QUALITY INSPECTION

with LINE SCAN CAMERAS

 Line Scan
Advantage XG-8000L Series

1 Inspection of a cylinder’s When using a line scan camera, the entire lateral surface of cylindrical
parts can be inspected as one image, making it much easier to inspect
lateral surface with a machine vision system.

u Defect inspection of the lateral surfaces of metal cylindrical parts

Proven
applications
u Defect inspection of bearing circumference, plus OCR or code reading

❚ Defect inspection of rollers ❚ Sealed bearing inspection

Two line scan cameras are used to inspect for any defects on a Curved surface are very difficult to inspect for defects due
long metal roller surface with high accuracy. to irregular reflections of light. Line scan, however, can
eliminate these effects by “unrolling” the curved surface into a
rectangular image for stable inspection.

POINT Inspection using a single, compiled image eliminates the need for capturing multiple images.
Conventional inspection of a large
Area camera Line scan camera
or curved surface requires multiple
captured images while the part moves
1st
to cover the target entirely. A line scan image
A compiled
capture
camera can inspect the entire surface view of
the whole
compiled as a single image
2nd circumfer-
image ence can
capture be obtained
with one
3rd
image
image capture.
capture

Proven experience Switching the lighting conditions during inspection can allow for detection of all defects even if some are only revealed by either
from professionals specular reflection or diffuse reflection.

Significantly improved performance with shading correction

If captured images have inconsistent shading, the shading correction function can convert the entire field-of-view to appear as if it were uniformly illuminated. Since the correction
is completed within the camera, there is no effect on processing time or performance even for high-speed production lines.

Setting example: Defects more easily detected with Defects more easily detected with
Using a single camera to switch between two lighting conditions specular reflection diffuse reflection

Example of image capture with specular reflection Example of image capture with diffuse reflection
Faint vertical streaks and dirt Flaws or dents

Specular Specular
reflection reflection
lighting Diffuse reflection lighting Diffuse reflection
lighting lighting

Camera Camera

Rotate the target twice in front of the camera. Different defects may be detected more easily by varying lighting conditions. Consequently, you
2 It is also possible to divide the station to use two cameras. can improve the performance by inspecting twice while switching between two lighting conditions.
Line Scan
Advantage XG-8000L Series

2 Inspection of objects with It may be difficult to determine suitable lighting condition for targets
with irregular surfaces or complex shapes. Such targets can be
complex shapes detected under uniform lighting conditions.

u Inspection of parts with complex shapes (pistons, screws, etc.)

Proven
applications
u Defect inspection of the lateral surfaces of resin containers or beverage cans

❚ Inspection of pistons ❚ Defect inspection of gears

The line scan camera allows various inspections of such as
hole in the base or irregular printing on the coated part.
The line scan camera captures a point on the circumference as
a line and develops the entire circumference as an image. This
image captured under a uniform lighting condition is not affected
by irregular lighting. The inspection of the entire circumference
of the target can be completed with one operation, resulting in
improved inspection accuracy and reduced processing time.

POINT Uniform lighting conditions improve defect detection performance.

The line scan camera can compile the entire circumference of a cylinder's lateral surface as an image.
This allows accurate appearance inspection of complex shapes where suitable lighting is typically difficult to
accomplish.

Area camera Line scan camera

1st
image A compiled
capture view of
the whole
2nd circumfer-
image ence can be
capture obtained with
one image
3rd capture.
image
Susceptible to irregular lighting Uniform lighting conditions can be
capture
achieved.

Proven experience PET bottles with patterns and irregular surfaces can be inspected for black spots or foreign particles without being affected
from professionals the shape.

The secret to stable detection is to open the aperture wide creating a shallow depth-of-field and adjust the focus on the front
surface of the bottle preventing detection of the rear surface.

❚ Example of the detection screen

Adjust the focus on the front

surface from the camera.

