EOM00208-000

PQA-C

OPERATION MANUAL

KOMORI CORPORATION

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Note

1. The contents of this manual may be modified without prior notice to the customer.
2. Due care has been taken in the preparation of this manual, but if the user notices any errors
or other points of concern, please contact KOMORI Corporation.
3. Please understand that KOMORI Corporation shall not be responsible for the results of
operating this product.

TRADEMARKS
Microsoft, Windows, Windows95/98/NT/Me/2000/Xp, Internet Explorer and IME 2000 are registered
trademarks of Microsoft Corporation of the United States of America.
Other product names and model names are the trademarks or registered trademarks of their respective
companies.

The copyright for this manual is protected by the Copyright Law. Please be duly
aware that reprinting or reproduction (copying) of the contents of this manual
without the express written permission of KOMORI Corporation could be an
infraction of the copyright.

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Safety
Safety Precautions
To ensure safe operation of this device, please carefully read and understand these safety
precautions before starting up the device.
This device is equipped with two types of safety devices for either protecting the safety of the
operator or for preserving the functionality of the device.
This device was manufactured giving due consideration to safety, but to promote greater safety,
please check the installation locations of the safety devices and be sure to understand their function
before starting up the device.

1. Safety promoting warning labels

Warning labels that promote safety are affixed to this device or printing press to identify areas where
there is high-voltage power, rotating parts or moving parts. Please use the device with being fully
aware of the areas where these warning labels are posted.

2. Protective clothing
Wear clothing that is suitable for the work when operating this device.

3. Safety precautions for daily operations

1) Immediately wipe off any oil, water or other substance that gets on the floor or
device to keep the walking and other areas around the device safe. Always keep
the working environment clean.
2) Bundle the power cords and other cables to promote safety.

4. Safety precautions for device operation

1) Do not operate the device with wet hands.
2) Do not place objects on the device and do not drop cigarette ashes, etc., into the device.
Also, do not use a pen or tool to push the operation buttons, etc. Doing so could damage the
device or cause it to malfunction.

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Operation Conditions and Precautions

● When the printing medium is a paper that strongly reflects light such as foil paper or hologram
paper, or when the paper is a dark color (black, etc.), has a pattern, or is a clear film, etc., the
paper is outside the operation specification range of this device. In addition, when the ink is
metallic or exceptionally reflective of light, it might not be possible to conduct the inspection.
● Paper with a strong curl, paper that deforms easily during printing due to the pattern balance or
stiff carton paper are difficult to inspect with high accuracy.
● The defect detection accuracy means that the detectable size of a process color CMYK ink
smudging of 0.26 x 0.26 mm or larger has occurred in the white background while the tolerance
setting is set to the normal tolerance setting. In addition, if there is a character, pattern, etc., close
to the ink smudging, it may not be detectable even if it satisfies the size condition of 0.26 x 0.26
mm.
The size of detected defect changes according to tolerance level.
● The inspection might terminate if the printing press speed changes abruptly (accelerates,
decelerates, etc.).
● Although the degree coming from fluorescent lights installed in the ceiling does not pose a problem,
if there is a strong light source (mercury lamp, UV or IR lamp, sunlight coming through the window,
etc.) in the vicinity of the camera light axis or the lamp house, this device might not operate
normally. In this case, take measures to block out the ambient light.
● If an insect passes over the camera light axis during the inspection, or powder or debris that has
accumulated in the device passes through the light axis, it could be erroneously detected as
defective printing. In this case, eliminate the insect or clean the inside of the device.
● Be sure to perform the maintenance presented in “9. Maintenance”. Not performing this
maintenance could hinder maintaining the specified performance of this device.
● To view the defect history data from a computer on the network, support for the browser Internet
Explorer Version 6.0 or later is required. However, for firewalls and other security setting related
restrictions, take appropriate measures from the computer on the network.
● KOMORI will determine whether or not to conduct software version upgrades. (Normally, KOMORI
will not meet requests to upgrade functions even during the product warranty period.) However, if
it is clear there is a problem with the software, the software will be revised at the discretion of
KOMORI. In this case, separate consultations will be held with the user.
● If applications other than those installed by KOMORI are installed on the PQA-C computer, the
inspection device may not operate normally.
● The LCD display may experience a slight color change caused by temperature changes or other
factors because of its construction.

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SAFETY 3

OPERATION CONDITIONS AND PRECAUTIONS 4

1.SYSTEM INTRODUCTION 7
Overview 7
2. SPECIFICATIONS 8
3. SYSTEM CONFIGURATION 9
4. OPERATION METHOD 11
4.1. Turning On/Off The Power 11
4.2. Starting the Inspection 12
4.3. Operation During Inspection 12
4.3.1. When a defect is detected 12
4.3.2. Light source error detection, template detection error 13
4.3.3. Inspection pause 14
4.4. Improper Printing Paper Inspection Operation Flow 15
5. JOB CONTROL 16
5.1. Defect History Data Identification Information 16
5.2. Repeat Data Selection 16
6. TOLERANCE CONTROL 17
6.1. Tolerance Parameters 17
6.2. Inspection tolerance selection and editing 18
6.2.1. Inspection Tolerance Selection 18
7. PRINT INSPECTION CONCEPTS 19
7.1.1 Digital Images 19
7.1.2 Standard Images 19
7.1.3 Inspection Tolerances 19
Detecting Printing defects 20
Detecting Printing defects 20
7.1.4 Pixel comparison 21
Measuring Print process Layer Registration 21
8 SYSTEM USER INTERFACE 22
Overview 22
User Interface Features 22
8.1.1 Main Interface Screen 22
8.1.2 Main Inspection Window 23
8.1.3 Status Indicator 23
8.1.4 Printing Speed Display 25
8.1.5 Used Sheet Count Display 25
8.1.6 OK Sheet/NG Sheet Display 25
8.1.7 Project Name / Job Name Display 25
8.1.8 Defect History Display 26
8.1.9 Tolerance Name Display 27
8.1.10 Job Selection Screen 27
Job Details screen 27
Mask setting screen 29
Menu Screen 31

