Checkbox (plc) Feeding Process

Checkbox

Total quality in the feeding process

Info 502

Incomparably convincing in action: the Checkbox

Unrivaled efficient Contact-free parts inspection using the Checkbox enables an uninterrupted flow of conveyed parts to be realized within the production process. The result: disruptions in the supply of parts caused by mechanical problems is a thing of the past downtime approaches zero for your assembly machines. Integrated quality inspection assures uniform, high product quality for conveyed parts. At the same time, this type of inspection prevents wear and tear at conveyed parts and guide elements.

Totally systematic A complete system: from the Identbox, the basic unit for separating good parts, incorrectly oriented parts and bad parts, to the Countbox which additionally counts good parts and can be programmed with a preselected setpoint quantity, right on up to the Sortbox with an additional sorting and compiling function.

A unique ability to learn Each Checkbox unit is capable of automatically learning the contours of up to 48 different parts by means of a Teach-in function – without any need of programming. The simple press of a button is enough to set up the conveyor system for the next part type. This is your assurance of the greatest possible degree of flexibility in production: even greatly differing parts can be run via the same conveyor system – and the expense associated with separate bowl feeders can be avoided.

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Optoelectronic orientation detection, quality inspection and sorting

Wherever small parts are conveyed to assembly and production equipment, the limitations of mechanical guide elements are very quickly exceeded, especially where complex part geometries, part diversity and high cycle rates are involved. The use of intelligent optics represents an ideal supplement in such cases. The Checkbox analyses the orientation and quality of complex parts based on their contours using its integrated camera.

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Optoelectronic systems: Conventional separation and positioning of small parts

– Parts of complex shape lead to malfunctions and reduced machine availability

– Adaption of mechanical facilities incur considerable development costs

– Retooling is often complicated and therefore time-consuming and expensive

– Quality control using mechanical systems subject to wear is not always possible and often not reliable

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Optoelectronic systems: Contactless separation and positioning of small parts

– Modular construction allows simple integration – also into existing systems – Learns new parts thanks to the Teach-in function without the need for time-consuming programming

IDENTBOX

– Optical detection – complements feed systems, increases system availability and prevents wear

IDENTBOX

– Retooling via push button – saves time and costs when changing parts IDENTBOX

– Integrated quality inspection – guarantees highest product quality, higher cycle rates and fast amortization

IDENTBOX

Defective and foreign parts Incorrectly oriented parts

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Identbox/Countbox/Sortbox CHB Key features at a glance

Optical orientation detection and quality inspection of small parts Identbox CHB-IB-... Countbox CHB-CB-... Sortbox CHB-SB-...

Reliable in operation – Easy to use

-V-

New Tunnel and OEM version for part sizes up to ∅ 30 and ∅ 80 mm.

The Checkbox is a system for the optical orientation detection and quality inspection of small parts. It consists of o a conveying co vey g uunitt with w t an a integral teg al camera and a control unit. The part to be inspected is fed past the camera on the conveyor belt. The control unit analyses the contour of the part and distinguishes between good parts and those which are incorrectly oriented or are defective or foreign parts.

All Checkbox units feature a Teach-in function which allows them to learn different parts automatically – without the need for time-consuming programming. They are easy to use – the press of a button is all that is needed to change your feed system over from one part to another.

The Checkbox is used wherever small parts need to be fed to assembly or machining units. This is where mechanical sorting devices reach their limits, especially where parts of complex shape or fast cycle times are involved. This calls for intelligent optical devices: The Checkbox family.

Incorrectly oriented parts

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Defective or foreign parts

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Identbox/Countbox/Sortbox CHB Key features at a glance

Industrial design

Simple operation

– Compact, integrated construction, protected against external light and maladjustment, protection class to IP 54 – Flexible installation through a modular system concept

– Automatic Teach-in of new parts in seconds, no programming required – Robust recognition algorithm based on part characteristics – Storage capacity of up to 48 different parts

Sturdy system design and high functionality

High reliability and checking performance

– High conveying performance through variable belt speed (standard: 300 mm/s) – Long service life through brushless DC servo motor – Sturdy pneumatics: Integrated valves and flow controls – Maintenance-free system

– Simple, sturdy optics with line-scan camera and LED light strip – Protected against light interference, with contour detection via back-lighting method – High resolution: 2/100 mm or 1/10 mm

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Identbox/Countbox/Sortbox CHB Key features at a glance

A tailor made range for your feed tasks

Identbox

Basic unit with separation of good parts, incorrectly-oriented and defective parts.

