April 2014

Tim Seymour

Vision Application Specialist, SICK Australia

: Improving Quality & Profits with Machine Vision

: SICK AG 2

Machine Vision Systems Contents

: What is Machine vision?

: When do we use it?

: What types of Cameras can be used in Industry

: Examples of Vision Solutions

: SICK AG

Machine Vision Systems

: When do we use it?

: The benefits of Machine Vision are;

: $$$$$$$$

- Improving quality of the finished product

- Simplifying, improving or increasing work flow,

- Reducing waste , both in materials and effort.

3

: SICK AG

Machine Vision Systems

: What is Machine Vision?

: Use of cameras in the context of process control

: Is defined as the analysis of images and extraction of data for controlling an

automated process or action

4

Image capture

Image analysis

Decision making

Data output

Repeat process

: SICK AG

What is Machine Vision

: Image capture

: 1 D, 2 D or 3 Dimensions ?

: Illuminating an Object and acquiring an image

- Front or back light?

- Visible or Infra Red?

: Moving or stationary ?

: Triggered or Free running?

5

Image captur

e

Image analy

sis

Decision

making

Data output

Repeat

process

: SICK AG

Image analysis

: to answer the following questions in highly repetitive situations....

Tim Seymour April 2014 6

Good/bad

Classification Position Identification Dimension

OK? Where? What does it say? How large?

: SICK AG

Decision Making and Data output

: What results do you need?

- Pass or Fail?

- Sort?

- Digital or Serial?

- Settings Adjustable or fixed?

: How much time do you have?

7

Image capture

Image analysis

Decision making

Data output

Repeat process

: SICK AG

Types of Machine Vision Components

: Vision ”Sensors”

- Easy to use

- Application-specific, or configurable but limited

- Works stand-alone

: ”Smart” camera

- Flexible, programmable with ready-to-use

toolbox

- Works stand-alone, no PC

: PC-based camera ”components”

- Fully flexible, programmable with low-level

languages (C++, .NET, etc)

- The camera only takes images, the PC

analyzes and controls the process using a

visual studio software package.

8

Vision sensor or

smart camera

PC-based

: SICK AG

Some terms explained…

: What is a pixel?

9

Pixel

: SICK AG

Some terms explained…

: FOV?

▪ Field of View;

: ROI?

▪ region of interest….?

: TOF?

▪ Time of Flight

: OCR

▪ Optical character recognition

: RGB

▪ Colour cameras

: IR or UV

▪ Type of light emitted or received?

: GUI

▪ Graphical User Interface that appears on the Human Machine Interface

10

: SICK AG

Simple Vision Sensors

: Just connect and align

- Easy to use

- Single purpose

- No parameters

- No Logic

: Examples are

- X,Y positioners

- Shingle counters

- Registration detectors

11

: SICK AG

Simple solutions using smart sensors

: object counters

: how many containers can I fit on a conveyor?

12

: SICK AG

Simple solutions using smart sensors

: X,Y positioners

: the challenge is to align the pallet

handling system to the shelf or bay

location.

13

: SICK AG

Simple solutions using smart sensors

: Labels without marks kept in register

: The saving may only be 2%.... However…...

14

: SICK AG

Complex Vision Sensors

: The Features of a Complex Vision Sensor include;

- Around 10 to 20 Algorithms or Vision ”tools”

- Ethernet or USB connectivity

- Simple logic functions

- Discrete outputs

- Fast processing times

- Low to medium image resolution

- Integrated light sources

15

: SICK AG

Example Applications…

: Interactive Edge Guiding on carpet

gluing line; 2 x cameras for 2 different

materials running simultaneously.

