Setup index at the top of the screen. The Camera Setup Screen will now be displayed. Place the OCR image in front of the read head so that the OCR text falls within the red alignment box. STEP 2: Touch the Test Run software button on the LCD monitor. If the system is set up correctly (iris and focus, and position) data will appear in the bottom right blue back ground box. STEP 3: Make sure the Photo-eye is aligned to trigger when the OCR image is in the red alignment box. The system will follow a 15% growth or shrinkage of the OCR image. It is best to set the read head at the center of good reads by observing its maximum and minimum object distance, then setting the read head at the center point of good reads. STEP 4: The Stop button will stop the Test Run.

13 2.3 The Job Setup Box STEP 1: Pushing the index tab marked Operate will cause not only the Operate screen to appear but will also cause the Job Setup box to pop-up on top of the Operate screen. The operator can then choose an existing job or create a new job. When choosing an existing job the operator selects a job within the list of previously established jobs. When choosing to create a new job the operator must select the yellow button marked Create new Job, then enter a new job name with description. STEP 2: There is a box located within the Job Setup window titled Job Sequence Check. The operator must choose which type of sequence check is required. STEP 3: There is also a box located within the Job Setup window titled Stop Motion Setting. Some jobs require the operator to stop the machine during a run when software detects an error. This is how this feature is enabled or disabled. STEP 4: Push the green Begin Roll button. Software will prompt the operator to enter his or her initials. Once this is done, the operator is set to turn the press or rewinder on.

14 2.4 The Operate Screen To start a run, press the green Begin Roll software button.2. A secondary pop-up screen will then appear for the Operator ID to be entered. Key in the Operator ID, but do not select the OK button until the operator is ready to receive data on the very next trigger. The best way to accomplish this is to turn the media by hand until the first numeral of the targeted information is just about to enter the red alignment box located within the field of view. Then choose the OK button to enter the Operator ID. Software will begin to collect data on the very next trigger. LVS software will store the first decoded information as the basis for all sequential or match-code checking. This is important to note. If this number is wrong, all subsequent data will also be wrong. When the operator needs to pause the run, push the yellow button marked Pause During Roll. This will stop all reporting activity as well as suspend any camera acquisitions. Be sure to take note of the last number decoded when running a sequence type job. The next number to be triggered must be the next sequential number. When finished, select the End Roll button. The operator will be prompted to save the roll or discard it.

15 2.5 The Reports Screen When a Job is done there are three types of reports available: Roll Report, Job Report, and Job Summary Report. Job Report Each Job will consist of many individual runs. (A run is called a roll.) A Job can be reviewed, printed or deleted by pushing the appropriate button on the Reports Screen. The Job Summary column will show a description, total number of rolls, total good reads, total errors, and total of all labels for the entire Job. To print a copy of the Job Report, push the View Job Report button. Roll Report A Roll is another name for an individual run within a Job. The Roll Summary column will show the roll number currently displayed, Operator ID, Start time, End time, First label read, Last label read, Good read total, Error reads, and total of all labels read for the selected roll only. The View Roll Report button will display this same information as shown in the Roll Summary column, plus the detail of all decoded data, such as date and time stamp. Push the View Roll Report to obtain a copy of the Roll Report. Job Summary Report The View Job Summary Report button will show the summery information for the Job and all existing Rolls without the detail of each individual label read. The Delete Roll and Delete Job buttons will delete the currently selected roll or job from the database. These will not be retrievable. The following pages will show examples of the Roll, Job and Job Summary reports.

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