Qualitron Manual Eng

QUALITRON INTERFACE
MANUAL
TYPE OF MANUAL
Unoriginal Instructions
In the event of doubts or conflicting interpretations of the Manual, the Italian version bearing the
words “ISTRUZIONI ORIGINALI” on the cover is to be taken as faithful. A copy of the said manual
can be obtained at http://extranet.system-group.it/stampe/esternastampamanuali.aspx
Code: ........................... MC000974

Revision: . .................................0.0
Status: ...................current version
ENGLISH
EN
Publication issued by: SYSTEM S.p.A. - Via Ghiarola Vecchia, 73 - 41042 Fiorano Modenese (MO) - Italy
Edition: 04-2015
Revision: 00
© 2015 - SYSTEM S.p.A.
All reproduction rights of this manual are reserved to SYSTEM S.p.A.; reproduction, even partial, is prohibited.
This manual has been written in compliance with standard CEI EN 82079-1:2013. SYSTEM S.p.A. reserves the right
to make any amendments deemed necessary to this publication at any time.
This manual:
– is an integral part of the supply and must be carefully read for proper use, in compliance with the essential safety
requirements;
– is drawn up according to the provisions of the Machinery Directive 2006/42/EC and contains the technical
information necessary to perform all the procedures in a correct and safe way;
– must be kept with care (protected by a transparent watertight cover to prevent deterioration) and must accompany
the machine throughout its lifespan, even if sold to third parties.
In the event of loss or deterioration, a copy can be received by making a request to SYSTEM S.p.A. indicating
the data on the identification plate;
– has been written in Italian as original language.
SYSTEM S.p.A. is not responsible for loss or damage due to operations not covered in this manual.
II
EN
Table of contents
1. GENERAL INFORMATION.............................................................................. 1-1
1.1. Introduction....................................................................................................................................1-1
1.2. Suggestions to the buyer...............................................................................................................1-1
1.3. Suggestions to the user.................................................................................................................1-1
1.4. New graphic design: faster, easier, better......................................................................................1-2
1.5. Purpose of this manual .................................................................................................................1-3
1.6. Unintended use..............................................................................................................................1-3
1.7. Symbols used in this manual ........................................................................................................1-3
2. DESCRIPTION OF THE MACHINE................................................................. 2-5
2.1. Operating principle.........................................................................................................................2-5
2.2. Main sections of the machine........................................................................................................2-5
2.3. Control panel.................................................................................................................................2-7
2.4. Panel controls................................................................................................................................2-8
3. MAIN INTERFACE.......................................................................................... 3-9
3.1. Launch Bar (QShell)......................................................................................................................3-9
3.1.1. Launch bar functions....................................................................................................................... 3-10
3.2. Main interface overview...............................................................................................................3-14
3.3. Lower bar.....................................................................................................................................3-15
3.3.1. Access to management program.................................................................................................... 3-15
3.3.2. Management of user rights............................................................................................................. 3-16
3.3.3. Machine Status .............................................................................................................................. 3-17
3.3.4. Machine Status LOG Window......................................................................................................... 3-17
3.3.5. List of alarms................................................................................................................................... 3-18
3.4. Upper bar.....................................................................................................................................3-19
3.4.1. Software version............................................................................................................................. 3-19
3.4.2. Product setting menu (hamburger menu)....................................................................................... 3-19
3.5. Side Bar.......................................................................................................................................3-20
4. CLOSED BATCH - MACHINE ADJUSTMENTS............................................. 4-21
4.1. Setting of belt position.................................................................................................................4-21
4.2. Positioning the reference colours (Pantone cards)......................................................................4-23
4.3. Image sizing.................................................................................................................................4-26
4.4. Calibration of the Line..................................................................................................................4-28
5. OPEN BATCH - USE OF THE MACHINE....................................................... 5-31
5.1. Load a batch previously saved....................................................................................................5-31
5.2. Set a new product........................................................................................................................5-33
5.2.1. New batch from Model.................................................................................................................... 5-34
5.2.2. New batch from previously saved batch (optional)......................................................................... 5-35
5.3. Shade check with 'automatic shader'...........................................................................................5-46
5.3.1. Activate the automatic shader......................................................................................................... 5-46
5.3.2. Use of the automatic shader........................................................................................................... 5-47
5.4. Shade check with 'Manual Shader'..............................................................................................5-50
5.4.1. Activate the manual shader............................................................................................................. 5-50
5.4.2. Manual shader parameters............................................................................................................. 5-51
5.4.3. Use of the manual shader............................................................................................................... 5-54
5.5. Check of defects..........................................................................................................................5-67
5.5.1. Diagnostics working concepts......................................................................................................... 5-67
5.5.2. The monitor of defects.................................................................................................................... 5-72
5.5.3. Search of a defect not detected by the machine............................................................................. 5-75
5.6. History of the tiles........................................................................................................................5-83
5.7. Outputs........................................................................................................................................5-86
5.7.1. Outputs printed on tile (Dicoprintosh)............................................................................................. 5-88
5.8. Statistics......................................................................................................................................5-90
III
EN
PAGE LEFT INTENTIONALLY BLANK
IV
EN
V
EN
VI
1 GENERAL INFORMATION
EN
1. GENERAL INFORMATION

1.1. Introduction
1
Congratulations for having chosen the machine. Please read carefully this manual and keep it in a safe
place, since information contained herein is essential for the proper use of the machine.
Through this manual, SYSTEM S.p.A. intends to establish a collaboration with you, in order to improve
our product and make it more flexible for your needs. For this reason, we invite you to report any error,
inaccuracy, malfunction, or suggestion, remark, opinion, through the contacts indicated in this manual.
Since a coordination among all the professional figures involved in production is required to ensure a proper
and safe operation of the machine, this manual has been conceived and drafted in order to provide details
and suggestions (responsibilities, training, procedures, use and maintenance) for each type of operator.
1.2. Suggestions to the buyer

We recommend to integrate the content of this manual with your internal safety procedures, and in particular
to take care of the following points:
- Analyse the machine documentation (in the event of an accident, the manual is the first document
acquired by the competent authority).
- Perform the analysis of the evident risks of the machine and of its integration in your working environment.
- Draft procedures for all the activities required on the machine (according to the instructions contained
in this manual).
- Define the list of personnel in charge for each procedure (maybe affixing it near the machine).
- Carry out and document the training of the personnel in charge for the use of the machine or being
part of the above mentioned lists (repeat training and update the lists when hiring new staff).
In this way, the buyer shows to have used all the possible methods to provide the users with a safe working
environment. Moreover, in case of accident caused by failure to respect the defined procedures, the buyer
can thus decline any liability.
1.3. Suggestions to the user

We recommend the users to respect the following points:
- Read the whole manual (for a better understanding of the procedures).
- Operate by fully respecting the company procedures and those indicated in this manual.
- Do not perform any actions or take any initiatives different from those indicated without the agreement
of the supervisor.
In this way the user shows to have operated in full compliance with the procedures. Any intervention other
than those indicated might be interpreted as an unsolicited and arbitrary action for which the single user
is liable.
1-1
EN
1.4. New graphic design: faster, easier, better.

In this manual we launch the new graphic interface developed for Qualitron machine.
The main goal of this new interface is to be easier and more user-friendly than the previous versions.
Moreover, the machine setup procedures have been accelerated, the adjustments have been made easier
and the systematic and repetitive procedures have been deleted or automated. We hope that the result of
these efforts is a better machine in terms of performance and usability.
1-2
EN
1.5. Purpose of this manual

The goals of this manual are: 1
• Be 'Quick and go'. This expression indicates the intention to be very straightforward during the
explanation and instructions for use of the machine. This means that the various steps required to
operate the machine in the shortest time possible are explained.
• Describe the new look of V4 software version. Through this software version, System has carried
out the graphic interface migration towards the latest HMI (Operator interface) technologies, in order
to be more user-friendly by applying the principles of smartphones and tablets that people use in their
everyday life. In this way the machine is provided with graphic elements and buttons similar to those
used for other activities, then the approach is easier and the learning process is faster.
• References to V2 version manual. Some parts of machine program are addressed to an expert
operator only and are non described in this manual. They are intentionally not mentioned, since they
are part of advanced programming that is not required for the daily use of the machine. For the study of
such advanced contents of the machine operation, please refer to V2 version of the interface manual,
in which they are explained in detail. Obviously, V2 version manual explains the old interface, that shall
not be considered. Instead, the following advanced descriptions can be considered:
Chapter 6: The shading process: Shade parameters, etc.
Chapter 7: The defect identification process. The diagnostics, The elaborations, The list of algorithms, etc.
Chapter 9: Machine configuration.
1.6. Unintended use

The operations that can be carried out using the machine interface but are not described in this manual can
be performed only by specialised technicians having attended the advanced training course on the use of
the machine. These parts of the program are usually password-protected and can be accessed only through
the management of user rights. The Customer is responsible to set and manage user rights, that must match
the actual skills of the operators using the machine, in order to prevent damage to persons and/or goods.
1.7. Symbols used in this manual

Symbols indicating situations of risk or very important information.
WARNING!
Indicates situations of risk for people, recalls accident prevention regulations, suggests behavioural procedures.
CAUTION!
Indicates situations of risk for the machine and/or the product under manufacturing.
NOTE!
Indicates useful information to consult the manual and for the proper operation of the machine.
Symbols indicating information for specialised operators.
MECHANICAL MAINTENANCE OPERATOR