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9. MAINTENANCE PROCEDURES 32
9.1 Overview 32
9.2 General Information and MAintenance Schedule 32
9.3 Cleaning the Operator Stand 32
9.3.1 Procedure to Clean the Operation Stand 32
9.4 Camera Cleaning 33
9.4.1 Procedure to Clean the Camera housing and lens 33
9.5 Illumination Lamp cleaning 33
9.5.1 Procedure to Clean the Illumination Lamps 34
9.6 Perform camera calibration 34
10 REPLACING SYSTEM COMPONENTS 35
10.1 oVERVIEW 35
10.2 Camera Replacement 35
10.3 LED Lamp Replacement 35
10.3.1 Procedure to replace the LED Lamps 35
10.4 Uninterrupted Power Supply Battery replacement 35
10.4.1 Procedure to replace the UPS Battery 35
10.5 Exchange of Motherboard battery 35
11 REMOTE BROWSING OF DEFECT HISTORY 37
11.1 Computer Default Network Setting 37
11.2 Browsing Defect History from Browser 37
11.2.1 How to browse from Internet Explorer 37
11.3 Viewing defect history 38
11.4 Understanding the defect history report 39
11.4.1 Filtering the defect history report 39
11.4.2 Selecting the defect history to be viewed 39
11.4.3 Choosing the images to view 39
11.4.4 Report detail information 40
11.4.5 Inspection tolerance 40
11.5 Viewing tolerance 40
11.6 Viewing maintenance information 40
11.7 REMOTE VIEWING DEFECT HISTORY WITH BROWSER 41
12 CHANGING PQA COMPUTER NETWORK SETTINGS 42
12.1 Precautions for Making Network Changes 42
12.2 Setting PQA Network communications parameters 42
12.2.1 Verify Computer Name 42
12.2.2 Set PQA IP Address 42
12.2.3 Set the PQA Port Number 42
12.2.4 Set the PQA Device ID 42
13 SYSTEM ERROR MESSAGES 43
14 TOUBLESHOOTING 46

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1.System Introduction
OVERVIEW

This device is attached to an offset printing press to be used for inline inspection of printed
materials. The detection unit uses an RGB 3-color CCD camera to detect smudging on paper
without differentiating the CMYK.
This device is interlocked with a KOMORI printing operation related system (PQC or KHS-AI,
KMS, etc.) that includes a printing press and automates the job changeover operation, eliminates
the need to perform almost any operations during printing and completes inspection preparation
inside the device.
For inspections, a standard pattern is read first, a comparison of the density difference between
the pattern being inspected and the standard pattern is made, and then a difference is detected
as a defect if the difference exceeds the tolerance range. The pattern read as the original paper is
held as the standard pattern until printing is completed. The detectable defects are ink spattering,
water stains, oil stains, ink smudges, etc. Detailed settings can also be made, such as the
improper printing paper detection level setting and continuous generated sheet count setting.
To reduce erroneous error detection, the optimum paper holding is conducted in response to the
paper thickness, paper quality and other factors using air control, image distortion caused by
paper floating or position offset is automatically detected, and the phase offset from the standard
pattern is automatically corrected. The detected defect image is displayed with the standard
image for comparison to make it easy to determine and confirm the defect on the screen.
Furthermore, the defect history data is automatically saved in the XML data, so if the computer of
this device is connected to a LAN, the defect history can be browsed remotely from a computer
installed with a browser that can display XML data (Internet Explorer Version 6.0 or later).

[Features]
- Very resistant to paper floating and can conduct inspections without making the tolerance
too lenient.
- The tolerance levels for darkening trend defects (density increase side) and lightening
trend defects (density decrease side) can be detected by being set separately to conduct
inspections that match the printing conditions.
For example, the device can be set strictly for water stains but not to detect double
detection caused by paper curling, register adjustment or other factors within the
tolerance level.
- Follow-up inspections for continuously occurring defects when the sheet count is set are
conducted, so minute defects, such as paper debris on the white background, can be ignored
and continuous quality defects caused by a hickey, etc., can be detected. Depending on the
setting, it is possible to detect large defects even on one sheet regardless of the defect
continuous occurrence count setting.

* Note
During inspection this device continuously monitors the amount of light and if It falls outside
of the control range, the inspection may be automatically interrupted and a tolerance
automatically created.
This device does not detect all quality defects of the printed matter. Defects in the
standard sample itself and defects that occur after the sheet has passed through
the inspection device are outside the purpose of this device. In addition, smudges
in complex patterns are harder to detect than quality defects in white areas, so
please continue to conduct regular sampling inspections of the printed matter.

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2. SPECIFICATIONS

Item Specification Remarks

3 CCD Line scan camera.(R/G/B)
Use 2 cameras for high resolution
Camera Pixel Size : 0.26 x 0.26mm.
inspection.
1 line scan : 2,048pixels.
Use a LED light mend for line scan
Lighting LED light
camera.
Inspection speed Max. rpm ×40% to Max. rpm 10,000 SPH (complies with machine
range 3,500 SPH to Max. rpm used)
19 inch LCD display (1,280×1,024), Laser mouse is supplied by KOMORI
Human interface POD (800×600 touch panel) and POD: Programmable Operating
mouse Display
The detection level changes
Defect detection CMYK ink smudge comparable to 0.26
depending on the tolerance parameter
accuracy x 0.26 mm on a white background
setting.
Density increase, density decrease,
Defect detection ink spatter, stain due to insufficient
description water, paper smudges, water stains, oil
stains, miss register, etc.
Alarm (signal tower, audio), reject
Defect warning
signal.
Output to XML file
1,000 jobs/month
Can be viewed from other computers
1,000 cases/job
Defect history without a special application
Holds the most recent 100 jobs
(Internet Explorer Version 6.0 or later)
In addition to the most recent 100 jobs,
preserves the history for the past year
Air control is performed using blower
Paper holding Paper holding mechanism employing control employing an inverter based on
mechanism an air nozzle commands from the POD in the
operation stand.
Operation stand Supply of power from the blower
AC200V single phase 1 kVA
power supply control panel is standard.
Blower panel The power supply specifications differ
3 phase 200V±10%
power supply depending on the machine conditions.

