ADVANCHECK 4 OPERATOR MANUAL (rel 1.

0)

1) General

After startup the interface shows Caliber main page, from here using the software keys at left is possible to
access Caliber menus.

In the upper part of the screen there are the software keys to access the other management sections.
 1) Timer activity password:
when a password is enabled it shows the time to end of password validity.
When this timer reach 0 the password expires and all unblocked functions returns to be protected.
2) Password introduction:
Shows password level, there are 3 password levels. Higher password level means more functions
unblocked and higher activation time. Pressing this key calls the window to introduce password.
3) Caliber selection:
calls menu of dimension measurements (Caliber).
4) Planar selection:
calls planarity control menu.
5) Caliber + Planar:
Calls menu of integrated Caliber and planarity group of pages.
6) Transport:
Calls menu of management belts, tile aligner, tile elevator, automatic change size.
7) Superuser setup:
Calls “Hardware configuration”, change product and language management pages.
8) Software version and license.

These menus are always accessible in the higher part of terminal.

2) DIMENSIONAL CONTROL UNIT (CALIBER)

The purpose of the size control part (Caliber) is divide the tiles into groups according to their size
and to control the dimensional defects.
The caliber divides the tiles into 6 groups, for each one of these groups is introduced the central
measuring both for side A and side B in the appropriate configuration page.
The association of a tile to a group of caliber can be carried out using different methods.
The characteristics of the various methods of assigning will be treated later in the chapter of the
"Hardware Configuration".
After assigning the tile to a group of caliber it checks the defects, they don’t change the caliber but
only reduce quality according to a table of thresholds set by type of defect in configuration.
Caliber defects are:

Difference:
Maximum difference of the dimension of each side of the tile from central value of the caliber
group assigned.

Parallelism:
Maximum variation of the distance between the opposite sides of the tile.

Curvature sides:
Maximum deviation of the center of each of the 4 sides with respect to the straight line passing
through the corners of the same side.

Curvature x 2:
Check if in the center of the tile both opposite sides tend towards the outside or towards the
inside.

Diagonals difference:
Check the difference between the 2 diagonals of the tile.
2.1) Main page

1) Main page: last tile measurements.

2) Main page: Camera images of the last tile.

 3) Main page: Production Statistics.

In visualization page there is the historical visualization of last 50 tiles.

Each one of the buttons of the array have inside the visualization of the caliber group and the information
of the quality via the background color:

Green = Treshold 0
Yellow = Treshold 1
Red = Treshold 2
Violet = Treshold 3
Marron = alarm
With belts stopped is possible to call the readings of one of these 50 tiles by pressing the corresponding
button.

In the window below is shown at the same time the message that the values displayed are those related to
the tile and not last past under sizing.

When production restarts this option is automatically disabled.

2.2) F3 – Configuration

2.2.1) Principal

In this page are inserted the dimensions of calibration tile (sample tile) and the selections of the type of
readings that you want to execute.

1) Side A:
Length in tenths of millimeter of the sample tile (in movement direction).
2) Side B:
Length in tenths of millimeter of the sample tile (transversal).
3) Square format:
If Side A and Side B are equal this parameter changes the way of work of parallelism analysis.
If this parameter is not 'selected analysis of parallelism checks if the opposite sides are the same
distance at the beginning and at the end of the tile, transversely and in movement direction.
WARNING! For example, if I want to check that the two sides A are parallel I must measure their
distance at the beginning and at the end of the tile, this distance are the 2 sides B. The parallelism
of sides A will be given by the difference of the sides B and vice versa.
 If "Square Format" is selected caliber checks the difference between the longest and the shortest
side, without distinction between side A and B, this difference becomes the value to be compared
with the thresholds of parallelism.
In this way Caliber simultaneously checks that the sides are parallel and that the tile is square.
Obviously in this mode threshold, and readings will be the same for side A and side B.
4) Only central measurements:
If production tiles have more than 4 sides, and in the center, both in belts direction and
transversely, there is an area sufficient to be able to measure the size with reliability, its possible to
perform a simplified measure of the sides.
This measure is executed at the center of the tile, both in belts direction and transversely.
Obviously in this mode defects of parallelism and curvature can not be detected.
5) Curvature on 7 points:
In this mode the defect of curvature (straightness of the side) is not controlled only in the middle
of the sides but on a greater number of points (5 points more 2 corners).
This mode allows to detect defects of complex straightness in which the side curvature changes,
but to work requires a mechanical option and the replacement of external derivation board.
6) Transport speed:
Speed in meters per minute of transport belts.
Needs to calculate the exposure time of the cameras and the time base of the internal counters
for photocells system.
In cases where the transport is with Step motors and is managed by the Caliber it also serves for
programming the driver setup.
If caliber is programmed to automatically detect the speed of transport and the transport is
managed externally this parameter is not displayed.
7) Total Bypass:
Total Bypass of the device.
8) Bypass Side A:
9) Bypass Side B:
In special cases like very strong rectangular tiles or tiles in which one side is not readable
(es.klinker) it’s possible to exclude the controls of one of the two sides.
This exclusion can be total (exclude dimension and defects of that side) or only in the calculation
of the caliber, it continues to check defects of this side.
10) Threshold alarm first choice:
Management of alarm for minimum percentage of first choice acceptable.
This function is excluded by setting the parameter to 0.
If the minimum percentage of first choice is below this value the output for alarm percentage goes
high, which can be connected to a buzzer or light.
The decision of the first choice is set in quality page in Configuration.
11) Pieces for first choice alarm:
Dimension for sample on which perform the check of minimum percentage of first choice.

