Newsletter of the UK Industrial Vision Association Autumn 2011 UKIVA Newsletter Foreword, Autumn 2011 The last six months has again seen changes at the UKIVA. We were all very saddened by the death of Don Braggins, who played such an instrumental role in the foundation and development of the UKIVA. Denis Bulgin worked closely with Don for many years and has written a tribute to him. There has also been a lot of great news and it has been particularly difficult to choose which items we should include in the newsletter. It is good to hear that the economic climate for vision companies seems to be improving steadily. Others have signed important agreements with overseas companies, which will lead to improved product lines or increased orders. Olmec and Multipix have taken on staff and I’m sure others have as well. Technology is advancing fast with members reporting exciting innovations, the development of new standards and the release of new cameras, hardware and software that will enable UKIVA members to develop better, faster or more cost effective solutions for their customers. This newsletter features four pages of exciting application stories, which are examples of UKIVA member’s successes. There were lots of stories submitted and it is with great regret that we don’t have sufficient space to include them all. Vision technology has huge potential to make a contribution in a vast and diverse range of applications and this is demonstrated in these stories which range from Stemmers contribution to train safety, quality control on a biscuit production line by Multipix or the development of a vision system by Cognex that will help blind people to work. PHOTONEX 2011 is rapidly approaching and we are proud to have been able to put together an exciting and diverse set of seminars from UKIVA members. As 3D cameras are becoming more affordable and better, then so 3D vision applications are taking increased prominence and this is reflected in the program with three of the six seminars discussing 3D vision with example applications. The seminars are free to attend; there will be demonstrations and an opportunity to talk to the presenters during the day. John Haddon, UKIVA Technical Consultant. Email: [email protected]Director, Panther Vision. Editor: Dr John Haddon Editorial Assistants: Janine Berriedale STEMMER IMAGING See our advert on page 5 OMRON See our advert on page 11 UKIVA will be running FREE seminars at the event Vision and Imaging Technology Demystified: Innovation and Application Advances • Software tools for 3D machine vision – how to select the right method, by Multipix Imagining • Live demo of a 3D stereo camera system, by Scorpion Vision • Structured Lasers as an aid to Machine Vision, by Alrad Imaging • The challenges of lighting – Too little, too much, the wrong kind, by Leuze electronics • IR and UV camera technology, by Stemmer Imaging • Hyper spectral Imaging – the journey of the photon and seeing the invisible, by Gilden Photonics For more details of the exhibition and what it has to offer please visit www.photonex.com ALRAD IMAGING See our advert on page 15
Transcript
Newsletter of the UK Industrial Vision Association Autumn 2011
UKIVA Newsletter Foreword, Autumn 2011The last six months has again seen changes at the UKIVA.We were all very saddened by the death of Don Braggins,who played such an instrumental role in the foundation anddevelopment of the UKIVA. Denis Bulgin worked closely withDon for many years and has written a tribute to him.
There has also been a lot of great news and it has beenparticularly difficult to choose which items we shouldinclude in the newsletter. It is good to hear that theeconomic climate for vision companies seems to beimproving steadily. Others have signed importantagreements with overseas companies, which will lead toimproved product lines or increased orders. Olmec andMultipix have taken on staff and I’m sure others have aswell. Technology is advancing fast with members reportingexciting innovations, the development of new standards andthe release of new cameras, hardware and software that willenable UKIVA members to develop better, faster or morecost effective solutions for their customers.
This newsletter features four pages of exciting applicationstories, which are examples of UKIVA member’s successes.There were lots of stories submitted and it is with greatregret that we don’t have sufficient space to include themall. Vision technology has huge potential to make acontribution in a vast and diverse range of applicationsand this is demonstrated in these stories which range fromStemmers contribution to train safety, quality control on abiscuit production line by Multipix or the development of avision system by Cognex that will help blind people towork.
PHOTONEX 2011 is rapidly approaching and we are proud tohave been able to put together an exciting and diverse setof seminars from UKIVA members. As 3D cameras arebecoming more affordable and better, then so 3D visionapplications are taking increased prominence and this isreflected in the program with three of the six seminarsdiscussing 3D vision with example applications. The seminarsare free to attend; there will be demonstrations and anopportunity to talk to the presenters during the day.
John Haddon, UKIVA Technical Consultant.Email: [email protected], Panther Vision.
