3D A1000 1 CognexWorkshopNotes

3D –A1000 Workshop
Adam Mokanszki / Heinz Gebel/ Jeremy Maudier | 2021
1 © 2021 Cognex Confidential

3D-A1000

3D Principal
Data Reconstruction
As the pattern is known
Baseline Baseline as well as projector and
camera setup, data can
be extracted from:
projector IR Cam projector IR Cam
VIS Cam VIS Cam - symbol sizes
- covered FOV
- gradient
Object
Object

Symbolic Light Technology
Cognex Symbolic Light Conventional Time of Flight
Clear Data Noisy Data

Instant In-Motion Requires Filtering
Unaffected by Movement High Processing Time

Application Types - Dimensioning

Application Types - Item Detection

Application Types - Tote Filling
Amazon

Application Types - Top Side Damage Detect

Model Selection Matrix for Dimensioner
Measurement Detection Utilities
Model Dimensions Position Volume Fill Categorization Flats Side-By-Side Tote Tracking Damage
3D/2D Clear Basic Analysis
Spot Scripting Report
L
• • • • • •
Q
• • • • • • • • • •
X
• • • • • • • • • • • •
Guidance
3D-A1000 Key Upgrades 3D-A1000 Kit Numbers
Model List Pricing Upgrade
FSU-DIM-L2Q 3D-A1000-XXX-Y-ZZZ
L $10,350 FSU-DIM-L2X XXX = Application (DIM, ITM)

FSU-DIM-Q2X Y = Key Level (L,Q,X)
Q $12,550 $2,500
ZZZ = Kit Level
000 = Head only
X $15,500 $5,500
200 = Head, bracket, cables
Note: Item Detection requires different FW: P/N:3D-A1000-ITM-L-ZZZ

Quick Start Guide
 Delivered with each device

 Default IP: 192.168.1.218
 Connect directly through
browser or use DataMan
Setup Tool
Recommended Browsers
Google Chrome Microsoft Edge

Connecting via DataMan Setup Tool
 DM Setup Tool can be

used to:
 Connect (opens default
browser)
 Change IP settings
 Configure DMRS System

Getting Help

Tool Tip & Side Panel

Side Panel Feedback
Feed us!

Specifications
 ~ 3 images/seconds
 300ms - 400ms execution time, depending on
activated features
 ~ 3 Amps surge current. Be careful when
selecting power supply
Message from the BU: “Technically the device ports (for the new
CIO) can handle up-to 3.5A for 1ms. The 3D-A1000 very rarely
goes above 1.5A unless using the 3D-A1000 HPIA (light). “

Wiring Flying Leads
 Pin compatible with DataMan

 Except: there is no RS232
 Accessible in 3D-A1000 help
menu

Dimensioning - Dynamic

Application Details
Dynamic window
Minimum Gap
Hover your mouse

over settings to see
an explanation
Trigger Distance

Application Details
Trigger Type
Production Type
Software/ PLC for Network Trigger
- Simple Matte for cartons only
Hardware if connected to I/O
- Complex Reflective for cartons
Long Package And polybags
Needs Hardware Trigger and Encoder
Can reduce working distance if used Object Attributes
A minimum object height is required
Belt Width
FLATS needed
Effective inner width of the conveyor
can be reduced if parcels are aligned
Min Gap / Max Line Speed

Will determine how many inspections
per second must be processed Working Distance
& Trigger Distance
Calculated values based on
entered parameters

Mounting the A1000
Spirit level
Keep centre
area free!
WD setpoint
Height Ignores whether

adjustment help adjustments are
correct or not.

Teach Baseline
 Baseline is a virtual plane

(zero plane), from where
height measurements are
taken
 Keep the area directly
under the A1000 clear,
providing a flat surface.
Needed < 1/4 of image
Continue
 If you have a roller type
conveyor, place a thin sheet Corrected
of paper on the roller Setup
 Every time the 3D-A1000 is

moved, teach a new baseline

Line Setup
 Set up the system from

your point of view
 Do you see the Cognex
Logo or the back of
A1000?
 Is the trigger left or right
from your POV?
 In which direction is the
conveyor moving?