Indicates standard and scheduled maintenance procedures to be performed by the mechanical maintenance
operator.
ELECTRICAL MAINTENANCE OPERATOR

Indicates standard and scheduled maintenance procedures to be performed by the electrical maintenance
operator.
1-3
EN
SERVICE TECHNICIAN
Indicates the procedures for installation, commissioning and/or extraordinary maintenance (electrical/mechanical
type) to be performed by the service technician, i.e., an employee of or technician authorised by the manufacturer.
GENERAL STAFF

Indicates the number of persons in charge of maintenance.
Example: = 1 person
= 2 persons
1-4
2 DESCRIPTION OF THE MACHINE
EN
2. DESCRIPTION OF THE MACHINE

We briefly describe the operation of the machine, taking for granted that we are talking about an automatic
sorting machine for tiles. To describe its operation, we use a 'Consumer' approach, with terms known from
telephony services and photography applications.
2.1. Operating principle

The operating principle of the machine is very simple if we compare it to what we regularly do nowadays:
take photographs. The machine contains three industrial cameras that photograph the tiles in motion from
2
three different angles. Photographs are taken from three different angles because different points of view
help to see different types of defects. Also when the operator tries to see a defect on the tile, s/he angles the
point of view between light and eye to see it at its best. The machine produces three images of the same tile:
• BW0: Black and white image, very angled to mainly see the surface defects.
• BW1: Black and white image with top view, to mainly see the defects of edge and corners.
• RGB: Colour image with top view to see decoration defects and to shade.
These images are processed by the management software of the machine, that carries out the programmed
elaboration and provides the output result of choice and shade. The operator can change the working
thresholds of these parameters in real time to perform the desired classification.
2.2. Main sections of the machine

We can divide the main sections of the machine as follows:
Conveyor system: Passing through the machine, it allows the flow of tiles under the cameras.
2-5
EN
Cameras: Allow scanning and photography of the tiles and are positioned at different angles.
RGB
BW1
BW0
Electric panel: Contains the live machine parts. It can be positioned in the booth, next to the cameras or
laterally. It connects the machine to the production system.
Access to the electric panel is an exclusive competence of an authorised technician or a service technician
sent by System S.p.A.
AIR CONDITIONER
COMPUTER
ELECTRIC PANEL
UPS
2-6
EN
Computer: is the core of machine management. The software that manages the machine is installed in
this computer and will be described in the following pages. The computer is connected to the cameras on
one side and to the electric panel on the other side.
POWER BUTTON
2
2.3. Control panel

It is the actual console of the machine. In this manual the software and its pages are described in sufficient
detail in order to be able to use the machine to manufacture new products or products already inspected in
the past, by using preset working models provided by System S.p.A. or customised by Customer's expert
operators.
WORKING SCREEN
PANEL CONTROLS
KEYBOARD AND
MOUSE
2-7
EN
2.4. Panel controls

A few electromechanical controls are positioned under the screen; they are used to set the machine working
status beyond the software adjustments. In fact, they directly operate on the electric panel.
STOP UPSTREAM
Ifpressed,itstopstheflowoftilesupstreamofthe
machine.
It is useful when it is necessary to perform
adjustmentsonsingletilesthatmustbemanually
inserted.
SPEED
Set the transport speed.
Speed can be set from 1 to 7.
1 = Minimum speed.
7 = Maximum speed.
AUTO/MAN
This is the selector that allows to send the elaboration results to the sorter.
MAN = Qualitron can be set and checked without any risks since no data are sent to the sorter.
WARNING:Inordertoactuallysortthetilesaccordingtotheautomaticsortingchoice,donotleavethe
selector in MAN mode.
AUTO=WiththekeyinAutomode,thedataprocessedbyQualitronsoftwareandtherelevantoutputs
aresenttothesorterthatwillsortoutthetilesaccordingtothechoice.Datacanbesentintwoways:
- By electronic means: the result of the choice is directly communicated to the sorter.
-Though printer on tile:The result of the choice is directly marked on the tile with UV or black ink.
These two systems can also be combined.
2-8
3 MAIN INTERFACE
EN
3. MAIN INTERFACE
3.1. Launch Bar (QShell)
The launch bar is placed in the upper part of the screen. In addition to opening and/or closing the machine
management program, it is used to provide some services that can be very useful.
Launch bar position
The launch bar can be hidden through the suitable opening and closing tab.
Press the tab to hide or show the launch bar.
3-9
3 MAIN INTERFACE
EN
3.1.1. Launch bar functions.

Please find below the list of functions for every button of the launch bar.
3.1.1.1. Launch of machine management program.
PressthisQualitron'Q'pushbuttontorunthemachinemanagementprogram.
Iftheprogramisalreadyrunning,thesystemaskstheoperatorwhethers/he
wants to close it.
3.1.1.2. Opening of the user’s manual of the machine, on the screen.
Press this button to open the PDF file of the machine user’s manual.
3.1.1.3. Widget of notes.
'fjJ Notes
Press this pushbutton to open a window on the screen that

can be used to take notes or to communicate with a remote
interlocutor through the screen.
3-10
3 MAIN INTERFACE
EN
3.1.1.4. Data backup
The following pushbutton allows to perform data backup and/or to automatically schedule a backup.
WARNING: it is recommended to have data backup set up by an expert operator or by a member of the
IT service staff of the system.
Pressthispushbuttontoopentheinterfaceonthescreento
set data backup.
Backup folder:
Z:/Qualitron_Backup Save now
It performs an immediate backup in the position of the
Save according to a schedule
highlighted folder.We suggest not to activate the backup
Day: Every day
during tiles production.
Hour: 8:08
Activates the backup schedule according to the rules set.
Addsaruletothelistofrules Deletes the selected rule from

for the scheduled backup. the list of scheduled rules.
Settingofbackupdateandtimethat
you wish to schedule.
Hour: 06:00
List of scheduled items.
3-11
3 MAIN INTERFACE
EN
3.1.1.5. Remote control
A System expert technician can activate the remote control of the machine.
In this way it is possible to carry out a first diagnostic check of the machine in case of malfunction or for
improving the settings of the product to inspect.
WARNING: Customer’s IT service is responsible for the network configuration settings for remote connection.
System S.p.A. provides for the HOST version of the remote control program Teamviewer and owns the
official connection licences for the operator side.
PressthispushbuttontoopenTeamViewerHostscreen.
Communicate Used ID and password

as shown on this page to System S.p.A.
interlocutor.
3.1.1.6. Switch to... command
From the launch bar, this command allows user to scroll through the several open pages.
Warning: it is not to be used as command to go from one page to another of the management program.
Press this pushbutton to toggle through the

several pages opened from the launch bar.
Example: Backup, Notes, etc.
3-12
3 MAIN INTERFACE
EN
3.1.1.7. Recycle bin.
In case of accidental elimination of any document or product plan, it is possible to recover it by searching
in the recycle bin.
Pressthispushbuttontoopentherecyclebin.
Recycle bin list.
Empty the recycle bin.
Restore the selected files or the whole

recycle bin.
3.1.1.8. System shutdown
Pressthispushbuttontoopenthebuttonsrequiredto
turn the system off.
Shutdown
Shutdown
3-13
3 MAIN INTERFACE
EN
3.2. Main interface overview.
The main interface is divided into several areas with a specific function that we are going to explain in
detail, i.e.:
• Upper bar: contains information on the product and the learning menu.
• Side bar: contains the navigation buttons to select the elements to insert in the working area.
• Lower bar: contains the machine and alarm status
• Tile flow box: Shows the defects of the last declassed tiles and the final choice for each inspected tile.
• Working area: for each selection carried out in the side navigation bar, the working area shows the
pages of use of the machine.
Working area
Blue upper bar.
Grey lower bar.
Tile flow box
Grey Side Bar.
3-14
3 MAIN INTERFACE
EN
3.3. Lower bar.