Editor: Dr John HaddonEditorial Assistants: Janine Berriedale
STEMMER IMAGINGSee our advert on page 5
OMRONSee our advert on page 11
UKIVA will be running FREE seminars at the event
Vision and ImagingTechnology Demystified:
Innovation andApplication Advances
• Software tools for 3D machine vision – how toselect the right method, by Multipix Imagining
• Live demo of a 3D stereo camera system, byScorpion Vision
• Structured Lasers as an aid to Machine Vision,by Alrad Imaging
• The challenges of lighting – Too little, toomuch, the wrong kind, by Leuze electronics
• IR and UV camera technology, by StemmerImaging
• Hyper spectral Imaging – the journey of thephoton and seeing the invisible, by GildenPhotonics
For more details of the exhibition and whatit has to offer please visit www.photonex.com
ALRAD IMAGINGSee our advert on page 15
UKIVAnews • 2
Don’s involvement with the UKIVA began in 1992 whenhis company, Machine Vision Consultancy was a foundermember. In 1995 he took over the administration of theAssociation and provided the first line of technical advice.He oversaw the transition of the Association into a
Don Braggins was hugely influential in establishing the UKIVA as the Association it has becometoday. In an imaging career spanning five decades, he was both well-known and respected in thevision industry and was a keen networker, visiting companies, exhibitions and events around theworld to keep himself informed of new developments. He was elected a Fellow of SPIE in 1990.
8 – 10 November 2011Messe Stuttgart
Use your Smartphone
Best Players go FUTURE
www.vision-fair.de
A Tribute to Don Braggins
‘Special Interest Group’ of the Processing & PackagingMachinery Association in 2009, and remained aconsultant to the Association until 2010. He also tookpart in the ad hoc meetings that led to the formation ofthe European Machine Vision Association in 2003 andserved on its Executive Committee for six years.
Don also authored numerous articles in publications inmany industries, including many in Automation - toinform industry at large of the benefits of vision. Hiswriting career included a spell as Associate Editor forMachine Vision for the SPIE journal, Optical Engineering.
Don’s consulting activities continued until 2008, thoughin the later years he mainly advised on actual or potentialstart-ups, or investments into companies offering visionproducts. Don passed away in May 2011, aged 70, leavinghis wife, Anne, two children and five grandchildren.
ACTIVE SILICONCoaXPress standard getsoverwhelming approvalActive Silicon are one of the threeprimary developers of this newtechnology. CoaXPress(http://www.activesilicon.com/products-coaxpress.php) which is now anofficial JIIA (Japan Industrial ImagingAssociation) standard (http://www.jiia.org/st_download_e.html) and set tobecome a world standard. ActiveSilicon technical director, Chris Beynon,is one of the three main authors of thestandard.‘We are pleased and proud to play amajor part in the development ofCoaXPress . . . . We anticipatesignificant industry take up of thistechnology over the next couple ofyears for which, of course, we are nowdeveloping products’ said Colin Pearce,Active Silicon CEO.
ALRAD IMAGINGPresent new camera lens suppliersAlrad can now provide camera lensesfrom some 15 different manufacturersand suppliers. Latest additions to therange of lens products arefrom Spacecom, Azure Photonics,Lensation and Schneider Optics. Wealso now have closer ties withFUJINON and we buy lenses directly,therefore enhancing our customerservice. So, with such a wealth ofproducts available, make us your firstcall for all your lens requirements. Formore details seehttp://www.alrad.co.uk/imaging/Lenses%20Home.html
COGNEXIn-Sight Explorer 4.5Cognex Corporation has released aversion of In-Sight® Explorer 4.5expanding the capabilities of In-Sight
vision systems and giving In-Sight themost advanced inspection toolsavailable today. In-Sight Explorer 4.5inspection tools now include an all-in-one edge and surface inspection tool,an all-in-one bead width and positiontool, and a robust ID tool that readsmultiple codes at one time, allowingIn-Sight cameras to read barcodes andprovide inspections simultaneously.The Flexible Flaw Detection (FFD) edgeand surface inspection tool works forboth colour and grayscale applicationsand is used to inspect for boundarydefects and can also be used for printinspections, like inspecting screenedlogos for defects. ReadIDMax, was alsoadded to In-Sight Explorer 4.5 and isbased on the powerful and field-proven ID algorithms 1DMax™ and2DMax™ for 1-D barcode and 2-Dmatrix code reading.
Members newsEditorial material in this section is provided by UKIVA Members. The UK Industrial Vision Association does not takeresponsibility for the accuracy of any statements
FRAMOSKyocera’s new seven-inch high-brightness WVGA LCD moduleFramos Electronics makes available thenew Kyocera seven-inch LCD module.Key features of Kyocera’s new seven-inch LCD within its enhanced productportfolio include WVGA resolution,long life LED backlight with up to70,000 operating hours, a brightness of700 cd, a slim housing and a viewingangle that covers the needs forindustrial use, thanks to its latestdisplay technology. A variety ofbenefits make this ideal for use insystems within industrial or medicalapplications.
