How To Easily Improve Quality Using Automated

Visual Inspection

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Before We Start

Moderator Presenter

Michael Jermann Design World

Jon Chouinard Baumer Ltd.

How to easily improve quality using automated visual inspection Baumer

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

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

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

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

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

•  Lighting is 80% of a vision sensor application!

•  Garbage In = Garbage Out •  We must create contrast!

Introduction to Vision Sensors: Lighting

1D  Code  Reading

•  Lighting is 80% of a vision sensor application! •  Contrast is Key! - Lighting will make break your

application!

Introduction to Vision Sensors: Lighting

Pa6ern  Match

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?

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

•  Proper  Location  of  Straw   •  Digital  output  for  “Go  /  No  Go” •  Tools:    Pixel  Counting

Vision Sensor Applications Presence / Absence

•  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

•  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

•  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

•  Identify  if  barb  has  been  completed •  Output:    Digital  I/O •  Tools:    Count  Edges

Vision Sensor Applications Completeness

•  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

•  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

•  Locate  part  on  conveyor  belt  and  provide  X,Y  and  rotational  coordinates  

•  Tools:    Locate  on  contours;    Padern  match

Vision Sensor Applications X,Y - Rotation

•  1D  Bar  Code  reading  +  OCR  

•  Output  and  compare  

expected  code  and  tablet  count

•  Tools:    OCR  +  1D  read

Vision Sensor Applications 1D Code + Character Recognition

•  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)

•  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

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!

VeriSens – Vision Sensor Step 1: Adjust Image

VeriSens – Vision Sensor Step 2: Check Features

VeriSens – Vision Sensor Step 2: Check Features -> Part Locate

VeriSens – Vision Sensor Step 2: Check Features -> Geometry

VeriSens – Vision Sensor Step 2: Check Features -> Geometry

VeriSens – Vision Sensor Step 2: Check Features -> Feature Comparison

VeriSens – Vision Sensor Step 2: Check Features

Inspections  are  now  setup! •  Locating  part

•  Checking  distance  (measurement)

•  Checking  Angle

•  Checking  hole  count

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?  

VeriSens – Vision Sensor Step 3: Configure Interfaces

Digital  IO •  5  Outputs,  Boolean  

logic •  Timing •  1  cable  for  I/O  and  

Power  required

VeriSens – Vision Sensor Step 3: Configure Interfaces

Ethernet  communication •  TCP/IP,  Profinet,  

Ethernet  IP   •  Results  communicated   •  2  cables  

•  I/O  and  Power   •  Ethernet

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

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

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

 

Monitor  line  remotely  with  Web  Interface    

VeriSens – Vision Sensor Activated! - > Inspecting.. Inspecting.. Inspecting..

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

Questions? Michael Jermann Design World mjermann@wtwhmedia.com Twitter: @DW_MikeJermann

Jon Chouinard Baumer Ltd. jchouinard@baumer.com Phone: 603-571-5031

Thank You q  This webinar will be available at

designworldonline.com & email

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