Option: remote monitor The operation stand screen can be viewed from a remote location
using a remote monitor.

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3. SYSTEM CONFIGURATION

Camera x 2

Relay Box

Impression
LED lamp house
Cylinder

Monitor x 2

Control line,
Unit IO,
Warming signal,
Reject gate signal.

Unit control System

Encoder(attached to pringing press)

Power supply AC200V 1 1kVA

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(1) Camera: Printed image capture unit

The printed paper surface is captured one line at a time in synch with the sampling signal. One
line in the paper horizontal direction is 4,096 pixels.
(2,048pixels x 2 cameras)

(2) Lamp house

This illuminates the camera input image area. The light on the white target is continuously
adjusted to a set brightness.

(3) Relay box

This contains the camera power supply and the lighting power supply. The camera input data is
converted to optical data and output to the operation stand. The lighting adjustment commands
to the lamp house are received by the operation stand, which outputs the light adjustment.

(4) Operation stand

Image input data processing: Inspection processing, lighting power control calculation, defect
warning, reject timing calculation
Computer: Human interface, defect history data control, inspection
parameter data control
POD (PQA T/P): Controls the volume of air to the air nozzle

(5) Rotary encoder

The encoder is attached to the end of the printing press designated cylinder shaft to output the
timing pulse for the image input camera scan in accordance with the printing press rotation. This
device calculates from this signal the output timing for the printing speed, rotation variation,
inserter, etc.

(6) Printing press interface

The printing press interface allows interlinking with the printing press for automatic inspection by
inputting the signals for interlinking with a KOMORI system (PQC, KMS, etc.) through
communication, inspection start and stop from an external switch, and blanket cleaning or other
signals in addition to outputting the alarm and reject signal to the printing press.

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4. OPERATION METHOD
4.1. TURNING ON/OFF THE POWER

Turning on the power Turn on the power to the printing press (main panel).
When the power switch built into the operation stand is turned on, the
PQA-S processing computer is automatically started up.
*Confirm that the breaker switch in the PQA-C operation stand is on. First,
the Windows operating system will start up, and then the PQA-C program
will start up.
*If the PQA-C program does not start up, double click on the desktop PQA-C
icon to start up the program.
Normally, after the Startup screen is displayed, the Inspection screen is
automatically displayed. The Maintenance screen will be displayed if
maintenance is required, so in this case conduct the maintenance.
The circuit board power on lamp and input device status indicators at the
top of the Inspection screen are used to check the image processing circuit
board, statuses of communications and other information, so the device is
on standby until the inspection can be started. Only in case of illumination
lamp is fluorescent light, the indicator status is set to be OK approximately
5 minutes after the device starts up (lamp is turned on). (The indicator light
color will change from yellow to green.)

Power shutoff When the printing press power is turned off and thus shuts off the power,
but the device’s operation stand is equipped with an uninterrupted power
supply (UPS), so the image processing computer will use the power from
this uninterrupted power supply and automatically shut down in about 3
minutes. If the power will be repeatedly turned on and off for printing press
maintenance, etc., turn off the power breaker switch in the PQA operation
stand in advance.

*The image processing computer power and monitor power may be off even if the device’s power
breaker switch is on. Open the front door of the operation stand and turn the computer power
switch on, and check if the monitor power is also on.

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4.2. STARTING THE INSPECTION

The inspection operates interlocked with the printing press. When the printing press begins
printing, the conditions required for the inspection are automatically prepared based on the input
image acquired from the device’s camera and the device enters the ready for inspection status.
When printing is in the OK status, press the [Start Insp.] button on the Inspection screen. The
OK sheet printed matter camera image is acquired and inspection begins. (The sampling
number of OK sheet can be changed from based on the tolerance setting.) The required
inspection items are given below.

Project, Job No. specification : Defect history data control name setting
Tolerance parameter selection : Tolerance level setting for the inspection
Air setting : Air volume setting for holding the paper

4.3. OPERATION DURING INSPECTION

4.3.1. When a defect is detected

The defect image is zoomed and displayed alternately with the standard image. Also, the
occurrence location is displayed at the top right.

Red zoom outline ⇔ Location of printing defect zoomed image

Red note outline ⇔ Location of defect note position.
Red ⇔ White flicker display: Density increase detection
Blue ⇔ White flicker display: Density decrease detection

When a defect is detected, an alarm sounds together with the screen display.

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4.3.2. Light source error detection, template detection error

The device continuously monitors the light source during the inspection, and if it determines that
it is not suitable for the inspection conditions, it automatically returns to the inspection
preparation status and re-conducts the inspection.

Light source error

When the light source control output is below 40% or higher than 115%.
When the white area RGB value variance is outside the set range.

Insufficient light volume alarm

If the white area reflected light amount does not reach the target value even if the light
source control output is greater than 115%, the inspection will pause, the white area reflected
light volume target value will be automatically lowered, and the inspection will be restarted
from the standard image acquisition. This status will be displayed at the bottom of the screen.
In addition, check around the lamp house, and if it is dirty, wipe it off. If the ends of the tube
are blackened, replace the tubes. *When replacing the fluorescent tubes, always turn off the
power to the device first and then follow the replacement procedure explained in Section 9.3.
During installation the device is adjusted using coated paper, so an alarm may be shown
even if everything is normal if the paper quality is poor or the printing paper is colored, but
inspection can be continued as is.
Excessive light volume alarm
If the white area reflected light amount is larger than the target value even if the light
source control output is less than 40%, the inspection will pause, the white area reflected
light volume target value will be automatically increased and the inspection will restart from
the standard image acquisition. The excessive light volume alarm will be displayed at the
bottom of the screen. This function allows the inspection to be continued without a
problem when continuously printing at low speed.

Out of offset control range

If the reflected light volume of the white area of the printing paper used for light source
control is out of the target value and the light source cannot be controlled, stop the
inspection and restart it from inspection preparation.

