Checkbox - Festo

Incomparably convincing in action:the CheckboxUnrivaled efficientContact-free parts inspection usingthe Checkbox enables an uninterruptedflow of conveyed parts to berealized within the production process.The result: disruptions in thesupply of parts caused by mechanicalproblems is a thing of the past downtimeapproaches zero for your assemblymachines. Integrated quality inspectionassures uniform, high productquality for conveyed parts. At thesame time, this type of inspection preventswear and tear at conveyed partsand guide elements.Totally systematicA complete system: from the Identbox,the basic unit for separating goodparts, incorrectly oriented parts andbad parts, to the Countbox whichadditionally counts good parts andcanbeprogrammedwithapreselectedsetpoint quantity, right on upto the Sortbox with an additional sortingand compiling function.A unique ability to learnEach Checkbox unit is capable ofautomatically learning the contours ofup to 48 different parts by means of aTeach-in function – without any needof programming. The simple press of abutton is enough to set up the conveyorsystem for the next part type.This is your assurance of the greatestpossibledegreeofflexibilityinproduction:even greatly differing partscan be run via the same conveyorsystem – and the expense associatedwith separate bowl feeders can beavoided.2Info 502 – Subject to change – 2004/04

Optoelectronic orientation detection,quality inspection and sortingWherever small parts are conveyed toassembly and production equipment,the limitations of mechanical guideelements are very quickly exceeded,especially where complex part geometries,part diversity and high cyclerates are involved. The use of intelligentoptics represents an ideal supplementin such cases. The Checkboxanalyses the orientation and qualityof complex parts based on their contoursusing its integrated camera.2004/04 – Subject to change – Info 502 3

Optoelectronic systems:Conventional separation and positioning of small parts– Parts of complex shape lead tomalfunctions and reduced machineavailability– Adaption of mechanical facilitiesincur considerable developmentcosts– Retooling is often complicated andtherefore time-consuming andexpensive– Quality control using mechanicalsystems subject to wear is notalways possible and often not reliable4Info 502 – Subject to change – 2004/04

Optoelectronic systems:Contactless separation and positioning of small parts– Modular construction allows simpleintegration – also into existingsystems– LearnsnewpartsthankstotheTeach-in function without the needfor time-consuming programmingIDENTBOX– Optical detection – complementsfeed systems, increases systemavailability and prevents wearIDENTBOX– Retooling via push button – savestime and costs when changing partsIDENTBOX– Integrated quality inspection –guarantees highest product quality,higher cycle rates and fastamortizationIDENTBOXIncorrectly oriented partsDefective and foreign parts2004/04 – Subject to change – Info 502 5

-V- NewVariantsCheckbox CHBKey featuresIndustrial design Easy to use Sturdy construction and highfunctionality Compact integrated construction,protected against external lightand maladjustment,IP54 protection class Flexible installation, thanks to amodular system concept Automatic Teach-in of new parts inseconds, no programmingrequired Robust recognition algorithmbased on part characteristics Up to 48 different parts can besaved to memory High conveying performancethanks to variable belt speed(standard: 300 mm/s) Maintenance-free system Sturdy pneumatic components:Integrated valves and flow controls Long service life thanks tobrushless DC servo motorHigh reliability and checkingperformance Simple, sturdy optics with highqualityindustrial line-scan cameraand LED light strip Insensitive to extraneous light,with contour detection via backlightingmethod High resolution:0.02 mm or 0.1 mm6Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBKey featuresThe Checkbox family CHBThe Checkbox is a system for theoptical orientation detection andquality inspection of small parts. Itconsists of an optical unit, e.g. aconveying unit with integral cameraand a control unit.Theparttobeinspectedisfedpastthe camera on the conveyor belt. Thecontrol unit analyses the contour ofthe part and distinguishes betweengood parts and those which areincorrectly oriented or defective andforeign parts.All Checkbox units feature a Teach-infunction which allows them to “learn”different parts automatically –withoutthe need for programming. They areeasy to use – the press of a button isall that is needed to change your feedsystem over from one part type toanother.The Checkbox is used wherever smallparts need to be fed to assembly ormachining units. This is wheremechanical sorting devices reach theirlimits, especially where parts ofcomplex shape or fast cycle times areinvolved. This calls for intelligentoptical devices: The Checkbox family.Defective or foreign partsIncorrectly oriented partsIdentbox CHB-IBThe Identbox is the basic unit in theCheckbox family and is used toseparate good parts, incorrectlyorientedparts and defective parts.Countbox CHB-CBThe Countbox combines the featuresof the Identbox with a function forcounting good parts with pre-selectionof the desired quantity.Sortbox CHB-SBThe Sortbox unites the functions ofthe Identbox and the Countbox in oneunit and also conveys, sorts andcompiles several different types ofparts.2004/04 – Subject to change – Info 502 7