Trigger Adjustment
 Helps you to position

the trigger correctly
 Indicator shows you if
device would be
triggered (lights up
green)
Target
Trigger Zone
Indicator

Trigger Alignment
Take a parcel, move it along the conveyor to target trigger zone

Use the parcel’s edge to physically position your trigger

Measurement Area
 Make sure the

measurement region
is aligned with the
conveyor belt
 No guide rail should
be inside the green
area
 If not aligned 
move A1000 or click
“No” to move the
measurement region

Moving Measurement Region
Double check with the 3D image by
clicking the "2D" button to see if items
like side guards are detected
 You can shorten or

extend the green
measurement area,
rotate it and set an offset
 Adjust the view to give
you a good overview of
the region
 Careful 3D image might
appear upside down

Setup Origin

Optimize
 Autotuning helps you

finding the right
exposure time for 2D
and 3D
 Take realistic samples
to tune
 If brown cartons only
use only brown cartons
 If various items use
bright, medium, dark,
reflective, opaque
samples

Optimize

Train Empty Conveyer
 Important when Flats is

enabled because this
feature use the intensity
of the 3D points cloud to
detect flat objects and
the intensity depends on
exposure time
 Needed for Flats to train
background
 Careful on Rollers
FLATS can’t be used

Communications
 Select only the

outputs you really Disabled if Long Package
need!
 Selecting more than
needed has a negative
impact on execution
time
 Some outputs might be
disabled, depending on
settings you chose.
E.g. Long Package,
Software Trigger Type

Communication - TCP Server
Discussed in next chapter
Note: FFP = Factory Floor Protocol

Runtime UI This button is used to
switch between Online
and Offline mode
Offline mode:
- No data output
- No signal output
- Some settings are
settable only in this
mode
- Trigger ID is not
incremented

Customer Acceptance Test
CAT gives you a mean to

evaluate the performance
of your system by
calculating statistics on
dimensions of boxes
passing below your
system compared to
reference values you
entered before.
 One CAT per parcel

Exercise - Set Up Dimensioning
Cartons
Min Max
 Your customer has following specifications:
Width 100 400
 Conveyor width: 450 mm
Height 200 350
 Gap: 350 mm
Length 200 500
 Speed: 1.6 m/s
 Communication: RS232 Polybags
Min Max
 Trigger: SW
Width 50 250
Task: Help him to set up the system. Height 50 200
Length 100 200
Goal: Understand the project.
Carton Envelopes
- Are there any constraints/limitations? Min Max
Width 100 200
- If yes, how can we solve them?
Height 5 200
- What model would you choose? Length 100 300

2 Ways of Data Output – Formatted String
 Configurable
 Only needed outputs
 Receiver handles result by
using string operations
 DataMan Primary script
 PLC
 Changes on A1000 result

string will also lead to
changes on receiving end

2 Ways of Data Output – JSON Format
 All available data is sent

 Receiver (e.g. DM Script)
parses results into a JSON
object
 Advanced operations and data
analysis can be performed
 Change of outputs will not
affect receiver

Communication - TCP Server
 Use TCP Server if you

want to distribute
results to multiple
clients
 3D-A1000 can accept
several connections
from an unlimited
number of devices to
give them access to the
result
 Issue a trigger by
sending a “START”
command
Communication - TCP Client
 Use TCP client for

point-to-point
connection
 This communication
mode is used when the
3D-A1000 has to be
connected to a server
to send the results. You
can connect to only one
server per session.

Communications – Industrial Protocols
 Is used to communicate
with PLC supporting
Ethernet/IP or Profinet
protocols.
 Ethernet/IP stand for:
Ethernet/Industrial
Protocol

Communication – Discrete I/O
 If you wire flying leads

 2 fixed Digital Inputs
 2 Digital Outputs
Outputs

Communication - DMRS
 A1000 acts as a slave

reader, sending data to
the master reader. Data
is considered as a 1D
barcode by the master
camera
 In order to use DMRS,
Software Trigger Type
must be selected

Setting up DMRS

Setting up DMRS
a1000-NormalDataF
ormatting-Script.txt

Setting up DMRS

Setting up DMRS
Results show up
as 1D code
result!