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4.3.3. Inspection pause

The 2 types of inspection pauses are described below.

Pause Type Description Causes
The standard image data and -Pause due to detection of
tolerance prior to the pause is unstable speed caused by a
maintained.
rapid printing speed change.
Inspection Pause 1 The light source continues to be
-Pause due to the light volume
controlled, so the inspection
restarts as soon as the pause is conditions, such as insufficient
released. or excessive light volume.
The standard image data and
tolerance prior to the pause is -Manually paused
maintained.
-When the printing press speed
Inspection Pause 2 The device is in standby for the
becomes lower than the speed
restart of printing. Inspection is
automatically restarted when at which inspection is possible.
printing restarts.

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4.4. IMPROPER PRINTING PAPER INSPECTION OPERATION FLOW

Job Setting
- Specify project, job name
- Set air blow
- Select tolerance parameter

Start printing

Color matching, register adjustment

NO
Actual paper?

YES

Turn on PQA T/P inspection start button

Defect confirmation
If necessary, click on the Retarget
button

NO
Printing finished?

YES

Stop inspection

YES
Is there another job?
(*1)

(*1) NO
Operator can decide to save
following informations. Turn off power
- Standard Image
- Tolerance and mask Images
- Inspection Parameters.

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5. JOB CONTROL
Job Data
Name Description Remarks
Project name Print job control group This is used by this device as
inspection history data
Job name Print job name
identification information.
The parameter value uses the
currently set value. (If the
parameter name is unchanged
tolerance Registers the front surface
when the contents are edited,
parameter name tolerance parameter name.
such as after a job is saved, the
changed contents will become
the current setting contents.)
Preserves the mask data (area
Mask level setting that changes the inspection
data level) and the level data
(inspection level).

5.1. DEFECT HISTORY DATA IDENTIFICATION INFORMATION

The project name, job name, tolerance parameter name and job start time are added to the
defect history data, and this is saved for each job.
Defect history data identification can be done when writing the project name and job name as
well as at the job start time. Setting this to show which job history data it is makes it convenient
when analyzing the defect history later.

5.2. REPEAT DATA SELECTION

The above items can be reselected by saving the repeat data. This is used for similar jobs that you
want to inspect at the same tolerance level. If the printed matter has the exact same pattern, the
mask information, the marginal pattern and other information can be used.

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6. TOLERANCE CONTROL
6.1. TOLERANCE PARAMETERS

This is performed using the Tolerance Creation screen.

<Tolerance Pattern>
Flexible 16 pattern inspection level setting (inc: No inspection / Default inspection)
Layer setting.(Intaglio region and Offset region setting)
Flexible inspection level setting.

<Tolerance Parameters>
Item Contents Remarks
This is the tolerance of base
darkness portion setting.
Base tolerance
They are mainly used to set the
(paper darkness)
strictness for inspections of white
areas with no printed pattern.
This is the tolerance of base
brightness portion setting.
Base tolerance
They are mainly used to set the
(paper brightness)
strictness for inspections of white
areas with no printed pattern.
This sets the increase portion (%)
for the standard pattern density. A
value higher than this is a defect.
During actual detection this
Density increase This tolerance is mainly used to
is added to the density
defect tolerance detect adhered matter quality
increase defect tolerance.
defects like a printing density
increase, ink smudge or insufficient
water stain.
This sets the decrease portion (%)
for the standard pattern density. A
value lower than this is a defect. During actual detection this
Density decrease
This tolerance is mainly used to is added to the density
defect tolerance
detect missing matter quality decrease defect tolerance.
defects like a printing density
decrease, water stain or oil stain.
Default setting:0.26 – 2mm
Detect defect size This sets detect the defect size The defect determination
setting(mm) (mm) block size is a maximum of
200.

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6.2. INSPECTION TOLERANCE SELECTION AND EDITING

6.2.1. Inspection Tolerance Selection

The following screen shows each tolerance for each color channel and for each inspection
mask. By choosing a specific mask level and color, the operator can define the tolerance level
that will determine what difference from the standard should be classified as a defect. At the
bottom of the screen, the operator can define the size of the defect within each inspection mask
that will determine if the defect should be rejected or not. Once all the inspection mask level
and area thresholds are defined the operator can exit from this screen by pressing the “Close”
button.

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7. Print Inspection Concepts

7.1.1 Digital Images

The PQA-C uses high-resolution cameras to capture digital images of each sheet under
inspection. A digital image can be thought of as a photograph that has been broken down into
tiny squares that range in both color and intensity. These squares are called pixels. The
following figure shows how a digital image is broken into pixels.

7.1.2 Standard Images

A Standard contains information that describes what an ideal sheet looks like and how the
sheets under inspection should be inspected. The inspection process is based on a pixel-by-
pixel comparison between the sheet under inspection and the Standard. At a minimum a
Standard contains the following:

Reference Image — is the result of several digital images of “known good” sheets combined to
produce an image of the ideal sheet for use during inspection. The value for each pixel in the
reference image is compared to the corresponding pixel value on the sheets under inspection.
The tolerance of the differences between the two determines whether or not it is considered a
flaw.

Masks — consist of areas defined within a Standard that are treated differently than other areas
during the inspection. Masks treat defects found within their areas more or less important than
defects found in other areas. The operator defines mask areas when creating a new Standard.
Masks can also be defined as a mask to ignore. The system ignores defects found in areas
defined as masks to ignore.

Security Thread Mask — allows the operator to define the location of the security thread in the
Standard reference image. Based on this definition, the inspection dynamically locates the
security thread on each sheet under inspection and ignores it to prevent falsely classifying it
as a defect.

7.1.3 Inspection Tolerances

Inspection tolerances control how strictly the inspection reacts to the size, location, and
number of flaws that a sheet can have and still be accepted. With a strict, smaller and fewer
defects cause sheets to be rejected. Each Standard defines default tolerances but the
operator can define new tolerances to tune or alter the inspection results. When a standard is
loaded, the system automatically loads the tolerances set for that standard. The operator can
also change the tolerances at any time, even during and inspection.

