what can machine vision technology do for...

What can Machine Vision Technology do for you? Precision Measurement Flaw Detection Colour Inspection Object Locate Presence/Absence Robotic Guidance Part Identification 2D Datamatrix Reading Barcode Reading Optical Character Recognition

ABCON Allen Bennett Controls

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What is Machine Vision? Introduction

Machine Vision is an electronic alternative to human or manual inspection that helps companies increase productivity and save money by eliminating defective products with 100% accuracy. The DVT Legend and In-Sight Micro cameras are digital devices that are small enough to fit in the palm of your hand. They are self-contained computers that incorporate a microprocessor and a CCD element that first capture a digital image and then subsequently inspect that image for flaws.

Typical Types Inspections: • Object Location • Robotic Guidance

• Presence/Absence • Precision Measurement

• Flaw Detection • Date/Lot Code Reading

• Part Identification • 1D Barcode Reading

• Colour Inspection • 2D Datamatrix Reading

Industries using Our Vision Systems: • Medical • Pharmaceutical

• Automotive • Plastics

• Packaging • Food

• Printing and Marking • Aerospace

Using the Windows-based Intellect or In-Sight Explorer software, features of a product can be evaluated based on criteria such as presence/absence, orientation, size, position, and many other specifications. This information can then be used to either immediately reject faulty products or alternatively instruct robots, HMI/SCADA devices, printers or other machines to perform the next step on a production line. Our camera systems are simple enough for an operator to maintain, flexible enough for the most demanding applications, and can be integrated onto any existing machine in your facility. We provide free training, free software and demonstrations offering the best value in machine vision.

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Plaster Inspection

Medical IndustryApplication Examples

Phial Tray Inspection

Needle Inspection

Blister Pack Inspection

Bottle Inspection

Pill Inspection

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Cog Measurement

Gearbox Inspection

Assembly Operation Inspection

Switch Print Quality Inspection

Insert Detection

ECU Assembly Inspection

Automotive Industry Application Examples


Connector Inspection

Trim Material and Colour Inspection

Fuse Box Assembly Check

Drive Plate Inspection

Thread Inspection

Mesh Inspection

Automotive IndustryApplication Examples


Gasket Impurity Inspection

Cosmetics Cap Moulding Check

Window Frame Profile Measurement

Gear Inspection

Washer Inspection

Moulding and Printing Confirmation

Plastics and Moulding Application Examples


Cap Alignment Inspection

Bottle Wrap Inspection

Sports Drink Cap Check

Spray Bottle Cap Inspection

Label Position Inspection

Tin Can Label Inspection

PackagingApplication Examples


Sandwich Assembly Inspection

Hot Cross Bun Inspection

Cashew Nut Colour Inspection

Bread Inspection

Fish Finger Inspection

Sweet Inspection

Food and Beverage Application Examples


Food Label Reading

Braille Printing Plates

Optical Character Recognition

Pack Reading

Datamatrix Reading

Barcode Reading

Printing and MarkingApplication Examples


Linescan System Inspects Medical Dressing for Contamination

Figure 2. The camera and light shown mounted in the machine.

Figure 1. The product being inspected as it passes under the DVT Linescan camera system.

When a leading manufacturer of Wound Management products required a high performance vision system to detect minute defects on their market leading products they approached ABCON Partner System Integrator,Olmec for a solution. Olmec, a company specialising in vision and automation projects, were asked to design and implement a solution for this challenging application. The manufacturer’s process brings together individual materials to form a unique product which has to be defectfree. Each of the materials used has special characteristics which provide imaging challenges, such as reflections and low contrast features.

Using the DVT’s range of image filtering and scripting functions a stable image is repeatedly obtained, despite the natural product variations. These variations have the potential to cause false waste, however the power of DVT’s inspection sensors overcomes this problem. The flaw tools are then applied to the filtered image to complete the inspection and determine whether the part is ok or should be rejected. The flexibility of the Linescan camera enabled a bespoke visualisation package to be deployed on a PC, tailored to the customer’s requirements, enabling operators and maintenance staff access to live images, stored images and also statistical data for off line quality and efficiency analysis. The end result is a DVT inspection system working non-stop to ensure medical dressings are always defect free.