Timing Guidance (DMRS)
A1000 Acq+Dim
3D-A1000 ~330ms
Secondary
Master Dataman Trigger Response
Time
ON OFF Timeout
A1000 Acq+Dim
3D-A1000 ~330ms
TON Secondary
Master Dataman Trigger Response
Time
ON OFF Timeout
Careful of short packages!

A1000 Acq+Dim
3D-A1000 ~330ms WORST CASE:
Secondary A1000 has not propagated its
Master Dataman Trig. Response result by timeout (M/S Timeout)
Time
ON OFF Timeout

Exercise - DMRS Setup
Task: Use the guide handed out to set up a DMRS system. Use the script
in the A1000 help files to get the results.
Hint: The results from the 3D-A1000 is considered as a 1D code so set the
number of codes on the DM accordingly to that.
Goal: You should be able to trigger both Dataman (Primary) and 3D-A1000
(Secondary) from DataMan Setup Tool. The 3D-A1000 measurement
results should be propagated.
Quick Setup Guide
DataMan MRS with A1000
Version: DRAFT 20-Feb-20 20
1. Connect & power up the DataMan & A1000.

2. When setting IP per customer requirements, make sure DataMan and A1000 are on the same
subnet & have the most recent Firmware:
3. Either restore the fully configured backup (if available), OR perform the following setups in Setup
Tool:
a. Create an MRS group – Do NOT add the a1000:
a1000-NormalDataF
ormatting-Script.txt
Script
b. In Setup Tool - Set # of codes (1D) to read for each trigger = 2.
c. Copy the Data Formatting script attached below into the reader:
a1000-No rmalDataF
ormattin g-Scrip t. txt
Guide

Accuracy vs. Repeatability
System 1
System 3
System 2
Repeatability =
Accuracy = 3 Systems with same Repeatability
How precise can you repeat
Deviation from known value But different System accuracy
one measurement

Increasing Accuracy - Repeatability
Static Dimensioning is Legal for Trade certified!

Increasing Accuracy – A1000 Repeatability
 Measured on rigid cuboidal object

 Excellent Repeatability and Accuracy
 When speed increases,
Repeatability „washes out“
 Accuracy remains stable in a small
Range
 On shape shifting objects (Polybags)
Accuracy and Repeatability cannot
be guaranteed

Quiz
 Why does the accuracy increase when the working distance decrease?
 Is the accuracy the same over the whole DOF?

Increasing Accuracy - Long Package
 The bigger the box, the higher you have to go, the lower will be your accuracy at the far FOV
 Long Package can increase your accuracy as the box does not have to fully fit the FoV. Data from
Encoder will be taken into account.
 Can’t work if Master/Slave communication is required (HW trigger required)

Choosing Trigger - DataMan Triggering
 DM acquires multiple images during trigger on time  Continuous mode
Polarity
Axis of the reader would point 1st DM image of a

directly at trigger position TOP/FRONT configuration
Choosing Trigger - A1000 Trigger Options
 Only one image is acquired, object must be fully in FOV
A1000 A1000 A1000
Polarity Polarity Polarity
Recommended OK but not best option Fail

(integration with DM tunnel)

Choosing Trigger - DMRS System
A1000 A1000 A1000
Frame must be Rising edge for DM

No Multi Reader Synch
designed tunnel would also
accordingly trigger A1000 Requires comms script,
Note: DMRS allows possibly queuing logic
only one delay for
all members
On DimMax
 Todays Gotcha’s
 No holes in the base
plane
 This means no rollers,
conveyor gaps
 GAP FILL!
 Settings to Use
 Size Ratio
 Min Height
 DimMax uses
“negative space”

FLATS

Tune FLATS
 Use with Sensitivity

Slider
 FLATS detection is
based on 3D points
intensity
Play Video

DMRS Frame Design Guidance
Discuss how a frame would need to be build that a tunnel can be merged with
A1000 using only 1 trigger and native DMRS. Conveyor left to right.
A1000
1) Will the trigger be left or right from the parcel?
2) Where does the 3D-A1000 need to be?
3) Where would the DMs need to be?
Note: External DM lights and parts of the mounting
frame could block the view of 3D-A1000

Dimensioning Side Panel
Segmentation Mode:
Can be seen as min blob
size. Separate might see
complex parts as multiple
packages. Cluster might
merge parcels close
together as one.
Flats Sensitivity
see previous chapter.