Strobe controller seriesFramos Electronics and Smartek, aCroatian electronics company,announce high-end LED illuminationcontrollers for professionalapplications. Smartek’s StrobeController (SC) series is renowned forits switching capacity and precision forindustrial machine vision applications.Latest models have Ethernet or RS232control interfaces, with full SDKsupport for both Windows and Linuxo/s. The family of strobe controllersfeatures 1, 2, 4 or 6 parallel channeloptions, both digital and analoguelight-head coding, an integratedtemperature sensor and built-in powersupply. They can deliver high powerpulses of up to 8A and 200V perchannel at 1µs pulse duration.
LAMBDA PHOTOMETRICSDual GigE technology doublesstandard GigE bandwidth to 240MB/s Baumer’s new SXG cameras combinestate-of-the-art Quad Tap sensors fromKodak with innovative Dual GigEtechnology.This provides the perfect solution forapplications that require excellentimage quality and high frame ratessimultaneously. Thanks to the new
interface technology, the images withresolutions from 1 to 8 megapixels andframe rates of up to 120 fps aretransferred to the PC via standard GigEinterface boards. With the capability oftransferring at 240 MB/s, the fullpotential of the Kodak Quad Tapsensors can now be utilised.With a transfer distance of 100m, theDual GigE interface offers all theadvantages of the standard GigEinterface. Baumer uses dynamic LAG to configurethe Ethernet ports automatically,eliminating possible error sources rightfrom the beginning. The redundantcommunication link of the Dual GigEsystem provides better transfersecurity, ensuring data transfer andreliable camera operation even if oneof the two Ethernet cables isdisconnected.
LEUZE ELECTRONCSThe world’s smallest contrast sensor Contrast sensors, also called contrastscanners, are widely used in packagingmachinery and automation technology,for example for the detection of printregistration marks. Leuze electronichave a wide range of contrast sensorsin a variety of housings, which helpensure labels are correctly positionedon many everyday items.Leuze electronic’s new KRT 3B contrastsensor is the smallest in the world,fitting within what Leuze call a ‘threeseries’ housing and being the same sizeas a hundred other Leuze sensors. It isalso a high-performance device, equalto larger units in terms of its functionand its range. Performance such as extremely shortresponse times of 50 µs and highrepeatability, as well as features suchas IO-link make configuration andimplementation easy. Three teachprocesses: 2-point teach, static 1-pointteach and dynamic 2-point teach,provide optimal set up for every typeof machine use.
MATROXIris GT smart camera now offers 5megapixel sensorHigh-resolution smart cameraaccurately inspects large parts andpackages. ‘A high resolution sensor, likethe one found on the Matrox IrisGT5000, is required to accuratelyinspect larger parts and packages.Matrox Iris GT5000 is the highestresolution version of the Iris GT smartcamera available today,’ explains FabioPerelli, smart camera product managerfor Matrox Imaging. The sensor on theMatrox Iris GT5000 is 2448 x 2050pixels @ 15 fps 2/3" monochromeCCD.Powered by an Intel® Atom® 1.6 GHzprocessor, Matrox Iris GT runsWindows® CE 6.0 or Windows® XPeand features an integrated graphicscontroller with VGA output, 512 MBDDR2 memory, and a 2 GB flash disk.
GatorEye GigE Vision® camerafeatures laser line extraction for 3DscanningIndustrial camera has IP67 rating andis designed for the harshestenvironments. For triangulation-based 3D digitizingapplications, the Matrox GatorEyeextracts the laser line in an image tosub-pixel accuracy and produces thecorresponding positional depth/heightarray. Only the resulting array istransmitted, which lightens the load onthe Gigabit Ethernet link and PC. ThePC can then focus on other tasks,including 3D measurement andanalysis.
MULTIPIX IMAGINGMultiPix evolve with newappointmentsMultipix Imaging is pleased toannounce that Simon Hickman hasrecently been promoted to the positionof sales director. Simon has been asenior member of the sales team at
Members newsEditorial material in this section is provided by UKIVA Members. The UK Industrial VisionAssociation does not take responsibility for the accuracy of any statements
UKIVAnews • 4
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CORE TECHNOLOGYFOR VISION DEVELOPERS.Explore state of the art vision technology from Europe’s largest provider.
Discover how we combine leading products with outstanding competence
Multipix since 2005, and sales managersince 2009, with many more years ofexperience in the machine visionindustry. Mike Morgan has also beenpromoted to senior sales engineer andthere is a new member of the team,Matthew Walsh, who is appointed asinternal sales engineer.
