SKIP AHEAD TO

Introduction

Safety Information

Assembly

Wiring

Software Tutorial

System Operation

Troubleshooting

Final images

 

Introduction

The Imago Chip Shot System allows for the acquisition of high-resolution images of chip trays. This raspberry pi controlled system utilizes a motor to increment a tray of chips under a fixed camera, acquires images, and transmits them to a computer to be analyzed. 

The software itself is customizable and user-friendly but has been optimized for the trays that you use. We will explore the UI in depth later in these instructions.

Required and Helpful Tools

• The only required resources to assemble the Chip Shot are included, which are an Allen Wrench set and zip ties. Each Chip Shot has a new metric Allen Wrench set as well as ample zip ties to route cables at that stage of the build.
• Other tools that are helpful to the assembly process:
  • Tape Measure
  • Square
  • Level

Safety Information

• The Power Supply is equipped for 120/240 VAC with manual switching. The power supply is already set to the 240V setting. The switch must be toggled to the appropriate setting for your country/region.
• Attempting to power on the supply with the incorrect setting selected may result in severe physical harm and/or damage to the system. DO NOT connect the power supply to power without confirming the switch’s setting.

• Once the appropriate setting is confirmed, replace the lid of the power supply. Do not open this lid again without instruction from a certified technician.

The system contains moving parts that also pose a risk. A few important things to remember:

• Place the system in a clear location and on a stable tabletop.
• Do not run the system until the entire range of motion is clear.
• Do not make adjustments to any part of the system while the system is running.
• Keep hands clear of the motor while the machine is powered on.

Assembly

Assembly – Items Overview

02-006 tray back support
02-005 Chip Tray Tab
A3-001 Alignment Jig (Dim 2)
Water Pump
VXZ232CGBSMC Water Valve
730-4514 Coolant Tank
Raspberry Pi
86-573 High-Res Camera
TMS IDs Dome Light
30345T347 Eye-t0-tab Lanyard
02-009 Crash bar (with spacers)
Drop In T-Nuts
Socket Head Cap Screw
Socket Head Cap Screw -Stainless
Flathead Screws
Button head Screws
Thumb Screw

 

Assembly- Step 1

  X3

M5x35mm

 

Size 4 Allen, Bag A Remove screw connecting the wedge and tray tab pieces	Feed screw through end hole and tighten Ensure tray tab is normal to inspection tray	Repeat for other pairs Line up in 1st – 3rd – 5th holes as shown

Assembly- Step 2

M6x12mm

 

Size 4 Allen Remove the flathead screws from these two risers	Size 4 Allen Feed them through the holes on the inspection plate Tighten the plate down into the risers

 

Assembly- Step 3

This is the Position one Tab	Size 5 Allen Slide Ext. 1 up against the Position one Tab	Make sure the extrusion is flush to the tab and bottom extrusion frame

 

Assembly- Step 4

Size 5 Allen Circled is the Pos. 2 TAB	Slide Ext. 2 onto bottom Extrusion Press Ext. 2 up against the tab. Make sure it’s flush

 

Assembly- Step 5

Size 5 Allen 39.5 cm from Motor End, you’ll see the pos. 3 drawing	Line up Ext. 3 onto pos. 3 drawing Make sure Ext. 3 slots line up with Ext. 2 and lower frame slots

 

Assembly- Step 6

Size 5 Allen the Space between Ext. 2 and Ext. 3 is circled above	Slide Ext. 4 between Ext. 2 and 3, with Screws facing out Ext. 4 height from the bottom frame is 30.5 centimeters

 

Assembly- Step 7

 

Size 5 Allen 1) Slide Ext. 5 between ext. 1 and ext. 2 (Plate side near Ext 2/3 as shown), alignment jigs are there to aid you 2) Slide Ext. 6 between ext. 1 and ext. 2 so that the top is flush across

 

Assembly- Step 8

Size 4 Allen, Bag A Unscrew the flatheads from the T-nuts Drop in T-nuts in between ext. 2 and ext. 3	Screw the flatheads through the Pump Mount Plate into The T-nuts

Assembly- Step 9

M6x10mm

 

Size 4 Allen Identify the H1 and H2 drawings on the side of Ext. 2 H1 position is top of bracket for the Tall trays, H2 position is for Short Trays	Remove Socket head Screws from T-Nut and drop the T-nuts in Position the Valve Mounting Bracket As indicated by the Desired Heights Drawing Tighten down socket head screws through the bracket Back into the T-nuts

 

Assembly- Step 10

Size 3 Allen See Ext. 2, 3, 4	Loosen the BUTTON HEAD Screws in The T-nuts on ext. 4 Feed SCREWS through at the Holes on the tank Mount the Tank onto Ext. 4 as shown