12) Pre-alarm exit:

Enable the management of an output which informs that the percentage of first choice is close to
the threshold.
2.2.2) Caliber group selection – Defect tresholds:

This is the part of configuration where to set the dimension of the center of each one of the 6 groups of
caliber and the thresholds of defects.

1) Caliber groups:
In this window is possible to set the central values for side A and B of the 6 caliber groups such
device divide tiles production.
Each tile is associated to the more similar group, the way to do it is decided in Hardware
Configuration and it will be 'explained in detail in another section.
When a new size is introduced the table of the gauges can be precompiled pressing Default button.
With this function the dimensions of sample tile are inserted in C4, calibers before and after are
scaled to 10 tenth of millimeter.
By pressing the keys with right and left the whole group of the calibers is moved by 10 tenth of mm
more or less.
2) Tresholds:
In this part of the page are inserted the limits for the various types of defect to determine if the tile
is directed into a stacker of first quality or must be declassed.
For defects of "difference", "Parallelism", "curvature" and " curvature x 2" there are separate
groups of thresholds for side A and side B in order to enter values proportional to the size of the
side (rectangular tiles).
Inside each type of defect the downgrading is the worst of that calculated for side A and side B.
Each group of thresholds consists of 3 values to define 4 scaled groups of quality.
A tile will be threshold 0 (S0) if the value in tenths of mm of the defect is less than the value
introduced for S1, threshold 1 if the defect is between the values S1 and S2, threshold 2 for values
between S2 and S3 and threshold 3 if the value is greater than S3.
 At the end of defects analysis of a tile it’s assigned a total threshold that will be' the worst of the
5 types of defect analyzed.
Above each one of the defect columns is present the option of enabling, so that they can be
enabled or disabled individually according to the requirements.

2.2.3) Quality allocation:

This page serves mainly for the management of the alarm outputs of out of caliber (no first choice).
In this page it is necessary to declare the quality 'of the tiles depending on the caliber and the threshold of
downgrading resulting from the analysis.
The declaration of first choice involves turning off of both alarm outputs, the second choice causes the On
of "Alarm 1", quality worst choices causes On "Alarm 2”.

2.2.4) Special:
This page manages the modality to analyze the images of the four cameras.

1) Encoder resolution:
2) CCD resolution:
These parameters are automatically set during calibration and are displayed on this page.
3) Border reading filter:
It’s the number of adjacent pixels of the same color (white or black) that the algorithm of image
analysis must find to consider the area as the leading edge of the tile.
Normally this value is at 1, but in case of presence of a lot of dust or in general of dirty pictures can
be useful to put at 2 or 3.
4) Perc.pos.Pt2 from vertex:
It’s the distance from the corner to which the algorithm of image analysis puts the first point for
the identification of the side.
The way to find the side can be made in 4 different modes, which will be explained in detail in the
section of "Hardware Configuration”.
5) Synchronous Reading T1-T2 and T3-T4:
This parameter decides the way to search the points to detect the sides in camera images.
The best modality is synchronous, but in this mode the position of the corners of the tile in the
camera input (T1 and T2) and output (T3 and T4) must be approximately in the same area.
In this way, once found the location in one image it looks in the same height for the point on the
edge in the other image.
This mode depends very much on the good working of of centering device, especially in the case of
strong rectangular tiles can lead to read errors.
In this case you can set the parameter to "Off" to free the research of the angle in the images of
four cameras making them independent, but this mode is a little less precise because of the angle
of the tile.
 The third possibility is Auto, this modality try to use before Synchronous algorythm, if this modality
fails try to use the second algorithm (4 cameras independent).
6) Measurement A sides:
The measurement of the size of the two sides A can be done using cameras or the integrated
system of photocells.
The default mode that is the most reliable is using photocells.
7) Speed Acquisition during calibration:
The belt speed can be acquired automatically at the beginning of the procedure of calibration or
set manually on the "Main" configuration of the caliber.
The best mode is to detect automatically the speed, but in this mode needs to run the belts empty
for a few seconds before inserting the sample plate.
Especially case of big products can be more comfortable insert the sample plate with belts
stopped, start the calibration procedure and then run belts.
In this case it must disable the automatic acquisition, but remember to insert the proper speed in
configuration, otherwise can have errors in the readings of the cameras because of wrong reading
times.

2.2.5) Options:

This page contains some special options and the offset adjustment of the exposure time of the cameras.

