how to easily improve quality using automated visual inspection
TRANSCRIPT
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How To Easily Improve Quality Using Automated
Visual Inspection
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q This webinar will be available afterwards at www.designworldonline.com & email
q Q&A at the end of the presentation q Hashtag for this webinar: #DWwebinar
Before We Start
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Moderator Presenter
Michael Jermann Design World
Jon Chouinard Baumer Ltd.
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How to easily improve quality using automated visual inspection Baumer
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Who is Baumer? Global industrial sensor manufacturer
Global Industrial Sensor Manufacturer
• Vision Sensors
• Industrial Cameras
• Vision Sensors
• Discrete Sensors
• Inductive, PhotoElectric, Ultrasonic, etc.
• Motion
• Encoders, Inclination sensors etc.
• USA HQ’s in CT
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How to easily improve quality using automated visual inspection
Agenda • Introduction to Vision Sensors • Lighting for visual inspection • Applications suited for Vision
Sensors • Configuring a Vision Sensor
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Introduction to Vision Sensors
• Vision Sensors contain array of pixels (CCD/CMOS Sensor)
• Pixels accumulate charge (photons) that result in grey scale value (0-255)
• Image Anaysis with software based on grey scales
1600 pixels
1200 pixels
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Introduction to Vision Sensors • In essence.. We’re taking a
picture and analyzing the image!!.. (Its basically a camera!)
• Grey scale analysis on specific features
Value -‐‑ 80
Value -‐‑ 200
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Introduction to Vision Sensors How does a Vision Sensor compare to low vs high end vision? • Sensors
• Binary (Photo-‐‑eye) • PC Based Vision
• Programming involved in many cases
• Complex algorithms can be utilized.
• Preprocessing & advanced logic • Vision Sensors
• Ease of use • 5-‐‑20 Tools, Multiple resolutions,
limited in preprocessing and logic
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• Lighting is 80% of a vision sensor application!
• Garbage In = Garbage Out • We must create contrast!
Introduction to Vision Sensors: Lighting
1D Code Reading
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• Lighting is 80% of a vision sensor application! • Contrast is Key! - Lighting will make break your
application!
Introduction to Vision Sensors: Lighting
Pa6ern Match
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Vision Sensor Applications How can we improve quality using automated visual inspection? What types of applications are suited for vision sensors? What can we do with the information provided from a vision sensor?
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Application Overview Presence and Completeness
o Verification o Measurement o Assembly attributes
Location and correct position
o X-Y o Rotation
Reading of human-readable characters
o Optical Character Recognition o Optical Character Verification
Reading of non-human readable characters
o 1D Barcode o 2D Barcode
Vision Sensor Applications
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• Proper Location of Straw • Digital output for “Go / No Go” • Tools: Pixel Counting
Vision Sensor Applications Presence / Absence
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• Detect sealing compound on closure (Baby jar lid) • Digital Output to ID if compound is missing • Tools: Locate on circle; Count areas (Blob)
Vision Sensor Applications Presence / Abscence
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• Identify if the part is right side up (indent on top) • Digital IO • Tools: Locate on Contour + Count Contour Points
Vision Sensor Applications Presence / Absence
12 Points 143 Points
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• Identify if label is present and rod in center • Output: Digital I/O • Tools: Count Areas tool, fixtured so no part locate required
Vision Sensor Applications Presence / Absence
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• Identify if barb has been completed • Output: Digital I/O • Tools: Count Edges
Vision Sensor Applications Completeness
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• ID if cap is fully seated within 0.005” • Digital Output if cap is not seated. SPC could be utilized • Tools: Locate on edges; Distance
Vision Sensor Applications Measurement
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• Measurement of key dimensions with accuracy to 0.0007 • Dimensions provided via Ethernet communications
• SPC could be utilized • Digital I/O available
• Tools: Distance
Vision Sensor Applications Measurement
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• Locate part on conveyor belt and provide X,Y and rotational coordinates
• Tools: Locate on contours; Padern match
Vision Sensor Applications X,Y - Rotation
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• 1D Bar Code reading + OCR
• Output and compare
expected code and tablet count
• Tools: OCR + 1D read
Vision Sensor Applications 1D Code + Character Recognition
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• Character Recognition and Verification
• Output read characters and provide verification on character quality.
• Tools: Locate on edges; OCR/OCV
Vision Sensor Applications Character Recognition + Verification (OCR/OCV)
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• Cap Presence + 2D Code reading • 2D code reading provided and digital I/O for presence of cap • Tools: 2D read; Area size (dark pixel count)
Vision Sensor Applications 2D Code Reading + Presence / Absence
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VeriSens – Vision Sensor Quality Control made easy
How can we easily conduct a Quality check using a Vision Sensor? 1. Adjust Image! (Lensing, Lighting) 2. Apply Check Feature tools (dimension -> pattern match) 3. Configure Interfaces 4. Activate!
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VeriSens – Vision Sensor Step 1: Adjust Image
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VeriSens – Vision Sensor Step 2: Check Features
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VeriSens – Vision Sensor Step 2: Check Features -> Part Locate
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VeriSens – Vision Sensor Step 2: Check Features -> Geometry
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VeriSens – Vision Sensor Step 2: Check Features -> Geometry
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VeriSens – Vision Sensor Step 2: Check Features -> Feature Comparison
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VeriSens – Vision Sensor Step 2: Check Features
Inspections are now setup! • Locating part
• Checking distance (measurement)
• Checking Angle
• Checking hole count
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VeriSens – Vision Sensor Step 3: Configure Interfaces
What do you want to do with the results? • Output results
• (i.e distances, angle, etc.) • Discrete I/O for pass/fail?
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VeriSens – Vision Sensor Step 3: Configure Interfaces
Digital IO • 5 Outputs, Boolean
logic • Timing • 1 cable for I/O and
Power required
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VeriSens – Vision Sensor Step 3: Configure Interfaces
Ethernet communication • TCP/IP, Profinet,
Ethernet IP • Results communicated • 2 cables
• I/O and Power • Ethernet
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VeriSens – Vision Sensor Step 3: Configure Interfaces
Web Interface • Configure for remote
access via IP address • Touch screen / PC • Used for
• Change job on factory floor
• Adjust parameters • Monitor Pass/Fail • Review Defective
images
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VeriSens – Vision Sensor Step 4: Activate Activate
• Loads job file to vision sensor and sets to run mode • Multiple jobs (255 in total) • Options to save to PC
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VeriSens – Vision Sensor Activated! - > Inspecting.. Inspecting.. Inspecting..
100% Inspection for Quality Control! • Multiple “Feature check” tools applied to check every part! • Provide continuous feedback / Reject of bad parts
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Monitor line remotely with Web Interface
VeriSens – Vision Sensor Activated! - > Inspecting.. Inspecting.. Inspecting..
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Summary Improve quality using automated visual
inspection! • Vision Sensors will provide 100% inspection to eliminate
defective parts • Contrast is Key! Lighting, Lighting, Lighting • Feature Checks setup easily for:
o Absence / Presence o Measurement o Part Orientation / Location (x,y, rotation) including robot guidance o Verification o OCR/OCV o 1D/2D
• Verify quality and provide feedback to detect defective parts o I/O & Ethernet communication
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Questions? Michael Jermann Design World [email protected] Twitter: @DW_MikeJermann
Jon Chouinard Baumer Ltd. [email protected] Phone: 603-571-5031
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Thank You q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com