Performance characteristics

Areas of application

– Basic unit with full checking functionality – Up to 48 parts can be taught-in – Three feed paths: – Good parts
To the assembly station – Incorrectly oriented parts
Back to the bowl feeder – Defective or foreign parts
To the reject bin – Automatic control of the bowl feeder – Monitoring of part buffer zones – Self-diagnosis – Can be remote-controlled

– Correctly oriented feeding, even at high cycle rates – Automatic rejection of defective or foreign parts – Quality inspection of turned and milled components for chips, burrs, etc. – Ejection of end pieces following automatic bar turning

As Identbox, plus: – Integrated counting function – 1 to 10 million parts preselectable – When desired quantity is reached
Signal to downstream machine – Upon acknowledgement
Start of next cycle – Alternative
Continuous counting for production monitoring

As Identbox, plus: – Feeding of predetermined quantities of parts for packaging and compiling functions – Set feeding of small parts on to assembly pallets – Machine monitoring and initiating of maintenance cycles

As Countbox, plus: – Simultaneous conveying of different parts and sorting into different buffer zones – Compiling of several parts – Numbers of required items selectable for each part

As Countbox, plus: – Feeding of several buffer zones from one bowl feeder (space saving) – Packaging terminal: Fully-automatic control and monitoring of compiling procedures with several parts and different numbers of items – Sorting of mixed parts (e.g. after galvanisation or grinding)

Countbox

As Identbox. Plus: Counting of good parts. The desired quantity can be preselected.

Sortbox

As Countbox. Plus: Simultaneous conveying, sorting and compiling of several different types of parts.

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Identbox/Countbox/Sortbox CHB Key features at a glance Which parts are suitable?

Here is a small selection of the many possibilities: – – – – – – – – – – – – – – –

Axes Bolts Brushes Buttons Ceramic seals Curtain hangers Drill bits Drills Fuses Game pieces Glass ampoules Inserts Insulating terminals Lever stoppers Link plates

– – – – – – – – – – – – – – –

Lipstick casings Lock nuts Mouldings Mountings Needles O-rings Pen tops Plastic housings Plug connectors Screws Self-locking nuts Sensor housings Shafts Sleeves Small wares

– – – – – –

Cosmetics industry Jewellery industry Textile and clothing industry Assembly-systems industry Food industry Precision engineering industry

– – – – – – – – – – – – –

Sockets Spring washers Springs Stampings Switch contacts Tablets Threaded pins Toothbrush components Turned parts Wall plugs Washers Wooden dowels Zip-fastener components

Which industries use the Checkbox family? – – – – – – –

Metalworking industry Electrical engineering industry Woodworking industry Electroplating industry Injection moulding industry Packaging industry Pharmaceutical industry

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Identbox/Countbox/Sortbox CHB Key features at a glance What does the camera see?

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Contour recognition using back-lighting method

Part check Brass plug

Part check Valve spring

Part check Plug connector

Camera image Brass plug

Camera image Valve spring

Camera image Plug connector

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Identbox/Countbox/Sortbox CHB Key features at a glance What does the camera see?

Part check Clevis blank

Part check Link plate

Part check Insulating terminal insert

Camera image

Camera image Link plate

Camera image

Clevis blank

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Insulating terminal insert

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Identbox/Countbox/Sortbox CHB Product range overview

Possible combinations

The Identbox

Basic unit for separation of good parts, incorrectly-oriented and defective parts.

Connecting cable Control unit/conveying unit Cable lengths: 2.0 m 3.0 m 5.0 m The Countbox

As Identbox. Plus: Counting of good parts. The desired quantity can be preselected.

The Sortbox

As Countbox. Plus: Simultaneous conveying, sorting and compiling of several different types of parts.