1) Notched/ chipped corner:

For particular products are available, in addition of the 5 defect analysis discussed above, also two
controls on the form of the angles.
These are simplified analysis at 1 threshold level (good/not good).
 2) Quality exit:
In addition to data passed to sorting line line for choice it’s also possible to use an ink jet marker
that prints a point on the edge of the tiles downgraded.
3) Offset S1 position (Only for Advancheck 5 Big Sizes):
Offset of the start reading quote of the cameras from position of photocell S2.
If the image is moved downstream or upstream is possible to move it using this offset.
Be careful using this parameter because when S2 goes off the image acquisition must be
completed.
If wrong value there is an error message of acquisition cameras incomplete.
4) Step Fw-Rev belts:
If belts are stopped and driven by step motors is possible to set a test cycle to pass continuously a
tile down cameras.
The lenght of the step Fw-Rev is inserted in this parameter.
5) Exposure time:
The exposure time of the cameras is automatically set during calibration, based on the speed of
the transport.
In special cases, such as in case of projectors worn, it can be necessary to modify slightly this time
using the four sliders.

2.3) F4 – Calibration

This function calibrate the device.

The gauge does not directly measure the size and defects but the differences between the sample
tile and production tile.

It’s very important that the sample tile is the most accurate as possible, typically with tolerance of
the tenth of mm, and that in the configuration is inserted the real dimensions of sample tile.

Pressing F4 Self-calibration appears the previous window.

If the parameter of automatic speed detection is enabled the "Start calibration" button remains
disabled for some seconds, it enables only after a few seconds when the belt speed is detected,
simultaneously appears in the alarm window the message speed acquired.
When start button enables push it, enter the sample tile and wait for the end of the procedure.

If at the end of the calibration appears the previous window the calibration is successful and the
caliber is in the best condition to operate.

If calibration fails in the window there is a red image.

If the calibration is successfully but the caliber recognizes an operating condition at risk report with
a series of images in yellow background that identify the type of problem (caliber too closed or
opened, rotated tile and so on).

These are warnings, the machine is able to work but it’s better to check the image of the camera to
see if it needs to improve the regulation.

If the function to return the sample tile is enabled appears in the window a button that manually
controls the output of belts reverse.
2.4) F6 Manuals

2.4.1) In-Out

This page displays the status of the inputs and outputs of the caliber.

By pressing one of the buttons with the picture of the hammer enables for that input or output the
function that allows manual forcing (a second button to force is shown).

It 'important when finished testing to remove all forces, otherwise the inputs or outputs will not
change status.

2.4.2) Encoder

This page displays the status of the encoders, normally is used only the first at the top.
2.4.3) Test Caliber

Visualization of the counter values of the system 7 photocells used to read the two sides A and
curvature of transversal sides (Sides B).

Measurements with red band (MC) are self-calibration values with the sample tile, those with blue
stripe are relative to the last tile passed.

MCO1 – MO1 = counter value at Off of the photocell W1, located on the camera T1 support.

MCO2 – MO2 = counter value at Off of the photocell W2, located on the camera T2 support.

MCO – MO = counter value at Off of the photocell W5, located in the middle of the caliber.

MCI1 – MI1 = counter value at On of the photocell W4, located on the camera T4 support.

MCI2 – MI2 = counter value at On of the photocell W3, located on the camera T3 support.

MCI – MI = counter value at On of the photocell W5, located in the middle of the caliber.

The maximum value of these counters depends on the kind of caliber and is visualized in Full scale
field.

2.5) F10 Print

Not used in this version.

2.6) F7 Image

This page display the image of the 4 corners of last tile passed down caliber.

The particular visualization of the sides perpendicular to the direction of belts depends to the fact
that the cameras are positioned at 45 degrees with respect to the movement of the tile.

Every corner is acquired by one of the four cameras, the acquisition is carried out in parallel by all
the cameras, so mechanically they must be appropriately positioned above the four corners of the
tile.

For reliable measurements in each of the 4 pictures the vertex of the angle should remain from
half to ¾ of the image, in both directions.

Pressing the "Test" button at the right of the images begins a cycle of continuous readings to verify
the correct working of the cameras.
It’s possible to expand the display of one of the cameras by pressing the corresponding button (T1,
T2, T3 o T4).

To exit from this page press the last right button down image (with door picture).

Pressing one of the two buttons with red arrow at the top and bottom in the center above and
below the image is shown another image that visualize the measurements done at the beginning,
middle and end tile on the side, these readings are used for the measurement of B-sides and the
curvature of A sides.
 The Up arrow key shows the measurements done by T1, the down arrow key the measurements
done with T2.

The image of last tile can be saved in internal database and reloaded from it using the "F9 Burn
Image" and "F8 Read image” keys.

In this way it’s possible to change parametrization of caliber tresholds and reanalize the saved tile
with the new setting by use the key “F11 Calculate” to see the new result of analisys.

2.7) F12 Export counters

This function saves production counters.

I conteggi vengono salvati in un file nella cartella Statistici, questa puo’essere creata su di una
memoria USB nel caso sia stata preventivamente inserita, oppure nella directory principale del
disco D.

The counters are saved in a file in the folder Statistics, this can be created on a USB memory in the
case has first been previously inserted, or in the root directory of the disk D.