Small but mighty Basler Ace 5-megapixel cameraAn incredible price and performanceratio in a compact housing! MultipixImaging launch the Basler Ace5MegaPixel Camera, the perfect choicewhen you face a price-sensitiveapplication that needs a highresolution. These cameras combine thecompact 29mm x 29mm x 42mmBasler ace housing with GigabitEthernet interface technology, powersupplied via Power over Ethernet, anda 5MP CMOS sensor that is able todeliver 14 frames per second. Theyconsume only 2.5 watts, which resultsin low camera temperatures andmeans that they can even be used insmall, closed environments.
NATIONAL INSTRUMENTSEngineers can more easily searchand download new drivers withIDFinder in NI LabVIEWNational Instruments now offers morethan 9,000 drivers from more than 350vendors through the Instrument DriverNetwork (IDNet, www.ni.com/idnet)that simplify and automate connectionto stand-alone instruments. IDNet, theindustry’s largest source of instrumentdrivers, includes more than 1,000 newdrivers added since November 2009.The drivers are written for the NILabVIEW graphical developmentplatform, the NI LabWindows™/CVIANSI C integrated developmentenvironment and Measurement Studiofor Microsoft Visual Studio.Engineers, scientists and instrumentmanufacturers around the world haverelied on National Instrumentssoftware and instrument drivers sincethe first version of LabVIEW wasshipped in 1986. With the latestversion, LabVIEW 2010, engineers canuse the new Instrument Driver Finder(IDFinder) to quickly search IDNet and
download different LabVIEW Plug andPlay instrument drivers for their stand-alone instruments. IDFinder scans thesystem for connected instruments;downloads and installs the appropriatedrivers; and presents ready-to-runexamples to the engineer. IDFindersignificantly reduces time to firstmeasurement by helping engineers getup and running without leaving theLabVIEW environment.
OLMEC UKExpansion at vision systemsintegratorVision systems integrator, Olmec-UKLtd, has announced the expansion ofits mechanical design and on-siteinstallation departments in response tosignificantly increased levels ofbusiness. Petra Millberg has joined thedesign group, while Andrew Pounderhas strengthened the company’s on-site systems integration team.Petra has a Masters degree inmechanical engineering from theUniversity of Florida and is specialisingin conceptual design anddocumentation on Olmec-UK projects.Using the latest 3D modellingtechniques, she is involved inspecifying the optics required for theparticular project and ensuring thatthe cameras, illumination sources andoptics can all fit into the availablespace and with the required geometry.
SCORPION VISIONSmartVision lights distributionagreementScorpion Vision Ltd is pleased toannounce it has been awarded a newdistribution agreement from US basedSmartVision Lights. The intelligent, orsmart driver provides a constantcurrent to every machine vision light,guaranteeing optimal performance atall times. This of course negates theproblem with failing vision systemsdue to faulty illumination problems.Smart Vision Lights uses only high-current, HB (high brightness) LED’s intheir machine lights. Smart VisionLights designs, manufactures andmarkets a line of products that applythe benefits of high current LED’s foruse in machine vision applications. All
machine vision lights us standardindustrial 24VDC for operation.For more info visit:http://scorpionvision.wordpress.com/
SICK Compact optical level switch forrapid commissioningSICK (UK) has added to its industrialinstrumentation product portfolio witha new compact optical level sensorswitch for aqueous fluids. Designed forrobust level monitoring of a range ofliquid media, the FDA-compliantMHF15 is ideal for a variety ofapplications, including tank levelmonitoring or dry running protectionfor pumps. The cost-effective plug-and-play solution, which requires nocalibration and minimal maintenance,can be used for overfill protection andlow level indication in tanks to monitorthe presence or absence of liquids. Anormally open or normally closedtransistor output is provided for use asan input to control PLCs or relaymodules.
STEMMER IMAGING3-CCD RGB colour cameras nowavailable with GigE VisionThe JAI AT-140GE and AT-200GE 3-CCD cameras are available fromStemmer Imaging. Bringing theconnectivity benefits of GigE Vision to3-CCD technology, these new camerasfeature a newly developed prism-blockassembly to support the three CCDs.The new dichroic prism block splits theincoming light into three distinctcolour channels for precise RGB valuesand provides higher resolution andbetter light gathering abilitythan earlier 3CCD camera models. Withprecise sensor alignment (less than1/4-pixel tolerance), this 3-CCDconfiguration offers better colour andspatial precision than single-CCDcameras which use Bayer filters andinterpolation algorithms.