Dimensioning Side Panel
Complex Shape
if enabled, DimMax and
Gap Fill can be selected
Sensitivity
depending on the contrast.
Low sensitivity if high
contrast app. High
Sensitivity might give false
alarms.

System
 System Overview
 To upgrade license an
RaC File must be
generated and sent to
support/sales. BU will
generate license to
apply

Accounts
 Operator: can change

parameters
 Viewer: Can only
access Runtime UI
 Default password:
 <no password>

Logging
Log result dta

FTP settings
Logs result string into a
Connect to a CSV file, onto the A1000
customer FTP
Server to
continuously log Log process data
data Logs data useful for Vision
BU, such as point clouds,
bitmaps, calibration files…
Log 2D image bitmaps

Circular buffer for images

Runtime Settings
 Adjust Display Settings to

get a better
understanding of what
the A1000 sees.
 Change Trigger and
Encoder Settings if you
encounter trigger issues.
Vertices = corner
points of the box

Time and Language Settings
 For data logging and

access to timestamp in
script
 Timestamp can’t be
selected as an output
 There is no RTC (Real
Time Clock) on the device
so every time you switch
off then switch on the
device you loose the Date
and Time setting

Backup and Restore

Advanced - General
Graphics Debug Level

Select which images to zip when
logging

Advanced – Object Detection 1/2
 DimMax ratio:
Min size ratio before
applying DimMax
 Voxel
 More connectivity = ++
 Less connectivity = --

Advanced – Object Detection 2/2
 Z-Strength: used to cut

off outliers value in Z
direction
 Vector: If condition
TRUE  will be
clustered. For FLATS.
 Segmentation mode is
directly linked to the
Height, Distance and
Volume parameters

Segmentation mode
Selection AND/OR
With these parameters you can create a logical operation

that allow you to merge blobs which satisfied the criteria
These parameters are related to the segmentation mode
slider
Height: merge blobs with a difference in height lower than

+- the value
Distance: merge blobs which are separated of less than
the value
Volume: merge blobs with a difference in volume lower
than the value

Scripting
 Gives the possibility to create

new variables based on
combination of standard
ones
 Can be added in data output
of affected to a digital IO

Side by Side
Sensitivity
Higher value detects more SBS,
Lower value ignores certain criteria.
Package spacing threshold

Below threshold is considered SBS
Liquid vs cuboid volume

If the calculated values differ too much,
it is an indicator for SBS.
Item count threshold

If more items than threshold are found,
it is considered SBS. Significant gap
required.
Report ROI errors

If an item is at the edge of ROI, you can
choose if they are considered as SBS

Object Characteristics
Categorization Threshold
Calculate the difference between
the lowest and highest point of the
top surface, and compare this
value to the threshold
Confidence score
Evaluate object “quality” based on
the number of points acquired for
the top surface

Dimension Limits

GH69
Scripting
Upload
upload a complex script.
Send in script requests
to BU

Slide 86
GH69 example advanced sscripting. DHL Box counting

Gebel, Heinz, 7/10/2021
Field Calibration
 Can be performed to
increase system
accuracy and
compensate for
distortions. Does not
need to be done by
default. 3D-A1000 is
factory calibrated.
 Is needed if acquired
point cloud of the base
plane is not planar.

Gap Fill
 Gap Fill closes holes

e.g. between 2
conveyors. Not meant
to close all holes in a
Roller type conveyor.
 DimMax extracts data
from missing point
cloud (e.g. shadows).
If gap is not filled,
wrong data.

Scripting
Your customer has cartons and polybags on the conveyor. He wants to

integrate binary flag into the result string, classifying small items as polybags
no matter if cuboidal or non cuboidal.
 Small Item (=TRUE):
 Height < 50mm OR
 Width < 100mm OR
 Length < 100mm
Task: Create a basic script to add an additional output flag. Bind the flag to a
digital output.
Hint: only 2 values can be in a logical operation. Cascade your operations.
Goal: Show and discuss your approach with the team.