First of all we analyse the lower bar, since it contains the button to access the management program.
Every user, in fact, must log in through a username and a password. The lower bar is also provided with
the inspection start and stop buttons and shows the machine status.
3.3.1. Access to management program
Press on the padlock in the bottom right corner to access the program. If the padlock is green, no user is
logged in the program. If the padlock is yellow, a user is logged in.
Press the padlock to access
Theselectionofauserandapasswordarerequired
for login.
Theyellowpadlockindicatesthattheuserloggedin
and the name of the connected user is indicated on
the side.
Exit: Allows to close the program Logout: Allows user to log out of the program.
3-15
3 MAIN INTERFACE
EN
3.3.2. Management of user rights

It is possible to manage the rights of the users that can access the working program. This is essential since
it allows to limit the access to machine functions to unauthorised users.
WARNING: The management of this function is restricted to a specialised technician or to the foreperson
that supervises the use of one or more machines and manages the users. Moreover, it is a good rule not
to disclose the administrator password, that is the one for the user who has access to all the functions of
the machine.
Press this menu to activate the

management of user rights.
Shows the rights enabled for the selected

user.Itispossibletoremoveoraddmachine
use rights.
Creates a new user starting from and

copyingtherightsofthecurrentlyopenuser
(usually the administrator)
3-16
3 MAIN INTERFACE
EN
3.3.3. Machine Status

The lower bar contains two very important buttons that enable or stop the automatic inspection.
The management program is independent of the tile transport, which is managed by the electromechanical
system of the line. The tile flow may occur with Qualitron in stopped, conversely Qualitron can be in inspection
mode and the flow can be stopped for other reasons.
3.3.3.1. Machine STOPPED
With the management program in STOP mode, the tiles are not inspected and all the functions that do
not provide for the passage of tiles or that must be required at certain times, e.g. during calibrations, can
be carried out.
3
The hand symbol sets the machine in STOP mode
3.3.3.2. Machine in INSPECTION mode (Activated production)
With the management program in activated production mode, the machine carries out the inspection and
provides the output information.
WARNING: The information is physically sent to the sorter only if MAN/AUTO selector under the screen
is in AUTO position.
The arrow symbol sets the machine in production mode.
3.3.4. Machine Status LOG Window

The LOG window shows the expert user the operation of the machine at a given moment in a descriptive
way. It must be used to understand the various changes of function.
Therightmostbuttonopensand
closes the Machine Status LOG
window
3-17
3 MAIN INTERFACE
EN
3.3.5. List of alarms

The machine displays the alarms in the alarm bar, that can be exploded by pressing on it to display the
full alarm list. It is also possible to enable or disable the operation of the attention levels on the limits set
in statistics (e.g. third choice maximum value) by pressing the signal symbol aside.
Alarm bar
Enablesordisablestheoperation
Alarmlistopened
of the attention levels.
3-18
3 MAIN INTERFACE
EN
3.4. Upper bar.

The upper bar, in the upper part of the screen, has two functions: indicates the software version details and
gives access to product data setting menu, that will be explained in detail in the next pages.
3.4.1. Software version

Click on the software version text to display the details.
3.4.2. Product setting menu (hamburger menu)
The product setting menu features the following commands that will be explained in detail in the next pages.
It is important to know that the various menus have a different aspect, depending on whether the product
to be inspected in the machine is open (open batch) or closed (closed batch). In the first case the working
menus are shown, in the second case the machine configuration menus are shown.
Open batch commands:
Theproductworkingparameters
are set with open batch.
3-19
3 MAIN INTERFACE
EN
Closed batch commands:
Themachineconfigurationsareset
with closed batch.
3.5. Side Bar
The side vertical bar on the left of the screen provides the navigation menu in the different software
functionalities that will be explained in detail in the next chapters.
Side Bar with closed batch, open batch and in automatic mode:
Themachineconfigurationsare Thenavigationbuttonsforthevarious
set with closed batch. softwarefunctionsareopenedwith
open batch.
Machine
Stopped
Machine
in Automatic
mode

3-20
4 CLOSED BATCH - MACHINE ADJUSTMENTS
EN
4. CLOSED BATCH - MACHINE ADJUSTMENTS

This chapter describes the basic calibration operations that must be known and must be carried out whenever
parts of the machine kinematic mechanism are changed. This includes the change of position of one or
more photocells, the change of one or more working speeds, the positioning of one or more cameras or the
positioning of conveyor belts. The simple product format change-over does not require such adjustments,
that are usually performed by a maintenance operator when necessary.
4.1. Setting of belt position.

The proper setting of belt position with respect to the image captured by the cameras is very important,
since it allows the machine to know where they are and, in that area of the image, to perform different
kinds of elaborations, to avoid to confuse them with the tile. Failed or wrong positioning does not allow the
machine operation, and the alarm message 'No edge removal' is displayed, since the software is not able
to detect the edges of the tile.
This adjustment must be carried out whenever the conveyor belts are physically moved for a change of
working format or for any standard or extraordinary maintenance operations. If belts must be replaced, we
recommend to check the calibration in any case.
To carry out this calibration, follow the steps below:
4
Select
'Positioning the belts' menu
Activate the belts and pass a tile.
4-21
EN
Once the tile has passed, the following screen is displayed for each camera. Perform the operations indicated.
3) Press Forward
1) Lower the threshold

until the belts are visible.
2)Positiontheredlinesoutofthebeltsas
shown.Theredlinescanbemovedwiththe
mouse and/or the arrows.
This operation ends when Forward is pressed and the operation is carried out for all the three cameras.
4-22
EN
4.2. Positioning the reference colours (Pantone cards)

Reference Pantone are grey cards positioned on the right and left extremities of the image. There are four
cards with different shades of grey, from the lightest to the darkest. Such shade references are used by
the colour camera to stabilise the shade with reference to a known grey colour. It is very important to clean
them on a regular basis, at least once a week. While the calibration, once performed, does not need to be
repeated, unless mechanical modifications to the machine are carried out on these parts. Pantone cards
are placed under the colour camera illuminator on right and left ends and are in a fixed position.
4
Set their position on the software as follows:
Select
'Positioningthereferencecolours'
menu
Activate the belts and pass a tile.
4-23
EN
Once the tile has passed, the following image will be displayed. The important element is not the position
of the detected tile, but the position of Pantone cards at the ends. To see clearly where such Pantone cards
are positioned, use zoom and positioning buttons.
1) Use + and -
pushbuttonstozoom
in and out.The arrow
to move.
Enlarge the left image as follows:
2) Position the red lines inside the two

vertical lines that represent the Pantone
cards on the left. The red lines can be
movedwiththemouseand/orthearrows.
4-24
EN
Carry out the same operation on the right.
4) Press 'End' 3) Position the red lines inside the two

vertical lines that represent the Pantone
cards on the right. The red lines can be
movedwiththemouseand/orthearrows.
It is normal that darker Pantone cards are not very visible: the camera signal should be strongly amplified
to make them stand out. There is no need to worry about this aspect.
4-25
EN
4.3. Image sizing
Image sizing is the calibration operation that allows the software to match the image resolution with the tile
size, by setting all the dimension units of the system. Usually this operation is carried out only once and
must be repeated only if camera and/or illuminator positions change. It is not mandatory, but recommended,
the use of a square tile, since it reduces the possibilities of error of the operator. In fact, if the setting of X
and Y axes is reversed, the whole operation is distorted.
Carry out image sizing as follows:
Select
'Image sizing' menu
Set the exact tile size to the mm. Pay attention not to reverse X and Y axes. Press OK.
Start the belts and insert the measured tile.
Press Forward
4-26
EN
The machine provides the image received of the tile; check that the red lines automatically positioned
match the profile of the tile itself.
Press Forward
Check also the two cameras BW0 and BW1 and press End.
4-27
EN
4.4. Calibration of the Line

The calibration of the line allows the software, through the line encoder installed on Qualitron, to learn the
physical positions of working photocells, in order to be able to photograph the tiles in the correct moments
and provide the output data to the machine downstream or to the printer. This operation must always be
performed when the working photocells are moved, for both ACQUISITION and OUTPUT photocells. The
calibration of the line is performed if the calibrations described above are successfully completed.
The calibration of the line is recommended also when conveyor speeds are changed. Ideally, a change of
conveyor speed does not require the calibration of the line, because the encoder provides this information. In
practice, however, since the encoder does not control the speed of the conveyors upstream and downstream
of the Qualitron, and since the output photocell is installed on the encoder, the calibration of the line must
be carried out for every change of conveyor speed.
Carry out this calibration as follows:
Select
'Calibrationoftheline'
menu
Enter the tile length.

We recommend to use a square tile in order to avoid errors between X and Y dimensions.
4-28
EN
Activate the conveyor belts, insert the tile and press Forward:
4
Now the machine displays the tile on RGB camera and automatically identifies its upper and lower edges.
Check the correct position of the lines and press Forward.
4-29
EN
The machine displays BW0 and BW1 camera images, check the correct position of the lines as follows:
and press FORWARD.
Finally, insert a tile for the final check of stored data:
Press END.
4-30
5 OPEN BATCH - USE OF THE MACHINE
EN
5. OPEN BATCH - USE OF THE MACHINE
This chapter describes the actual use of the machine for automatic tile inspection. To use the machine with
a product, it is necessary to set the machine for such product by creating or loading a 'batch'. The batch
contains all the settings about the product under inspection: format, images, diagnostics, shade, working
thresholds. The batches can be saved to be recalled in a second step; in this way the user creates a
working database that increases as the machine is used. When all these settings can be shared among
several types of products, then it is possible to create 'models'. Models can be, e.g., smooth products, glossy
products, etc. So, in summary:
• The batch: is a working file referred to a single product, includes all the data about it and allows
inspection. From a batch that works and which is set properly, it is possible to create the model for
that type of product.
• The model: is a file containing the general settings of a type of product. From the model, it is possible
to create the batch of a new product similar in type to the base model.
Let’s now describe how to recall/load a saved batch or how to create a new one.
5.1. Load a batch previously saved

To load a batch previously saved, enter the FILE menu and open:
5
Select
the 'Open’ Menu
5-31
EN
The machine provides the list of batches created in the past, divided into the folders that have been created,
if any. The batch file is located in the relevant folder and is productname.qng.
Choose the one corresponding to the product to inspect and press OK.
Position of the batch general folder.
Typicaldivisionofthefoldersintoformats
Batch folder
Batchfiletoload(selectitwiththemouse)
Modelusedtocreatethisbatchandofwhichitis
part (indicates the type of product)
Creation date and last use date of the selected

batch.
Size (format) of the product in this batch.
Providesadditionaldatausefulforexpertusers
whofollowedtheadvancedcourseontheuseof
the machine.
Press OK to select the required batch.
5-32
EN
5.2. Set a new product