-V- NewVariantsCheckbox CHBKey featuresWhich 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 Sockets Spring washers Springs Stampings Switch contacts Tablets Threaded pins Toothbrush components Turned parts Wall plugs Washers Wooden dowels Zip-fastener componentsWhich industries use the Checkbox family? Metalworking industry Electrical engineering industry Woodworking industry Electroplating industry Injection moulding industry Packaging industry Pharmaceutical industry Cosmetics industry Jewellery industry Textile and clothing industry Assembly-systems industry Food industry Precision engineering industry8Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBKey featuresContour recognition using back-lighting methodWhat does the camera see?Part to be checkedBrass sleevePart to be checkedValve springPart to be checkedPlug connectorCamera imageBrass sleeveCamera imageValve springCamera imagePlug connectorPart to be checkedUnmachined rod clevisPart to be checkedLink platePart to be checkedInsulating terminal insertCamera imageUnmachined rod clevisCamera imageLink plateCamera imageInsulating terminal insert2004/04 – Subject to change – Info 502 9

-V- NewVariantsCheckbox CHBProduct range and peripherals overviewPossible combinationsIdentbox CHB-IB Countbox CHB-CB Sortbox CHB-SBTechnical data 5 / 4.2-14 Technical data 5 / 4.2-14 Technical data 5 / 4.2-14Connecting cableControl unit/conveying unitCable lengths:2 m3m5mConveying unit Tunnel version OEM versionwith reject positions and conveyor belt without reject positions and conveyor belt without reject positions, conveyor belt and housingPart ∅Part length:0.5 … 10 mm3 mm and abovePart ∅Part length:3…30mm3 mm and abovePart ∅3…30mm3…80mmPart length:3 mm and abovePart ∅3…30mmPart ∅3…80mmPart length:3 mm and abovePart length:5 mm and abovePart ∅3…80mmPart length:5 mm and above10Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBSelection aidProduct featuresPerformance characteristicsBasic unit with full checking functionalityUp to 48 parts can be taught-inThree feed paths:– Good parts > to the assembly station– Incorrectly oriented parts > back to the bowl feeder– Defective or foreign parts > to the reject binAutomatic control of the bowl feederMonitoring of part buffer zonesSelf-diagnosisCan be remote-controlledIdentbox CHB-IB Countbox CHB-CB Sortbox CHB-SB Integrated counting function:– 1 … 10 million parts can be pre-selected– When desired quantity is reached > signal to downstream machine– Upon acknowledgement > start of next cycle– Continuous counting for production monitoringSimultaneous conveying of different part types and sorting into different bufferzonesCompiling of several partsSample applicationsCorrectly oriented feeding at high cycle ratesAutomatic rejection of defective or foreign partsQuality inspection of turned and milled components for chips, burrs, etc.Ejection of end pieces following automatic bar turning Feeding of predetermined quantities of parts for packaging and compilingfunctionsSet feeding of small parts on to assembly palletsTriggering of maintenance cyclesFeeding to several buffer zones from one bowl feeder (space saving)Packaging terminal: Fully-automated control and monitoring of compilingprocedures with several parts and different numbers of itemsSorting of mixed parts (e.g. after galvanising or grinding)2004/04 – Subject to change – Info 502 11