The name of the file containing the statistical counters includes date and time so you can create a
historic of production.

If decide to leave the statistics in disk D of Advancheck need 'cyclically to provide for deletion of
oldest files, otherwise the folder "D: \ Statistics" could reach a size dangerous for proper
functioning of the device.
3) Planarity of surface control (PLANAR)

The purpose of the planarity control is to detect surface defects.

These defects are divided in two main groups, total surface defects and localized defects.

total surface defects are:

1) Curvature of the center:

Deviation of the center of the tile with respect to the middle plane passing through the edges.
This type of defect has two separate sets of thresholds for concavity (the center of the tile is
lower than edges) and convexity '(the center of the tile is higher than edges).
2) Curvature borders:
Deviation of the center of each one of the 4 borders with respect to the middle plan passing
through the 2 corners of the same side.
Also this defect has groups of separate thresholds for concavity 'and convexity' and further to
Side A and side B in order to use treshold values proportional to side dimensions in case of
rectangular tiles.
3) Twist:
Deviation of each of the 4 corners with respect to the plane passing for the other 3.
This defect has thresholds in absolute value (there is no distinction between positive and
negative).

Localized defects are:

1) Continuous reading:
The tile is divided into areas of size defined by the distance between 2 heads transversally and
in belt direction by continuous reading distance in configuration of Planar.
Inside each one of these areas is calculated the variation between the highest point and the
lowest point.
For this type of defect is present a group of thresholds in absolute value.
2) Corner:
In the 4 quadrangles identified by continuous reading frame on the 4 angles of the tile instead
of continuous reading analisys is performed the corner analisys.
This involves comparing the reading done on the corner of the tile and the other three at the
top of the quadrangle to see if the corner is up or down.
This defect has separate groups of thresholds for corner up (+) and corner down '(-).
It Can happen that the same tile has some corners up and other down, in this case the defect is
the worst between the two.
3.1) Main page

1) Main page – Last tile values

This page contains the results of analisys carried out on the last tile.
Also here as in the Caliber there is the visualization of the last 50 tiles.
Over previous versions is added the possibility of introducing an offset on measurements made
at the center of the tile and center of sides A and sides B.
This offset can be used for example when the tiles that pass under the planar are not yet stable
and will tend to straighten up later during cooling .
Since, however, these are parameters that false the measurement so they are also displayed
on the main page and become a red background if nonzero (OfsC, OfsA e OfsB).
2) Main page – Reading points last tile.
These are the readings done by sensors on last tile.
Each sensor is represented by a different color of graphics.

3) Main page – Sensor error counters

These are the error counters of sensor readings of the planar.
If one of the sensors reads with difficulty the number of his errors will be greater than that of
other sensors.
It should be borne in mind that in this page are counted also errors due to broken tiles, it’s
then quite normal that these counters have non-zero value.
4) Main page-Production statistics
Even here as to the caliber are available statistical counts divided by type of defect.
3.2) F3 – Configuration

3.2.1) Main

This page contains the main data of planar configuration:

1) Sample Length - Sample Width:

Length and width of the sample tile in millimeters.
As for the size of the sample tile in the gauge, in the planar needs that the sample tile have
surface free of defects, with accuracy of a tenth of mm.
The size of the sample plate of the planar may be slightly different from those of production, in
this case the device must be informed of the difference by setting the parameter Deviation
length pc.
2) Thickness tiles (mm):
Thickness production tiles.
This parameter is used in case of automatic size change in height to manage the height of the
sensors of the planar from the tile surface.
WARNING!!
Planar sensors have zero reading at 40mm from the lower surface of the body of the sensor,
from this reading center they have a field of work that goes from + 6mm to -6mm.
It 'is therefore important that the height of the support bar of the sensors is adjusted so that
the two external heads are in the center of this area of work (40mm from tile surface).
It 's not important that all heads reads exactly 0 ,the reference plan is taken automatically
during calibration, it’s more important that all sensor must be vertical.
3) Number of sensors
Number of installed sensors, the planar can manage from 3 to 11 sensors, the standard
configuration has 5.
4) Distance from border reading:
Distance from the front edge to the point where the sensors make the first reading.
 The length of the successive readings is then calculated so that even the last reading of the
heads is at the same distance from the edge behind.
5) L.C.Distance
Parameter that manages the dimensions of the frame of measures that are performed by
Planar for localized defects.
To detect the Concavity-convexity of the center of the tile must be performed a reading at the
center of it.
For this reason, the number of sensors installed must always be odd with the central sensor
fixed to the center of the transport, so as the number of readings for each head must be odd
and with a step length calculated suitably for dropping a measure at the center of the tile.
The calculation of the step of reading is performed by removing from the length of the tile the
distance of the first reading from the front edge and the last from the edge behind, the
remaining dimension is divided by the LC step, if the result (N.Reads) is odd It is maintained, if
even is incremented by one, then the new length of the step is recalculated.
The second and third parameters in the box ("LC Distance" and "N.Reads") are the real step
length and number of readings that the planar will perform on the tiles.