Contact Information

Olmec-UK limited Web : www.olmec-uk.com Email : [email protected]

Olmec selected the Cognex DVT Linescan camera for the application owing to its high-resolution, pre-processing tools and powerful flaw detection. The additional benefits of a small footprint and narrow lighting requirements enabled the camera to be installed in a space constrained area. Specific image filtering and flaw routines are required in order to provide a stable image and an end product that has zero defects.

Linescan System Inspects Dressing for Contamination

Case Study


Case Study

Contact Information

S.P Technology Limited Camperdown Industrial Park, Dundee, Tayside. DD2 3SP www.sptechnology.co.uk

ABCON Partner System Integrator S.P Technology has an outstanding track record in the design and manufacture of bespoke automation systems. They were recently approached by an industrial manufacturer who required an automation system that would automatically feed, test and assemble an industrial tension-hanging device. Richard Torrie, S.P Technology’s Project Coordinator, had no hesitation in recommending Cognex DVT vision systems to provide the inspection requirements of the project. Richard said, “Our experience of dealing with ABCON has been first class and the Cognex range of cameras allows us to offer our customers the best technology available but at an affordable price.” The machine consists of a bowl feed system where the main component parts are loaded, a conveyor based camera inspection station, a rotary table where the parts are assembled along with a final inspection point consisting of a second camera system.

Figure 1. A high resolution DVT554 camera and dome light positioned above the conveyor. The initial inspection point consists of a high-resolutionCognex DVT 554 camera and dome light. Parts pass underneath the camera at a rate of approximately one part per second. Five critical dimensions of the part are inspected along with presence of a thread. All of these checks are crucial for the correct operation of the device when in service. Any parts that exhibit dimensions which are outside the required specifications are ejected into a reject hopper. Parts which have passed the initial inspection proceed to the rotary table where they are assembled into the completed device.

Figure 2. Initial inspection station. Part image as displayed in the Cognex Intellect software. The last rotary table station consists of a second Cognex DVT camera which is used to inspect the device to ensure that it has been assembled correctly.

Figure 3. Final inspection station. “Using the Cognex DVT Intellect software allows us setup each inspection with ease,” says Richard, “and since the customer has 22 product variants, fast change over times were crucial and had to be kept as simple as possible. One of the key benefits in using this camera system is the ability to connect to the systems remotely and be able to interrogate, debug and offer further training. This is important since it allows us to set up further products as required and is key to us being able to offer excellent customer support.”

Vision Systems inspect the Thin Edge of the Wedge

Case Study


We provide solutions based on two main ranges of Machine Vision Systems – DVT Legend and Cognex InSight Micro. Whilst there are areas of functionality and price which overlap between the two ranges, each range has some unique features and benefits which make them more suited to certain types of application.

DVT Legend Range The DVT range of cameras covers the broadest spectrum of products from the standard resolution CMOS based 515 model, through high-resolution colour and Linescan cameras. The Intellect software is user friendly yet incorporates many powerful features. The Legend series offers 8 on-board fully configurable I/O and it supports a vast array communication protocols, making connection to external devices (PLCs, HMIs, robot controllers e.t.c.) particularly easy.

In-Sight Micro (ISM) Range In-Sight Micro range of cameras provides world-class performance in the smallest package available. A full vision system but with the size of a remote-head camera, they are ideal for mounting in very tight spaces on robots, production lines and machinery. The new In-Sight Explorer with EasyBuilder configuration software makes even the most powerful vision tools easy to use. With a simple point and click approach, EasyBuilder walks users through the process of setting up a vision application, step by step. EasyBuilder eliminates the need for programming, yet provides the flexibility to customize complex applications when needed.

Range Overview Machine Vision Systems


DVT Legend Cameras

515 535 535C 545 545C LS 550 554 554C

Resolution 640 x 480 640 x 480 640 x 480 640 x 480 640 x 480 2048 x 1 640 x 480 1280 x 1024 1280 x 1024

Camera CCD Sensor Size 3.84 x 2.88mm 4.74 x 3.55mm 4.74 x 3.55mm 4.74 x 3.55mm 4.74 x 3.55mm 14.3mm x 7.0µm 4.74 x 3.55mm 5.95 x 4.76mm 5.95 x 4.76mm