 

Assembly- Step 11

Size 5 Allen Slide the Raspberry Pi’s Extrusion into Ext. 1	Line up with the Alignment tab The Raspberry Pi Ext. Height should be 32.5 cm above bottom Frame

 

Assembly- Step 12

Size 3 Allen Unscrew the 4 Corner socket head screws, not the two central flathead screws.	Feed the Screws through the camera stage into the Camera Stage mounting plate

 

 

Assembly- Step 13

This is the Camera after It is mounted in the previous step	Slide the Dome light up onto the Camera Position the dome light such that the cable is on the Pi Side	The thumb screws on the Dome Light cap must line up with slots on the camera as shown Tighten each thumb screw down evenly

 

Assembly- Step 14

Size 3 Allen Unscrew THE TWO BLACK SOCKET HEAD SCREWS	Feed the screws through the lanyard eye and into the Camera Stage Mounting plate

 

Assembly- Step 15

Size 4 Allen Remove screws from t-nuts	Feed screws through crash bar into t-nuts Ensure crash bar is parallel with the Chip Tray plate above the Chip Tray Tabs, and below the bottom of the dome light

 

Assembly Front view

Assembly Top View

Assembly- left and right Views

Assembly- Rear View

Wiring

• No wiring is necessary for the completion of the assembly. The wiring has been completed with Quick connectors for your convenience. Simply connect the cables with like labels when you are ready to plugin.
• Zip tie mounts are located at recommended intervals for routing. Place the cables on the mount (as shown) and use a zip tie to secure them
• Cable wrap has also been included for post routing, for aesthetic purposes if desired

Wiring-Cable Inventory

• Complete list of cables in the system:
  • POWER – VAC MAIN POWER SUPPLY CABLE
  • Pi Pwr – Power to the Raspberry Pi
  • Lim Switch – Signal between Pi and limit switches
  • Light – Power and CONTROL OF the Dome Light
  • Water – Power and CONTROL OF the Water System
  • PUMP – Section of Water cable that breaks away for pump power
  • Cam TRG – Trigger for the Camera
  • CAM USB – POWER AND EXTERNAL CONNECTION TO CAMERA
  • Ethernet – COMMUNICATION between Pi and Motor
  • Serial – USB to serial TTL connection for routine start from external reck

Wiring-Cable Inventory

Image One: power Supply bundle
Image 2: Extrusion 1 Base
Image three: Motor and Limit Switch Cables
Image four: Main Bundle
Image Five: Camera and Water cables

 

• Image Six: Pump, valve, and tank

Software tutorial

• The software has been specially designed to be both easily interfaceable and highly functional. We will explore the menus, controls, and various other notes on things that could come up
• If you’re in the software and are confused, give this Question Mark a tap

 

This is the first screen to pop up at startup. Press the home button and allow the motor to home itself

This is the Main Menu, the first thing the screen will show upon power up. There are a few options from here:

• Start – Runs the currently selected routine. Changes to “running” when a program is running
• Stop – Appears when running a routine. Stops the routine
• Routine – Selects the desired routine (Shown “No Routine”)
• Delete – Removes the selected routine

• Use Spray – toggles the water spray function on for the routine
• Home – House icon in the top right. Returns User to the home screen
• Settings – gear icon. Takes User to the Settings Menu Selection Screen
• Manual – Takes the User to the manual motion control screen

Shown is the Settings Menu

• Motor Settings – Displays the Motor Settings
• General Settings – Displays Non motor settings

Motor Settings

• Acceleration: Adjusts rate of Acceleration
• Deacceleration: Adjusts rate of Deacceleration
• Max Velocity: Adjusts top Velocity During Routine
• Current: Adjusts the motor current
• Home motor – rehomes the motor. This is a good idea Before teaching a new routine, which we will go over later
• Restore Defaults – reverts all settings to their default values. Do not hit this button unless instructed

General Settings

• Trigger Delays – Sets the delay timer before and after the camera triggers during a routine
• Pump Prime – Timer for how often the pump activates
• Spray on – Timer for nozzle spray
• Nozzle offset – Distance from Camera to Water Nozzle. This is a critical measurement, do not change without following the procedure as directed

Manual Jog

• Position – Jogs the inspection tray
• Speed – adjusts Jog Speed
• Camera – Takes an image
• Light – Toggles the light on/off
• Droplet – Toggles Pump On/off
• Spray Bottle – Manually sprays the nozzle

 

Software Tutorial- Routines

• To make a new routine, tap the routine selector on the home page and select “New Routine”
• There are two ways to teach a new routine. Descriptions of process listed under both options
  • Step Mode
  • Distance Mode
• The bottom right icon returns the user to the home screen

