Motion and Vision Convergence
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Many motion based applications have a vision component to them as well as the electronic controllers and the mechanical components. These three elements of an application represent the bulk of the engineering in any machine design. This webinar will discuss the challenges each element brings. Typical applications of these combined elements will be represented. It is the aim of the webinar to demonstrate three distinct applications where these elements converge on simple and complicated machinery.
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Motion and Vision Convergence
- 1. M ot ion and V is ion C onv er gence
- 2. Introduction Moderator: Miles Budimir Senior Editor Presenters: David Kaley Commercial Marketing Manager Jonathan R. Schroeder Business Development Manager
- 3. Agenda • Introduction • MOVI as a concept – Elements – Typical Applications – Challenges • Application 1 – Bottle Inspection • Application 2 – Inspection In Motion • Application 3 – Automated Storage & Retrieval
- 4. Inspection History • In the past: – Inspect & Reject • Today: – Vision Guided Motion – Cameras In Motion
- 5. = Motion + Vision • Taking Vision beyond Inspect and Reject • Integrating Motion and Vision – – – – Move, Inspect and Reject Move, Inspect and Orient Inspection in Motion Storage and Retrieval
- 6. Not A New Concept Automated Optical Inspection (AOI) • Critical Inspection of precision products like Circuit boards and Semi Conductor Wafers • Either the camera or the product is moved for precise inspection
- 7. 3 Key Elements Motion Control • Controller • I/O • Drives • Motors Mechanical • Actuators • Gear boxes • Couplings • Sensors • Cable carriers • Mounting Hardware Vision • Controller • Cameras • Lighting • HMI
- 8. Challenges • Speed • Accuracy • Communication • Selection • Software • Speed • Accuracy • Selection • Torque Calculations • Wear • Environment • FOV • Triggering • Color Discrimination • Communication • Selection • Environment
- 9. Speed • Network data • Processing • Acceleration • Deceleration • Function of load • Trigger time • Processing time • Measured in uSec update cycles •Measured in meters per second •Measured in mSec
- 10. Accuracy • Overshoot • Hysteresis • Settling time • Backlash • Repeatability • Rigidity • Color discrimination • Resolution
- 11. Not every company does it all Many only do 1 of the 3 disciplines
- 12. Collaboration Is Key • Companies are beginning to leverage each other’s strengths – Customers receive products designed to work together • Omron Industrial Automation and PBC Linear collaboration – Omron controls and PBC Linear mechanicals • By combining strengths, it is easier for customers – This focus on strength helps each company to reduce energy spent on non-core products
- 13. Why Customers Want Convergence • Reduced selection time – Shorter design cycles • Fewer technical support conflicts – Less finger pointing between vendors • Common communication protocols – Faster communication between devices • Vision systems that speak directly to the motion controller – Easier to program and less hardware
- 15. The Application • Bottle filling • Cap inspection • Varying bottle sizes
- 16. Static Mount, Manual Adjust Manual Adjustment w/set screw
- 17. The Problem • System used manual adjustments for change-over – Time consuming – Inaccurate – Enclosure integrity – Limited space
- 18. The Solution Linear Actuator with built in motor and coupling MLB Series by PBC Linear
- 19. Dynamic Mount, Automatic Adjust Upper Position
- 20. Dynamic Mount, Automatic Adjust Lower Position
- 21. The Result • Eliminated errors during change over • Reduced change over time from 10 minutes or more to roughly a minute • Improved water ingress resistance resulting in fewer moisture related repairs • Smaller footprint for total enclosure • Parts count reduction by 40%, justifying the added cost
- 24. The Application • Lab automation • Inspecting cultures • Logging the data – Date & Time – Color – Physical Size • Diameter • Area – Change from previous size
- 25. Sample Culture
- 26. The Problem • Manual process • 24/7 human monitoring – One hour increments • Manual measurements – Subjective measurements, not typically repeatable from one person to the next (due to frequent odd shape/size) • Image logging data base manually input – Time intensive & data entry error prone
- 28. The Solution • Cartesian robot • Trajexia controller • X and Y planes • Low profile, high precision linear actuators • FZ Vision System • Vision system can auto guide motion controller to ensure optimal image capture (offset move)
- 29. Vision Capture
- 30. The Result • Automatic Process • Eliminated 24-hour staff – Reduced Cost • Auto measured culture size and color – Improved accuracy • Auto logged images – Reduced data entry errors
- 33. The Application • Automated pharmaceutical dispensing machine • Robot picks drug to be dispensed • Vision system records bottle barcode, locates edge and calculates offset movement distance
- 34. The Problem • Incorrect dispensing is a major liability Complicated by… • Mechanical Tolerances – Inexpensive frame creates huge tolerance stack up • Recording Barcodes • Label Verification
- 35. The Solution • The Cartesian Robot was installed with a home sensor located on a sheet metal component • The vision system provided final move coordinates to the controller • The vision system reads the barcode which is then verified against the order • The vision system also verifies the printing on the label • The vision system stores applicable images/data using onboard PC (for liability reasons)
- 37. The Result • The vision system’s ability to do edge detection and calculate offset moves reduced assembly tolerances and decreased assembly cost • The motion and vision interface ensure accuracy of the medicine picked – Allows for minimized levels of liability • Fast, accurate medicine dispensing without the need for costly pharmacist staff
- 38. Other Storage & Retrieval Systems • Automated Parking System • High Bay Storage
- 39. SUMMARY
- 40. 3 Key Elements Motion Control • Controller • I/O • Drives • Motors Mechanical • Actuators • Gear boxes • Couplings • Sensors • Cable Carriers • Mounting Hardware Vision • Controller • Cameras • Lighting • HMI
- 41. Challenges • Speed • Accuracy • Communication • Selection • Software • Speed • Accuracy • Selection • Torque Calculations • Wear • Environment • FOV • Triggering • Color Discrimination • Communication • Selection • Environment
- 42. Benefits Of Convergence Better Communications = Faster Machines Easier Selection = Faster Design Unified Tech Support = Less Wasted Time Networked Cameras = Less Hardware
- 43. Stay Tuned S Motion + Vision + Safety
- 44. QUESTIONS www.pbclinear.com 1.800.962.8979 Jonathan R. Schroeder Business Development jonathan.schroeder@pbclinear.com www.omron247.com 1.800.556.6766 David Kaley Commercial Marketing Manager david.kaley@omron.com
- 45. Thank y ou for at t ending!