Details Colour No No Yes No Yes No Yes No Yes

Acquisition Rate 60fps 60fps 30fps 60fps 30fps 18K lines /s 60fps 8fps 8fps

High-speed Input/Outputs 8 8 8 8 8 8 8 8 8

I/O Options I/O Breakout/Expansion Modules Yes Yes Yes Yes Yes Yes Yes Yes Yes

Ethernet I/O Support Yes Yes Yes Yes Yes Yes Yes Yes Yes

Lighting Integrated LED Lighting Option Yes Yes Yes Yes Yes No Yes Yes Yes

Software Compatible with FrameWork Yes Yes Yes Yes Yes No Yes Yes Yes

Preprocessing Yes Yes Yes Yes Yes Yes Yes Yes Yes

Positioning Yes Yes Yes Yes Yes Yes Yes Yes Yes

Counting Yes Yes Yes Yes Yes Yes Yes Yes Yes

Vision Tool Measurement Yes Yes Yes Yes Yes Yes Yes Yes Yes

Support Identification (modeling) Yes Yes Yes Yes Yes Yes Yes Yes Yes

Readers (1D, 2D OCR/OCV) 1 No Yes Yes Yes Yes Yes Yes Yes Yes

Flaw Detection Yes Yes Yes Yes Yes Yes Yes Yes Yes

Script Yes Yes Yes Yes Yes Yes Yes Yes Yes

Application Specific Yes Yes Yes Yes Yes Yes Yes Yes Yes

Power Voltage Required 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC

Consumption Maximum Current 300mA 300mA 300mA 300mA 300mA 300mA 300mA 300mA 300mA

Max Temp. Camera 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C

In-Sight Micro Cameras

1020-00 1050-00 1100-00 1100-10 1400-00 1400-10 1403-00 1403-10

Resolution 640 x 480 640 x 480 640 x 480 640 x 480 640 x 480 640 x 480 1600 x 1200 1600 x 1200

Camera CCD Sensor Size 4.74 x 3.55mm 4.74 x 3.55mm 4.74 x 3.55mm 4.74 x 3.55mm 4.74 x 3.55mm 4.74 x 3.55mm 7.18 x 5.32mm 7.18 x 5.32mm

Details Colour No No No No No No No No

Acquisition Rate 42fps 42fps 42fps 42fps 42fps 42fps 13fps 13fps

High-speed Input/Outputs 3 3 3 3 3 3 3 3

I/O Options I/O Breakout/Expansion Modules Yes Yes Yes Yes Yes Yes Yes Yes

Ethernet I/O Support Yes Yes Yes Yes Yes Yes Yes Yes

Lighting Integrated LED Lighting Option No No No No No No No No

Software Spreadsheet Programming No Yes Yes Yes Yes Yes Yes Yes

Vision Tool PatMax Algorithm No No No Yes No Yes No Yes

Support Standard Tool Set Yes Yes Yes Yes Yes Yes Yes Yes

Readers (1D, 2D OCR/OCV)1 No No Yes Yes Yes Yes Yes Yes

Power Voltage / Current Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2 Class 2Consumption Requirements PoE Device PoE Device PoE Device PoE Device PoE Device PoE Device PoE Device PoE Device

Max Temp. Camera 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C 45 deg C

Note 1: 2D codes include: Data Matrix, SnowFlake, Rectangular code. 1D Stacked codes include: Interleaved 2 of 5, Code 39, Code 93, Codabar, PharmaCode, BC412, UPC/EAN & Composite, RSS Limited, 14, Expanded, Composites A,B,C, Code 128, Composite Postnet and Planet Code, PDF417, Micro PDF and PDF417 truncated.

SpecificationsMachine Vision Systems


Intellect is the latest software for DVT vision sensors, providing an intuitive user interface and a library of powerful vision tools. With Intellect, setting up a vision application is fast and easy, significantly lowering integration costs and speeding time to deployment.

Vision Toolbox Dedicated vision tools make the setup for common applications fast and easy. • Positioning ● Colour ● Replicator Tool • Counting ● Defect detection ● Measurement • Filters ● Identification ● Optical Character Recognition • Script ● Barcode Readers ● 2D Datamatrix Readers

Tool Referencing Diagram The diagram leads a user through the inspection setup process with a graphical display from start to finish.

Real-time Feedback Various graph formats provide data for fine tuning your application.

Result Table This configurable table displays a number of tool outputs including Pass/Fail rates and execution timing.

Video Display Displays the real-time image from the camera. Descriptive tool markings help operators understand and diagnose bad parts.

DVT Intellect Software


Application Steps The user is methodically taken through the necessary steps required to setup an inspection from scratch.