New range of low-cost LEDillumination announcedStemmer Imaging has introduced theMetaWhite™ ExoLight range of LEDs asan alternative to fluorescent lightingfor machine vision. Patented and
UKIVAnews • 6
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patent-pending LED technology andadvanced optics create an extremelyeven and diffused cool whiteillumination three times brighter thanfluorescent sources over a longerworking distance. The LEDs featureanisotropic plastic micro-lens diffusersto create a highly diffused light frommultiple point source emitters. Theresultant output mimics that offluorescent emitters, but with morepower and a greater stability, combinedwith the legendary LED lifetime and alow cost of ownership.
New models in affordable GigEcamera rangeStemmer Imaging announces that AVThas added a new camera to each endof its highly competitively priced rangeof Manta GigE Vision cameras.Available in both monochrome andcolour variants, there are new 5Mpixeland VGA (0.33 Mpixel) resolutionversions of these robust cameras whichcan be used in industrial inspectionand automation, logistics, intelligenttraffic solutions and traffic monitoring.
Also new for the entire range is themodular concept which includes aPower over Ethernet (PoE) option. Foreven more flexibility, all Manta modelsnow offer optional housing variationsfrom the AVT modular concept. A newrange of IDS uEye GigE cameras is nowalso available.
To distribute LMI technologies’ 3Dsmart camera in EuropeStemmer Imaging and LMITechnologies Inc have signed adistribution agreement that will makeLMI’s Gocator 2000 series of smart 3Dsensors available in Germany, UK,Ireland, France, Austria andSwitzerland. Gocator is a new, simple-to use, all-in-one solution that makes3D measurement and control for
factory automation accessible to alllevels of users. Gocator 2000 series isan exciting new breed of pre-calibratedsensors that make industrial 3Dmeasurements more affordable andavailable to a wider range ofapplications. Ease of use is leveragedby the built-in web server as aneffective GUI for rapid set-up andcontrol. Users can connect, set-upexposure and speeds, visualise profiles,measure dimensions, selectcommunication outputs, and monitorresults using Firefox, Internet Explorer,Chrome, or Safari web browsers. Thisbuilt-in web connectivity enables usersto access the sensor from any PCwithout software, drivers, controlboxes, amplifiers, or dependency on aspecific operating system.
ExtrasensoryThe LSIS 400i ‘Smart’ camera gets even smarter.
Extremely bright and homogeneous illumination.
99 × 2D or barcodes plus vision analysis in one shot.
IP65 housing with motorized focus adjustment.
Easy setup - No extra software or hardware required.
Superb object detection and very fast read.
For more information call 01480 408 500 or go to www.Leuze.co.uk
NEWPharmaCode reading
version.
Look for UKIVA and several of its members on Twitter.http://twitter.com/ukiva
Members directory 2011SUPPLIERS OF COMPLETE VISION SYSTEMS
ACADEMIC MEMBERS
Cardiff University http://bruce.cs.cf.ac.uk/bruce/ Cardiff School of Computer ScienceCranfield University www.cranfield.ac.uk/soe/amac Applied Mathematics and Computing GroupDublin City University www.vsg.dcu.ie Vision Systems GroupKingston University http://dirc.king.ac.uk Digital Imaging Research CentreOxford Brookes University http://cms.brookes.ac.uk/research/visiongroup/ School of Technology - Computer Vision GroupUniversity of Leeds www.comp.leeds.ac.uk/vision School of ComputingUniversity of London www.cs.rhul.ac.uk Royal HollowayVision Academy www.vision-academy.org Systematic Training for Machine VisionUniversity of the West of England www.uwe.ac.uk/cems/research/melsmith/ Faculty of Computing Engineering and
Mathematical ScienceUniversity of York www.elec.york.ac.uk/research/intsys/visual.html Department of Electronics, Visual Systems Lab
Alrad Imagingwww.alrad.co.ukT 01635 30345
Active Silicon Ltdwww.activesilicon.comT 01753 650600
Scorpion Vision Ltdwww.scorpionvision.co.uk T 01590 679 333
UPM Conveyorswww.upmconveyors.co.ukT 01753 548801
Alrad Imaging is a prime UK distributor of vision products. Products include cameras and sensors, framegrabbers, illumination, imaging software and sub system solutions for OEMs and system integrators.
Suppliers of leading edge vision technologies to OEM's, integrators and end users.
Cognex is the world's leading vision company, with over 150,000 systems delivered. We offer acomplete range of vision solutions, from smart cameras to powerful framegrabbers.
FS Systems is a UK specialist in machine vision. Our product range covers, Vision & Control machinevision components, and GenVis and RoboVis PC-based vision systems and vision training.
Loop Technology Ltd provides development and integration services for automated processes involvingmachine vision systems and/or motion control systems. They produce automation systems for theelectronics, automotive, printing and packaging industries.
Olmec supply, install and integrate vision systems into existing, new and OEM machinery processes.