If the product has never been inspected before, it must be set as new. The setting of a new product in the
machine is carried out through an automatic wizard that simplifies the steps and the operations to perform.
Once these operations are made, the new batch will be saved.
There are two opportunities to create a new batch:
• RECOMMENDED Start from a model that, as described above, contains the information on the type of
product, e.g., smooth, structured, glossy, matte, etc.
• OPTIONAL Start form a batch previously inspected. Start form a batch previously inspected only if the
new product is almost like the one of the batch chosen as a starting point. For instance, this is fine if
only the colour or the shade is different.
Set a new product as follows:
Select
the 'Batch - New’ Menu
The following menu is available:
Decide whether to create the new batch starting from Model or from a Batch previously saved.
5-33
EN
5.2.1. New batch from Model

To select the model, open the 'Base model' drop-down menu
Openthedrop-downmenu.
Choose the model

correspondingtotheproductto
be inspected.
5-34
EN
5.2.2. New batch from previously saved batch (optional)

Choose the last option of the base model drop-down menu, 'Open batch'
Select 'From batch'
The 'Open batch' menu already seen for the choice of the starting batch will open.
Select the initial batch
Press OK
5-35
EN
Once the starting model or batch has been chosen, set the format (the size of the tile to inspect) and the
name to give to the batch.
WARNING: do not reverse tile width and length:
All the tile visualisations on the screen refer to this nomenclature: the arrow indicates the tile movement
direction. As reference, we can imagine that tiles move bottom-up.
X - Width: is the measure perpendicular to the movement; if a rectangular format moves with the shorter
side forward, it is the narrow side.
Y - Length: is the measure parallel to the movement; if a rectangular format moves with shorter side forward,
it is the long side.
Set the product name.
Set the format size.
If necessary, choose a program for

outputsandprinterinline,ifpreviously
saved.
Press Forward
Then press Forward to start adjustments.
5-36
EN
The first adjustment to carry out is the calibration of cameras. In fact, they must be 'adapted' to the type of
product. The same operation allows to select the proper working Pantone.
WARNING: This operation must be carried out with the key selector in AUTO position, to allow the machine
to stop the tile under it.
The following screen is displayed, showing that the prohibition symbol indicates that the operation has not
been performed yet and the ‘Forward’ pushbutton is not active:
Press 'Run Adjustment'.
Provides additional data

useful for expert users who
followedtheadvancedcourse 5
on the use of the machine.
Activate the belts and insert a tile of the product to be inspected. Wait until the machine stops the tile and
performs the adjustments, then press END.
Press End
5-37
EN
If the camera adjustment is completed correctly, the prohibition symbol becomes an OK tick and the ‘Forward’
button is enabled to go to the next step.
Adjustmentcorrectlymade.
Press Forward
The next step is the actual identification of the tile. The machine, in fact, asks to insert a piece of the new
product to set by pressing 'RUN ADJUSTMENT'.
Pass a tile and press FORWARD.
5-38
EN
The machine displays in sequence the tile identification on the three cameras RGB, BW0 and BW1.
The operator must check that the four red lines are positioned on the tile profile.
If that is not the case, it is possible to manually move the single lines using the mouse or the arrows.
Check that the red rows are

positionedonthetileedges
and press Forward.
If the tile is square, it must appear square on RGB camera image.

For images of BW0 and BW1 cameras this is not always true; it depends on the machine configuration.
They might be square or compressed.
5

and press Forward.
5-39
EN
Lastly, check BW1 and press END.

and press End.
The machine displays the calibration screen of tile positioning, but the prohibition symbol has become an
OK tick. If so, press END.
Press End
5-40
EN
Now the batch information is available to be saved, and the machine prompts the first saving of the new
batch. Choose where to save it, creating or choosing a suitable folder, changing or confirming the name
given to the new batch.
Check that the name is

correct and press 'Save'
Now the product/machine setting operations are over, and it is necessary to acquire the specific information
5
of the product: Surface, Decorations, Shades etc. The machine displays the following screen:
Set the shade name and

press Forward.
5-41
EN
Before pressing Forward, let's analyse what are these three ticks - that must always be enabled - and
what is their use.
SAMPLE LEARNING. ‘Samples' are the product tile images to inspect and that are saved in the machine; the
machine uses them as a reference and compares them to the following production images to inspect. It is
important to store the samples correctly, following this procedure. For black and white cameras BW0 and
BW1, the samples correspond to the drawings of the press blocks. For the colour camera, the samples
correspond to the various decorations (or patterns) coming from the digital decorator. Once the samples
are correctly stored, the machine compares them with the tile to inspect. If this comparison exceeds the
threshold called 'COUPLING THRESHOLD', this comparison will become more specific to identify the
single defects.
SHADE. In this self-learning phase, simply indicate the shade name of the product.
SELF-CALIBRATION. It is required in the last passage. With this procedure the machine uses the sample images
(that are loaded as a reference) to carry out a first rough calibration of defect thresholds and of general
product settings, so that the machine, at the end of this operation, is 80/90% ready to start the production.
Warning:thedeactivationofoneofthesethreeticksSAMPLELEARNING,
SHADE and SELF-CALIBRATION could indicate the choice to use the
machineinadvancedmode,thereforeitcanbeperformedonlybyusers
who have followed the advanced course about the use of Qualitron.
Press Forward; the fast self-learning screen is displayed.
Several tiles have to pass, therefore this step provides for a manual sorting of the product on the sorting
bench. The machine always requires a minimum of twenty pieces, but this is just a starting value, since
the actual number of pieces required depends on the type of product, and it is necessary to proceed as
follows. Once several tiles have passed, press the arrow pushbutton and check that the tile images do not
show evident defects. It is possible to check every image by using again the arrow pushbutton.
Passsometilesandpressthearrowpushbuttontosee
the images.
5-42
EN
Once the arrow pushbutton is pressed, tile images will appear.
Checkthetilesandpressthe
arrow pushbutton.
Eliminateanydefectivetiles.
Images to be checked Indicators
For each tile stored, it is necessary to check that there are no evident defects. Any minor defects do not
create problems, since they are part of the mean resulting from all the stored tiles and then do not affect
the final result of the batch programming. While the tiles that show major defects must be rejected.
As the images are added in the computer memory, the program analyses the data and provides two
indicators for each camera representing the adequacy of the learning until then.
Upper
indicator
The indicators change their colour according to the result. The higher it is (max 100) the better the machine
is programmed.
The upper indicator provides the instantaneous value of the presence of that tile in the memory. If the image
of that sample is already stored in the computer, this indicator increases.
5-43
EN
While the lower indicator shows the adequacy of the learning as a whole, analysing the categories of
samples stored until then.
Lower
indicator
The operator must insert tiles using the arrow pushbutton until the two indicators are in a good and constant
condition for a given number of tiles inserted (at least a dozen). The ideal condition is that both indicators
are green, but with complex products if the first indicator is green and the second indicator is yellow the
result can still be considered good.
Consider that a modern product, made for instance with twenty decoration patterns and then cut in sub-
listels that reach the sorting machine with various orientations, may require the storage of over one hundred
tile sample images.
Perfect
indicators
it is not necessary to
continue.
When both indicators are greenish (desirable situation) the learning procedure can be ended by pressing OK.
5-44
EN
Finally (self-calibration) it is necessary to pass a further batch of tiles to allow the machine to check the
learning and automatically calibrate the diagnostics:
As soon as the last tiles have been learnt, press OK and the machine will automatically carry out all the
calibrations with the following screen:
At the end of the learning, press END.
5-45
EN
5.3. Shade check with 'automatic shader'
With version 4 of Qualitron software, the shader has been completely rewritten to face the needs of the new
digital decorations, increasingly 'diversified'. It is based on the storage of decoration images and assesses
the difference between the shade inspected and such images. The working parameters of this shader are
matched to reach a single result, in order to be easier and more user-friendly. Anyway, it is possible to work
with the old ‘manual shader’ (see next chapters).
5.3.1. Activate the automatic shader.
The choice between automatic shader or manual shader is made in batch settings, where it is possible
to select the shader to work with. After activation, this selection is stored in batch settings and it must not
be repeated.
Warning:Themodificationoftheparameters
present inside the Batch Settings implies
an advanced knowledge of the machine,
thereforeitcanbeperformedonlybyusers
who have followed the advanced course
about the use of Qualitron.
Activate the Automatic Shader.

