Service Home How To Procedures Broken Tool Detection (BTD) - Calibration - AD0702
Last updated: 10/21/2023

Broken Tool Detection (BTD) - Calibration

AD0702

Broken Tool Detection (BTD) - Calibration - AD0702

Introduction

The Broken Tool Detection (BTD) is a feature that detects the length by capturing an image of a tool before and after use. With a noticeable difference in length, an ALARM 9300 Broken Tool will be triggered stopping all machine motion.

Before the system can successfully detect a broken tool, the camera needs to be set up and calibrated. This procedure will show you how to manually adjust the camera mount into the proper position and calibrate the Region of Interest. 

NOTE: For more information on the Broken Tool Detection feature, refer to the Broken Tool Detection - Troubleshooting Guide.

Software Requirements:

  • 100.23.000.1110 version or higher

Calibration

1

IMPORTANT: With the machine in service mode, make sure that Setting 430 is set to ON.

Set Setting 431 Region of Interest to 50% by default. This setting will be adjusted later in the calibration process. 

NOTE: If the machine has a pallet pool, Setting 433 gives the option to skip to the next pallet on a broken tool instead of throwing ALARM 9300 Broken Tool. 

2

Press DIAGNOSTICS.

Navigate to the Maintenance menu and then to the BTD Calibration tab.

Follow the on-screen instructions of engaging [E-STOP] to enter calibration mode.

NOTE: At any time if [E-STOP] is released, it will exit calibration mode and back to the default screen.

Press [F1] to turn on the camera feed on the machine's screen. 

3

Press [F2] to turn on the remote display tab. In this tab, an external device can view the camera feed making the calibration process easier.  

Follow the on-screen instructions of turning off WiFi on the remote device.

Scan the QR code on the remote device. 

You will be then be prompted to join the machine's network. 

Scan the QR code on the remote device again. 

The QR code will refresh to the remote display web page showing the camera's live feed. 

4

With the camera live feed displayed on the remote device, test the camera's feed to ensure it is live.

Do this by turning the work lights [ON/OFF]. The change in brightness will be visible from the video live feed. 

5

Open the machine window on the tool changer side to access the camera. The camera and lights assembly can be adjusted as a whole to ensure proper calibration. 

Set the positioning by slightly loosening the side [1] and top [2] housing screws. 

The side screws [1] allow for forward and backward movement of the camera assembly.

The top screw [2] allows for side to side movement of the camera assembly. 

The pivot screw [3] sets the camera assembly angle. This fine tunes the system.

6

Make sure to view the remote display of the camera live feed while adjusting the screws.

The area within the green lines is known as the Region of Interest (ROI). The tool should be positioned horizontally in the middle of the ROI. The ROI determines how much of the image the system is detecting. 

Position the camera so that the tool holder is shown on the left and the tip of the tool is shown on the right.

 NOTE: The tool holder should be far enough on the left side so that it is only partially visible and ensure that other tool holders aren't within the region of interest. 

Try to align the tool with the ROI centerline.

Make sure that the black brushes are in the backdrop behind the tool in question.  

NOTE: The straightness of the tool within the middle of the ROI directly effects the quality of the tool detection. In order to get the most accurate centerline, use a longer tool.

Once the tool is sufficiently aligned, press [F2] to leave the remote display page. 

7

Press [F1] to display the live camera feed on the machine's screen. 

Adjust the ROI to be able to accommodate different sizes of tools. Make sure that the ROI is wide enough to capture both the tool holder and the tool of the widest tool in the carousel. 

IMPORTANT: If the ROI covers two pockets rather than one, there is potential for the camera to detect the wrong tool. Avoid this. 

Press [PAGE UP] and [PAGE DOWN] buttons to adjust the width of the ROI by one digit at a time OR type a whole number between 1-100 then press [F4] to set that ROI value. 

NOTE: For example, the first image [1] shows the tool with the default ROI of 50%. There is too much extra space surrounding the pocket and tool holder. This caused the ROI to be reduced to 40% in the second image [2]. Now, the ROI is more focused on the tool, while still leaving some extra space to accommodate wider tools. 

8

Once the camera is calibrated, it is time to tell the machine which tools it should detect under the Tool Table. For more information on this, refer to the Broken Tool Detection - Operation reference document to learn how to use this feature.