Omron Electronics manufactures a wide range of vision-based industrial solutions, ranging from costeffective vision sensor products to high-end vision controller and camera products.
PCS Industries is an independent automated solutions provider offering specialist machine vision andcoding & marking solutions.
Scorpion Vision Ltd is the UK representative of Tordivel AS of Norway. Founded in January 2006, the company has the remit to promote, advise and manage sales and support of Scorpion VisionSoftware.
UPM Conveyors provide complete automated conveyor & vision sytems
For information on courses and job vacancies from our members please visit www.ukiva.org
UKIVAnews • 9
SUPPLIERS OF VISION RELATED SERVICES AND COMPONENTS
Vision & Control GmbHwww.vision-control.comT +49 3681 7974 - 0
ClearView Imaging is a supplier of vision components, including a wide range of cameras, frame grabbers,software, embedded systems, smart cameras, vision processors, lighting and optics.
CAS Ltd provides a full range of services to support both suppliers and users of automation.
FLIR Systems has been at the forefront of industrial thermal imaging for more than 30 years and is nowthe technology’s world leader. Recent acquisitions have significantly widened its technology base.
Framos is a specialist distributor of digital and electronic imaging devices and complete cameras. Both area and linear CCD and CMOS devices are offered with full technical support for design andintegration.
Imperx, Inc. was founded in 2001 by a seasoned team of senior executives with a proven track record indeveloping advanced digital imaging products. Imperx designs, develops and manufactures state-of-the-art imaging products for a variety of markets.
Lambda Photometrics distributes a broad range of machine vision products. These include fibre & LEDlighting, lens systems, cameras (CCD, linescan, smart CMOS), framegrabbers & software.
Leuze electronic ‘the sensor people’ are the experts for sensors. They also specialise in smart cameras andindentification products.
Matrox Imaging is a leading designer & manufacturer of PC-based hardware & software for machinevision, image analysis & medical imaging drawing on an unparalleled 25 years of industry experience.
The wide range of products offered includes frame grabbers, cameras, lenses & imaging software togetherwith a highly experienced support service.
Multivac UK is a wholly-owned subsidiary of Multivac Sepp Haggenmüller GmbH & Co, the world's leadingsupplier of packaging machines.
National Instruments manufactures hundreds of integrated software & hardware products, which are used to replace &/or communicate with traditional instrumentation.
Panther Vision provides independent consultancy and bespoke product development and is interested injoint development opportunities.
RNA are specialists in the supply of parts handling and orientation equipment, including vision systemsand pick and place handling units.
IVP offers cameras for high-speed 3D machine vision for OEMs and vision integrators. IVP’s 3D technologycan replace or complement traditional 2D inspection. The outstanding performance is a result of aproprietary CMOS sensor technology.
The premier UK machine vision components distributor providing leading vision technology, advice anddevelopment services to OEMs, integrators and corporate customers.
Vision Control produces a comprehensive system of precise components suitable for industrial machine vision. This includes our PICTOR smart cameras, VICOTAR range of lenses and VICOLUX range of illuminations.
UKIVAnews • 10
Application storiesSTEMMER IMAGINGOn-board and trackside railwayinspection Cameras and image processing techniques originallydeveloped for machine vision applications have been usedfor a host of railway inspection applications. Dependingon the application, cameras of various types can belocated on the train itself or by the side of the track.Railway inspection techniques present a significantchallenge to the vision industry. Not only is a wide rangeof imaging devices, including area scan and highdefinition cameras, linescan cameras and thermal imagingcameras, required, the operational conditions aredemanding. Cameras and imaging systems can be exposedto extremes of weather, vibration and physical wear.Stemmer Imaging has a comprehensive set of productsthat cover the entire range of components and servicesrequired by an imaging solution and have experience ofworking on a number of railway projects throughoutEurope.
Trackside applicationsTrackside mounted cameras can carry out a variety oftasks. Cameras mounted on posts can be used, forexample, for vehicle identification and to inspect passingtrains for graffiti. Other trackside applications includecameras mounted in troughs on the track pointing at thebrake shoes which can be used to evaluate brake shoewear or to examine the wheel profile for damage andwear as part of a predictive maintenance schedule.
Train mounted applicationsMonochrome, colour and thermal cameras can all bemounted in a forward facing position (to give a driver’s
eye view). General monochrome cameras give a goodunderstanding of the items that are beside the line suchas trackside cabinets and huts etc and so can be used forasset recording and mapping with accuracy to within acouple of metres. Thermal cameras can be used to checkthat heaters are working in trackside cabinets (which canbe important for operation of the signals); that pointsheaters are working to clear winter ice or to locatehotspots generated by the breakdown of insulators on thethird rail. Forward facing cameras can also be mountednear the top of the train pointing downwards to give the‘4ft view’. This replicates the view a track inspector wouldhave and is used for checking ballast, missing clips, tiebars, inspecting points etc. Although the assessments arestill made by a human inspector reviewing the videorecorded by the cameras, the use of cameras avoids theneed to close the track for the inspection, saving bothtime and money.
