This document provides an overview of machine vision and examples of its applications. It discusses what machine vision is, when it is used, and common camera types. Machine vision is defined as using cameras to analyze images and extract data to control automated processes. It is used to improve quality, simplify workflows, and reduce waste and costs. Examples are provided of simple vision sensors, smart cameras, and PC-based camera components used for applications like object counting, positioning, and inspection. The benefits of machine vision for quality control and profits are highlighted.

1. April 2014
Tim Seymour
Vision Application Specialist, SICK Australia
: Improving Quality & Profits with Machine Vision

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Machine Vision Systems
Contents
: What is Machine vision?
: When do we use it?
: What types of Cameras can be used in Industry
: Examples of Vision Solutions

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Machine Vision Systems
: When do we use it?
: The benefits of Machine Vision are;
: $$$$$$$$
- Improving quality of the finished product
- Simplifying, improving or increasing work flow,
- Reducing waste , both in materials and effort.
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Machine Vision Systems
: What is Machine Vision?
: Use of cameras in the context of process control
: Is defined as the analysis of images and extraction of data for controlling an
automated process or action
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Image
capture
Image
analysis
Decision
making
Data
output
Repeat
process

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What is Machine Vision
: Image capture
: 1 D, 2 D or 3 Dimensions ?
: Illuminating an Object and acquiring an image
- Front or back light?
- Visible or Infra Red?
: Moving or stationary ?
: Triggered or Free running?
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Image
captur
e
Image
analy
sis
Decisi
on
makin
g
Data
output
Repe
at
proce
ss

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Image analysis
: to answer the following questions in highly repetitive situations....
Tim Seymour April 2014 6
Good/bad
Classification
PositionIdentification Dimension
OK? Where?What does it say? How large?

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Decision Making and Data output
: What results do you need?
- Pass or Fail?
- Sort?
- Digital or Serial?
- Settings Adjustable or fixed?
: How much time do you have?
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Image
capture
Image
analysis
Decision
making
Data
output
Repeat
process

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Types of Machine Vision Components
: Vision ”Sensors”
- Easy to use
- Application-specific, or configurable but limited
- Works stand-alone
: ”Smart” camera
- Flexible, programmable with ready-to-use
toolbox
- Works stand-alone, no PC
: PC-based camera ”components”
- Fully flexible, programmable with low-level
languages (C++, .NET, etc)
- The camera only takes images, the PC
analyzes and controls the process using a
visual studio software package.
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Vision sensor or
smart camera
PC-based

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Some terms explained…
: What is a pixel?
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Pixel

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Some terms explained…
: FOV?
▪ Field of View;
: ROI?
▪ region of interest….?
: TOF?
▪ Time of Flight
: OCR
▪ Optical character recognition
: RGB
▪ Colour cameras
: IR or UV
▪ Type of light emitted or received?
: GUI
▪ Graphical User Interface that appears on the Human Machine Interface
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Simple Vision Sensors
: Just connect and align
- Easy to use
- Single purpose
- No parameters
- No Logic
: Examples are
- X,Y positioners
- Shingle counters
- Registration detectors
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Simple solutions using smart sensors
: object counters
: how many containers can I fit on a conveyor?
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Simple solutions using smart sensors
: X,Y positioners
: the challenge is to align the pallet
handling system to the shelf or bay
location.
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Simple solutions using smart sensors
: Labels without marks kept in register
: The saving may only be 2%.... However…...
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Complex Vision Sensors
: The Features of a Complex Vision Sensor include;
- Around 10 to 20 Algorithms or Vision ”tools”
- Ethernet or USB connectivity
- Simple logic functions
- Discrete outputs
- Fast processing times
- Low to medium image resolution
- Integrated light sources
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Example Applications…
: Interactive Edge Guiding on carpet
gluing line; 2 x cameras for 2 different
materials running simultaneously.
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Example Applications for Vision sensors…
: APPLICATION; Ultra Violet Light source to inspect a optically challenging product
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Example Applications for Vision sensors…
: APPLICATION;
- Look for correct insertion of wafer in packaging, before dosing of ice cream
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Example Applications for Vision Sensors…
: APPLICATION: Cheese Sticks
: Formation checks
:
: TECHNOLOGY: 2D Vision Camera
: LED Diffuse Back light
:
: METHODOLOGY: Back Lit image for Length and shape check
:
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Courtesy of

