Introduction to Machine Vision

Joe Wesoloski | October 3, 2019

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 Agenda

 What is machine vision?

 Why use machine vision?
 Machine vision applications
 Types of machine vision systems
 Vision system components
 Machine vision terms
 Improving vision system performance
 Summary
 Q&A

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 What Is Machine Vision?

The camera lens and sensor capture images…

Cognex advanced
vision software
interprets what’s
being seen

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 Evolution of Machine Vision

3D Displacement
Sensors
Vision
Sensors

Barcode
Readers

Modular
Vision
PC Vision
Embedded
Boards

Proprietary Box

1982 Today

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 Simple Examples

 Machine vision systems analyze images

 Then makes decisions and/or returns numeric results about
each image it gets
Good Oil
Filter – all
holes are
open

Reject oil
filter – some
holes are
The center tab on this bracket is
blocked
37.255 mm wide

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 Image Analysis

The primary purpose of machine vision is image analysis

Decision

Answer
Image
Location

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PRODUCTS
ACROSS

ALL
INDUSTRIES

ARE MADE BETTER AND

AT L O W E R C O S T W I T H

COGNEX VISION

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 Why Use Machine Vision?

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 Critical for Achieving Strategic Goals

 High speed production lines

 Clean room environments
 Hazardous environments
 Microscopic inspection
 Closed-loop process control
 Robot guidance
 Precise non-contact
measurement

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 Benefits of Machine Vision
Strategic Goal Machine Vision Applications
Higher Quality Inspection, measurement, gauging, and
assembly verification
Increased Productivity Repetitive tasks formerly done manually
are now done by MVS
Production Flexibility Measurement and gauging / Robot
guidance / Prior operation verification
Less Machine Downtime Changeovers programmed in advance
and Reduced Setup Time
More Complete Manual tasks can now provide computer
Information and Tighter data feedback
Process Control

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 Benefits of Machine Vision
Strategic Goal Machine Vision Applications
Lower Capital Equipment Adding vision to a machine improves its
Costs performance, avoids obsolescence
Lower Production Costs One vision system vs. many people /
Detection of flaws early in the process
Scrap Rate Reduction Inspection, measurement, and gauging
Inventory Control OCR and Identification

Reduced Floorspace Vision System vs. Operator

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 Machine Vision Applications

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 Think: GIGI

Guidance Inspection Gauging Identification

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 Guidance
Determines part position (x, y, and angle)

Automates handling of parts for machines:

 Alignment & Placement
 2D & 3D Picking
 Eliminates need for fixturing & improves robot
flexibility

Vision tool alignment, fixturing

 Locate at least one feature on a part for the
purpose of calculating the (x, y) position and
rotation of the part to position other vision tools
precisely

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 Geometric Pattern Matching

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 Part Location Challenges

Appearance changes

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 Part Location Challenges

Variation in part appearance

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 Inspection

Broad category of vision applications:

Correct location
 Orientation
 Skew
Quality
 Defect Detection
 Surface Inspection
 Contaminants
Completeness
 Fill Level
 Feature Presence
 Counting
 Assembly Verification

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 Gauging
Precise dimensioning
 Automated metrology and
data recording

Ensure tolerances
 Diameters
 Gaps
 Bushings
 Threads, etc.

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 Identification

Read codes
 Bar codes & 2-D Matrix
 Labels & direct part mark

Read characters
 OCR / OCV

Recognize objects
 Based on color, shape, or size

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 Types of Machine Vision Systems

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 1D Machine Vision

 100% continuous web

inspection and classification
 Uses line-scan cameras
 Materials inspected include:
 Metals
 Non-wovens
 Plastics
 Paper

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 2D Machine Vision – Area Scan

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 2D Machine Vision – Line Scan

 Image is built line by line

 Movement is needed
Built Image
 Requires encoder to
track movement Line Acquired

 Short exposure times

Camera
and Lens

Line Light

Conveyor
Belt
Movement

Encoder Shaft

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 Four Reasons To Use Line Scan