The positioning of the heads and the decision of the step of reading must be managed properly
depending on the type of defect and the results obtained.
If for example the size is square and needs to have more or less the same values of defects
turning the tile in 4 directions needs that the measures fall into the same points regardless of
the direction of travel.
To do this it will be necessary that the measuring frame is symmetrical, so the heads must be
positioned at the same distance one from the other, the distance between heads must be set
as "LC step" in configuration.
In this way the grid of continuous read is symmetrical (length = width) and the readings are
done more or less in the same positions independently from the direction.

If you want to inspect the tile in as many points as possible will need to set the "LC step" low,
in this way the grid will be more thick, but rotate the tile will change the positions of reading,
so the values of localized defect will be different depending on the direction of the tile.
(an eventual defect detected in one direction of the tile because passes down a sensor could
not be detected in other directions because pass in the space between sensors) .

If you wish to detect defects on the corners of the tile, separating from curvature of the same
edge it's necessary to position the intermediate sensors (2 and 3) close to the external ones (4
and 5) and set their distance as " LC step". In this way it is possible to detect better corner
defects, but it should be noted that also in this case by rotating the tile the localized defect can
change value because the readings are done in different positions.

6) Bypass:
Planar, like Caliber, can be placed in Bypass, in this mode stop completely defect analisys . In
this mode can gives in output a fixed code that depends on exit allocation page.
7) Heads Distance:
This parameter is used only in case of automatic change size of planar sensors.
 The heads have a placement that, starting from head 1 that is always the central, have in one
side all odd heads and in the other side the even heads.
In automatic change size heads 2 and 3 are simultaneously moved by a motor, and heads 4 and
5 by a second motor through worm screws.
The two parameters "T1-T2 = T1-T3" and "T1-T4 = T1-T5" are the position to be reached
respectively for the intermediate heads and external heads.
8) First class treshold:
Management of the minimal percentage treshold to enable percentual alarm output.
This function is disabled by setting this parameter at 0.
If first class percentage is below the value the alarm output percentage goes high, which can
be connected to a buzzer or light.
The decision of the first choice setting is done in the quality management page in the
configuration.
9) Tiles to check first class percentage:
Dimension of the sample of tiles in wich analyze the first class percentage.

3.2.2) Treshold defects page

Page to set the threshold values for the various types of defect.

For each type of defect are present four threshold levels, then the tiles can be divided into 5 groups
of quality .

It's possible to enable or disable individual types of defect.

For “Curvature Center”, “Curvature Border A” and “Curvature Border B” is possible to insert an
offset on the reading done in the central position to correct eventual problems of hot material that
can change shape cooling.
 WARNING !! The estimated value is in charge of the operator !!
Periodically check that the entered value corresponds to settling of cold material.

3.2.3) Quality Introduction

As in the case of caliber the values of this table manages the alarm outputs.

1 Quality clear both outputs, Grade 2 sets the output of Alarm1 superiors set Alarm2 output.
3.2.4) Special

This page groups the internal configurations of the planar:

1) Encoder Resolution:
Parameter automatically calculated and displayed on this page.
2) Distance between 3 readings:
Each reading in reality is composed by 3 consecutive measurements, within which a check is
made to remove errors.
The distance between these measures can be set in this parameter, normally is 1mm, on
particular surfaces can be increased to 2.
3) Internal Dark:
The Dark signal is a presence signal that informs the presence of a tile down planar.
Normally this signal is supplied by sensor 1 (Internal Dark).
On some dark and non-reflective materials it can be that this signal is interrupted while the
Planar has not finished its cycle of readings.
The tile is then discarded and the message cycle readings not completed is shown.
In these cases is possible to use an external photocell type projector-receiver separated
horizontally positioned within the columns of the sensor holder that reads little above the
plane of the belts.
The color of the tiles does not affect more on the measuring cycle, but care should be taken
that the photocell can not read between the tile and the belts and that it is positioned exactly
in axis with the centerline of the sensors in the transversal direction.
If this is not in line with the sensors it could be the first or the last cycle of readings from falling
out of the tile causing the read error.
This configuration only appears if in "Hardware Configuration" is enabled the external Dark.
3.3) F4 Calibration

Pressing F4 Calibration It enters the calibration procedure of Planar.

The standard calibration requires a sample tile flat and of equal size to the production.

For big sizes also exists the possibility to calibrate the sensor statically on a calibration bar,
this bar must be of a width equal to the maximum size, depth' enough to affect the heads
(minimum 100mm) and thickness similar to that of production.

Prior to calibrate the mean plane must however also be performed a calibration in
movement with a tile of normal production, it acquire the size of the tile in encoder pulses
and the distance from the exit point given.

3.4) F6 Manuals

3.4.1) Inputs-Outputs

Even here there is a control page for inputs, outputs and encoders.
 3.4.3) Test Planarity

Entering the page Test Planarity with belts stopped can control the sensor readings of the
planar, level 0 is the distance of 40mm between the sensor and the surface of the tile, the
resolution is 2 units for tenth of mm.

