omron and indusoft web studio vision systems

1Confidential © Omron

Leveraging InduSoft for your Machine Vision Applications

Robert FellOmron Strategic Accounts Group


AgendaAgenda

• Introduction to Omron

• Machine Vision Basics

• Managing a successful Vision Installation

• Leveraging InduSoft for Machine Vision Applications


Introduction to Omron


Omron By the NumbersOmron By the Numbers


Omron Product PortfolioOmron Product Portfolio

• Automation Control Systems– Programmable Controllers

– Operator Interfaces (HMI)

– Distributed I/O

– Software

• Motion Controls, Servos, AC Drives– Motion Controls & Servos

– AC Drives

• Sensors and Vision– Proximity and Photoelectric Sensors

– Fiber-optic Sensors

– Amplified Photomicrosensors

– Measurement, Ultrasonic & Pressure Sensors

– Vision Sensors

• Industrial Components– Temperature & Process Controls

– Code Readers & RFID

– Relays, Pushbuttons & Indicators

– Limit Switches

– Timers & Counters

– Power Supplies


Business Development GroupBusiness Development Group

• International project implementation and resource planning

• Fully integrated turnkey solutions

• Factory Accountability


Machine Vision Basics


Machine Vision BasicsMachine Vision Basics

• Machine vision (MV) is the technology and methods used to provide imaging-based automatic inspection and analysis for such applications as automatic inspection, process control, and robot guidance.


Key ComponentsKey Components


Basic Terms and UnderstandingBasic Terms and Understanding

Field of View (Blue Area) - Complete area of inspection as viewed upon the vision monitor or HMI.

Region(s) of Interest (Yellow Squares) – Specific areas of interest where a particular feature is being inspected for.

In this case the blue square represents the field of view while the yellow inspection areas represent the individual regions of interest and the red stars are the features being inspected for.


Basic Terms and UnderstandingBasic Terms and Understanding

Resolution – Defines the theoretical smallest detectable object per a given field of view and as a function of a certain resolution cameraExample:Standard Camera= 640 pixels x 480 pixelsField of View= 4” x 5” Resolution= Dimension of applicable axis in FOV / Pixels per that same axis (per aspect ration of camera)

5”

4”

640 Pixels

480 Pixels

5”/640= .0078” per pixel4”/ 480= .0083” per pixel

Stable detection is typically on the order of 15x the dimension per pixel or 15 x .0078 = .117


System Configuration- Vision SensorSystem Configuration- Vision Sensor

• Streamlined Hardware• Lower Cost• Limited Lensing / Lighting• Limited Tool Set• Single Camera Inspection


Vision Sensor ApplicationsVision Sensor Applications


System Configuration- Box StyleSystem Configuration- Box Style

• Flexible Hardware Configuration• Mid Range Cost• Multitude of Lensing / Lighting Options• Capable Tool Set• Up to 4 Cameras per controller


Box Style ApplicationsBox Style Applications


System Configuration – Gig ESystem Configuration – Gig E

• Flexible Hardware Configuration• Higher Camera Count• Multitude of Lensing / Lighting Options• Most Capable Tool Set and Programming flexibility• 16 Cameras per instance of software• Ease of Indusoft Utilization


Gig E ApplicationsGig E Applications


Managing a Successful Vision

Installation


Identifying a viable vision applicationIdentifying a viable vision application

• Identify

• Quantify

• Dollarize

• Key Features• Machine Discretion & Rationalization

• Managed Expectations• Start & Stop• Scope Creep

• Quantifiable Return on Investment• Known issue• Risk Management/ Litigation• Re-allocation of personnel • Reduced QA Testing