Aftertheactivation,itisnecessarytorepeat
the shade learning.
5-46
EN
5.3.2. Use of the automatic shader.
To display the shader page, press the relevant shade pushbutton on the navigation menu.
Press to display the shade page
After having recalled the shade page, the main screen appears as the following figure and the shade page
is positioned on the right. The shader has a vertical line for each tile that passes and the more this line is
high, the more the inspected tile deviates from the shade. If the tile line exceeds the horizontal threshold
lines, the tile is set aside as out of shade (OoS) or declassed.
5
Declassing thresholds
Out of Shade Thresholds
Shade inspection results

Activation of declassing thresholds in addition to the out of
shade
It is possible to activate one or more declassing thresholds besides the out of shade one by switching on
the relevant boxes: white for out of shade, yellow for second choice, light blue for third choice, blue for
fourth choice, red for reject.
5-47
EN
The shader function buttons are positioned in the upper part of the shade display and have the following
functions:
Cancel threshold
Recall shade modification.
Recall shade Clear the shade
management page or
parameters page screen
new shade page.
Confirmthreshold
modification.
5.3.2.1. Shade parameters.
After having recalled the shade parameter page with the suitable button, the following screen is displayed,
where it is possible to enable, disable or adjust the importance of the shade features to be checked.
Operation based
on the mean value
(recommended) or on
maximum values.
Shade parameters
active.Everyparameter
has a name that clearly Reset the values
describesthefunctions.
Shadeparametersweight.Eachparameter
canbegivenagreaterorlowerimportance
bychangingitsweight(Valuesfrom1to3)
5-48
EN
5.3.2.2. Insert a new shade or manage the current shade.
After having recalled the shade management page with the suitable button, the following screen is displayed,
which lists in a table the shades present. The columns of the table correspond to the shade name, to its
activation (1 active, 0 not active) and to the corresponding output number for the output table. (See next
paragraphs). Moreover, it is possible to add further tiles to the current shade or insert a new shade in order
to inspect several shades at the same time.
Delete all the shades in the machine

Delete the selected shade in the table
Insert new tiles to the selected shade, to enlarge the shade if necessary.
5
Add a new shade. If several shades are enabled, they will operate
simultaneously creating several working graphs in the shade page.
To add or create a new shade, a suitable screen is displayed to insert new reference tiles.
Insert the tiles on the conveyor. A minimum number of tiles according to the current format is required.
When this minimum number is reached the OK button will be available. Press OK to end the operation. The
new shade learnt will appear in the shade table. Correct the name and the destination output if necessary.
5-49
EN
5.4. Shade check with 'Manual Shader'
In this new software version we have intentionally kept the manual shader for two reasons:
• From a historical point of view, this shader is the most known and the most used by our Customers
with excellent results, and many of them do not intend to replace it.
• It allows to use and manage every single shading parameter. Although this characteristic makes its
usability slightly more difficult, it ensures an increased selectivity of the types of decoration to be checked.
Anyway, the final choice of the type of shading is at the discretion of the user, according to the specific
production needs.
5.4.1. Activate the manual shader

The choice between automatic shader or manual shader is made in batch settings, where it is possible
to select the shader to work with. After activation, this selection is stored in batch settings and it must not
be repeated.
Warning:Themodificationoftheparameters
present inside the Batch Settings implies
an advanced knowledge of the machine,
thereforeitcanbeperformedonlybyusers
who have followed the advanced course
about the use of Qualitron.
Activate the Manual Shader.

Aftertheactivation,itisnecessarytorepeat
the shade learning.
5-50
EN
5.4.2. Manual shader parameters.

The manual shader operates through a series of independent parameters that the operator has to activate
according to the shading needs. The independence of every parameter allows a focused selection of the
shader functions. Each parameter processes the tile image and provides a value. The operator sets the
working range for each parameter of the single shade. It is possible to set several ranges for each parameter,
in order to work with several shades, with different colours for each one. The basic rule for the attribution
of a shade is that when the results of all parameters are within the ranges with the same colour - therefore
are assigned to the same shade - this is the final shade assigned. If just a single parameter does not assign
a range, or it falls into a different colour range, the tile is 'out of shade'.
Since many parameters are available, it is possible to enable or disable them for groups of functions. In
fact, if some types of checks are not necessary because the decoration requires other checks, it is possible
to choose the specific ones in the batch configuration.
As you can see in the page of shader parameters, first of all they are grouped according to the main camera
that uses them:
Colour analysis means the use of the colour camera, therefore the effective shading.
Surface analysis means the use of the two black and white cameras, therefore the check of surface gloss
and/or roughness.
Each parameter is added to its group according to its type of operation, such as 'Background', 'Colour',
'Decoration', 'Gloss', etc.
5-51
EN
In order to help the operator to make an appropriate choice according to his/her needs, please find below
the list of all the parameters available with their names, the camera that uses them, the group they belong
to and the type of work for which they are conceived. Moreover, according to our experience, we highlight
the parameters that, in our opinion, must always be enabled.
Name Description To be used for
R Mean of red component Tile background: 'terracotta, brick red'

G Mean of the green component Tile background: generic colour
B Mean of blue component. Tile background: light colours/grey/white
VarR Variance of the red component Decoration
VarG Variance of the green component Decoration
VarB Variance of the blue component Decoration
H Mean of the hue Colour stability

VarH Variance of the hue Uniformity of colour and decoration
S Saturation mean Colour intensity
VarS Saturation variance. Uniformity of colour intensity
L Brightness mean. Brightness: darker or lighter.
VarL Brightness variance Brightness uniformity.
L* Brightness intensity Darker/lighter tile

a* Amount of green and red Dark shade
b* Amount of blue and yellow Light shade
Gr1R Mean of the red component contrast Veins, points, salt and pepper...
Gr1G Mean of the green component contrast
Gr1B Mean of the blue component contrast
Gr2R Contrast variance of the red component Decoration stability.
Gr2G Contrast variance of the green component.
Gr2B Contrast variance of the blue component
Mov1 Colour Movements: Slight variations in the design (e.g. flame texture and veins)
.........
Mov8 Colour Movements: Sudden variations in the design (e.g. dotted decoration)

LucBw0 Mean of BW0 camera Surface gloss of the tile
LucBw1 Mean of BW1 camera
VarBw0 Variance of BW0 camera Uniformity of structure
VarBw1 Variance of BW1 camera.
Gr1Bw0 Mean of BW0 camera contrast. Roughness of the surface

Gr1Bw1 Mean of BW1 camera contrast.
Gr2Bw0 Variance of BW0 camera contrast. Stability of the structure.

Gr2Bw1 Variance of BW1 camera contrast.
Mov1L Structure Movements Smooth or almost perfectly smooth surface.......

Mov8L Structure Movements Presence of a lot of veins or "gaps" in the structure
Warning: The choice of manual shader parameters implies an advanced knowledge of

the machine. If you are not sure of the effectiveness of a parameter chosen, use the
recommended parameters written in green.
5-52
EN
It is possible to recall a shader parameter description by pressing the 'Lamp' pushbutton
Press to display the parameter features
5-53
EN
5.4.3. Use of the manual shader
To display the shader page, press the relevant shade pushbutton on the navigation menu.
Press to display the shade page

After having recalled the shade page, the main screen appears as the following figure and the shade page
is positioned on the right.
Shade parameters
For every shader parameter, the page shows a horizontal black 'stripe' in which the algorithm shows the
result in a scale of values. The result is highlighted by a down arrow. The areas of inclusion of the values
in the desired shade are positioned under the scale of values.
5-54
EN
Scale of results.
Shade area.
5
Final result of the shade.
Graphicresultofthealgorithm Numericresultofthealgorithm,valuesof
every single tile, the last one is on top of
the list.
5-55
EN
5.4.3.1. Enabling and/or disabling a shade parameter.
Once the group of algorithms to be used for the manual shader has been chosen in the batch parameters,
it is possible to enable or disable every single parameter on the shader graph.
Every parameter can have three working statuses:
• RED: Parameter not active

• LIGHT BLUE: Parameter working as algorithm, but not as output. In this mode, the parameter processes
the tile but does not affect the final result of the shade. It is used to assess the suitability of the algorithm
for that specific product or for test purposes.
• GREEN: The parameter is fully active and affects the final result of the shade.
To change to parameter working status click on its name (coloured button). If inactive parameters are
not displayed (in red) that means that only the display of active parameters is enabled, and not of all the
parameters available.
Display all the parameters (also

those in red).
Lightblueindicatesthatparameter
isworkingwithoutaffectingthe
output result. Used for tests and
evaluations.
Redindicatesnotactiveparameter;
it can be hidden by deactivating
the display of all the parameters.
Green indicates fully active

parameter.
5-56
EN
If the display of all the parameters available is disabled, the red parameters are hidden and the shader
page shows only the light blue and green parameters, thereby becoming more essential and easy to read.
Disablethedisplayofparameters
in red.
5.4.3.2. Set a shade

5
A shade can be set in the machine in two ways: through tile passage or by manually entering the values. It
is preferable to set the shade using real tiles of the proper shade, but since they are not always available
it is possible to manually enter the shade values.
5.4.3.2.1. Set a shade with real tiles.
To set a new shade using the passage of real tiles of that shade press the shade management button.
Ensurethattheinspectionis
active.
Press Shade
Management button
5-57
EN
Shade management menu will be displayed. It is a table in which every line corresponds to a set shade.
Press 'Learn' to learn the new shade.
Press to start the new shade learning.
The learning window is displayed; pass the tiles of the shade involved. Minimum three tiles.
Once the tiles are learnt, press OK
Now the machine has automatically generated the values for the new shade and has inserted the new line
in the table, where it is possible to change the name of the new shade and the output, if necessary. Output
means the physical connection of the new shade with the tile sorter. Such outputs are identified by alphabet
letters and can be recalled on the output table (towards the sorter). For instance, if there are two shades, the
two outputs can be A and B. The advantage of this method is that, once the different shades of the product
are set, it is possible to convey a specific shade towards the desired output by simply changing the letter.
For instance, to reverse the two shades it is not necessary to re-learn them, but simply to reverse A and B.
5-58
EN
Set the Shade name.
Press OK to end.
The result is the creation of shade cells already positioned on tile values already learnt.
Once the machine is in automatic mode, it is possible to increase or reduce the cells using the mouse,
positioning it on the cell edge and dragging it to the right or to the left.
5
New cells created from learning.