The detection is stable, because the contrast of foreign particles is higher

than that of the patterns on the PET bottles. 3
 Line Scan
Advantage XG-8000L Series

3 Wide-field, high-resolution
inspection
When its field-of-view covers the width in the direction of target
movement, the line scan camera can capture images under a uniform
lighting condition while the target is moving.

u Defect inspection of lead frames or printed electrodes

Proven
applications
u Inspection of paper container surfaces for foreign particles or flaws

❚ Inspection of solar cells for interrupted patterns
Use of high-resolution line scan camera
for the inspection of the pattern printed
on solar cells achieves high-accuracy
inspection.
❚ Defect inspection of lead frames
The appearance of lead frame surfaces
and their plating position are inspected
during the transfer process.
❚ Appearance inspection of sanitary products
The camera can be installed in a small
gap of the conveyor to achieve various
inspections for stains, smudges, or
misaligned tapes.

POINT A single camera allows inspection across a wide field-of-view.

The line scan camera allows
Conceptual illustration of an area camera Conceptual illustration of a line camera
inspection in a wide range under the
same lighting condition. Irregular brightness Image with uniform
brightness
This ensures more stable appearance
inspection across a wide field-of-view
Image capture range
3.15" Inspection target
which are susceptible to irregular 80 mm
3.15"
80 mm Inspection target
lighting with area cameras.

160 mm 160 mm
6.30" Image capture range 6.30" 1-axis stage

POINT Ultra high-resolution inspection is now possible!

Compared with area cameras, the line scan camera uses a higher number of pixels to capture an image, which
significantly improves inspection accuracy. In a 100 mm 3.94" field-of-view, for example, even defects of around
50 μm 1.97 Mil can be detected.

Proven experience It is unnecessary to divide the field-of-view for inspection, because a single camera can capture an image across a wide field-of-
from professionals view with consistent lighting conditions.

Conceptual illustration of an area camera Conceptual illustration of a line camera

Movement Movement

Advantages of the line scan camera

1) A single camera can capture an
image across a wide field-of-view.
2) No need for integrating multiple
4 judgment results.
Line Scan
Advantage XG-8000L Series

4 In-line, high-speed
inspection
Continuous capturing of images significantly reduces the adjustment of
the camera and lighting.

u Inspection for foreign particles on sheet or pin holes/flaws on film

Proven
applications
u Appearance/width measurement inspection of electrode sheet

❚ Dimension inspection of rubber sheet
With the conventional method, width
measurement required two cameras to
detect the ends respectively. The high-
resolution line scan camera completes this
type of measurement in a single camera.
❚ Inspection of sheet for pin holes/stains
Defect inspection of film or sheet for
foreign particles, flaws or pin holes can be
achieved even on high-speed production
lines.
❚ Appearance inspection of hoop material
Pressed parts stamped out continuously
can be inspected at high speed while
improving inspection accuracy.

POINT The number of cameras/lighting size can be reduced for cost reduction
and space saving.
Using an area camera for the inspection of wide sheets required the installation of multiple large lighting devices.
The line scan camera can be used with a simple lighting device, resulting in cost reduction and space saving.

Conceptual illustration of area camera inspection Conceptual illustration of a line camera

Since large lighting devices are used, the installation The inspection is achieved with a bar light, resulting in
requires a lot of space and cost. cost reduction and space saving.

Proven experience The single line scan camera can complete inspection which requires two or more area cameras.
from professionals

The high resolution line scan camera with 8192 pixels in the X-direction can achieve inspection accuracy higher than
conventional cameras with uniform lighting across the inspection.
370 mm 14.57" = 8192 pixels

Entire image

Even minute defects can be detected with a line scan camera.

Defect of 0.5 mm 0.02"
(about 10 pixels)

5
 Advanced Lighting Techniques

This section introduces special techniques which effectively use the features of the line scan camera and which are
impossible with an area camera.
They allow inspections which were considered impossible or unstable.

Creating a uniform lighing condition.

Expert
technique How to achieve stable inspection for foreign particles or pin holes

1 Specular reflection

When foreign particles or dents exist on the target surface, the defects
are shown in black because the light does not return to the camera.

Example: Inspection of cylindrical parts for foreign particles

Line light Camera

Target

Using diffuse reflection effectively.

Expert
technique How to achieve stable inspection for flaws on the surface

2 Diffuse reflection

The defects are shown in white because the light reflects on burrs or
flaws and returns to the camera.