16

: SICK AG

Example Applications for Vision sensors…

: APPLICATION; Ultra Violet Light source to inspect a optically challenging product

17

: SICK AG

Example Applications for Vision sensors…

: APPLICATION;

- Look for correct insertion of wafer in packaging, before dosing of ice cream

18

: SICK AG

Example Applications for Vision Sensors…

: APPLICATION: Cheese Sticks

: Formation checks

:

: TECHNOLOGY: 2D Vision Camera

: LED Diffuse Back light

:

: METHODOLOGY: Back Lit image for Length and shape check

:

19

Courtesy of

: SICK AG

“Smart” Vision Cameras

: The Features of a Smart Camera are;

- Around 200 Algorithms and logical processes

- Ethernet connectivity

- Complex logical and mathematical functions

- Multiple outputs

- Fast processing times

- Medium to high image resolution

- Usually 2D ( some 3D)

- Multiple lens options

20

: SICK AG

Example Applications for Smart Cameras…

: APPLICATION: Glass Bottle Rim & Neck validation

: Break, crack & foreign matter detection

:

: TECHNOLOGY: 2D Vision system with PLC control for ejection

: LED illumination, Operator HMI for sensitivity adjustment

:

: METHODOLOGY: Front Lit image

: Greyscale value mapping.

21

Courtesy of

: SICK AG

Example Applications for Smart Cameras…

: APPLICATION: Frozen Pie packets

: Packet formation & closure verification

:

: TECHNOLOGY: 2D Vision system

: LED illumination,

:

: METHODOLOGY: Back Lit image to silhouette packet to confirm edge formation

:

22

Courtesy of

: SICK AG

Example Applications for Smart Cameras…

: APPLICATION: Sanitary pads;

: Pad thickness, feature presence & location

:

: TECHNOLOGY: “Linescan” smart cameras

: LED illumination, Operator HMI for sensitivity adjustment

:

: METHODOLOGY: Silhouetted image

: Greyscale value mapping and measurement,

23

Courtesy of

: SICK AG

Example Applications for Smart Cameras…

: APPLICATION: Lid & tub label validation

: Correct ID & position, Internal tub defect detection

:

: TECHNOLOGY: 2D smart cameras with bar code reading tools

: LED illumination, Operator HMI

:

: METHODOLOGY: Front lit image

: Greyscale; 2D Code reader & Pattern match.

24

Courtesy of

: SICK AG

Camera Components

: High end Camera components;

- High resolution, 1, 2, & 3D

- Special Intefaces

▪ GigE, Camera Link, Firewire, etc

- Most analysis functions completed by seperate software in an external PC

- Fast imaging times

- Usually high image resolutions

- Multiple lens options

25

: SICK AG

Camera Components used with 3rd party software

: APPLICATION: Batch Mixing Verification;

: Scanning Powdered Ingredients Bags

:

: TECHNOLOGY: 2D camera

: LED illumination, Operator HMI

:

: METHODOLOGY: Front lighted image,

: Intuitive pattern matching linked to customer data base for

ingredient lists and quantities.

26

Courtesy of

: SICK AG

Camera Components used with 3rd party software

: APPLICATION: Detect “Off Centre Core”;

: “News Print” Paper rolls

:

: TECHNOLOGY: Hi res 2D camera

: Infra Red LED illumination, Operator HMI

:

: METHODOLOGY: Front lighted image,

: edge detection followed by mathematically calculations to

determine centre of roll vs centre of core. .

27

Courtesy of

: SICK AG

Camera Components used with 3rd party software

: APPLICATION: Print Inspection

: Foil sealed trays

: TECHNOLOGY: Hi res 2D camera

: Diffuse LED illumination, Operator HMI

: METHODOLOGY: Front lighted image,

: complex pattern matching software.

28

Courtesy of

Missing Label

Extra Print

Misregistration

Blob

Damaged

Smudge

: SICK AG

Camera Components

: APPLICATION: Parcel Sortation ( & dimensioning)

: freight logistics

: TECHNOLOGY: Line scan camera

: Fixed LED line illumination tracked to moving objects.

: METHODOLOGY: Image software in both the Camera and

attached PC.

29

Courtesy of

: SICK AG

When to use 3D?

: 3D using

: structured light?,

: Stereoscopic?,

: triangulation?

30

: SICK AG

Camera Components integrated to Machine controls

: APPLICATION: Robotic Bin Picking

: metal parts

: TECHNOLOGY: “scanning” 3D camera

: Moving laser line illumination.

: METHODOLOGY: Image software

compatible with standard CAD files and

Robot coordinate systems.

31

: Thank you for your attention.