Pressing the Ref button at left you enter in extended display mode, where are displayed also the
status of the Dark, the Ref + and Ref- values.
3.5) F7 Image

Displays graphs of readings taken by the sensors on the last tile.

As the caliber it can be saved the data of last tile, read them and rerun the analysis.

3.6) F11 Calculate

Analyzes newly data readings on last tile or picture called up via the menu 'image.

3.7) F12 Export counters

This function saves the counts of production as in the group of pages of Caliber.
 4) INTEGRATED VISUALIZATION CALIBER – PLANAR

This part provides the integrated view of the main results of the analysis of planar and caliber during
production.

Calling from here the calibration procedure is performed simultaneously caliber and Planar calibration.

It's 'preferable, if possible, to calibrate separately Caliber and Planar because there are more opportunity
to control if the operation is successful.

5) Transport Menu
In this group of pages is grouped the accessory part of Advancheck, centering, aligner, lift and
possible automatic format change are managed from here.

5.1) F3 Configuration

Page for management of group of alignment of the tiles.

This group can be of two types, pneumatic or large format, the selection between the two is in
Hardware Configuration.
The pneumatic type is composed only of the centering and this only the duration of the
electrovalve in seconds.

The group for Large sizes consists of centering, lift and aligner, aligner can be pneumatic or
electronic.

Both groups have a single start photocell, in the first case (pneumatic) should be positioned so as
to be interested in the point in which it is necessary that you close the centering.

In the second case the photocell must be a few before the center of the centering device.

Configuration parameters are:

Big sizes alignement:

1) Enabling centering device:

Enables centering device to work.
2) Distance center clamps (mm):
Distance between photocell and center of the group centering device-elevator.
3) Duration centering UP (mm):
Duration in millimeters of closing of centering device with elevator UP (elevator must be
enabled).
4) Duration centering Down (mm):
Duration in millimeters of closing of centering device with elevator DOWN (if the elevator is
enabled the tile is lifted and centered a first time at the top, then the centering device opens
and the tile back on the belts, after the centering closes again to drive the tile).
If the elevator is not enabled only works this parameter.
5) Enabling elevator:
Enables the working of elevator (heavy tiles).
6) Enabling aligner:
Enables the working of aligner (strong rectangular tiles).
7) Aligner -> Centering dev.:
Enable it if aligner is installed before the center of centering device, the waay of work became
sequential, at the end of works of aligner start centering device sequence.
8) Distance aligner (mm):
Distance between photocell and aligner axis.
9) Aligner duration (mm):
Duration in millimeters of intervention of aligner.
When the aligner is enabled is normally low, then this parameter should be slightly greater
than the length of the tiles.

Pneumatic centering device:

1) enabling centering device:

 enables working of centering device.
2) Centering Device Duration:
Time in seconds of centering device closed from photocell interested.

Electronic aligner:

Option actually not used.

Reset:

Reset command to clear working of centering-Aligner-Elevator.

5.2) F6 Manuals

5.2.1) Change size (optional)

This page controls the manual movements of the motors of the automatic change size(if enabled)
and, if managed, of the transport.

Accessing this page with belts stopped is possible to move manually the transport.

To enable the change size management needs to press the software key to enable Manuals.
Caliber manuals:

1) Closing X axis Depth caliber.

2) Opening X axis Depth caliber.
3) Closing Y axis Depth caliber.
4) Opening Y axis Depth caliber.
5) Closing X and Y axis Depth caliber.
6) Opening X and Y axis Depth caliber.
7) Closing width caliber.
8) Opening width caliber.
9) Automatic positioning change size caliber.
The device automatically goes to width and depth set in the configuration of Caliber.

Planar Manuals:
1) Closing heads T2-T3 (X axis).
2) Opening heads T2-T3 (X axis).
3) Closing heads T4-T5 (Y axis).
4) Opening heads T4-T5 (Y axis).
5) Closing simultaneously heads T2-T3-T4-T5.
6) Opening simultaneously heads T2-T3-T4-T5.
7) Planar sensors bar Down.
8) Planar sensors bar Up.
9) Automatic positioning change size planar.
The device automatically goes to the width and height set in the configuration of Planar
(parameters “T1-T2 = T1-T3” , “T1-T4 = T1-T5” and “Thickness” + 40mm).

It’s possible to force the current positions to the values inserted in the configurations of Planar
and Caliber for the current format using the "Store size” part.

5.2.2) Driver Step Motor

On this page is possible to check status and internal parameters of the drivers for step motors.

6) MENU FILE
This menu includes the hardware configuration, the Change production lot (product change) and
the management of the language of the terminal.

6.1) Hardware configuration:

6.1.1) Caliber

1) Caliber:
Enables the hardware of caliber installed.
2) Caliber Heads Selection:
Selection of number and positioning of the heads.
1) 2 heads (no diagonals):
Hardware 2 CCD cameras installed at 45 degrees from belts direction.
Diagonals are not inspected.
2) 4 heads 90 degrees:
Advancheck first type with cameras at 90 degrees from belt direction.
Inspects measure and diagonals.
3) 4 heads 45 degrees:
Hardware 4 heads at 45 degrees from belts direction.
Inspects measure and diagonals.

