introduction to machine vision - cognex · 1 © 2018 cognex confidential introduction to machine...
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© 2018 Cognex Confidential1
INTRODUCTION TO MACHINE VISION
Thibaut van Baer | February 2018
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© 2018 Cognex Confidential2
Agenda
▪ What is machine vision?
▪ Why use machine vision?
▪ Machine vision applications
▪ Types of machine vision systems
▪ Vision system components
▪ Machine vision terms
▪ Improving vision system performance
▪ Summary
▪ Q&A
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© 2018 Cognex Confidential3
What is machine vision?
The camera lens and sensor
capture images…
Cognex advanced vision tools
interpret what’s being seen
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© 2018 Cognex Confidential4
Proprietary Box
Embedded
Boards
Modular
Vision
Barcode
Readers
PC Vision
Vision
Sensors
1982 Today
3D Displacement
Sensors
Evolution of machinevision
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© 2018 Cognex Confidential5
Machine vision systems:
1. Analyze images
2. Makes decisions and returns results about each image
Simple examples
The center tab on this bracket is
37.255 mm wide
Good Oil Filter:
All holes are
open
Bad Oil Filter:
Some holes
are blocked
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© 2018 Cognex Confidential6
Image analysis
The primary purpose of machine vision is image analysis
Image
Decision
Answer
Location
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© 2018 Cognex Confidential7
Where is machine vision used?
Automotive
Industry
Graphic Arts/ Packaging
Consumer
Products
Semiconductor
Industry
Shipping
Transportation
Electronics
Medical
Pharmaceutical
Food Packaging
Industry
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▪ Automate manufacturing processes
▪ Improve product quality
▪ Protect brand image
▪ Reduce operational costs
Why is machine vision used?
▪ Overcome inefficient manual inspection processes
▪ Increase manufacturing throughput
▪ Reduce material waste
▪ Minimize the risk of recalls
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© 2018 Cognex Confidential9
Critical for achieving strategic goals
▪ High speed production lines
▪ Clean room environments
▪ Hazardous environments
▪ Microscopic inspection
▪ Closed-loop process control
▪ Robot guidance
▪ Precise non-contact measurement
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© 2018 Cognex Confidential10
Manufacturing Goal Machine Vision Applications
Improved product quality Inspection, measurement, gauging, and
assembly verification
Increased productivity Repetitive tasks done manually are
automated with machine vision
Production flexibility and
less machine downtime
Automatic product changeovers
Increased manufacturing
throughput
High-speed inspection keeps up with the
fastest production lines
Reduce manufacturing
waste
Detecting defects earlier in the process
prevents adding value to defective
products
Benefits of machine vision
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© 2018 Cognex Confidential11
MACHINE VISION APPLICATIONS
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© 2018 Cognex Confidential12
What does machine vision do?
GUIDE INSPECT GAUGE IDENTIFY
© 2016 Cognex Confidential12
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© 2018 Cognex Confidential13
Determines part position (x, y, and angle)
Automates handling of parts for machines:
▪Alignment & Placement
▪2D & 3D Picking
▪Eliminates need for fixturing & improves robot flexibility
Vision tool alignment, fixturing
▪Locate at least one feature on a part for the purpose of calculating the (x, y) position and rotation of the part to position other vision tools precisely
Guidance
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© 2018 Cognex Confidential14
Trained Image Out of focus
Uneven LightingOcclusions
Confusing Background
Rotation and Scale Changes
Geometric pattern matching
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Appearance Changes
Part location challenges
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Part location challenges
Variation in part appearance
1
6
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© 2018 Cognex Confidential17
Correct location
▪Orientation
▪Skew
Quality
▪Defect Detection
▪Surface Inspection
▪Contaminants
Completeness
▪Fill Level
▪Feature Presence
▪Counting
▪Assembly Verification
Inspection
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Precise dimensioning
▪ Automated metrology and data recording
Ensures tolerances
▪ Diameters
▪ Gaps
▪ Bushings
▪ Threads, etc.