-V- NewVariantsCheckbox CHBSample applicationsFeeding of partsVibratory bowl feeder Centrifugal bowl feeder Linear conveyorTransfer of partsSlide into the processing centre Chute Downpipe Triple buffer zone12Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBType codeCHB – SB – F30 – L4P – K20 – D – EC – V33 – VA – BTA – UE – MPBasic functionCHB Checkbox familyControl functionIB IdentboxCB CountboxSB SortboxComponent sizeF10 for ∅ 0.5 … 10 mmF30 for ∅ 3…30mmF80 for ∅ 3…80mmTransport functionL2P 2 reject pos., belt transport dir.: to the leftR2P 2 reject pos., belt transport dir.: to the rightL4P 4 reject pos., belt transport dir.: to the leftR4P 4 reject pos., belt transport dir.: to the rightL6P 6 reject pos., belt transport dir.: to the leftR6P 6 reject pos., belt transport dir.: to the rightTU without reject positions and conveyor beltOEM without reject positions, conveyor belt and housingConnecting cableK20 2mlongK30 3mlongK50 5mlongUser manualD GermanE EnglishF FrenchS SpanishI ItalianAdditional functionEC EncoderField of viewV10 Adjustment to 10 mmV20 Adjustment to 20 mmV33 Adjustment to 33 mmGuiding bar materialVA Stainless steelAlternative conveyor beltsBTA with longitudinal ridgesBTB with longitudinal recessesBTD with smooth surface, made of siliconeBelt endUE Guide roller unit with beltAccessoriesMP Mounting plates2004/04 – Subject to change – Info 502 13

-V- NewVariantsCheckbox CHBTechnical dataIdentboxCHB-IBCountboxCHB-CBSortboxCHB-SBCHB-IB-...CHB-CB-.../CHB-SB-...General technical dataFor part sizes ∅ 10 mm ∅ 30 mm ∅ 80 mmComponent ∅ 0.5 … 10 3…30 3…80Component length [mm] 3andabove 3andabove 5andaboveComponent rangeRotationally symmetrical parts and pre-oriented parts of any shapeCamera resolution [mm] 0.02 0.1Exposure time [µs] 72 … 8 192 136…8192Number of part memories 48OrientationMax. 8 different orientations per part typeBelt speed [mm/s] 200(adjustable: 100 … 250)Conveyor rate for good parts300(adjustable: 100 … 400)Dependent on part size, as well as number and frequency of actual and required part orientation.Example: 4 screws (M3x25) per second, correctly oriented for assembly4shafts(∅ 18x5mm)persecond,forqualityinspectionOnly with CHB-CB and CHB-SBQuantity pre-selectionCounting rangeRequired quantities can be pre-selected separately for all stored parts1 … 10 million per part typeElectrical connection technologyFor part sizes ∅ 10 mm ∅ 30 mm ∅ 80 mmOperating voltage [V AC] 85 … 264 (at 50/60 Hz), automatic detectionMax. power consumption [VA] 100Nominal value for short-circuitprotection[A] 1, slow-blow, automatic circuit-breaker integrated into mains switchOperating and environmental conditionsFor part sizes ∅ 10 mm ∅ 30 mm ∅ 80 mmOperating mediumFiltered, unlubricated compressed airOperating pressure [bar] 0…6Temperature range [°C] 10 … 50 (non-condensing)Protection classIP54Installation siteDry, screened from extreme external light sources, cleanest possible ambient air14Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBTechnical dataInterfacesFor part sizes ∅ 10 mm ∅ 30 mm ∅ 80 mmPLC couplingoutputsPLC couplinginputsDiagnostic interfaceAdditionally withAdditionally withCHB-CBCHB-SBCHB-SBCHB-CBCHB-SBThe connection of an external power supply is recommended in order to achieve full electrical isolation. Load peroutput: < 100 mA, total load < 1AReady for operationError outputFeeder controlConveyor belt controlPart acceptable and correctly orientedPart acceptable but incorrectly orientedWrong partPre-selected counter reading reached1…6(recognisedtype)External type selectExternal startBuffer zone sensorsExternal sensorStart new counting cycleRS 232 interface for laptop connection (cable included in scope of delivery)Weights [g]For part sizes ∅ 10 mm ∅ 30 mm ∅ 80 mmControl unit 6 000Conveying unit with 2 reject positions 4 000 7 000 12 0002004/04 – Subject to change – Info 502 15