3) Analysis algorithm camera images:

1) G0: Reading of all sides and diagonals with 4 cameras, the sides are read at
3mm from the angle.
2) G1: Reading of B sides and diagonals with the 4 cameras, the A sides are
read by a system of 7 photocells as in Newcheck.
3) G2: Reading of B sides with input cameras (T1 and T2) at 15 mm from the
corners, A sides are read by the system of photocells.
4) G3 (Default): Equal to G2, detection algorithm for corners at 2 points per
side modified to calculate diagonals.
5) G4: Detection algorithm of the sides for the calculation of the diagonals
that detects in each image one point on each one of the two sides, this
point is connected with the point on the same side in the adjacent camera
image for the calculation of the straight line of the side.

4) Caliber group association algorythm:

 Una volta rilevate le dimensioni dei 4 lati occorre come prima cosa costruire
una tabella che contiene per ciascuno dei 6 calibri la differenza di ciascun lato
dal centro di quel calibro.
After detection of the size of the 4 sides of the tile, the first thing is build a
table which contains for each of the six caliber groups the difference of each
side from the center of that caliber
Example:

Tile sides : A1=2980; A2=2985; B1=5993; B2=5999

Table of the 6 center caliber groups introduced:

C1 C2 C3 C4 C5 C6
Side A: 2970 2980 2990 3000 3010 3020
Side B: 5970 5980 5990 6000 6010 6020

Differences Table:

Caliber 1: DA1=(2980-2970)=+10 : DA2=(2985-2970)=+15 : DB1=(5993-5970)=+23 : DB2=(5999-5970)=+29

Caliber 2: DA1=(2980-2980)=+0 : DA2=(2985-2980)=+5 : DB1=(5993-5980)=+13 : DB2=(5999-5980)=+19

Caliber 3: DA1=(2980-2990)=-10 : DA2=(2985-2990)=-5 : DB1=(5993-5990)=+3 : DB2=(5999-5990)=+9

Caliber 4: DA1=(2980-3000)=-20 : DA2=(2985-3000)=-15 : DB1=(5993-6000)=-7 : DB2=(5999-6000)=-1

Caliber 5: DA1=(2980-3010)=-30 : DA2=(2985-3010)=-25 : DB1=(5993-6010)=-17 : DB2=(5999-6010)=-11

Caliber 6: DA1=(2980-3020)=-40 : DA2=(2985-3020)=-35 : DB1=(5993-6020)=-27 : DB2=(5999-6020)=-21

The previous table is used for all the algorithms.

Algorithm 1: Average of the differences in absolute value lower (unsigned)

Caliber 1 = (10+15+23+29)/4 = 19,25

Caliber 2 = (0+5+13+19)/4 = 9,25

Caliber 3 = (10+5+3+9)/4 = 6,75

Caliber 4 = (20+15+7+1)/4 = 10,75

Caliber 5 = (30+25+17+11)/4 = 20,75

Caliber 6 = (40+35+27+21)/4 = 30,75

The lower average is Caliber 3

Algorithm 2: Average of the differences lower (signed)

Caliber 1 = ((+10)+(+15)+(+23)+(+29))/4 =(+)19,25

Caliber 2 = (0+(+5)+(+13)+(+19))/4 = (+)9,25

Caliber 3 = ((-10)+(-5)+(+3)+(+9))/4 = (-)0,75

Caliber 4 = ((-20)+(-15)+(-7)+(-1))/4 =(-) 10,75

Caliber 5 = ((-30)+(-25)+(-17)+(-11))/4 =(-) 20,75

Caliber 6 = ((-40)+(-35)+(-27)+(-21))/4 = (-)30,75

The lower average is Caliber 3

Algorithm 3: Maximum difference lower (no average)

Caliber 1 = (+10) (+15) (+23) (+29) => Max difference +29

Caliber 2 = (0) (+5) (+13) (+19) => Max difference +19

Caliber 3 = (-10) (-5) (+3) (+9) => Max difference +9

Caliber 4 = (-20) (-15) (-7) (-1) => Max difference -1

Caliber 5 = (-30) (-25) (-17) (-11) => Max difference -11

Caliber 6 = (-40) (-35) (-27) (-21) => Max difference -21

Maximum difference(signed) lower(unsigned) is Caliber 4

Algorithm 4: Calibers separated for A side and B side(Calculated with signed average)

Caliber 1: Side A = ((+10)+(+15))/2 = +12,5 Side B = ((+23)+(+29))/2 = +26

Caliber 2: Side A = ((0)+(+5))/2 = +2,5 Side B = ((+13)+(+19))/2 = +16

Caliber 3: Side A = ((-10)+(-5))/2 = -7,5 Side B = ((+3)+ (+9))/2 = +6

Caliber 4: Side A = ((-20)+(-15))/2 = -17,5 Side B = ((-7)+(-1))/2 = -4

Caliber 5: Side A = ((-30)+(-25))/2 = -27,5 Side B = ((-17)+(-11))/2 = -14

Caliber 6: Side A = ((-40)+(-35))/2 = -37,5 Side B = ((-27)+(-21))/2 = -24

A side is caliber 2, B side is caliber 4, the bigger is Caliber 4.