Move the edge to the right or to the left
to enlarge or reduce the shade of that
parameter.
5-59
EN
5.4.3.2.2. Insert a shade manually.
It is possible to create new shade cells manually, directly on the shader screen, without passing the tiles
inside the machine. First of all, it is necessary to create the cells by positioning the cursor arrow on the shade
parameter for which the new cell must be created. Using the right mouse button, select 'Create New Cell'
Tocreateanewcell,gowiththemouseonthedesiredparameterand
press the right button. Select New Cell
By inserting several cells for the same parameter, the new cells increase their cell code, i.e. the first is 0,
the second is 1 and so on.
New cells manually created.

New cell code passing from 0 to 1
Move the edge to the right or to the left
to enlarge or reduce the shade of that
parameter.
5-60
EN
Lastly, it is necessary to assign the new shade cell code to the desired output. To do so, recall the shade
management table.
PressShadeManagementbutton
to assign the cell code to the
corresponding output.
As you can see, the first cell created automatically has already been assigned to output A.
To understand which combination is assigned to output A, recall the truth table by pressing the right arrow.
5
Presstherightarrowtoexpandthe
display of the truth table.
The truth table indicates that shade B50 actualises and takes output A only if the values of VarG and L*
parameters reach the cells with code 0. In other words, if the tile reaches the two cells 0 (purple), then we
have shade B50 output A.
Truth table of the first shade.
5-61
EN
Now we add a new line in the truth table to assign it to the new cells created manually using the 'Create'
button.
Press'Create'toinsertanewlineandthenew
shade.
Assign the name and the combination of cell to the new Shade using code 1 and output B.
See the two lines corresponding to two independent shades on two outputs A and B as an example
Assignmentofcellscode0toShade
Assignment of output A to Shade 1 and
1 and code 1 to Shade 2.
output to Shade 2.
5-62
EN
5.4.3.2.3. Manually set the values of shade cells.
Besides the graphic movement through edge positioning, it is possible to manually set the values of shade
cells. Access Edit menu.
Pressthisbuttontoaccess
cell values
The table of shade management in manual mode activates.
Min and Max are the two extremes of the cell.

Mean is the mean value.
Barycentre is the value of shade centre acquired during learning with tiles.
Warning: Max and Min cannot be higher or lower than the barycentre. To further increase Min or reduce
Max, it is necessary to suitably change Barycentre.
5-63
EN
5.4.3.3. Create areas out of the shade cells to declass the tiles.
When a tile does not fall in a shader cell, it is automatically classified as 'Out Of Shade'. The Out Of Shade
class is managed as a separate class in the output table.
As an alternative, it is possible to add these tiles to a declassing class (e.g. third class) to avoid that they
might be assessed as out of shade and so that they are declassed as if they presented a defect.
To set the declassing classes, position the mouse in the black area of the algorithm for which the class
should be created and press the right button:
Presstherightmousebuttonand
select 'New Class'
A fully grey area appears, that can be resized by moving the edge, like for the cells. The tiles that will fall
on this area will be declassed according to the rule set.
To set the rule, move to the area just created and, using the right button, select the required declassing class.
New Class just created
Presstherightmousebuttonand
select the required declassing
class.
5-64
EN
It is recommended (but not mandatory) to set a declassing class also in the other end of the cell.
We recommend to carry out the

work also on the other end of the
shading area.
This is the final result of a shading algorithm for which two declassing classes have been set.
Warning:Everytimeamodificationismadeontheshaderpanel,remembertopress'Apply'
to apply the modifications.
5-65
EN
5.4.3.4. Two-dimensional shade monitor (simplified)
If only two parameters are used to shade (possible but strongly discouraged, except if the product to inspect
is very simple), it is possible to enter these two parameters in a two-dimensional graph X - Y and obtain a
different kind of representation, maybe easier to use.
Only two parameters

active
Enable '2D Graph'.
Result obtained with the two-dimensional graph in which the cells create a working area.
5-66
EN
5.5. Check of defects

The check of defects is performed through the algorithms set in the machine software.
These algorithms are designed to create working diagnostics. Every working diagnostics can be connected
to one or more algorithms that operate in the various areas of the tile and use the most suitable camera
for that type of defect. System provides a basic group of diagnostics, preloaded in the working model, that
solve most problems according to our long experience in the machine development. However, it could be
necessary to create further customised diagnostics for a special defect of the Customer's production that
must be inspected.
Warning:Thecreationofnewdiagnosticsisreservedtoatechnicianwhohasfollowedthe
advanced course about the use of Qualitron
5.5.1. Diagnostics working concepts

It is important to know some basic concepts in order to understand how the machine operates to inspect
defects. They are listed below.
5.5.1.1. Use of the proper camera.
The machine has three cameras installed at different angles with respect to the tile. It is very important to
understand that some types of defects are more visible form a point of view but less visible from another.
It is useful to help the machine to detect the defects in the best way by using the suitable camera.
5
BW1blackandwhitecamera.Suitable
for edge defects such as chipping of RGB colour camera. Suitable for
cornersoredges.Itcanalsobeusedfor decorationdefects,suchasdrops,lines,
surface defects. bands, lack of print. The defect should
bewellvisiblebywatchingthetilefrom
the top.
BW0blackandwhitecamera.Suitableforsurfacedefectssuchas
holes, lumps, cracks, hollows.The defect must be well visible by
holdingthetileuptothelightandinspectingitataverytiltedangle.
5-67
EN
5.5.1.2. Choice of the correct working area.
Since all the algorithms cannot analyse the tile in its entirety, because this operation would need too high
computational times, every algorithm must operate in a specific area of the tile. This is very intuitive since,
for example, the search of an edge defect in the centre of the tile makes no sense, because it cannot be
detected. The figure below shows the division of the tile areas identified by the corresponding numbers.
Area 1 Top Edge (the first to enter and exit from the machine)
Area 3 Right Edge
Area 5 Low Edge (the last to enter and exit from the machine)
Area 7 Left Edge
Areas 2,4,6,8 Corners
Area 0 Tile Centre

Area 9 The whole tile
Areas 10, 11, 12, 13 The whole edge of the tile, including corners.
5-68
EN
5.5.1.3. Storage of reference samples
Reference samples are the images of tiles without defects that are stored in the machine, to allow it to
compare them with those to be inspected.
This concept is the base of the proper operation of defect check, since the machine, before searching
a defect through the dedicated algorithm, carries out a 'clearing' of the good part of the tile using the
reference sample. If the tile to be analysed and the reference sample are identical, the result is void and
there is nothing to highlight or declass. Instead, if the tile to be analysed shows some differences, they are
highlighted after the comparison with the reference sample. The differences from the sample are potential
defects, easier to be analysed by the relevant defect algorithm. The reference samples are stored during
the initial learning of the new batch. They can also be stored at a later time if the set of samples is not
complete and the machine displays the alarm 'Sample not assigned'. It is possible to simplify the operation
of reference samples according to the following phases:
1st Phase - Learning. Reference sample are stored
Tiles without defects
5
2nd Phase - Inspection. The tiles to check are compared to the samples.
Tile without defects Sample Result is void
Tile with defects Sample Result is the defect only
5-69
EN
To see the stored images of the reference samples, proceed as follows:
From 'Hamburger' menu recall the sample

learning page.
Make sure that the machine is stopped
The following page is displayed:

Camera involved
Similarity threshold
Tableofsamplesstored:everycolumncorrespondstoadifferentsample.Similarsamples
are stacked in the same column.
5-70
EN
A table of elements is shown. Each element corresponds to a tile image stored as reference sample. Every
column corresponds to a different type of image. For instance, if three blocks are at the same press, it is
very likely that on page referred to BW0 camera, that has a good view of the tile structure, there are at
least three columns multiplied by the number of possible rotations. On RGB colour camera page, it is likely
to find a number of columns equal to the number of patterns or decorations that are printed on the tile.
'Corrections' are stacked in vertical. If we imagine the flow of tiles we can guess that the tiles produced
can be divided into equal groups of tiles. After all, if this is not possible, the whole concept about the use of
reference samples has no meaning. In reality, the tile images that look the same to the human eye show
small differences if analysed by the computer. They are similar, but not identical. Therefore we introduce
the concept of similarity. When the computer compares two images, it processes the similarity. The more
the two images are similar, the more the similarity percentage is high. If the same image is processed,
the similarity result is 100%. When there are two images of the same type, the similarity can even reach
95%. During sample learning, the machine processes the tile images and stacks the images of similar tiles
on the same column. Again during learning, the mean similarity value of similar tiles (that look the same
to the human eye) is written on the right in the 'similarity threshold' box. During inspection, the machine
compares every tile to the reference samples. The search of the best sample more similar to the tile to
inspect is carried out. The threshold that determines whether the sample is fine for the comparison with the
tile to inspect is the similarity threshold. If the similarity to the reference sample exceeds the threshold, it
is considered valid and is used for the comparison. In technical jargon we say that this sample is 'linked'. If
during the inspection the machine displays the alarm 'non-existent sample', no sample among the stored
ones has a similarity with the tile to inspect higher than the threshold set. Firstly, lower the threshold by a
few percentage points so that the samples are linked. If this is not enough, the reference sample for this
tile is not available, therefore it must be added to the table. Normally, the machine proposes to add the
samples not linked when this page is opened.
To see the images of the reference samples click on the element to see.
5
Click on the element to recall the
image of that sample
Arrows to press in order to scroll the various

sample images stored.
IndicationoftheSampleandofthecorrection
currently displayed.
5-71
EN
5.5.2. The monitor of defects.