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DETECTING PRINTING DEFECTS

The inspection system compares each digitized image of a sheet under inspection to the
reference image in the Standard. Each inspection compares each pixel in the digitized image
captured by the camera to the same pixel location of the reference image in the Standard. If a
pixel in the digitized image from the sheet under inspection differs in color or intensity from the
same pixel in the reference image, and the difference exceeds the acceptable tolerance, it is
considered a defect. Each defect detected is then classified as acceptable or not depending on
its size and location.

DETECTING PRINTING DEFECTS

The inspection system compares each digitized image of a sheet under inspection to the
reference image in the Standard. Each inspection compares each pixel in the digitized image
captured by the camera to the same pixel location of the reference image in the Standard. If a
pixel in the image of the sheet under inspection differs in color or intensity from the same pixel
in the reference image, and the difference exceeds the acceptable tolerance, it is considered a
defect. Each defect detected is then classified as acceptable or not depending on its size and
location.

Standard Image Sheet Image

Compare Images
to Identify
Differences

Measure Size of
Defects

Size >
Threshold

Accept Reject

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7.1.4 Pixel comparison

The pixel comparison determines the severity of the defect according to its location in the image.
Differences identified during the comparison in user defined masked areas are measured
against higher or lower thresholds than those in other locations, depending on the sensitivity
defined by the operator. Additionally, once defects are classified, their size is also compared to
size thresholds defined by the operator for the masked area the defect is located within. All of
these thresholds can be set and changed before and during the inspection.

MEASURING PRINT PROCESS LAYER REGISTRATION

The inspection system can measure the registration of each printed layer on each sheet under
inspection relative to the position of other print layers. It measures the registration between
layers relative to the ideal registration between the same layers stored in the inspection
standard. Any difference found between the registration between any two layers in the sheet
under inspection and the standard image is considered an error. If this relative error exceeds
the tolerance, the sheet under inspection is rejected.

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8 System User Interface

OVERVIEW

The print inspection system user interface provides access to all the features for setting up,
running, monitoring, and adjusting the inspection performance. Use the mouse and keyboard to
access and control these features. This chapter focuses on the characteristics of the user
interface and how to use it.

USER INTERFACE FEATURES

The following sections describe the features within the inspection system user interface.

8.1.1 Main Interface Screen

The Main Interface Screen presents buttons along the top and side of the screen. These
buttons allow you to choose specific actions or access other menus for additional choices.

The following figure shows the Main Interface Screen..

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8.1.2 Main Inspection Window

At the center of the Main Interface Screen is the Inspection Window. The Inspection Window
provides a visual image of the sheet being inspected. While the inspection is proceeding, this
window is updated constantly to show the operator when and where print defects are being
detected in the sheet. If a print defect is detected that causes a sheet to be rejected, the
Inspection Window will change to show the full sheet image with a red box highlighting the
locations where defects were found on the left side of this window. Below this image will be the
time this defect was detected from the start of the inspection. On the right side of this window, a
zoomed image of the worst defect found on the sheet will be displayed alternating with the
same location in the standard image as shown in the image below.

8.1.3 Status Indicator

At the top of the Main Interface Screen is the Status Indicator. This indicator reflects the current
state of the system.

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Status Description Indicator

The image processing board is
Inspection System
starting after the computer is turned
Initializing
on.
Inspection Stopped The inspection has been stopped.

Searching for the The system is searching for print

template characteristics (templates).
The template search has finished
and the inspection standard is
Inspection Ready
loaded. The system is ready to
begin inspection.
After the standard is defined, the
Standard sampling in system begins to sample the printed
progress sheets to create the inspection
standard.
After the tolerance is created, this is
Tolerance creation
displayed to show that the system is
completed
ready to conduct inspections.
After the standard is loaded and the
Inspection in progress machine is feeding sheets, the
machine will begin inspecting.
Transferring inspection area
Transferring Mask information to image processing
board.
This is displayed when a defect is
Defect detected
detected.
The inspection has been paused in
Inspection Pause 1 mid operation due to speed
fluctuations.

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8.1.4 Printing Speed Display

The speed bar is displayed in blue when ready for inspection, but it will change to
red when not ready for inspection.

8.1.5 Used Sheet Count Display

After the job starts, the system displays the number of sheets that are fed through
the machine.

8.1.6 OK Sheet/NG Sheet Display

The system displays the number of OK sheets inspected or accepted sheets for
the current job. The count begins when the inspection status is inspecting. The
count stops when the inspection is stopped or paused.

The system also displays the number of sheets rejected or NG Sheets for the
current job.

8.1.7 Project Name / Job Name Display

The currently selected project name / job name is displayed in these widgets.
The defect history data is identified by these names in addition to the job start
time. Pressing the button for the project name or job name allows the operator to
edit the currently selected project or job name.

When this button is pressed, the report output setting of defect history data of the
current job is displayed. For more details please see the Defect History section.

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8.1.8 Defect History Display

The defect history is displayed below the Main Interface Screen. The displayed
items are the time of occurrence, the sheet number within the job the defect
occurred, defect description, number of defects, number of sheets, number of
consecutive sheets a defect occurred and the total number of sheets with defects.
The most recent defect is shown at the very top. A maximum of 12 cases can be
displayed. To check more history than this, select History Data from the Menu
Screen. The defect data of the 12 cases shown in the history can be checked by
pressing the ▼▲ buttons on the right side of the display window. This will also
update the Main Interface Screen to show the detected defect image.

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8.1.9 Tolerance Name Display

This displays the name of the tolerance being used for the current inspection.
Pressing this button on the bottom of the inspection screen will display the
Tolerance Selection Screen. The tolerance can be selected and edited from this
screen. For more information on this operation refer to the INSPECTION
TOLERANCE section below.

8.1.10 Job Selection Screen

The job data consists of the project name, job name, tolerance name and mask
data. The system can store up to 100 jobs. By clicking on the “Job Menu”
button at the top right of the Inspection Screen, the dialog box above will be
displayed. This dialog box allows the operator to choose three options:

Select: A project name or job name already registered can be selected

and its contents edited. An operator can also create project or job
name.