10 Steps to a Successful Vision Project

1. Identify and document the known issue

2. Quantify specific tolerances and criteria

3. Develop a preliminary scope document detailing expectations

4. Provide a comprehensive set of samples to the vision vendor

5. Request the vision vendor provide a detailed report on the results

6. Pending successful bench testing, schedule an on line trial

7. Upon trial completion re-evaluate scope document and adjust as necessary

8. Develop an acceptance document based on the scope of work detailed

9. Develop budget based on inclusion of comprehensive mechanical, electrical, controls, and installation plan.

10. Agree to a realistic timeline for design, implementation, and run off of the system


Scope of WorkScope of Work

• Project Team

• Team Roles

• Primary Intent of the Project

• Associated partners

• Description of current process

• Description of desired process

• Identification of all key parameters including

◦ Product Types

◦ Defect Types

◦ Line Speed

◦ Environment implications

◦ Machine types

• Definition of responsibilities

• Requested Timelines


Acceptance DocumentationAcceptance Documentation

“Intention:This document is the formal acceptance documentation for the Omron quality control inspection station being provided to Company XYZ by Omron Industrial Automation. The Company XYZ purchase order to which this document pertains is 8675309 which is being installed on machine ABC in X Location. The criteria by which the system will be judged is below. This information is the exact criteria that Omron committed to in the final version of the Performance Guarantee document dated 7/15/2011 Structure:This document is structured into 4 major categories, each with their own acceptance sections.Machine SpecificationsInspection SpecificationsCommunicationsSAT Criteria General Notes: Production of Defects:During the SAT Test described above defects will be produced as follows:Manually creating the (4) described defects.Actual machine created defects . Manufacturing Variation/ Provided Samples:All defects will be created by Omron on site during installation.”

Example Verbiage


Leveraging InduSoft for Machine Vision

Applications


What is OEE

Calculation: OEE = Availability x Performance x Quality

•Loading: The portion of the TEEP Metric that represents the percentage of total calendar time that is actually scheduled for operation.

•Availability: The portion of the OEE Metric represents the percentage of scheduled time that the operation is available to operate. Often referred to as Uptime.

•Performance: The portion of the OEE Metric represents the speed at which the Work Center runs as a percentage of its designed speed.

•Quality: The portion of the OEE Metric represents the Good Units produced as a percentage of the Total Units Started. Commonly referred to as First Pass Yield FPY


What is OEEWhat is OEE


How do we get there?How do we get there?

Collection

Segregation

Visualization

Drive down to the ….


Complaints of Machine VisionComplaints of Machine Vision

• Complicated Custom Interface

• Complicated recipe management

• Very little custom display capability

• Misunderstanding drives un-necessary customer interaction and modification

• Every application run differently


Advantages of InduSoft and VisionAdvantages of InduSoft and Vision-Removing the stress--Removing the stress-

• Visualization of collected data (non-vendor specific)

• Consistency in Interface

• Streamlined Recipe Control

• Centralization of Information

• Simplified User Experience

• Custom Adjustment Options

By leveraging Indusoft to collect and display data we’re taking a band-aid and

turning it into a manufacturing tool.


Actual Screen Shots – Splash ScreenActual Screen Shots – Splash Screen


Actual Screen Shots – Current StatsActual Screen Shots – Current Stats


Actual Screen Shots- Reject QueActual Screen Shots- Reject Que

Customer XYZ


Actual Screen Shots – Production HistoryActual Screen Shots – Production History

Customer XYZ


Actual Screen Shots - DiagnosticsActual Screen Shots - Diagnostics

Customer XYZ


Actual Screen Shots- Help DocumentsActual Screen Shots- Help Documents

Customer XYZ


Where can you see it…Everywhere!Where can you see it…Everywhere!

Web Thin ClientsLocal or Enterprise/Cloud

Automation Data

Studio Mobile Access (SMA)

Secure Viewers


Re-CapRe-Cap

• Properly understanding and deploying inspection equipment throughout your manufacturing process will greatly improve your process and end product.

• Utilizing Indusoft as a data collection and visualization tool will take your investment to the next level with its flexibility, ease of use, and ability to turn your inspection data into valuable and actionable production data.


Contact Information

Robert Fell

Omron Industrial AutomationStrategic Accounts [email protected]

http://elearn.omron247.com

www.omron247.com