The monitor of defects is used for the actual management of defects on the tiles.
Press to display the defect page
It is divided into three different working areas. Sensitivitymonitor.Everyverticallineisatile.

Thelinedimensionisproportionaltotheresult
of the algorithm.When the line exceeds the
dottedthresholdthealgorithmresultmoves,
Diagnostics currently available. Dataofthealgorithmselectedin withreferencetointensityanddimension,to
diagnostics the underlying declassing monitor.
Displayoftheimageofthemost Diagnosticsmonitor.Indicatesthe
serious defect that caused tile resultofallthealgorithmsofthe
declassing. Every square is a last tile. Declassingmonitor.Whenthealgorithmresult
differenttile.Thearrowshowsthe exceedsthesensitivitythreshold,itispositioned
last declassed tile. on this graph as a white dot, with reference
todimension(X)andintensity(Y).Thecolour
of the area in which it falls establishes the
declassing.
5-72
EN
How it works when the machine is in inspection mode:
Tile to inspect
Comparison with the model
Analysis with
diagnostics
Result
5
Does the result exceed

the sensitivity threshold? No = 1st Choice
Yes, it is positioned
in the declassing
graph.
1st 2nd 3rd 4th Reject

Green Yellow Light blue Blue Red
5-73
EN
5.5.2.1. How to recall and adjust diagnostics
Diagnostics can be recalled from various points of the monitor of defects.
Click on the tile defect shown to Click directly on the diagnostics

recall the diagnostics. involvedtorecallthecorresponding Click on the tile defect shown to
classification graphs recall the diagnostics.
Then the intervention thresholds are adjusted by moving them with the mouse.
Light defects upwards
Monitor of thresholds with positive values only.
Dark defects downwards
Adjust the threshold using the mouse.
Enables or disables completely a choice.
5-74
EN
5.5.3. Search of a defect not detected by the machine.
It is possible, in particular in the first phases of adjustment of a product just inserted in the machine, that,
during the inspection, a defect is not detected by the machine and the tile is not declassed.
In this case the experience with the machine is essential, but we can define some procedures that, if carried
out, help the machine to detect the defect.
5.5.3.1. Simulation (CRTL - R)
Simulation is a special work mode of the machine that allows to pretend that the tile to analyse continues
to pass under the cameras. This continuous virtual passage of the tile allows to perform adjustments until
the tile can be declassed with the defect. Once the result is reached, it is possible to exit the simulation
and pass again the real tile with the defect, to make sure that the result is actually obtained.
Before running simulation mode, make sure that the tile to analyse passed under the machine as last or
second to last piece. In fact, the simulation access menu allows to select the tile to simulate within the last
four or five passages, according to the tile format size. To make sure that the correct tile is available, pass
it as last piece, then activate the simulation menu from the hamburger menu above.
Enter in simulation through the menu after having

passedthroughthemachinethetiletobeusedforthe 5
simulation.
Use the same menu to quit the simulation.
Selectthetileinvolvedthroughthearrow
pushbuttons.Thefirsttileproposedisthe
last one inspected by the machine.
Alsotheimagesfromtheothercameras
canbedisplayedtobetterseethedefect.
Press OK to start the simulation.
5-75
EN
When the machine is in simulation mode, it is possible to adjust the thresholds and the parameter settings
in order to reach the desired result for the search of a defect or its correct positioning in the final choice. We
recommend to clearly identify the algorithm required to identify the defect, at least for the correct camera
and working area. On first examination, it is possible to scroll the list of active algorithms to see if the defect
to search has already been identified by the machine but remains below the threshold.
Clickonthediagnosticsinvolvedto Checkifthedefectinvolvedisincludedin
Simulation active
recallthecorrespondingthreshold the list of algorithm elaborations. In this
graphs and adjust them. case, click twice to recall the relevant
diagnostics.
Assess which camera the selected

diagnostics should use.
Assessthetypeofalgorithmthatyouare
using as well.
Check also the proper use of the

Reference sample.
5-76
EN
5.5.3.2. Images of the elaboration algorithm.
If a defect cannot be detected, it could be useful to analyse the images that the algorithm is processing, in
order to understand if it is the correct one and, if necessary, adjust the parameters. These images allow to
understand if the working area is correct and if the algorithm is able to extrapolate the defect.
PressViewtheimagestoenterthedisplay
page.
The images available are the following, ordered according to their importance and the sequence of analysis.
1 - Original image: It is the tile which is currently being analysed and where the defect must be seen. If the
defect is not visible, try another algorithm in another area or one that uses another camera. 5
Check the camera being used.
Select Original Image.
The defect must be visible,

otherwisethealgorithmcannot
find a missing defect.
5-77
EN
2 - Mask image: It is the image that filters the visible part from the invisible one. If the defect is in the black
area, the algorithm cannot see it. Warning: in this image the defect cannot be seen. The user must only
understand if the defect is in the white area by toggling between Original Image and Mask Image. If that
is not the case, enlarge the mask by adjusting the parameters.
Select Mask Image.
Check that the defect falls in the

whitearea(theinternaloneinthe
example)
3 - Sample Image: It is the reference sample image used for the comparison. It should be the image of the
same tile free from defect. If that is not the case, maybe the sample is not present or it is wrong due to a
too low linking threshold.
Select Sample Image.
Check that the comparison tile

is the same used in the original
image.
5-78
EN
4 - Result Image: It is the actual result of the algorithm. Every algorithm can have a different image according
to the type of elaboration. If the algorithm does not process a result image, the problem may be caused by
incorrect working parameters or even by the incorrect algorithm.
Select Result Image.
Thedefectthatappearsonablack
backgroundisaverygoodresult.
Separatethedefectfromtherest
oftheimageasmuchaspossible.
5
5 - Defect classification: The final choice of the defect is displayed with the suitable colour. This choice can
be changed by adjusting the classification thresholds.
Select Defect Classification.
Please note that the pink area

showsthelimitsofthemaskthat
hidesthedefecttothealgorithm.
In this case defect declassed in

third choice.
5-79
EN
5.5.3.2.1. Parameters of the algorithms.
Even if the initial setting provided by System for the internal parameters of the algorithms is correct for the
majority of defects based on our experience, it is possible that they must be customised according to the
specific types of products of the Customer.
The names of the internal parameters are intuitive and describe the operation that the parameter carries
out on the algorithm, but in our opinion the modification of such parameters should be performed by an
advanced user.
Warning:Themodificationofthealgorithmparametersimpliesanadvancedknowledgeofthe
machine for expert users who followed the advanced course on the use of the machine.
Presstoopenthepageofinternal
parameters.
List of algorithm internal

parameters.
5-80
EN
5.5.3.3. View the camera images.
During simulation, as well as during automatic inspection, it is possible to view the images of the cameras
in real time. This page is very useful to actually see what the cameras see and how the potential defect
appears. They are used to immediately understand if a defect can be seen and with which camera. Moreover,
there are working areas that allow to understand whether the defect is in the correct area.
Press on the camera symbol to

recall the display page.
Select the camera involved.
5-81
EN
This page contains two important functions. The first one is the possibility to see the binarisation threshold,
i.e. the threshold that deletes all the parts different from the tile. When the binarisation threshold is displayed,
it is important that only the tile and possibly the conveyor belts remain white, otherwise the machine may
be mislead in case of dirt or shards in the background.
Activatethebinarisation
threshold.
White tile OK!
The rest all black OK!
The second one is the activation of the working areas. Looking at the working areas allows to understand
if the machine is able to remove the edges and correctly detect the tile. In normal operation, the working
areas are displayed in red and the belts in green, like in the following figure.
Activation of working areas
The working areas grid must be as in the figure. If fully