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Identbox/Countbox/Sortbox CHB Product range overview

Possible combinations Conveying unit for part sizes: Diameters: Lengths:

0.5 ... 10 mm from 3 mm

Diameters: Lengths:

3 ... 30 mm from 3 mm

Diameters: Lengths:

3 ... 80 mm from 5 mm

Tunnel version for part sizes: Diameters: Lengths:

3 ... 30 mm from 3 mm

Diameters: Lengths:

3 ... 80 mm from 5 mm

OEM version for part sizes: Diameters: Lengths:

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3 ... 80 mm from 3 mm

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Identbox/Countbox/Sortbox CHB Typical applications

How are parts conveyed to the Checkbox?

Examples of part feeders: Vibratory bowl feeder

Centrifugal bowl feeder

Linear conveyor

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Identbox/Countbox/Sortbox CHB Typical applications

How are parts conveyed from the Checkbox?

Examples of the parts transfer: Slide into the processing centre

Chute

Downpipe

Triple buffer zone

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Identbox/Countbox/Sortbox CHB Overview and ordering data Tick or enter data

Modules View from above: Direction of belt run to be right

Mandatory entries Module no. Function Basic function Control function

Direction of belt run to the left

Size

Transport p function1)

Connectingg cable

Manual

Optional entries Auxiliary function Field of vision2)

Guiding bar material Alternative conveyor y belts3)

Belt end (F30 only) Accessories (enclosed separately) 1) 2) 3)

Code –

X

Entry

197 890 Description/characteristics Checkbox Identbox Countbox Sortbox For part sizes ∅ 0.5 ... 10 mm For part sizes ∅ 3.0 ... 30 mm For part sizes ∅ 3.0 ... 80 mm 2 reject positions, direction of belt run to the left 2 reject positions, direction of belt run to the right 4 reject positions, direction of belt run to the left 4 reject positions, direction of belt run to the right 6 reject positions, direction of belt run to the left 6 reject positions, direction of belt run to the right No reject positions, no conveyor belt No reject positions, no conveyor belt or housing Cable length: 2.0 m Cable length: 3.0 m Cable length: 5.0 m German English French Italian Spanish

CHB -IB -CB -SB -F10 -F30 -F80 -L2P -R2P -L4P -R4P -L6P -R6P -TU -OEM -K20 -K30 -K50 -D -E -F -I -S

X

CHB

Encoder Adjustment of field of view to 10 mm Adjustment of field of view to 20 mm Adjustment of field of view to 33 mm Stainless steel Conveyor belt with longitudinal ridges Conveyor belt with longitudinal recesses Conveyor belt with crosswise ridges Conveyor belt with smooth surface, made of silicone Guide roller module Mounting plates Power switching module

-EC -V10 -V20 -V33 -VA -BTA -BTB -BTC -BTD -UE -MP -PS

4 and 6 reject positions not available in combination with -F80; -TU and -OEM not available in combination with -F10 Not in combination with -F10 Not in combination with -UE

Order example with order code: 197 890 CHB-SB-F30-L4P-K20-D-EC-VA 197 890 CHB SB F30 L4P K20 D EC VA

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= Module no. = Checkbox = Sortbox = Part size ∅ 3.0 ... 30 mm = 4 reject positions, direction of belt run to the left = 2.0 m connecting cable = Manual, German = Encoder = Guiding bar, stainless steel

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Identbox/Countbox/Sortbox CHB Overview and ordering data Accessories Designation Part No. Type Software CheckKon with manual: 194 496 P.SW-CB-KON-DE (German) 194 497 P.SW-CB-KON-EN (English) Software CheckOpti with manual: 192 144 P.SW-CB-OPTI-DE (German) 192 145 P.SW-CB-OPTI-EN (English) Diagnostic cable: 150 268 KDI-SB202-BU9 Adapter cable: (for buffer zone sensors) 18 685 KM12-DUO-M8-GDGD (DUO cable) Extension cable: (for buffer zone sensors) 18 684 KM12-M12-GSGD-2,5 (2.5 m in length) 18 686 KM12-M12-GSGD-5 (5 m in length)

-H-

Note

Additional accessories upon request

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Identbox/Countbox/Sortbox CHB Product range overview

Software to match individual requirements

CheckKon Performance characteristics Using this software the processes within the Checkbox can be displayed, logged and adapted from the image evaluation of the camera through to the I/O-parameters. In detail this involves: – Transfer of new programs to the Checkbox – Display and change of the system parameters

– Display of the evaluation of the checked parts – Display and logging of the part contour and the characteristics derived – Display and print-out of the system configuration

The “CheckOpti” software is used if the standard learning process of the Checkbox reaches its limits due to contour differences being too weak, i.e. the orientation and/or quality recognition cannot be reliably ensured for a test part. “CheckOpti” enables a complete analysis of the recognition processes of the Checkbox based on the contour data of the parts to be checked.