1. Unwrap cylindrical objects for

inspection

2. Add vision to space-constrained

environments

3. Meet high-resolution inspection

requirements

4. Inspect objects in continuous motion

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 3D Machine Vision

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 Machine Vision System
Components

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 Key Parts of a Vision System
Light Source

Communication

I NPUT I NPUT O UT PUT

S L C 5 /0 4 C P U
R U N F O R C 0 4 0 4 0 4
P O W E R
F L T D H + 1 5 1 5 1 5
B A T R S 2 3 2 2 6 2 6 2 6
R U N R E M P R O G 3 7 3 7 3 7

A- B AL L EN- BRADL EY

Inputs/Outputs: switches, PLCs, robots, lights

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 Putting It All Together

Parts

Light Source

Lens Camera
Monitor
Input:
•Serial
•Parallel Output:
•ISA, PCI, VME bus •Serial
Vision System
•Parallel
•ISA, PCI, VME bus
Operator Pointing Device
(Trackball, Mouse, Touchscreen)

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 How the System Works
1. Part arrives at inspection station

2. Sensor detects part and sends a trigger to the vision

3. Strobe is system
flashed to
illuminate part 4. Vision System acquires the image from the sensor.

5. Software algorithms running on vision system

FAIL performs image processing and/or image analysis on
acquired image

6. Vision system sends signal along a discrete

output line which activates a diverter if the part
is bad

7. Operator can view rejected parts and ongoing statistics on display, and can take
system off-line if necessary

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 Machine Vision Algorithms

Algorithms used by Vision Tools

transform raw numbers into useful
higher level features
 Raw numbers turned into edges,
colors, characters, and other
characteristics
… then makes decisions
 Returns answers such as position,
similarity, distance, presence,
quality

All within just one to tens of milliseconds!

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 Machine Vision Terms

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 Vision Definitions
Field of View (FOV)
 The part which can be
seen by the machine
vision system at one
moment.

 The field of view

depends on the lens of
the system and the
working distance
between object and 5” x 7”
camera.

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 Field of View
What is my field of view?
3”

4”

8”

15”

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 Working Distance and Resolution

Working Distance (WD)

 Distance between the
FRONT of the lens and the
target

Resolution 10”
 The minimum feature size of
the object under inspection.

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 Working Distance and FOV are
Interrelated

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 Depth of Field
Depth of Field (DOF)
 The distance in front of and
behind the object which
appears to be in focus

3”

More DOF with a small aperture

(high f/number) than with a
large aperture (low f/number)

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 Improving Vision System
Performance

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 Different Lens … Same Image?
 Lighting
 Depth of field
 Working distance
 Line speed
 Exposure time
 Aperture
 Budget

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 Lighting Techniques
Light can be structured in different ways. Angle and direction of the
light determine how the mark and space is seen by the camera.

Back Lighting Axial Diffuse

Structured

Dark Field Bright Field Diffuse Dome

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 Optics

To learn more about choosing the right optics go to Cognex.com >

Resources > On-Demand Webinars
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 Filtering Techniques

 Control quality and

quantity of light
 Block all unwanted
ambient lighting
 Pass only the output of
lighting used for
inspection
 Increase contrast
and resolution

For more on optical filters, go to Cognex.com > Resources > On-

Demand Webinars
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 Image Pre-Processing Tools

To learn more about image pre-processing, go to

Cognex.com > Resources > On-Demand Webinars
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 Summary

 Make products better, faster, and less expensively

 Gauging, Inspection, Guidance, and Identification are
the key applications
 Key components are the lens, camera, lighting, vision
software and communications
 Learn more about optics, lighting, filters and image pre-
processing to improve system performance
 Don’t go it alone…get help from experts!

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 Questions?

CONTACT COGNEX SALES: 844-GETCGNX (844-438-2469)

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