The belts must be within the redareasappear,itmeansthatinthatpointthemachine
green areas. isnotabletodetectthetilebecauseofanobstruction.It
isnecessarytounderstandthereason.Byenlargingthe
image, shards or dust are usually found.
5-82
EN
5.6. History of the tiles
During automatic operation, the machine stores the images of the last tiles passed. Normally, the images
of the last two hundred tiles are available, but this value depends on the configuration set by System S.p.A.
and the format of the material in production.
Using these data, it is possible to recall any tile stored and assess its situation even if the machine is
choosing. It is also possible to set it in simulation mode. In this case, as it usually happens with the simulation
function, the automatic inspection stops.
To recall a tile, proceed as follows:
Press on the ‘timer’ symbol to

recall the history.
5
The history page shows the list of tiles available.
List of tiles present in the

history.
5-83
EN
The first thing to be noted is the number of the tile in PZ column, which corresponds in a unequivocal way
to a single tile; this is the same numbering displayed by the machine in the main page.
Unequivocalcorrespondenceon
numberingandondeclassing
result.
Algorithm situation at the

moment of tile declassing.
5-84
EN
From the history page it is possible to carry out two other important manoeuvres, using the images of the
tiles stored:
• Set the stored tile in simulation mode. This allows to virtually recover the declassed tile and put it in
simulation mode, as if it were physically available. See paragraph: 5.5.3.1 This operation is important
when the operator needs to further check the declassing reasons. WARNING: The tile has been
declassed based on the parameters and the thresholds set when it passed through the machine, and
the data stored in the history refer to that moment. Instead, if the tile is put again in simulation mode,
the elaborations are carried out with the new parameters and thresholds, therefore result may be
inconsistent if the operator has changed such data.
• Send the image to the list of reference samples. This possibility is useful when the tile is erroneously
declassed because it is part of a sample not present and therefore not linked.
Press to select the desired tile to

be analysed from the list of the
available ones.
The tick 'Locked’

indefinitelykeepsthetilein
thehistorylist.Itisusedto
avoidthatitisoverwritten.
5
Presstosendtheselected
tile in the list of Reference
samples
Presstoactivatethesimulationof
the selected tile
5-85
EN
5.7. Outputs
This paragraph explains the way in which the machine communicates the final choice of the tiles to the
downstream machines.
The final destination of the tile is identified by a binary numerical code applied to the physical/electrical
outputs of the machine through four BITs + a Strobe signal. When the main computer has processed the
final choice information, the PLC that manages the machine outputs the data in binary form in the physic
outputs and sets the Strobe signal high for a set time limit.
Therefore, the values can range from 0 to 15 and the setting follows a truth table that can be recalled.
Press to recall the output table.
Buttons: New, Open, Addsand/orremovesthe

Delete,Savetheoutput output rules.
table.
The following table is displayed:
Firstlineanalysedbythemachine
for the truth table.
Last line analysed with all the

outputsactiveifnoneofthelines
above is true.
5-86
EN
The main rule about the operation of this table is that the machine scrolls the lines starting from the top
and when all the line cells are 'true' the machine assigns the code of the first column to the tile involved.
Columns have the following meaning:
Output: it is the physical output assigned to the downstream machine for that combination. The last line
of this column is number 63, corresponding to all the active outputs (set to one). This last line cannot be
deleted and is active if none of the above lines is true
Shade: The shade result is chosen as per the setting of the first column of the shade table. The desired
shade is set with the corresponding letter from A to Z. Also the star (*) can be set, meaning 'any shade'.
Normally the star is set in the rows of the outputs that are not the first choice ones, because they are not
shaded. It is also possible to set 'FT', i.e. 'Out of Shade', meaning that the shade of the tile is not assigned
by the shader.
Choice: The result of the final choice of the defects is chosen. It is possible to set the choice, from first
choice to reject. Also in this case the star (*) can be set, when the choice is not important for that specific
line. For instance, any choice (*) is set in the same line as the out of shade.
Lost: It is selected if the machine has actually inspected the tile or if the tile has not been inspected because
of an error or alarm. The possible options are: Star (*) means indifferent, one (1) means the tile is lost or
not processed, minus (-) indicates that the tile is not lost, therefore correctly processed.
Please find below an example of line in the truth table: we want that the first choice tiles with shade A,
correctly inspected, have code 1 sent to the sorter.
Output = 1 Shade = A Choice = First Lost = -
We want that the third choice tiles, whose shade is not important and correctly inspected, have code 5 for
the sorter.
5
Output = 5 Shade = * Choice = Third Lost = -
We want that the tiles not inspected have code 7 for the sorter.
Output = 7 Shade = * Choice = * Lost = 1
The next columns are used to set alarms for each line of the truth table and the operation is user-friendly:
When the No. of pieces is reached out of the Total pieces of that specific line combination (output) it
is possible to carry out a Stop or activate a specific Output, possibly connected to an alarm or siren, if
necessary. Please note that this control and any alarms set can be enabled or disabled through the button
available in the lower bar. This may temporarily disable the alarms, e.g. for a not good production period
or in case of adjustments.
Enableanddisablethealarmsof
the output table.
5-87
EN
5.7.1. Outputs printed on tile (Dicoprintosh)

A special accessory called Dicoprintosh allows to print the result of the choice of the machine directly on
the tile. It is an ink printer whose head may be positioned over the tile passage to print the surface with
fluorescent ink, or whose head is positioned on the side of the tile passage to print the edge with black
ink. Also both functions can be available. The upper head that prints the surface prints dashes. The side
head prints points. The management of the position of these marks is made through the suitable page:
Press to recall the printer

programming page.
Indicates the tile advancement

direction
The following page is displayed:
Table of output codes Positionofthemarks Position of the

set on output table. set for head 0 marks set for Expand the page to
head 1 downloadthedatato
the printer
5-88
EN
The page shows a graphic table in which every line of the first column corresponds to the output code
programmed in the machine output table. In the two following columns it is possible to graphically set the
position of the mark to be printed on the tile, considering that the top right-hand arrow indicates the tile
feed direction. The width of the column represents the total length of the tile. If the arrow is facing to the
right and a mark must be printed on the head of the tile, position it fully to the right; while if a mark must
be printed on the tail, position it fully to the left.
Once the position of the marks is set, it must be loaded to the printer memory. Expand the page by pressing
the downward arrow, the arrow will then face upward; press it to close the page. Moreover, other printing
parameters appear; they are normally set by System S.p.A. And must not be changed.
Save settings to disc.
Timeofprintstartdelay
from the beginning of
the tile.
Pointsize(broadenthe
printfromstarttoend).
1 - Download 3-CheckprinterEprom. 2 - Program printer

configurationonprinter.
Eprom.
To download the programming on the printer carry out the three operations as described: 1 - Download,
2 - Program, 3 - Check data on Eprom.
Once the configuration is saved, press OK to close the page. The machine asks if you want to link the
settings just carried out to the current batch; normally this operation is performed.
5-89
EN
5.8. Statistics
It is possible to display the production statistics, which are grouped in a page that can be recalled form
the side menu.
Press to recall the statistics page
Distributionofproduction
to the single tile
They are displayed in three different modes: Distributionofproduction

to the tile batch
Button to reset statistics.

Overall statistics: they Partial statistics can be
are calculated from the reset more often, e.g. at
beginning of the use of every work shift.
this working batch.
5-90
EN

SYSTEM S.p.A.
Via Ghiarola Vecchia, 73
41042 Fiorano Modenese (MO) - Italy
Tel. +39/0536/83.61.11
Fax: +39/0536/83.62.85
www.system-group.it
info.ceramics@system-group.it

Qualitron Manual Eng

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Qualitron Manual Eng

Uploaded by

Copyright:

Available Formats

QUALITRON INTERFACE

Code: ........................... MC000974

© 2015 - SYSTEM S.p.A.

PAGE LEFT INTENTIONALLY BLANK

PAGE LEFT INTENTIONALLY BLANK

PAGE LEFT INTENTIONALLY BLANK

1. GENERAL INFORMATION

1.2. Suggestions to the buyer

1.3. Suggestions to the user

1.4. New graphic design: faster, easier, better.

1.5. Purpose of this manual

1.6. Unintended use

1.7. Symbols used in this manual

Symbols indicating information for specialised operators.

MECHANICAL MAINTENANCE OPERATOR

ELECTRICAL MAINTENANCE OPERATOR

Indicates the number of persons in charge of maintenance.

2. DESCRIPTION OF THE MACHINE

2.1. Operating principle

2.2. Main sections of the machine

2.3. Control panel

2.4. Panel controls

3. MAIN INTERFACE

3.1. Launch Bar (QShell)

Launch bar position

Press the tab to hide or show the launch bar.

3.1.1. Launch bar functions.

3.1.1.1. Launch of machine management program.

3.1.1.2. Opening of the user’s manual of the machine, on the screen.

3.1.1.3. Widget of notes.

Press this pushbutton to open a window on the screen that

3.1.1.4. Data backup

Activates the backup schedule according to the rules set.

Addsaruletothelistofrules Deletes the selected rule from

List of scheduled items.

3.1.1.5. Remote control

Communicate Used ID and password

3.1.1.6. Switch to... command

Press this pushbutton to toggle through the

3.1.1.7. Recycle bin.

Recycle bin list.

Empty the recycle bin.

Restore the selected files or the whole

3.1.1.8. System shutdown

3.2. Main interface overview.

Grey lower bar.

Tile flow box

Grey Side Bar.

3.3. Lower bar.

3.3.1. Access to management program

Press the padlock to access

3.3.2. Management of user rights

Press this menu to activate the

Shows the rights enabled for the selected

Creates a new user starting from and

3.3.3. Machine Status

3.3.3.1. Machine STOPPED

3.3.3.2. Machine in INSPECTION mode (Activated production)

The arrow symbol sets the machine in production mode.

3.3.4. Machine Status LOG Window

3.3.5. List of alarms

3.4. Upper bar.

3.4.1. Software version

3.4.2. Product setting menu (hamburger menu)