Application Details
 Enter conveyor data and

outside tote dimensions
 Are items in the tote
Simple - Matte (cartons)
or Complex- Reflective
(polybags)
 Confirm there are no
warnings in warning
display

Baseline – Teach Baseline
 Teach an empty
conveyor as baseline,
tote should not be in
FOV
 If you have Rollers use
a sheet of paper and
place it on the rollers.
Paper should cover
~1/4th of the image in
the center.

Baseline – Line Setup
 Set up the system from

your point of view
 Do you see the Cognex
Logo or the back of
A1000?
 Is the trigger left or right
from your POV?
 In which direction is the
conveyor moving?

Baseline – Trigger Alignment
 Align the trigger as

discussed in
Dimensioning section.

Measurement Area
1. Train Container
2. Train Tote

Train Tote
 Align Tote to the center

FOV.
 Use Trigger Button to
grab a new image.
 Use Brightness control
to increase exposure
time.
 Click on Edit Region
once you have a usable
image

Autotune
 Place different items

in the tote. Use a
selection of dark,
bright, opaque,
reflective items.
 Vary fill level of the
tote.
 Only tune realistic
scenarios.

Communication Fields
 Tote Fill Applications

can report back:
 Fill Volume in % (of tote)
 Fill Volume in mm^3
 Volume Pass/Fail
 Fill Height in % (of tote)
 Fill Height in mm
(high/low)
 Fill Height Pass/Fail

Troubleshooting on
Site
 Visualize what is going on
 Settings – Runtime
 Turn on full point cloud
 Turn on ROI
 Turn on Multi-Object & Rejects
 Adjust Settings
 Settings – Advanced Settings – Object
Detection
 Minimum Package Height – override if
object is smaller?
 Minimum Volume – Is the object
smaller than this?
 DimMax

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3D A1000 1 CognexWorkshopNotes

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3D –A1000 Workshop

Adam Mokanszki / Heinz Gebel/ Jeremy Maudier | 2021

1 © 2021 Cognex Confidential

3 © 2021 Cognex Confidential

4 © 2021 Cognex Confidential

Cognex Symbolic Light Conventional Time of Flight

Clear Data Noisy Data

5 © 2021 Cognex Confidential

6 © 2021 Cognex Confidential

7 © 2021 Cognex Confidential

8 © 2021 Cognex Confidential

9 © 2021 Cognex Confidential

L $10,350 FSU-DIM-L2X XXX = Application (DIM, ITM)

Note: Item Detection requires different FW: P/N:3D-A1000-ITM-L-ZZZ

 Delivered with each device

Google Chrome Microsoft Edge

12 © 2021 Cognex Confidential

 DM Setup Tool can be

13 © 2021 Cognex Confidential

14 © 2021 Cognex Confidential

15 © 2021 Cognex Confidential

16 © 2021 Cognex Confidential

17 © 2021 Cognex Confidential

 Pin compatible with DataMan

18 © 2021 Cognex Confidential

20 © 2021 Cognex Confidential

Hover your mouse

21 © 2021 Cognex Confidential

Min Gap / Max Line Speed

22 © 2021 Cognex Confidential

Height Ignores whether

23 © 2021 Cognex Confidential

 Baseline is a virtual plane

 Every time the 3D-A1000 is

24 © 2021 Cognex Confidential

 Set up the system from

25 © 2021 Cognex Confidential

 Helps you to position

26 © 2021 Cognex Confidential

Take a parcel, move it along the conveyor to target trigger zone

27 © 2021 Cognex Confidential

 Make sure the

28 © 2021 Cognex Confidential

 You can shorten or

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30 © 2021 Cognex Confidential

 Autotuning helps you

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 Important when Flats is

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 Select only the

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Discussed in next chapter

Note: FFP = Factory Floor Protocol

35 © 2021 Cognex Confidential

36 © 2021 Cognex Confidential

CAT gives you a mean to

37 © 2021 Cognex Confidential

39 © 2021 Cognex Confidential

 Changes on A1000 result

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 All available data is sent

42 © 2021 Cognex Confidential