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“Smart” Vision Cameras
: The Features of a Smart Camera are;
- Around 200 Algorithms and logical processes
- Ethernet connectivity
- Complex logical and mathematical functions
- Multiple outputs
- Fast processing times
- Medium to high image resolution
- Usually 2D ( some 3D)
- Multiple lens options
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Example Applications for Smart Cameras…
: APPLICATION: Glass Bottle Rim & Neck validation
: Break, crack & foreign matter detection
:
: TECHNOLOGY: 2D Vision system with PLC control for ejection
: LED illumination, Operator HMI for sensitivity adjustment
:
: METHODOLOGY: Front Lit image
: Greyscale value mapping.
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Courtesy of

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Example Applications for Smart Cameras…
: APPLICATION: Frozen Pie packets
: Packet formation & closure verification
:
: TECHNOLOGY: 2D Vision system
: LED illumination,
:
: METHODOLOGY: Back Lit image to silhouette packet to confirm edge formation
:
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Courtesy of

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Example Applications for Smart Cameras…
: APPLICATION: Sanitary pads;
: Pad thickness, feature presence & location
:
: TECHNOLOGY: “Linescan” smart cameras
: LED illumination, Operator HMI for sensitivity adjustment
:
: METHODOLOGY: Silhouetted image
: Greyscale value mapping and measurement,
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Courtesy of

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Example Applications for Smart Cameras…
: APPLICATION: Lid & tub label validation
: Correct ID & position, Internal tub defect detection
:
: TECHNOLOGY: 2D smart cameras with bar code reading tools
: LED illumination, Operator HMI
:
: METHODOLOGY: Front lit image
: Greyscale; 2D Code reader & Pattern match.
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Courtesy of

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Camera Components
: High end Camera components;
- High resolution, 1, 2, & 3D
- Special Intefaces
▪ GigE, Camera Link, Firewire, etc
- Most analysis functions completed by seperate software in an external PC
- Fast imaging times
- Usually high image resolutions
- Multiple lens options
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Camera Components used with 3rd party software
: APPLICATION: Batch Mixing Verification;
: Scanning Powdered Ingredients Bags
:
: TECHNOLOGY: 2D camera
: LED illumination, Operator HMI
:
: METHODOLOGY: Front lighted image,
: Intuitive pattern matching linked to customer data base for
ingredient lists and quantities.
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Courtesy of

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Camera Components used with 3rd party software
: APPLICATION: Detect “Off Centre Core”;
: “News Print” Paper rolls
:
: TECHNOLOGY: Hi res 2D camera
: Infra Red LED illumination, Operator HMI
:
: METHODOLOGY: Front lighted image,
: edge detection followed by mathematically calculations to
determine centre of roll vs centre of core. .
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Courtesy of

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Camera Components used with 3rd party software
: APPLICATION: Print Inspection
: Foil sealed trays
: TECHNOLOGY: Hi res 2D camera
: Diffuse LED illumination, Operator HMI
: METHODOLOGY: Front lighted image,
: complex pattern matching software.
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Courtesy of
Missing Label Extra Print Misregistration
Blob Damaged Smudge

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Camera Components
: APPLICATION: Parcel Sortation ( & dimensioning)
: freight logistics
: TECHNOLOGY: Line scan camera
: Fixed LED line illumination tracked to moving objects.
: METHODOLOGY: Image software in both the Camera and
attached PC.
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Courtesy of

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When to use 3D?
: 3D using
: structured light?,
: Stereoscopic?,
: triangulation?
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Camera Components integrated to Machine controls
: APPLICATION: Robotic Bin Picking
: metal parts
: TECHNOLOGY: “scanning” 3D camera
: Moving laser line illumination.
: METHODOLOGY: Image software
compatible with standard CAD files and
Robot coordinate systems.
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32. : Thank you for your attention.