Vision Sensors –
no engineering, no risk?
Dr. Herbert Hufnagl
Festo AG & Co. KG, Esslingen
BU Machine Vision
OI-MV/MASN
IPT 2003
12.03.2016
1
Machine Vision?
"The use of devices for optical, non-contact sensing to automatically receive and
interpret an image of a
real scene in order to obtain information and/or control machines or processes"
AVA, 1985
(Batchelor/Whelan)
„Vision Sensor“ – my definition
„A Vision Sensor is a machine vision device;
the setup and operating maintenance of this device can be performed by nonvision experts“
OI-MV/MASN
IPT 2003
12.03.2016
2
MV vs. Vision sensors: Engineering vs. „Plug and Work“
MV needs engineering  system integrators
• Most system integrators have < 10 employees and act locally
• Germany > 100 system integrators
• Depts at big endusers can also be system integrators
Vision Sensors: reduced complexity, setup by non-vision experts
• Focused and standardized products enable standardized services (Hotline…)
Main problems:
• Identification of „killer applications“
• Danger: too much simplification for real applications
OI-MV/MASN
IPT 2003
12.03.2016
3
Machine vision in factory automation
Quality inspection
• Check completeness
• Non contact measurement (part geometry)
• Surface inspection
Identification
• OCR
• Code reading
Handling and assembly
• Part recognition / part position determination
• End effector positioning
• Navigation of mobile robots
Machine setup / diagnosis
• Recording of highspeed videos
OI-MV/MASN
IPT 2003
12.03.2016
4
„Vision Sensors“: possible application fields
Quality inspection
• Check completeness
• Non contact measurement (part geometry)
• Surface inspection
Identification
• OCR
• Identification
Handling and assembly
• Part recognition / part position determination
• End effector positioning
• Navigation of mobile robots
Machine setup / diagnosis
• Recording of highspeed videos
OI-MV/MASN
IPT 2003
12.03.2016
5
Machine vision: how it works
light
illumination
media
control
object
reflexion
result
lens
sensor
Processing, analysis, recognition,
…
image
…also for vision sensors!
OI-MV/MASN
IPT 2003
12.03.2016
6
Lighting
…also for vision sensors!
OI-MV/MASN
IPT 2003
12.03.2016
7
Optics, filters
…also for vision sensors!
OI-MV/MASN
IPT 2003
12.03.2016
8
Optics
…also for vision sensors!
OI-MV/MASN
IPT 2003
12.03.2016
9
Machine Vision integration…
„Vision Sensor with binary output like light
barrier “
versus
„an image is more than a thousand words“
e.g. position information, deviation…
OI-MV/MASN
IPT 2003
12.03.2016
10
100% quality control of parts: good/bad, orientation, part type
OI-MV/MASN
IPT 2003
12.03.2016
11
Festo Checkbox® – a vision sensor for moving parts
Steps to take to integrate the Checkbox
• Integrate Checkbox (and actuators) in the machinery
• Parameterise the integrated PLC to handle the feeding process
and actuator functions (engineering tool “CheckKon”)
• Teach-In the different parts and/or use engineering tool
“CheckOpti” for setup of inspection task
OI-MV/MASN
IPT 2003
12.03.2016
12
Checkbox Compact - Product description
Checkbox Compact Classic
Actuators
Buffer sensors/feeding device
Diagnosis via PC (RS232)
24 V power supply
Display
Teach
Start/Stop
Checkbox Compact PLC
Checkbox Compact Plus
Checkbox Compact Flex
PLC connection
Input Encoder
OI-MV/MASN
IPT 2003
12.03.2016
13
Festo Checkbox features
•
•
•
•
•
•
•
•
2D-geometry check - backlighting
Part rates to the mechanical limit (really 30 parts/s)
Part speeds up to 3 m/s
Part management (Actuators, jam, control of feeder, counting, minimum
distances…)
Part length l=2mm to l=2m
Part height h=0,5 mm to h = 80 mm
Integration from automation experts (not vision experts)
Minimum engineering from Festo necessary
OI-MV/MASN
IPT 2003
12.03.2016
14
Compact Vision System SBOx-Q-… - area besed
Vision sensor for
• Detection of the position of parts within its field of view to
control Festo servo drives
(x- an y-coordinates and rotation angle)
•
Type identification
•
Orientation detection
•
2D quality inspection
•
sorting
Integration of
Image sensor, electronics, Ethernet and CAN
interfaces, some 24 V I/Os.
SBOI-Q-…: + optics and lighting
OI-MV/MASN
IPT 2003
12.03.2016
15
Compact Vision System SBOI-Q-…/SBOC-Q-…
Compact Vision System SBOI-Q-R1B
• Integrated optics and lighting system (high-capacity LED)
• Working distances: 22 – 1000 mm
• Field of view: 14 x 10 mm … 540 x 390 mm
• Adjustment of lens: approx. 1:5 via screw
• Dimensions: 45 mm x 45 mm x 83,7 mm
Compact Vision System SBOC-Q-R1B
• Field of view and working distance variable thanks to connecting facility for C-Mount
and CS-Mount lenses (standard lenses)
• Lighting system not integrated
• Dimensions: 45 mm x 45 mm x 136,7 mm
OI-MV/MASN
IPT 2003
12.03.2016
16
Compact Vision System SBOI/SBOC – Connectivity
Ethernet (TCP/IP, Easy IP)
• PC for set-up, diagnosis
Ethernet
• Connectivity to intranet/internet; live image viewable via Internet
Explorer
• FED for teach, status messages, type select…
• FEC for reading feature values (e.g. coordinates and rotation angle
of parts)
CAN
OI-MV/MASN
CAN (Festo CP)
Additional I/Os (at sales release one input and
one output module)
IPT 2003
12.03.2016
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CPX-CP: converts Festo CPI to Fieldbus „X“
• SBO is CP – Slave (16I, 16O)
• Up to 4 cameras to: Profibus, Interbus-S, CC-Link,….
OI-MV/MASN
IPT 2003
12.03.2016
18
Application example: inspection of brake/fuel tubes
OI-MV/MASN
IPT 2003
12.03.2016
19
Layout
Camera 4
192.168.28.13
MAC: 00-1B
End test
Camera 2
192.168.28.11
MAC: 00-19
End test
OI-MV/MASN
right
Checkbox right
Camera 3
192.168.28.12
MAC: 00-1A
Screw inner diameter
left
IPT 2003
Camera 1
192.168.28.10
MAC: 00-0D
Screw inner diameter
Checkbox left
12.03.2016
20
Image sensors: conclusions…
• Even simple machine vision applications need a minimum of user interaction, the possibility to change
parameters and to understand their behaviour
(more than „Teach“)
- highly standardized application specific engineering tools
- simple Interface to standard decentral HMI
• Every machine vision device needs minimum communication channels to machine control systems
(more than RS232 and some 24V I/O)
- high bandwidth interface for setup (live image…)
- support of industrial fieldbus standards for apps with more than good/bad
- no „black box“ behaviour to PLCs – e.g. integration of plc runtime
OI-MV/MASN
IPT 2003
12.03.2016
21