-V- NewVariantsCheckbox CHBTechnical dataDimensions – Conveying unit, part sizes up to ∅ 10 mm2 reject positionsDownload CAD data www.festo.com/en/engineering1 4x connecting thread M6 for80x80 mm profile support2 2x connecting thread M8 for50x50 mm profile support3 Encoder (optional)4 reject positions6 reject positions2004/04 – Subject to change – Info 502 17

-V- NewVariantsCheckbox CHBTechnical dataDimensions – Conveying unit, part sizes up to ∅ 30 mm2 reject positionsDownload CAD data www.festo.com/en/engineering1 4x connecting thread M6 for80x80 mm profile support2 2x connecting thread M8 for50x50 mm profile support3 Encoder (optional)4 reject positions6 reject positions4 Guide roller unit with extendedguiding barGuide roller unitReject positions2 6324 7826 932L18Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBTechnical dataDimensions – Conveying unit, part sizes up to ∅ 80 mm2 reject positionsDownload CAD data www.festo.com/en/engineering1 4x connecting thread M6 for80x80 mm profile support2 2x connecting thread M8 for50x50 mm profile support3 Encoder (optional)2004/04 – Subject to change – Info 502 19

-V- NewVariantsCheckbox CHBTechnical dataDimensions – Tunnel variant, for part sizes up to ∅ 30 mmWithout reject positions and conveyor beltDownload CAD data www.festo.com/en/engineering1 2x connecting thread M8 for50x50 mm profile support2 Part sizes ∅ 3…∅ 30 mm3 Conveyor belt4 Guiding bar5 Provide cutout for camera lightbeam (approx. 5°)Dimensions – Tunnel variant, for part sizes up to ∅ 80 mmWithout reject positions and conveyor beltDownload CAD data www.festo.com/en/engineering1 2x connecting thread M8 for50x50 mm profile support2 Part sizes ∅ 3…∅ 80 mm3 Conveyor belt4 Guiding bar20Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBTechnical dataDimensions – OEM variant, for part sizes up to ∅ 30 mmWithout reject positions, conveyor belt and housingDownload CAD data www.festo.com/en/engineering1 Camera with adapter, lens andextension tube2 Camera bracket3 Lighting bracket4 Guiding bar for part guide5 Parts conveyor6 Viewing slot, 1 mm wide7 Connection for light8 Connection for cameraLighting bracketCamera bracket2004/04 – Subject to change – Info 502 21

-V- NewVariantsCheckbox CHBTechnical dataDimensions – OEM variant, for part sizes up to ∅ 80 mmWithout reject positions, conveyor belt and housingDownload CAD data www.festo.com/en/engineering1 Camera with adapter, lens andextension tube2 Camera bracket3 Lighting bracket4 Guiding bar for part guide5 Parts conveyor6 Viewing slot, 1 mm wide7 Connection for light8 Connection for cameraLighting bracketCamera bracket22Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBAccessoriesDimensions – Mounting options50x50 mm profile supportDownload CAD data www.festo.com/en/engineering1 50x50 mm profile support2 Profile connector HV-50as adapter80x80 mm profile support1 80x80 mm profile support2 Automatic profile connector3 4 socket head screwsM6x40 DIN 9122004/04 – Subject to change – Info 502 23