Save: This saves the job data selected at the current inspection screen.
This newly created job is not saved unless this button is pressed.

Save as New: This saves the job data selected at the current inspection screen
to the database as new data.

JOB DETAILS SCREEN

At the Job Details screen, a job registered in the project list can be edited,
deleted or added.

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Operation Description
New Job Creation By editing the Project Name or Job Name at the
top right side of the screen an operator can create
a new job.
Selecting a tolerance and Choose the name of the desired tolerance from the
registering a new job to list. Once chosen, press the “Add” button at the
the list. bottom of the screen to add the edited job to the
project list.
Selecting a registered job Click on the job name at the left of the screen and
then press the “Select” button at the bottom right.
Then press the “OK” button in the dialog box that is
displayed

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MASK SETTING SCREEN

Press the “Mask Settings” button on the Inspection screen to display the following
screen:

From this window the operator can define the product to be inspected. The
operator can choose a predefined product from the list in the window at the top
right of the screen or define new product information by entering the data in the
list to the right. Once the product is defined, the operator can define the masks to
be used by the inspection by clicking on one of the banknotes in the displayed
image. When this is done the following window is displayed:

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This window allows the operator to define all the inspection masks for the
banknote, define the layer templates used to measure proper registration and
define the thread masking data if a security thread is present in the design.

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MENU SCREEN

By pressing the “Menu” button at the top right side of the Inspection screen, the
Menu Screen is displayed.

Button Name Description

Inspection Displays the Inspection Screen. The system defaults to
this screen at power up.
Tolerance Displays the Tolerance Creation screen
Camera Test Displays the screen for checking the camera input data
History Displays the screen for viewing the defect history. The
defects for the past 100 jobs can be viewed.
Maintenance Displays the screen for viewing the maintenance
information. Notifies the operator when the system
needs maintenance.
Version Displays the current software versions of all subsystems.
System Reset Initializes the inspection system. This is typically not
used.
Backup Tool Perform save and restore functions
Marker Settings This is used by KOMORI service personnel
Application Exit This is used to perform a controlled exit of the system.

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9. MAINTENANCE PROCEDURES
9.1 OVERVIEW

This chapter describes the maintenance procedures for the inspection equipment.
These procedures focus on cleaning the system components.

9.2 GENERAL INFORMATION AND MAINTENANCE SCHEDULE

Dust interferes with the operation of Image Guard in various ways. The
accumulation of dust on glass covers on the strobe lights and camera filter and
lens causes deterioration of image quality. This is detrimental to consistent
and accurate inspection performance.
Dust can also get into the computers and electronic cabinets causing a variety
of failures ranging from unexpected inspection results to disk crashes.
The following table lists maintenance tasks and the recommended frequency.
Maintenance Task Frequency
Clean monitors and Operator Stand As needed
Clean/replace the system cabinet air filters Clean monthly
Clean cameras Clean monthly
Clean illumination lamps Clean monthly
Perform camera calibration As needed

9.3 CLEANING THE OPERATOR STAND

Please regularly clean inside the PQA operation stand.

If dust and other debris collect inside the operation stand, it could interfere with the
air intake of the computer installed inside the operation stand and cause it to fail.

9.3.1 Procedure to Clean the Operation Stand

Step Procedure
1 Release the lock on the
front of the operation
stand and turn the handle
to the right.

2 Carefully wipe away the

dust from inside the
operation stand

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3. Remove the filter from the

back of the computer and
use compressed air or
other means to remove
the dust.

4. Open the read doors of

the operation stand and
use compressed air or
other means to remove
the dust from the vents in
the operation stand.

9.4 CAMERA CLEANING

Dust on the camera lens and camera case window reduces the light sensed by the
camera. Since the purpose of the inspection system is to detect small changes in
reflected light into the camera, dust can significantly affect the inspection
performance. The recommended camera cleaning interval is per month.
Proper operation of the system depends on the alignment of the cameras and the
illumination with respect to the substrate. It is very important not to disturb the
camera alignment when cleaning.
To clean the camera, use a soft cloth moistened with alcohol to carefully wipe off
the camera case window.

9.4.1 Procedure to Clean the Camera housing and lens

Clean each camera with a light brushing movement using only a soft cloth
moistened with alcohol. Be careful not to disturb the camera alignment or focus.
Do not use a rubbing motion when cleaning.

9.5 ILLUMINATION LAMP CLEANING

Dust on the illumination lamp can reduce the light that reaches the target sheets
under inspection. Since the purpose of the inspection system is to detect small
changes in reflected light into the camera, dust can significantly affect the
inspection performance.
Even if the illumination lamps are pointing downwards, dust can still accumulate
on the glass. Komori recommends cleaning the illumination lamps per month.
Proper operation of the system depends on the alignment of the cameras and the

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illumination lamps with respect to the sheets under inspection. As such, it is

important not to disturb the light alignment when cleaning.

9.5.1 Procedure to Clean the Illumination Lamps

Ensure that the power to the lamps is off.

First, turn off the power to the device. To clean the illumination lamp use a soft
cloth moistened with alcohol to carefully wipe them off.
Caution: Be very careful when handling the illumination unit.
For more details, refer to the attachment “Maintenance Information.”

9.6 PERFORM CAMERA CALIBRATION

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10 REPLACING SYSTEM COMPONENTS

10.1 OVERVIEW

This chapter describes how to replace various components. Where required,

alignment procedures are also provided.

10.2 CAMERA REPLACEMENT

The inspection system cameras have very low malfunction rates. However,
once it has been determined that a camera is defective, consult Komori
Service Department for confirmation.
The procedure for replacing a camera involves many steps, all of which need
to be followed carefully. Only trained personnel who are familiar with using the
maintenance functions of the system should replace the cameras. These
functions are for use by trained technicians and can cause inspection
problems if set up with incorrect parameters. Therefore it is recommended
that Komori trained service personnel be contacted to change the cameras.
Use care to follow these procedures accurately.

