With the advent of Industry 4.0, machine vision is playing an increasingly important role in intelligent manufacturing. To help more users acquire basic knowledge about machine vision, including how this technology works and why it's the right choice for process automation and quality improvement, we've prepared this informative resource on machine vision.
▲Image sourced from the internet
What is machine vision?
Let's start with the definition of machine vision. According to the Society of Manufacturing Engineers, machine vision is the use of optical non-contact sensing devices to automatically receive and interpret images of real-world scenes to obtain information for controlling machines or processes.
So, what does this actually mean? Simply put, machine vision is the automatic extraction of information from digital images for process control or inspection of manufactured products. See the example below:
Machine Vision Application Diagram
To better understand machine vision, we will use a liquid level detection system as an example:
▲Figure 1: On-site application image
As each bottle moves past the detection sensor, the camera captures an image and saves it to memory. The vision software then processes or analyzes the image to determine whether it passes inspection. If it fails inspection, the vision system sends a signal to remove the bottle from the production line.
In this application example, the fill level inspection system only needs to provide two results, which demonstrates the characteristics of a binary system:
1. If the product is qualified, the test result is "pass".
2. If the product is substandard, the test result will be "failed".
In addition, machine vision systems can also measure objects, such as determining spark plug gaps or providing positional information to guide robots to align components during manufacturing and assembly. The example shown in Figure 2 mainly illustrates how machine vision systems can be used to detect whether an oil filter (right) passes or fails, and to measure the width of the central shaft head on the bracket (left).
▲Figure 2 shows a machine vision system that can perform real-time measurement and inspection on the production line, such as processing brackets (left) or oil filters (right) (Image from the Internet)
What are the advantages of machine vision?
While human vision excels at qualitatively interpreting complex, unstructured scenes, machine vision, with its advantages in speed, accuracy, and repeatability, is adept at quantitatively measuring structured scenes. For example, on a production line, machine vision systems can inspect hundreds or even thousands of components per minute. Equipped with cameras and optics of appropriate resolution, machine vision systems can easily examine details of objects too small for the human eye to see.
Furthermore, by eliminating direct contact between the inspection system and the inspected components, machine vision can prevent component damage and avoid the maintenance time and costs associated with mechanical component wear. By reducing human intervention in the manufacturing process, machine vision also offers additional safety and operational advantages. In addition, machine vision can prevent cleanroom contamination by human intervention and protect workers from hazardous environments.
The important role of machine vision:
Application areas of machine vision:
Identification
Decoding standard one-dimensional and two-dimensional barcodes;
Optical Character Recognition (OCR) and Authentication (OCV).
Detection
Color and defect detection;
The presence or absence of parts or components is checked;
Target position and orientation detection.
Measurement
Size and capacity inspection;
Measurement of preset markers, such as the distance between holes;
robotic arm guidance;
Output spatial coordinates to guide the robot arm to precise positioning.
Classification of machine vision:
Since its inception, Banner Engineering has been committed to providing customers with professional automation products and solutions to help them improve product quality, eliminate production errors, and reduce manufacturing costs. As a leading global supplier in the machine vision field, Banner offers a variety of vision systems, categorized into the following three types:
Visual sensors;
Smart camera;
PC-based machine vision software.
●Banner Vision Products●
1. Banner Vision Sensor - iVu Series
iVu and iVu color image sensors are used to monitor the type, size, orientation, shape, position, color, or color changes of parts. The device can be set up and monitored using an integrated or separate touchscreen display, without a PC (or connected to a PC for setup). The following functions are available:
An integrated solution that includes camera, controller, lens, and lighting;
Depending on your application, use various grayscale or color tools to inspect multiple points;
Configuration can be completed in minutes via the onboard touchscreen on the device, or easy access and monitoring can be achieved using a separate touchscreen.
Compact, rugged, IP67 housing available with or without a variety of integrated ring lights - red, blue, green, white, infrared or ultraviolet - and Type C mounting models are also available.
Factory communication (EtherNet/IP, Modbus/TCP, PROFINET, PCCC, and serial RS-232) is used for integration in the production workshop;
The online editor allows for dynamic parameter changes, reducing costly downtime.
2. Banner Smart Camera - VE Series
Banner's free and easy-to-use camera software offers a wealth of tools and features that enable smart cameras to meet a variety of vision applications, such as project inspection, component location, feature measurement, and defect analysis.
Available in 5MP (2400x2000 pixels), 2MP (1600x1200 pixels), 1.3MP (1280x1024 pixels) and WVGA (752x480 pixels) models, with powerful detection capabilities;
Online debugging capabilities reduce costly downtime, and the software simulator supports offline building and application troubleshooting.
Factory communications (Ethernet/IP, Modbus/TCP, PROFINET, and serial RS-232) are used to achieve integration in the production workshop;
The sensor has six optically isolated I/O ports and an external light source interface;
The two-line, eight-character onboard display provides inspection information and focal length values, and allows for easy updating of sensor settings, facilitating rapid product changeover.
The IP67-rated rugged metal housing with optional lens cap allows for use in harsh environments with high temperatures, vibrations, or humidity.
Bright indicator lights make it easy to check the camera status.
3. PC-based vision software - BVI software
Powerful 1D and 2D barcode reading capabilities;
Intelligent OCR reading function;
It has a rich set of camera drivers and can connect to cameras from multiple manufacturers;
It can support cameras with tens of millions of pixels, providing the necessary guarantee for high-precision measurement;
Hundreds of processing and preprocessing tools to meet the needs of any complex project application;
It has scripting tools and provides interfaces for users who need secondary development.