-V- NewVariantsCheckbox CHBOrdering data – Modular productsMMandatory dataModule No. Basic function Control function Component size Transport function Connecting cable User manual197 890 CHB IBCBSBF10F30F80L2PR2PL4PR4PL6PR6PTUOEMK20K30K50DEFSIOrderingexample197 890 CHB – SB – F30 – L4P – K20 – DOrdering tableM Module No. 197 890Basic function Checkbox family CHB CHBControl function Identbox -IBCountbox-CBSortbox-SBComponent size Part size ∅ 0.5…10mm,partlength3mmandabove -F10Part size ∅ 3…30mm,partlength3mmandabove -F30Part size ∅ 3…80mm,partlength5mmandabove 1 -F80Transport function 2 reject positions, belt transport direction: to the left -L2P2 reject positions, belt transport direction: to the right -R2P4 reject positions, belt transport direction: to the left 2 -L4P4 reject positions, belt transport direction: to the right 2 -R4P6 reject positions, belt transport direction: to the left 2 -L6P6 reject positions, belt transport direction: to the right 2 -R6PNo reject positions and conveyor belt 3 -TUNo reject positions, conveyor belt and housing 3 -OEMConnecting cable Cable length 2 m -K20Cable length 3 m -K30Cable length 5 m -K50User manual German -DEnglish -EFrench -FSpanish -S Italian -IConditionsCodeEntercode1 F80 Not in combination with field of view V10 and V20.2 L4P, R4P, L6P, R6PNot in combination with component size F80.3 TU, OEM Not in combination with component size F10.Transfer order code197 890 CHB – – – – –24Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBOrdering data – Modular productsOOptionsAdditional function Field of view Guiding bar material Alternative conveyorbeltBelt endAccessoriesECV10V20V33VABTABTBBTDUEMP– EC – V33 – VA – BTA – UE – MPOrdering tableConditionsCode Additional function Encoder -ECO Field of view Adjustment of field of view to 10 mm 4 -V10Adjustment of field of view to 20 mm 4 -V20Adjustment of field of view to 33 mm 5 -V33Guiding bar material Stainless steel -VAAlternative conveyor belt Conveyor belt with longitudinal ridges 6 -BTAConveyor belt with longitudinal recesses 6 -BTBConveyor belt with smooth surface, made of silicone 7 -BTDBelt end Guide roller unit with belt 8 -UEAccessories (supplied loose) Mounting plates -MPEntercode4 V10, V20 Not in combination with component size F10, F80.5 V33 Not in combination with component size F10.6 BTA, BTB Not in combination with component size F80.Not in combination with belt end UE.7 BTD Not in combination with belt end UE.8 UE Not in combination with component size F30.Transfer order code– – – – – –2004/04 – Subject to change – Info 502 25

-V- NewVariantsCheckbox CHBAccessoriesProgramming cable KDIMaterial:Cable sheath: Polyvinyl chlorideRound connector:PolybutylenterephthalateSocket: SteelTerminal allocationRx DTx DGNDScreenPin 1: Received dataPin 2: Transmitted dataPin 3: 0 VPin 4: ScreenTx DRx DGNDPin 2: Received dataPin 3: Transmitted dataPin 5: 0 VOrdering dataCable length Plug Socket Weight Part No. Type[m][g]5 M12, 4-pin 9-pin 181 150 268 KDI-SB202-BU9DUO cable KM12-DUOfor buffer zone sensorsTerminal allocation+(24V) 11 +(24V)Material:Cable sheath: PolyurethanePlug, socket: PolyurethaneKnurled screw, locknut: Brass–(0V)x (signal x)x+1 (signal x+1)3423 –(0V)4 x (signal x)1 +(24V)3 –(0V)4 x+1 (signal x+1)Ordering dataCable length Plug Socket Weight Part No. Type[m][g]0.6 M12, 4-pin M8, 3-pin 58.2 18 685 KM12-DUO-M8-GDGDConnecting cable KM12-KM12for buffer zone sensorsTerminal allocationMaterial:Cable sheath: PolyurethanePlug, socket: PolyurethaneKnurled screw, locknut: Brass+(24V) 11–(0V)x (signal x)x+1 (signal x+1)342342Ordering dataCable length Plug Socket Weight Part No. Type[m][g]2.5 M12, 4-pin M12, 4-pin 100.32 18 684 KM12-M12-GSGD-2,55173.17 18 686 KM12-M12-GSGD-526Info 502 – Subject to change – 2004/04