OMRONFor potato packing, Omron goesbeyond inspectionWhen Greenvale, one of the UK’s leading suppliers forfresh potatoes told Omron that it needed a visioninspection system to check that the correct promotionallabels had been applied to packs of potatoes destined formajor supermarkets, the Omron engineers decided to lookat the requirements in a little more detail. The result oftheir deliberations is a system that goes beyond simpleinspection, and integrates tightly with Greenvale’s ERPsystems to eliminate the risk of packaging and labellingerrors. At PPMA Exhibition in 2008, managers from Greenvalediscussed with Omron requirements for an automatedsystem to check that thecorrect promotional labels
RNA Automation • Multipix • Cognex
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FQ VISION SENSOR
Omron’s new FQ redefi nes the vision sensor market, off ering unrivalled functionality, crystal clear images and totally fl exible operation. Intuitive, icon driven menus provide users with simple and fast set-up, requiring no previous vision knowledge.The FQ includes many unique functions including HDR processing and built in polarisation fi lters to provide crystal clear images, an industry fi rst for vision sensors, resulting in robust and reliable inspections, without any complication.
had been applied to packs of potatoes before beingshipped to retailers. At first sight, the solution seemedstraightforward – equip the packaging line with anOmron vision system to inspect the labels and therebyensure that they correctly matched the label type enteredby the line operator.However further analysis revealed, that there was asignificant flaw in this approach. Relying on the lineoperator to tell the vision system what type of label toexpect was unlikely to be satisfactory, as the operatorwould be virtually certain to select the type of label he orshe had just loaded into the machine, even if this was thewrong type. In these circumstances, the vision systemwould pass all of the packs as satisfactory, but they couldstill be leaving the plant incorrectly labelled.
What was needed was some way of telling the visionsystem which labels should be affixed to a batch ofpotatoes, without involving the line operator. Omronengineers discovered that when a new order is set up onthe packaging line, the plant’s ERP system can downloadall of the data corresponding to that order – includingthe type of promotional labels to be used. All that wasneeded was to find a way of making the label data fromthis available to the vision system.For most automation suppliers, the only way of doing thiswould have been to develop special software routines toallow the transfer of data between the ERP system andthe vision system. This would have been a timeconsuming and expensive process. However, Omron’s CJ1programmable controllers (PLCs) can optionally be fittedwith an SPU (storage and processing unit) that isspecifically designed to make it easy to transfer databetween the PLC and external computers. By using theSPU, the labelling data could be acquired fromGreenvale’s ERP system using only standard hardware andsoftware, thereby providing a straightforward, reliableand inexpensive solution. The packaging line automationand inspection system can be readily linked with the ERPsystem and this opened up additional opportunities. Forexample, it was now possible to check automatically thatthe correct type of film was being used for packing thepotatoes. This was done by adding a two-dimensional(2D) matrix code to the packaging.
MULTIPIXMachine Vision Imaging Solutiontakes the biscuitThe Food and Beverage industry has become extremelycompetitive and consumers continue to expect highquality and excellent presentation. Those who buy apacket of biscuits want consistent size, weight and qualityof each single biscuit. The main objective of the biscuitmanufacturer is to achieve economic production by beingsmart with the resources and packaging. They need toreact quickly and reliably to disturbances in theproduction process. Therefore, process data has to beacquired and stored continuously.One of Europe’s leading biscuit manufacturersapproached Machine Vision Technology Ltd. to automatethe size and the weight control of their biscuits duringthe production process. The biscuits are on a conveyorbelt with 120 columns of 30 cooked biscuits. Two of thebiscuits are combined with a filling and result in a‘sandwich biscuit’ with two 'sides' and a fondant filling(such as chocolate) in between. The aim is to ensure all'sandwich biscuits' are the same height and weight. Fillingis expensive in comparison to biscuit costs so the idea isto minimise how much filling is used to create the correct'sandwich biscuit'.