Software Tutorial- Step Mode

• First Screen: Sets the start position for the routine
  • Jog to the desired starting position
  • Adjust jog speed with the speed function
  • Use the camera and light functions to dial in how you want your first image to look

• Second Screen: Sets the End position for the routine
  • Jog to the desired End position
  • Adjust jog speed with the speed function
  • Use the camera and light functions to dial in how you want your Last image to look

• Third Screen: Sets the number of steps in the routine. This is essentially the amount of images that will be acquired between the starting and end points
• The images will be evenly spaced between the user start and end positions defined in the previous screens

• Final Screen: Names the routine
  • Name the routine anything you want
  • Hit set when finished. This will cause the System to reset position. The newly created routine will be saved
  • Hit The escape button in the bottom right to return to the home screen without saving the routine

 

Software Tutorial- Distance Mode

• First Screen: Sets the start position for the routine
  • Jog to the desired starting position
  • Adjust jog speed with the speed function
  • Use the camera and light functions to dial in how you want your first image to look

• Second Screen: Sets the Distance per step for the routine
  • Helpful to get the consistent distance between images. Particularly useful for Chip trays with uniform slot sizes
  • Figure out the desired distance before making it to this screen

• Third Screen: Sets the number of steps in the routine. This is essentially the amount of images that will be acquired between the starting and endpoints
• The images will be evenly spaced Given the step distance specified in the previous step
• Exceeding the overall machine range of motion will cause the routine to not run

System Operation 

If everything has been assembled, plugged in, and powered on properly, the system operation itself is simple! Most of the operation is carried out by the system itself, but there is a small operator role. This short section will detail that role, and offer some tips that should help in the daily operation.

Operator Role:

• Check the belt tension (see slide 65)
• Load Chip Tray onto inspection plate
• Slide Chip Tray lid into finger slots
• Adjust inspection plate tab with thumb screws to secure in place
• Ensure the tray is pushed back all the way against the stop
• Set the water nozzle offset value (see slide 66)
• Ensure water is toggled on/off according to your preference
• Ensure the nozzle is primed (manually dispense water out of the nozzle to check)
• Plug in the Camera USB to the External Computer
• Open Spinview and connect to the camera
• Start the routine from the Start button or over Serial Connection

 

System Operation- Tensioning the Belt

The motor belt might need to be tensioned if the belt is too loose

1. Loosen the M8 hex nut and mounting screws on the sides of the bracket
2. Tighten the m8 screw on the end of the mount until the belt is tensioned
3. Tighten the M8 hex nut and the mounting screws

 

System Operation- nozzle offset

 

The distance between the water nozzle and the camera must be set

1. Home the motor, then Open manual jog screen
2. Line up the first slot on the Chip tray under the water nozzle and record the position value
3. Line up the first slot on the chip tray under the camera and record the position value
4. Calculate the difference
5. In settings – General Settings – nozzle offset, set the calculated value

 

 

Troubleshooting

 

Troubleshooting- Bad Images

• Out of Focus
  • Out of focus while machine is still:
  • Rotate the camera lens (easiest to do this by rotating the dome light itself)
  • Take images periodically to analyze the focus using the manual jog menu’s camera function
• Out of focus while Machine is running:
  • Drop Acceleration, Deacceleration, Max Velocity in Motor Settings
• Low/high Lighting
  • Adjust Exposure: dial on the camera itself
  • Adjust Gain: spin view settings
• Crooked
  • The tray was not set in properly. Follow the alignment instructions detailed in the System Operation section

Troubleshooting- Inconsistent Water

• Check that the water tank is full
• Clean nozzle
• Manually dispense water (check software tutorial, Slide 40)
• Loosen the socket head screws and slide the nozzle closer or farther from the tray (check that the valve remains above the chip tray tabs)
• Adjust water “Spray On” Timer in General Settings

Troubleshooting- Images are Crooked

• The tray was not set in properly. Follow the alignment instructions detailed in the System Operation section

Troubleshooting- Software Frozen

• Cycle Power:
  • Shut off the power supply
  • Wait a few seconds
  • Turn the power supply back on
• Allow System to cool

Troubleshooting- Inspection Tray Not moving

• Go to the manual jog menu. Does it say “collision Detected”?
  • Yes
    • Tension the belt according to the next slide
    • Decrease Acceleration, Deacceleration, max velocity via the motor settings menu
  • No
    • Cycle Power. Turn of the system, wait 10 seconds, turn on the system and allow normal boot up
    • Home Motor

 

Final images 

Final Machine: Front

 

Final images: Angle 1

Final Images: Angle 2

Final Images: Side

Final Images: back