Gauging
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Read Codes
▪ Printed 1-D Barcodes & 2-D Matrix
▪ Direct Part Mark
Read Characters
▪ OCR / OCV
Recognize Objects
▪ Based on color, shape, or size
Identification
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MACHINE VISION PRINCIPLE
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1D machine vision
▪ 100% continuous web inspection and classification
▪ Uses line-scan cameras
▪ Materials inspected include:Metals, non-wovensPlastics, Paper
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1. Unwrap cylindrical objects for inspection
2. Add vision to space-constrained environments
3. Meet high-resolution inspection requirements
4. Inspect objects in continuous motion
Four reasons to use line scan
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2D machine vision – area scan
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3D Machine Vision
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Profiler principle of operation
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Displacement sensor
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VISION SYSTEMS AND SENSORS
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COGNEX VISION SENSOR
Compact, modular
body design fits into
tight spaces
Field changeable, high power,
diffuse illumination
Powerful, proven In-Sight®
vision tools for reliable
inspection performance
Field changeable
lenses and filters
for optimal image
quality
Step-by-step setup
with EasyBuilder®
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▪ Industry-leading image acquisition and optical character recognition
▪Powerful and precise pattern matching algorithms
▪Most reliable and flexible inspection systems
Cognex 2D Vision
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© 2018 Cognex Confidential30
Cognex 3D Vision
▪ 3D laser displacement sensors provide three dimensional inspection of products to optimize quality
▪ Measure height, volume or tilt with cross section and plane fitting tools –regardless of contrast or light variations
▪ Expanded range of 3D sensors, factory calibrated to deliver real-world values
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SYSTEM COMPONENTS
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Key parts of a vision system
Light Source
Vision System
Vision Software
I/O Comm.
CameraLensPOWER
A- BALLEN- BRADLEY
I NPUT
10
23
4567
SLC 5/04 CPURUNFLTBAT
FORCDH+RS232
RUN REM PROG
I NPUT
10
23
4567
O UTPUT
10
23
4567
Inputs/Outputs: switches, PLCs, robots, lights
Communication
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© 2018 Cognex Confidential33
Putting it all together
Camera
Monitor
Operator Pointing Device
(Trackball, Mouse, Touchscreen)
Parts
Light Source
Vision System
Output:
•Serial
•Parallel
•ISA, PCI, VME bus
Input:
•Serial
•Parallel
•ISA, PCI, VME busa
Lens
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How the system works
1. Part arrives at inspection station
5. Software algorithms running on vision systemperforms image processing and/or image analysison acquired image
6. Vision system sends signal along a discrete output line which activates a diverter if the part is bad
7. Operator can view rejected parts and ongoing statistics on display,and can take system off-line if necessary
2. Sensor detects part and sends a trigger to the vision system3. Strobe is flashed to illuminate part 4. Vision System acquires the image from the sensor.
FAIL
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Machine vision algorithms
All within just one to tens of milliseconds!
Algorithms used by Vision Tools transform raw numbers into
useful higher level features …
- Raw numbers turned into edges, colors, characters, and
other characteristics
… then makes decisions
- Returns answers such as position, similarity, distance,
presence, quality
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TERMINOLOGY
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Vision definitions
Field of View (FOV)
▪ The part which can be seen by the machine vision system at one moment.
▪ The field of view depends on the lens of the system and the working distance between object and camera.
5” x 7”
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Field of view
What is my field of view?3”
4”
8”
15”
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Working distance and resolution
Working Distance (WD)
▪Distance between the FRONT of the lens and the target
Resolution
▪The minimum feature size of the object under inspection.
10”
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Correlation working distance/FOV
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Depth of field
Depth of Field (DOF)
▪ The distance in front of and behind the object which appears to be in focus
3”
More DOF with a small aperture
(high f/number) than with a large
aperture (low f/number)
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SYSTEM COMPONENTS
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Different lens … same image?
▪ Lighting
▪ Depth of field
▪ Working distance
▪ Line speed
▪ Exposure time
▪ Aperture
▪ Budget
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Lighting techniques
4
5
Bright FieldDark Field
Back Lighting
Diffuse Dome
Axial Diffuse
Light can be structured in different ways. Angle and direction of the light determine how the mark and space is seen by the camera.
Structured
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Optics
To learn more about choosing the right optics go to
Cognex.com > Resources > On-Demand Webinars
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Filtering techniques
▪ Control quality and quantity of
light
▪ Block all unwanted
ambient lighting
▪ Pass only the output of
lighting used for inspection
▪ Increase contrast
and resolution
For more on optical filters, go to Cognex.com >
Resources > On-Demand Webinars
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Image pre-processing tools
To learn more about image pre-processing, go to Cognex.com > Resources > On-Demand Webinars
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Summary
▪ Make products better, faster, and less expensively
▪ Gauging, Inspection, Guidance, and Identification are the key applications
▪ Key components are the lens, camera, lighting, vision software and communications
▪ Learn more about optics, lighting, filters and image pre-processing to improve system performance
▪ Don’t go it alone…get help from experts!