Example: Inspection of cylindrical rollers for flaws

Camera
Line light

Target

6
 XG-8000L Series

Inspection for minute irregularities on sheets of material.

Expert
technique “Ultra low-angle lighting”

3 Ultra low-angle lighting

Minute irregularities, such as thin wrinkles or shallow dents, are

emphasized. Inspection is possible by detecting the shade of
irregularities.

Example: Inspection of wrinkles/dents on coiled metal material

Camera
Line light

Transmitted lighting technique made possible by the line scan camera

Expert
technique “Transmitted diffuse lighting”

4 Transmitted diffuse/scattered lighting

Bubbles or foreign particles, which cannot be seen with normal transmitted light due to stray light, brightly
glow for easy identification.

Example: Inspection for tears, bubbles, or foreign particles on laminated film

Camera
Bubble shown with transmitted lighting Bubble shown with transmitted diffuse lighting

Line light

7
 XG-8000L Series

Features of the XG line scan camera — Easy full-scale inspection —

HIGHLY-FLEXIBLE MACHINE VISION SYSTEM WITH SIMPLE SETUP & USAGE
The XG-8000 Series makes using or incorporating a line scan camera into an existing setup very easy. The XG method
eliminates the need for conventional, complex, and specialized PC based line scan systems that require multiple parts from
different vendors. In addition, the interchangeable camera module makes combining technologies onto one platform very
simple and hassle free.

[XG LINE SCAN SYSTEM] [CONVENTIONAL LINE SCAN SYSTEM]

Company B
Industrial PC

XG Series Company A Company C Company D

XG-8500L/8700L Line Scan Camera Image Capture Board Inspection Software
Line Scan Camera

XG SERIES FEATURES CONVENTIONAL PROBLEMS

• Compatibility issues are eliminated since all the hardware is from the same manufacturer. • Compatibility issues arise due to connecting multiple devices from different manufacturers.
• Simple connection of the camera to the controller allowing the user to obtain images quickly. • A great amount of time and effort is needed in order to capture good images.
• Robust solid state hardware design. • Concerns with freezing or crashes due to the PC-based design.
• Minimal programming knowledge required. • Specialized programming knowledge is typically necessary.

MULTI-CAMERA, SIMULTANEOUS ACQUISITION SYSTEM

The XG-8000 Series offers the choice of up to 22 types of area cameras and 3 types of line scan cameras.* This allows the
same XG programming interface to be used no matter which camera is connected and provides the flexibility to easily adapt to
changes that may occur with the inspection criteria.
*Some combination may not be possible. Contact us for details.
*The 5MP area type camera is compatible with the XG-8702L controller only. (Used with XG-EC80 camera input unit connected)
*The XG-HL04M/08M are compatible with the XG-8702L controller only. (Used with the XG-EC80L camera input unit connected)

<MULTI-CAMERA SYSTEM> EXAMPLE: XG-8702L ❚ DIFFERENT CAMERA COMBINATION EXAMPLE

XG-E800 The entire circumference of the cylinder
+
XG-8700L XG-EC80(L) side is captured into a single image using
22 types of the line scan camera while it is rotated.
area cameras The top surface is captured with an area
scan camera and the entire workpiece is
inspected in one cycle. The combination of
two different types of cameras results in
reduced inspection times and cost.

3 types of line
scan camera

High resolution and world’s smallest size for more flexible installation
Conventional
camera

A high-sensitivity, compact 4/3" CMOS Support for C-mount lenses

sensor is used in the 21 megapixel F-mount size allows for the use of lenses
XG Series
camera. This allows the use of C-mount with short focal lengths.
The minimum installation
lenses designed for 4/3" sensors, distance is reduced to
Minimum
resulting in a wider range of lens installation approximately 1/5.
distance
selection. Installation flexibility is greatly
EXAMPLE
improved compared to conventional 1
C-mount size 5 Comparison of the WD
required for a field-ofview
systems.
of 100 mm 3.94"

E-mail: keyence@keyence.com
XGLinecamera-KA-EN-US 1046-1 E 611C29 KA3-1017