-V- NewVariantsCheckbox CHBAccessoriesSoftware to meet individual requirementsCheckKonPerformance characteristicsUsing this software the processeswithin the Checkbox can be displayed,logged and adapted from the cameraimage evaluation through to the I/Oparameters.This means: Transfer of new programs to theCheckbox Display and editing of systemparameters Display of the evaluation of the lastinspected parts recorded Display and logging of part contourand characteristics derived Display and print-out of systemconfigurationCheckOptiPerformance characteristics“CheckOpti” is used in cases wherethe standard Checkbox learningprogram reaches its limits due to thefact that contour differences are toosmall, meaning that part orientationor quality features cannot be reliablyrecognised.“CheckOpti” facilitates a completeanalysis of the Checkbox recognitionprocesses based upon contour datafor the parts to be checked.Additional, high performance testfeatures can be defined andoptimised if necessary. The newconfiguration can be subsequentlytransferred to the Checkbox.Ordering dataVersion Language Part No. TypeCheckKon software with manual German 194 496 P.SW-CB-KON-DEEnglish 194 497 P.SW-CB-KON-ENCheckOpti software with manual German 192 144 P.SW-CB-OPTI-DEEnglish 192 145 P.SW-CB-OPTI-EN2004/04 – Subject to change – Info 502 27

© Copyright by Festo AG & Co. KGWhilst every effort is made to ensurethat all dimensions and specificationsare correct, any printers’ errors notrectified are outside the control ofFesto, who cannot be held responsibleforsame.ForLiabilityandGuaranteeconditions, refer to our standard”Conditions of Sale”, available onrequest from your local Festo office.All rights reserved, including translationrights. No part of this publicationmay be reproduced or transmitted inanyformorbyanymeans,electronic,mechanical, photocopying or otherwise,without the prior writtenpermission of Festo AG & Co. KG.All technical data subject to changeaccording to technical update.28Info 502 – Subject to change – 2004/04

Everything under optoelectronic control – The CheckboxFeed technology is child’s play withthe Checkbox.Benefits for designers1. Standardized system solution No costly in-house fabricationrequired Greatest retooling flexibility No required programmingBenefits for purchasers Immediate availability Reduced ordering costs2. Greatest possible systemavailability Minimized downtime thanks tocontact-free inspection Shortest possible set-up times No procurement expenses formaintenance and repair Quality inspection integrated3. Easy initial start-up and operation Plug-in and go! Thanks toTeach-in function No complex logistics sequencesresulting from in-houseengineering One system for different conveyedparts – no extra training required2004/04 – Subject to change – Info 502 29

Festo automation componentsImportant components in our product rangeParts sorting and testing Checkbox familyCompressed air preparation D-series service unitsControl technology Individual valve CPE Valve terminal CPV Smart Positioning Controller SPC200 Front End Controller IPC FEC ® Standard FC640Long linear movement Rodless cylinder DGPL Electric toothed-belt drive DGE Standard cylinder DNC and DSNU Compact cylinder ADVUShort linear movement Linear module HMP Guided drive DFM Mini slide SLT Flat slide SLG Linear module HMPL Short-stroke cylinder ADVCRotary movement Rotary drive DRQD Swivel module DSM Swivel/linear module DSLGripping, mechanical …… or with vacuum Precision gripper HGPP MicrogripperHGWM Three-point gripper HGD Suction gripper ESG Vacuum generator VADMI Vacuum generator VNConnecting and installing Basic elements Screw connectors Fittings and restrictors TubingFurther products and details: http://catalog.festo.com or consult your Festo technical advisor.30Info 502 – Subject to change – 2004/04

Pneumatic PictogramsStroke lengthServiceFlow rateRepair serviceVoltageWorldwide serviceForceHotlinePressureCollection facilityTemperatureDelivery timeDiameterIn stockVacuumImportantWidthType discontinuedNewSpare parts service2004/04 – Subject to change – Info 502 31