If necessary additional high performance test features can be defined and optimised. The new configuration can subsequently be transferred to the Checkbox.

CheckOpti

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Identbox/Countbox/Sortbox CHB Technical data Conveying unit for part sizes

∅ 10 mm

∅ 30 mm

Part range Length 1) Diameter Conveying and checking performance

Rotationally symmetrical parts and pre-oriented parts of any shape from 3 mm from 3 mm 0.5 ... 10 mm 3 ... 30 mm

Camera resolution Exposure time Number of part memories Belt speed

2/ 100 mm

∅ 80 mm

from 5 mm 3 ... 80 mm

1/ mm 1/ mm 10 10 72 ... 8 192 µs 72 ... 8 192 µs 136 ... 8 192 µs max. 48 max. 48 max. 48 200 mm/s 300 mm/s 300 mm/s (adjustable from 100 ... 250) (adjustable from 100 ... 400) (adjustable from 100 ... 400) Dependent on part size, number and frequency of the part fed and the required part orientation Examples: 4 screws (M3x25) per second correctly oriented for assembly 4 shafts (∅ 18x5 mm) per second for quality inspection

Conveying rate of the acceptable parts Counter function (Countbox and Sortbox only) Quantity preselect Counter range Orientation

Desired quantities can be preselected separately for all stored parts 1 ... 10 million per part Consideration of max. 8 different orientations per part type within checking and counting process; can be switched off

Connection technology Power supply Power consumption Fuse protection Compressed air supply Ambient conditions

85 ... 264 V AC (at 50/60 Hz), automatic detection max. 100 VA 1 A (slow-blow), automatic circuit-breaker integrated into main switch 6 bar (unlubricated, filtered 40 µm)

Temperature range Degree of protection (complete unit) Installation site Interfaces

+10 ... +50 °C (non-condensing) IP 54 Dry, screened from extreme external light sources, cleanest possible ambient air

PLC coupling

The connection of an external power supply is recommended in order to achieve complete electrical isolation. Load per output < 100 mA, total load < 1 A 2 bits (ready signal), 3 bits (error messages) part acceptable and correctly oriented / part acceptable but incorrectly oriented / wrong part 5 bits (external type preselect), externally enabled Counter preselect reached Start new counting cycle 1 ... 6 (recognised type) 24 V DC (standard sensor connection, 2 inputs) 24 V DC (normally-open contact), 100 mA, floating RS 232 interface for laptop connection (cable included in scope of delivery)

Outputs

Additionallyy for Countbox Additionally for Sortbox Buffer zone sensors Power signal for small-parts conveyor Diagnostic interface Weight

Inputs Outputs Inputs Outputs

With respect to part size Control unit Conveying unit2) 1) 2)

∅ 10 mm 6 kg 4 kg

∅ 30 mm

∅ 80 mm

7 kg

12 kg

Other lengths upon request With 2 reject positions

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Identbox/Countbox/Sortbox CHB Dimensions

Identbox Countbox Sortbox

Rear view (turned through 180°)

1 PLC coupling 2 RS 232 diagnostic interface

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3 Power signal for small-parts conveyor 4 Buffer zone sensors

5 Cable to conveying unit

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Identbox/Countbox/Sortbox CHB Dimensions

Conveying unit for part sizes up to ∅ 10 mm 2 reject positions

4 reject positions

6 reject positions

1 Four M6 connecting threads for 80x80 mm profile support

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2 Two M8 connecting threads for 50x50 mm profile support

3 Encoder (optional)

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Identbox/Countbox/Sortbox CHB Dimensions

Conveying unit for part sizes up to ∅ 30 mm 2 reject positions

4 reject positions

6 reject positions

1 Four M6 connecting threads for 80x80 mm profile support

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2 Two M8 connecting threads for 50x50 mm profile support