Once assigned, the caliber does not change more, if at least one of the sides have a difference from the
center of this caliber bigger than difference treshold it will be downgraded for difference defect.

6.1.2) Planar

1) Integrated Planar:
Hardware planar installed.
2) Instantaneous reading:
Not used, disabled.
3) Sensor type:
1) Analogic sensor 0..5V:
Standard option, analogic sensors TEMA MET55.
2) Digital sensors 8 bits:
Digital sensors TEMA MET60.
3) Analogic sensors 4..20mA:
Analogic sensors SICK OD25.
4) Digital sensors SPI:
Never used.
4) External Dark:
Enable if installed the projector-receiver horizontal photocell aligned transversally to the center
of the sensors.
This option can be then managed from planar configuration.
5) Static Calibration:
Option to calibrate alignement of the sensors with belts stopped and a calibration bar instead
of a sample tile.
 This option involves the splitting of the calibration procedure:
1) "F4 Self-calibration" with a production tile to calculate step of continuous reading and
distance for code output.
2) Calibration midplane from the "F6 Manuals" -> "Test planar" with a calibration bar of about
the same thickness of production tiles.

6.1.3) Global

1) Change size:
Disable:
No change size managed from Advancheck.
Change size:
Change size managed directly from derivation card via external amplifier (unused option).
Change size with DVPP:
Automatic change size with step motors managed via drivers DVPP12.
 Enabling this option appears the programming table of the axes managed by automatic
change size.

2) Planar – Caliber data out selection:

Synthesis:
Caliber group and downgradings transmitted separately to sorting line. No exit
allocation page.

Data Planar and Caliber in parallel on FCRIF:

Planar and Caliber directly transmitted separately to sorting line on 4+4 bits (exits).
Codes are assigned via local Exit Allocation both in Planar and Caliber.

Data in series:

Planar transmits internally the result of analisys , assigned via exit allocation table,
to Caliber that after his analisis decide the exit code via 4 bits to sorting line.

4 bits pulse:

Equ

al to data in series but data at the exit remains high for a programmed time.

3) Quality exit bits:

Change the operation mode of the alarm outputs of planar and caliber to transmit binary
quality code for each tile.
4) Extended Outputs:
In some cases is required to use outputs that in the present configuration would not be
used for other purposes.
In this case, enabling extended outputs is possible to change the use of the desired
output.
5) DVPP Transport:
Enabling of local management of transport motors to Advancheck (step motors).
Disable:
External management.
Single:
Simple 2 belts transport management with 1 DVPP12 driver.
Double:
4 belts transport in electrical axis with 2 DVPP12 drivers
.
6) DVPP Aligner:
Electronic Aligner management with Step Motors.
7) Transport Direction:
Reverse graphic visualization of the pages according to the direction of the transport.
8) Uv Scan:
Enables Uv camera management in charge of Advancheck (Planar).
9) Return sample tile management (reverse):
Management of the exit that drives the motors reverse to return sample tile.
10) Derivation card Model:
Model of external derivation card, verify model from code on metallic grid.

11) Mechanical configuration:

Mechanically exists 2 models of Advancheck, little-medium size (Advancheck 1-2-3) and big
sizes (Advancheck 4).
The two models are recognizable by the fact that while the Advancheck 1,2,3 has a structure
downstream that supports the cameras (T3 and T4) and the photocells (W3, W4, W5 and S1),
in Advancheck 4 the two cameras downstream (T3 and T4) are released and mounted on two
carriages that slide along rails laterally to the belts.
Another difference is the absence in Advancheck 4 of group S1-W5 at the center of the 2
downstream cameras (T3 and T4), S1 was removed and simulated via software, W5 is moved
upstream in the middle between Ft2 and FT9.
 Advancheck 1-2-3:

Advancheck 4:

Advancheck 4 can have automatic change size on depth of caliber.

Options to use in standard machines are “Advancheck 1,2,3” for little-medium sizes and
“Advancheck 4 Step motor” for big sizes.
Options “Advancheck 4” and “Advancheck 4 Simulator” are expecial frames, “Advancheck 5”
and “Advancheck 5S” are options in developement.
12) Encoder resolution:
Kind of coupling encoder – motor.
13) Reduction transport:
Reduction coupling motor-pulley.
14) Centering device:
Pneumatic centering device simple with timing management.
15) Big Sizes Centering device:
Centering device -Elevator-Aligner for big sizes,with encoder management.
16) Display resolution 640x480 pixels:
Reduced Resolution terminal screen.

6.1.4) Extended Outputs :

This option appears only if extended outputs are enabled in the Global menu.

Setting at 0 disable the extended exit.

To set the extended output position count the outputs starting from one with first at right.
6.1.5) Change size:

This option appears only if change size with DVPP12 is enabled in Global menu.

In this page for each of the axes of the change size is possible to set reduction ratio, step
worm and software limits of minimum and maximum.