10.3 LED LAMP REPLACEMENT

Be sure to use the specified LED lamp. Using a different LED lamp could prevent
normal detection performance due to different illumination characteristics. If you
have any questions, please contact the KOMORI Service Department.
The average LED light has a life of 20,000 hours. The lifetime may vary
depending on the operating conditions.

10.3.1 Procedure to replace the LED Lamps

When replacing the illumination lamp, first turn off the power to this device. Be
very careful when handling the illumination lamp.
Use the following procedure to replace the LED lamps:

When finished replacing the illumination lamp, open the Maintenance screen and
press the [Changed (U)] button (if back surface, [Changed (L)] button) in the Lamp
Change menu. This will clear the LED lamp’s cumulative operation time.

10.4 UNINTERRUPTED POWER SUPPLY BATTERY REPLACEMENT

The life of the uninterrupted power supply battery is approximately 3 years.

(Please note that the life could be shorter due to the number of repeated
discharges and the operation environment.) New batteries can be ordered from
the KOMORI Service Department.

*The battery can be replaced without turning off the power to the device.

10.4.1 Procedure to replace the UPS Battery

Please refer to section 5-2-1 of the UPS Instruction Manual for the battery
replacement procedure. To prevent damage to the unit, or personal injury, be sure
to review the entire manual and follow all the precautions provided.

10.5 EXCHANGE OF MOTHERBOARD BATTERY

The life of the Motherboard battery is approximately 5 years. (Please note that the

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life could be shorter due to the number of repeated over-discharges and the
operation environment.) Order ne

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11 Remote Browsing of Defect History

11.1 COMPUTER DEFAULT NETWORK SETTING

The computer factory settings of the device are shown below:

Item Setting Remarks

Any subsequent machines are set
Computer name pqa
as pqa2, pqa3 …
Work group WORKGROUP
Any subsequent machines are set
IP address 192.168.120.1
as 192.168.120.2, 192.168.120.3 …
Defect history folder
pqa_ErrorHistory Fixed
name

11.2 BROWSING DEFECT HISTORY FROM BROWSER

The XML file containing the defect history of this system is stored in the folder
pqa_ErrorHistory_VS on the C drive. When accessing the defect history from a
different computer, use Internet Explorer (Ver. 6.0 or later) to access the
“main.html” file in the folder.

11.2.1 How to browse from Internet Explorer

Step Procedure
1. Start up Internet Explorer on the external computer
2. Select [File -> Open
(O)] from the Menu

3. On the next screen

press the [Browse
(R)] button.

4. Click on My Network
on the left of the next
screen and specify
the computer of the
inspection unit.

5. Click on the
inspection unit
shared folder
Pqa_ErrorHistory_VS

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6. Specify “main.html”
and press the [Open
(O)] button.

7.

10.2.2. Viewing default 10.2.4. Viewing

history maintenance information

The above Main screen is displayed and used to view the

defect history for the most recent 100 jobs, the defect history
for the jobs performed during the most recent 12 months and
the maintenance information for the system.

11.3 VIEWING DEFECT HISTORY

Use the following procedure to view the defect history:

Step Procedure
1. Press the Main screen [Recent 100 jobs] button.
Most Recent 100 jobs

2. Click on the desired serial number will open up the report of the
inspection.

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11.4 UNDERSTANDING THE DEFECT HISTORY REPORT

11.4.1 Filtering the defect history report

The functions shown above allow filtering of the report. The data to be viewed can
be filtered by inspection camera and type of defect simply by choosing accordingly
and pressing the [Ok] button. To view defect images that are unrelated to the
specified side of the sheet and kind of error, press the [“All”] button.

11.4.2 Selecting the defect history to be viewed

The operator selects the appropriate

defect history to view by clicking it with
the mouse or clicking the up / down
arrows at the bottom to cycle through
the list.

11.4.3 Choosing the images to view

The operator can

then select which
images to view by
selecting the
appropriate button
shown above.

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11.4.4 Report detail information

The date and time of the defect,

location, type and other relevant
information is shown in the error
details window.

11.4.5 Inspection tolerance

The inspection tolerance is explained in the next section.

11.5 VIEWING TOLERANCE

By clicking on the [Tolerance] button of the defect history report will display the
following screen.

11.6 VIEWING MAINTENANCE INFORMATION

Press the Main screen

[Maintenance Information]
button to display the following
screen to view the previous
camera light cleaning date and
time, previous light replacement
date and time, current light
lighted time, and previous
uninterrupted power supply
battery replacement date and
time.

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11.7 REMOTE VIEWING DEFECT HISTORY WITH BROWSER

The remote viewing method described in Section 8.8.5 “Saving defect history” is
given below:
Step Procedure
1. Open the defect
history folder saved
from the save
destination media.

2. Specify “main2.html”
and press the [Open
(O)] button. For
details regarding the
defect history
browsing method,
refer to Section
10.2.2 “Viewing
defect history”.

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12 CHANGING PQA COMPUTER NETWORK SETTINGS

12.1 PRECAUTIONS FOR MAKING NETWORK CHANGES

Customers who have purchased this device and have changed the network
settings may experience the network problems if configured incorrectly. Carefully
follow the steps below when changing the settings. Furthermore, the network
administrator should make the changes to the network.

12.2 SETTING PQA NETWORK COMMUNICATIONS PARAMETERS

12.2.1 Verify Computer Name

Press the [Check] button to acquire and display the computer name.

12.2.2 Set PQA IP Address

The IP address can be entered by pressing the [Edit] button to the right of the
PQA IP Address. Once pressed, a dialog box will be displayed to allow the
operator to choose the correct IP Address and settings. After choosing the
correct IP settings, the operator should press the [Select] button to apply the
settings.

12.2.3 Set the PQA Port Number

The PQA Port No. allows the operator to define the machine’s network port No. A
dialog box will be displayed to allow the operator to define the correct port
number by pressing the [Edit] button to the right. In the dialog window, enter the
port No. to be used in the dialog box and then click [Select]. This port number
is normally set to 80.