Tool Palette Displays each inspection tool along with their results. I/O status and comprehensive Help system are also accessible.

Vision Toolbox A powerful set of vision tools to suit most common applications. • Presence/Absence • Counting Tools • Optical Character Recognition • Barcode Readers • 2D Datamatrix Readers • Precision Measurement • PatMax Algorithm

Video Display Displays the real-time image from the camera. Descriptive tool markings help operators understand and diagnose bad parts.

Tool Information Display Displays tool parameters and allows users to simply specify pass and fail criteria.

In-Sight Explorer is used to program and configure the Cognex In-Sight Micro range of cameras. It incorporates the user-friendly EasyBuilder interface (shown below) along with the traditional spreadsheet based programming environment. Users are shown each logical step required in order to setup each inspection. Informative tool markings on the image aid rapid development resulting in the smartest, easiest camera setup ever.

In-Sight ExplorerSoftware


The simple low cost VisionView Operator Interface panel facilitates monitoring the production process without ever having to connect a PC, making operator decisions easier than ever. A tiled view of images from up to nine DVT or InSight Micro camera systems can be displayed. Standard built-in automation protocols provide information to the control system and HMI simply and easily.

Automatic System Detection... automatically detects any Cognex vision system on the network Mix and Match… Cognex vision systems and view them all at the same time Plug and Go Configuration… no PC required, just use the simple setup within VisionView Optimised for Vision… 800x480 touch screen (widescreen) displays full colour images System Expansion… five Ethernet ports and three USB ports provide system flexibility Fast Image Updates… provide the most recent inspection images – fast

Applications often require customisation to prevent unauthorised users from interrupting a critical process. VisionView offers a wide range of ‘run mode’ features, including control customisation. With VisionView critical controls, such as trigger and online status, can be configured so that only authorised users are able to modify them.

• Quickly change online/offline status

• Fast refresh mode makes it easy to focus

• Manual trigger to capture image

• Turn on-screen graphic areas on and off

• Select tiled (multiple) view

• Return to main configuration screen

The “Filmstrip” feature enables a review of the recent part failures, as well as trouble-shooting the manufacturing process.

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VisionView Operator Interface Accessories


DVT Camera Dimensions (all dimensions in mm)

112

60

30

30.74

34

6.49

95.75

4 x M4x0.7 7.8 deep mounting holes

47 6.5

I/O Connector (10-way RJ type connector) 24V DC supply to the camera and 8 configurable PNP Inputs and Outputs.

Ethernet Connector (Standard RJ45 connector) Allows the camera to be connected to a PC (or any other ethernet based device) using a standard ethernet cable. Once connected, the camera can be configured using the Intellect software package.

In-Sight Micro Camera Dimensions (all dimensions in mm)

30

30

70.1

60

I/O Connector 1 high-speed trigger input and 2 high speed NPN/PNP outputs.

PoE (Power Over Ethernet) Connector Uses the PoE standard to provide power to the camera along with ethernet TCP/IP protocol communications. Once connected, the camera can be configured using the In-Sight Explorer software package.

DrawingsTechnical Information


Selecting the correct lighting components can be the difference between a successful and unsuccessful installation. Most importantly, selecting the correct geometry of light enables some applications to be solved when it would otherwise not be possible. There are five principal types of lighting techniques which can be employed.

Back Lighting

Direct / Bright Field Illumination

Diffuse Dome Light

Diffuse On-Axis Light (DOAL)

Dark Field Illumination

Back lighting generates instant contrast as it creates dark silhouettes against a bright background. The most common uses are detecting the presence/absence of holes, part placement/orientation and for the precision measurement of objects.

This is the most commonly used lighting technique. It is directional in its nature, normally from a single point source, and it is a good choice for generating contrast and enhancing topographic detail.

Diffuse dome lights are very effective at lighting curved, specular surfaces. To be effective, diffuse lights, particularly dome varieties, require close proximity to the sample.

With a DOAL, light rays reflect off the beam splitter directly on to the object at nearly 90°. With this approach, specular surfaces perpendicular to the camera appear bright, while surfaces at an angle to the camera appear dark.

This type of lighting is characterised by low angle of light incidence and typically requiresclose proximity. Only small amounts of light are reflected back to the camera from edgessatisfying the “angle of reflection equals the angle of incidence” equation.

