RCount User Guide

1.0 Overview

The RCOUNT™ system is designed specifically for non-contact counting of folded stacked products such as inserts, outserts, and cartons. Tray contents are counted and validated in milliseconds resulting in reduced labour costs and improved product dependability.

The RCOUNT™ requires minimal setup. Folded stacked products are counted by placing the tray under the camera, and the total count is displayed at the push of a single button. The system displays the row counts and the accumulated total. The RCOUNT™ is capable of counting single or multiple-row insert trays. It can also count folded cartons, folded leaflets, Vials, and many other stacked parts.

Fig. 1 RCount can count Folded Carton, Inserts & Vials.

1.1 Software

The RCOUNT™ software operates on an Intel processor using Microsoft Windows operating system and is compiled using a high-level programming language.

The counting software is intuitive and easy to use in part to the latest technology in both hardware and software. Counting is in real-time, so the RCount is always armed and ready to count.

For additional support in using the RCount system, please visit the Global Vision website Help Center → RVision Training Videos.

1.1.1 Software Installation

The software installation is typically performed at the factory and sold as a turnkey system. If you are using your own PC, simply run the installer and follow the steps.

Now you are ready to calibrate your RCOUNT. Go to this section at the end of this guide.

1.2 Hardware

The RCOUNT™ is a computer vision product. Image input is through an industrial high-resolution camera, minimum 10 megapixels, with output to a hi-resolution computer monitor.

The hardware is easy to set up. It comes 80% preassembled. The assembly instructions can be accessed by scanning the QR code located in the box. All the hardware components are attached to a single column. Including the Digital camera, Monitor, lighting, tray guide (rip-fence) and canopy.

It is recommended to purchase the electric table option. Alternatively, the column can be attached to your own desk with either the clamp or bolts that are supplied.

Fig 2. RCount system showing Canopy, Monitor, Camera, Lighting, Guide & mounting clamp.

1.2.1 Specifications

The following table describes the system specifications:

Table 1

2.0 Getting Started

This section provides the information and procedures required to use the RCount™ software.

2.1 Logging into the System

• Select RCOUNT™ software.

• The RCOUNT™ Log In Screen appears.

• Enter User Name and corresponding Password.

Fig. 3 RCOUNT™ LOG IN SCREEN

3.0 Setup

The RCOUNT™ main system window will load after logging in and it will be in Live counting mode as shown in Fig 4.

Place the item to be counted on the table, under the camera.

Open the aperture and focus the lens.

The next step is to calibrate the system. See Section 4.0.

Fig. 4 RCount Main User Interface

4.0 Calibration

An initial calibration is necessary prior to counting. The digital camera requires a white balance in order to function at its peak performance.

The calibration tool comprises of a solid white, opaque sheet of photographic paper. If this is not available, use a pack of 5 sheets of regular white paper.

1. Click the Camera icon in the main tool bar.

2. Place the calibration sheet under the camera and fill the red rectangle with the white target.

3. Click Calibrate.

4. You may notice the image quality and/or brightness quickly change.

5. Remove the Calibration tool and set aside for future calibrations.

Fig. 5 RCount Calibration

From the main toolbar go to Camera Profile to select the item to be counted

Fig. 6 Camera Profile Selection

5.0 Camera Setup

1. Select the Setup icon.

2. Select Default.

3. The main camera parameters will automatically adjust.

4. If you wish to manually adjust the Camera Brightness, Contrast, Gamma and Exposure, use the sliders or spin boxes.

5. After setting these parameters, select Save Profile. Then Close.

Fig.7 Camera Setup

6.0 Start Counting

Fig. 8 RCOUNT™ Insert Counting – Multi-Row

• Enter the #Rows in the Count Settings

• Enter the Count/Row in the Job Mode

• Enter the Target amount for the current job.

• If a Target amount is not required, turn off Job mode.

Fig. 9 Counting Dialog Box

1. A red rectangular counting box will appear at the top left of the image for each Row. They can be lengthened and widened by dragging the box edges.

2. Now drag each Red rectangle (Counting Box) over the parts to be counted.

3. A white tick will appear over each part and the total quantity will be displayed in the Current Count.

4. Check the accuracy of the count and adjust the camera setting as necessary.

Fig 10. Red Counting Regions showing white tick marks for each part found

6.1 How to Remove the Tray from your Count

RCOUNT will recognize the tray and not include it in the count only if it is a different color and/or thickness from the other parts being counted. There should not be a white tick on the tray itself on each end.

Select Automatic Offset in order to automatically subtract the tray or container from the count.

Fig. 11 Count Settings window

If the tray is too similar, a white tick will appear on the tray. Simply deselect Automatic Offset. Now enter a quantity to subtract from the count in the Manual Offset field. (Typically 2)

The part count should be accurate now.

7.0 Reports

In order to generate a Counting report, select the Report icon from the main toolbar. Select the report template and complete the form. It is recommended to select “Save & View” to see the final report. It is also recommended to add your company logo to the report using this dialog box.

Go to the Main Menu.

Select General settings.

Fig 12. Report Logo setup

Fig 13. RCount Report Template

Here is an example of an RCount report.

Fig 14. Example of an RCount Report

8.0 General, Administration & Compliance Settings

• All the Administrative and Compliance controls are located here and outlined in this section.

• Click Main menu to access the main menu shown below.

Fig 15. RCount Administration Main Menu

8.1 General

• General Settings - This function allows you to add your company logo to the Reports

• Change Password - This function allows you to change your password

Fig. 16 Change Password Window

8.2 Administration

• Security Settings - This function allows you to manage passwords and system security including system time out, log out, password security, and more.

• User Management - This function allows you to manage user access. Select User Management from the Main Menu and you will see this dialog box appear.

Fig. 17 User management window

To add a new user, click on the ADD icon and enter all the User information including the email address.

• Group Management - This function allows you to arrange all active users into groups and manage them as a group.

• Licensing/Updates - This function allows you to manage licensing and software updates. When a new software version from GlobalVision is available, this function will automate the upgrade process.

8.3 Compliance

• Compliance Settings - This function allows you to enable electronic signatures. From the Main menu, select Compliance Settings. You will now be able to toggle this feature ON.

Fig. 18 Electronic Signatures

• Audit Trail – This function allows you to view the audit trail. Simply select this feature from the Main Menu.

Exiting the Main Menu

To Exit from the Main Menu in the RCOUNT™, click on the Home button.

Logging out of the RCOUNT Software

Click on the Main Menu button and select Logout.

Fig. 19 Logging out of RCount

9.0 Camera Lens Adjustment

The adjustments on the camera lens are as follows:

Table 2. Camera Lens Adjustments

9.1 Camera Image Setup

Camera Setup adjusts the image settings from the camera. To open Camera Setup, click Camera Setup from the Setup menu. The Camera Setup Information window appears.

Table 3. Camera Image Setup

10.0 Troubleshooting

Table 3. Basic problems that may occur are:

11.0 Counting Analyzer

If the count is not accurate, the RCount has a built-in tool to visualize how the camera is seeing the individual parts.

On the main toolbar, click the analyzer tool.

At the bottom of the image, you will see a graph appear. Use the slider at the bottom to scroll the parts from Left to Right.

Fig. 20 Part Analyzer showing average part width & standard deviation between parts

12.0 Importing & Exporting Images

The RCount allows the saving of camera images for the purpose of Importing or Exporting images. This can be useful for supporting your system with Global Vision technical teams and troubleshooting.