3 Encoder (optional)

Info 502 – Subject to change – 2003/04

Identbox/Countbox/Sortbox CHB Dimensions

Conveying unit for part sizes up to ∅ 80 mm 2 reject positions

1 Four M6 connecting threads for 80x80 mm profile support

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2 Two M8 connecting threads for 50x50 mm profile support

3 Encoder (optional)

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Identbox/Countbox/Sortbox CHB Dimensions

Tunnel version for part sizes up to ∅ 30 mm

1 Two M8 connecting threads for 50x50 mm profile support 2 Part sizes ∅ 3 ... 30 mm 3 Conveyor belt 4 Guiding bar 5 Recess provided for camera lightbeam (approx. 5°)

Tunnel version for part sizes up to ∅ 80 mm

1 Two M8 connecting threads for 50x50 mm profile support 2 Part sizes ∅ 3 ... 80 mm 3 Conveyor belt 4 Guiding bar

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Identbox/Countbox/Sortbox CHB Dimensions

Item profile mounting options 80x80 mm

1 80x 80 mm profile support 2 Item automatic connector 3 4x socket head screw M6x40 DIN 912

Heron profile mounting options 50x50 mm

1 50x50 mm profile support 2 Heron connector HV-50 as adapter

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Identbox/Countbox/Sortbox CHB Dimensions

OEM version for part sizes up ∅ 30 mm

1 Camera with adapter, lens and extension tube 2 Camera bracket 3 Lighting bracket 4 Guiding bar 5 Parts conveyor 6 Viewing slot, 1 mm wide 7 Connection for light 8 Connection for camera

Lighting bracket

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Camera bracket

Info 502 – Subject to change – 2003/04

Identbox/Countbox/Sortbox CHB Dimensions

OEM version for part sizes up to ∅ 80 mm

1 Camera with adapter, lens and extension tube 2 Camera bracket 3 Ligthing bracket 4 Guiding bar 5 Parts conveyor 6 Viewing slot, 1 mm wide 7 Connection for light 8 Connection for camera

Lighting bracket

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Camera bracket

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©Copyright by Festo AG & Co. KG

Whilst every effort is made to ensure that all dimensions and specifications are correct, any printers’ errors not rectified are outside the control of Festo, who cannot be held responsible for same. For Liability and Guarantee conditions, refer to our standard ”Conditions of Sale”, available on request from your local Festo office. All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Festo AG & Co. KG. All technical data subject to change according to technical update.

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Everything under optoelectronic control – The Checkbox

Feed technology is child’s play with the Checkbox.

Benefits for designers

Benefits for purchasers

1.

Standardized system solution


No costly in-house fabrication required
Greatest retooling flexibility
No required programming


Immediate availability
Reduced ordering costs

2.

Greatest possible system availability


Minimized downtime thanks to contact-free inspection
Shortest possible set-up times


No procurement expenses for maintenance and repair
Quality inspection integrated

3.

Easy initial start-up and operation


Plug-in and go! Thanks to Teach-in function


No complex logistics sequences resulting from in-house engineering
One system for different conveyed parts – no extra training required

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Festo automation components Important components in our product range Parts sorting and testing
Checkbox family

Compressed air preparation
D-series service units

Control technology





Individual valve CPE Valve terminal CPV Smart Positioning Controller SPC200 Front End Controller IPC FEC® Standard FC640

Long linear movement





Rodless cylinder DGPL Electric toothed-belt drive DGE Standard cylinder DNC and DSNU Compact cylinder ADVU

Short linear movement







Linear module HMP Guided drive DFM Mini slide SLT Flat slide SLG Linear module HMPL Short-stroke cylinder ADVC

Rotary movement
Rotary drive DRQD
Swivel module DSM
Swivel/linear module DSL

Gripping, mechanical …

… or with vacuum


Precision gripper HGPP
Micro gripper HGWM
Three-point gripper HGD


Suction gripper ESG
Vacuum generator VADMI
Vacuum generator VN

Connecting and installing





Basic elements Screw connectors Fittings and restrictors Tubing

Further products and details: http://catalog.festo.com or consult your Festo technical advisor.

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Pneumatic Pictograms

Stroke length

Service

Flow rate

Repair service

Voltage

Worldwide service

Force

Hotline

Pressure

Collection facility

Temperature

Delivery time

Diameter

In stock

Vacuum

Important

Width

Type discontinued

New

Spare parts service

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