Lighting Techniques Accessories


Lenses We offer a full range of high quality compact lenses designed specifically for machine vision applications. These include high-magnification, telecentric and zoom lenses from the worlds leading manufacturers. However, the majority of applications will employ one of the following standard lens types.

Focal Length Part Number

6mm LFC-06F 9mm LFC-9F1B

12mm LFC-12.5F1 16mm LFC-16F1 25mm LFC-25F1 35mm LFC-35F1 50mm LFC50F1 75mm LFC-75F1

Formula for Calculating Lens Focal Length Focal Length =

Working Distance x CCD Size Field of View Size

Notes; (1) All parameters in mm (2) Working Distance is measured from end of lens to part to be inspected. (3) CCD size depends on the camera model - see page 12

Lighting We can supply over 1000 different lights from the following manufacturers; Siemens NER, Advanced Illumination, Spectrum, CCS and Stocker and Yale. Some of the most commonly used are listed below.

Type Size Part Number

50 x 50mm IXRB-22

50 x 100mm IXRB-24 Back Light 100 x 100mm IXRB-44 150 x 150mm IXRB-66 200 x 300mm IXRB-812 50mm Spot IXRS-2 65 x 65mm Array IDRA 140mm Spot IXRS-5.5 100mm Linear Array (BALA) IARA-4424 Direct / Bright Field 230mm Linear Array (BALA) IARA-4524 500mm Linear Array (BALA) IARA-26 60mm Ring Light R60-2 V2

100mm Ring Light IXRR-4 140mm Ring Light IXRR-5.5

Diffuse Dome 55mm Dome IARD-2224 185mm Dome IXRD-7.25 Diffuse On-Axis (DOAL) 50 x 50mm DOAL IARD-2424

100 x 100mm DOAL IARD-38 Dark Field 125mm Ring Light IARR-3524

175mm Ring Light IARR-1624

Light and Lens DetailsAccessories

With many years of extensive experience, and as the UK’s only Cognex Platinum Partner, ABCON are able to provide the best and most cost effective solution, whatever your application and budget. Additionally, we offer... Free Evaluations We provide free, comprehensive evaluations of your application. This allows us to establish the best solution, both in terms of type of camera but also lighting and lens. Free Workshops We run half-day Workshops which can be tailored around your specific application. Such events give you the opportunity to see how your application can be solved and allows us to discuss the software and mechanical setups required. If you require assistance to install and commission your vision solution, we also have a network of Partner System Integrators who are experts in such work and are able to offer complete turnkey solutions. Training

Free Classroom Courses: Training offered at our premises gets you up and running quickly with Cognex DVT vision sensors. Free Online Courses: Live and recorded, instructor led courses are offered over the internet. Access expert instruction from your office or factory location. On-site Courses: Can be arranged at your own premises for an additional fee. However, we charge a day rate rather than a per student rate. Therefore, larger organisations are able to train large numbers of personnel at a lower cost.

Free Support

Download Area: A variety of download files including software updates, utility applications, integration notes, technical drawings and support materials are available on our website. Telephone Support: Direct telephone support is provided by experienced vision engineers dedicated to assisting our customers. Remote Internet Support: If you have the necessary equipment at your facility, we are able to remotely access your installed systems. This allows us to configure and troubleshoot without the need to attend your site.

About ABCON Since its foundation in 1967, ABCON has supplied automation controls and sensor technology into most types of manufacturing process and industry sector. We have always moved with the times, supplying the latest sensing technology as it becomes commercially available. Throughout our history we have continually formed alliances with some of the Worlds leading manufacturers of sensor technology. The combination of their innovation along with our application expertise provides an enviable partnership, which is of significant benefit to our customers. Our experienced Applications Engineers work as partners in the design process, discussing ideas from the earliest concept and providing full support throughout development. We have Engineers nationwide available immediately to give help and advice, however diverse your application. Today, our products range from simple inductive sensors right through to the most advanced machine vision systems. It includes photo-electric, fibre-optic and laser sensors, liquid level controls, ultrasonic systems and much more. Whatever your application, whatever your industry you can rely on ABCON to have…everything in control.

Allen Bennett Controls is a Division of Abtech Limited Sanderson Street, Lower Don Valley, Sheffield, South Yorkshire S9 2UA Tel : 0114 2442424 Fax : 0114 2434312 [email protected] - www.ab-controls.co.uk

How can we help you? ABCON

what can machine vision technology do for...

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