12.2.4 Set the PQA Device ID

The PQA Device ID allows the operator to identify which computer the PQA is
installed. Press the [Edit] button to display the dialog box. In the dialog box, enter
the device ID to be used. This is normally set to 1.

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13 SYSTEM ERROR MESSAGES
No. Message Description
The non-printed area is not in
Light control target
100 the image capture start
error
position.
Stop Inspection by R The non-printed area is dirty,
101
gap contamination. so the white area cannot be
Stop Inspection by G supplemented and light
102
gap contamination. source control cannot be
Stop Inspection by B done, so inspection has been
103
gap contamination. stopped.
The illumination lamp output
has reached the upper limit,
Re-adjustment by
104 but the brightness has not
insufficient light
reached the light source
standard value.
The illumination lamp output
has reached the lower limit,
Re-adjustment by
105 but the brightness has not
excessive light
declined to the light source
standard value.
The template mark used for
DSP template position alignment during
106
detection error inspection cannot be
detected.
The paper width is
automatically detected, but if
Sheet Width areas other than the paper are
107
detection error white and are captured by the
camera, the paper width
cannot be detected.
This occurs if there is a large
variation between the white
area RGB that is monitored to
Over range of Offset
108 control the light output. The
Control
threshold at which this
warning is output is the base
tolerance.
43
EOM00208-000
Problems and Countermeasures
Change the gap phase correction amount so
that the non-printed area is in the image
display of the Inspection screen. (See
Section 4.1.) If this adjustment has been
made, then the phase could be out of place
due to a loose screw of the encoder
coupling, etc.
Light source control is performed on the gap
non-printed area. If the non-printed area is
dirty with ink, etc., white control cannot be
performed and the inspection is stopped.
Stop the printing press and clean the gap.
*This is not a problem if the light source
standard value can be automatically
reduced and inspection started.
Is the light volume insufficient due to a dirty
camera lens or lamp house?
Is printing being done on paper that is much
darker than that used for camera
adjustment?
*This is not a problem if the number of
camera lines can be changed automatically.
Is the paper being used brighter than the
paper used for camera adjustment?
Is printing being performed at 40% or less of
the printing press’ maximum printing speed?
Is the printing faint such as that used for the
pattern on graph paper? For printing such
as this, the position correction mark cannot
be detected, so the device does not enter
the ready for inspection mode. There is
probably a solid margin, so put marks on the
solid margin similar to that shown in the
figure below.
Before marking After marking
Check if the guide roller edge is dirty with
white color. Silicone could have gotten on
the roller and turned white and hardened.
Check the lamp house window. If the
window is covered by paper waste and
debris, clean it off.
This occurs when the gap is dirty. The RGB
processing systems remake the shading
tables when the RGB offset values are out
of range to eliminate the variance between
the white area RGB data. However, the
shading tables cannot be rewritten when the
gap is dirty, so the white offset value
exceeds the base tolerance and an error
message is output.
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The printing press line speed may not be

stable or the light output by the illumination
lamp could be fluctuating. The light could
The light RGB is out of be dirty. The gap could also be dirty, etc.
Light Control balance. The is displayed Also check if ambient light is affecting the
109
deviation is bigger when the light exceeds the camera. Ambient light could also cause this
base tolerance error.
If checking the above scenarios does not
address the error, set the base tolerance to
be more lenient.
CPU memory check
200 System error Contact KOMORI
error

The USB communication

This is not a problem. The computer is
PC Health check between the computer and the
201 functioning properly even when this error is
error image processing board is not
displayed.
functioning properly.

R DSP memory
202
Check error
G DSP memory
203 System Error Contact Komori
error

204 B DSP memory error

R DSP Health check

205
error
G DSP Health check
206 System Error Contact Komori
error
B DSP Health check
207
error
R DSP inspection
208
overflow
G DSP inspection
209 System Error Contact Komori
overflow
B DSP inspection
210
overflow

211 IPS1 illegal com System error Contact Komori

212 DSP Illegal data System error Contact Komori

SH4 Inspection
213 System error Contact Komori
Overflow
The encoder cable connection
Encoder is not
300 could be faulty or Contact Komori
connected
disconnected
Step 1: Check if the relay box power is on.
The camera power is not on Step 2: Restart the system computers
Camera is not
301 or the cable connection could
connected
be faulty or disconnected If this does not solve the problem, contact
Komori
Step 1: Check if the relay box power is on.
The camera power is not on Step 2: Restart the system computers
Junction board is not
302 or the cable connection could
connected
be faulty or disconnected If this does not solve the problem, contact
Komori.
Step 1: Check if the relay box power is on.
Camera The camera power is not on Step 2: Restart the system computers
303 communication time or there could be a system
out error If this does not solve the problem, contact
Komori

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The gain adjustment function
Camera gain control is not operating normally and
304
error the digital image brightness
cannot be controlled.
45
EOM00208-000
Step 1: Check the gap phase setting
Step 2: Check if there is something
abnormal, such as a dirty light.
Step 3: Check if there is debris in the
camera position or the camera field of view.
Step 4: Check if a paper other than white
paper is being used for printing.
If this does not solve the problem, contact
Komori
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14 TOUBLESHOOTING

Phenomenon Possible Cause Explanation and Countermeasures

Open the console door and turn on the
computer power.

The computer used by this device is

interlinked with the printing press
power and senses when the printing
The power to the
press power is turned off and then
printing press is turned The printing press power was
begins shutting down MS Windows.
on, but nothing is turned on again immediately
displayed on the after being turned off.
If the printing press power is turned on
device’s LCD display.
again during this shutdown operation,
the shutdown operation will continue.
This means the computer is not
operating even though the printing
press power is on, which causes this
phenomenon.
Replace the battery.
Each time the device When the device’s power was
The uninterrupted power supply battery
power is turned on, turned off, the computer
could be discharged.
scan disk is executed power was turned off without
on the LCD display the uninterrupted power
Continuing to use the device in this
screen. supply operating normally.
state could corrupt MS Windows files
and prevent the system from booting.

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