Machine Vision Technology Ltd approached MultiPixImaging, a UK vision components supplier for advice onCamera and Image Processing Software selection. Thesolution consists of three Basler Scout cameras (scA1390)being used to grab images of the biscuits from above andHALCON Imaging Software which will analyse the imageto measure the length and width and ascertain if thebiscuit is the correct size. A fourth camera, the BaslerscA640-120gm is used in partial scan mode for higherframe rates, grabbing a laser line profile of the biscuitfrom which the HALCON Imaging Software constructs a3D image and obtains accurate height measurements.Using this procedure, accuracies of ± 0.17 mm can beobtained for the length width and thickness.The custom front end of the software incorporates anaverage size display for the measurement over the last100 rows. These statistics are stored against time and date
for four years to satisfy customer traceability demands.Information on the system is available on a duplicatescreen display 100 meters which can be monitored by anengineer. The operator can easily select from a drop downmenu for product changeover.
OLMEC UKMissing codes and characters, partially printed codes,smudged print and incorrect codes were just some of theproblems faced by one leading supplier of vitamins,minerals and supplements in its coding and labellingprocess. Differing lot code demands and requirementsworldwide posed the greatest challenge for Olmec as thecustomer sought a turnkey, fully integrated vision systemcapable of inspecting the lot code quality of all itsproduct labels. The sheer volume of label variants meantthat the solution had to be capable of verifying codeswhilst simultaneously detecting changing batch codeorientation, differing quantities and location ofcharacters and of neutralising the numerous backgroundcolours presented such as yellow, blue and red.A single, intuitive vision solution capable of fullyvalidated character recognition, character verification androbust 2D data matrix handling and grading, wasdeveloped and installed on 3 inspection lines. This can beused for tasks ranging from simple verification through toGS1 and CIP13 conformance. The system uses an OmronSC2M 2 Megapixel colour camera connected to an OmronFZ-9 vision controller which enables the use of multithreading for high speed processing. The code to be readwas illuminated using an on-axis light source. The systemquickly checks characters and label format by autodetecting the lot code location and then automaticallysetting itself up for the forthcoming job. By filtering outall the background colours, the system is able to extractonly the lot code, which is then verified against operator-entered information. From 100s of label variants thepossible format combinations were condensed into 6,quickly configured job files. Capable of inspecting labelsstatically or at high speeds the system provides a batchreport at the completion of each job, supportingproduction traceability. The system is completed by asimple, touch screen user interface allowing for rapidoperator configuration.As a systems integrator, a key role in the project wasensuring that the code reading system integratedseamlessly with the production lines. Olmec workedclosely with the labeller manufacturer to interface theinspection system so that incorrect labels could berejected before application to the product. In additionremote connectivity via a VPN was built-in to provide aremote monitoring and diagnostics capability. Full IQ andOQ documentation was provided and the IQ and OQphases were confirmed with the clients’ engineers duringinstallation of the vision system before handing over tothem for the PQ phase.
RNA AUTOMATIONMachine Vision Solutions for Food& Beverage IndustryRNA were contacted with a request for a fully automatedquality control and inspection system to handle andinspect plastic moulding components. The request wasfrom a recently built UK based production requirementfor a global leader in the food and beverage industry. Thesystem must handle with minimum changeover twocomponents that are physically different in size andshape. A major consideration in this application was thecomplexity and fragility of the component parts. Thesystem must not cause any damage to these parts, whichhave a detailed periphery. The system must inspect from all three planes: 1. Top fordamage and OCR (optical character recognition); 2.Bottom for diameter and damage; 3. Side for damage,height and profile. The system must detect and expel100% of those reject components, but critically must notdamage the components. Additionally, the customerrequired a complete system with minimum requirements:1. The system must be capable of operating at up to a
rate of 1200 parts/minute2. It must be designed to meet food and GMP
To enable the system to deliver 1200 parts per minute thedesign utilised a twin headed system with duplicaterotary feeders, conveyors, glass disc and rejectsegregation, with a common good part collection. Thishandling solution involved the innovative idea of a“rotating glass disc”. The components are fed from acentrifugal feeder onto a conveyor system and fedindividually onto a rotating glass disc. Due to the designof the components, they have a unique tendency to“castle or double up”, causing problems in the handlingand inspection, resulting in false rejects. These problemsare one of RNA strengths and were solved with the expertuse of gating and a non contact accumulation system,while still ensuring that there was no damage caused tothe components.An encoder and trigger sensor were fitted on the rotatingglass disc. Once a component part had passed throughthe trigger sensor an encoder count is stored. The PLCthen tracks the components around the disc triggeringthe appropriate cameras and ejecting reject components.Good components continue around the disk being gentlyswept off down a chute into a collection box. PLCmonitors a count of all good and reject the componentsfrom both heads which maintain correlation overcontinuous 24/7 production.
Leuze Electronics3D sensor systems –A new era is now affordableNew high performance 3D sensors and ever moreaffordable computing power offer an alternative to visionsystems, enlivening the 3D discussion. As a manufacturerof both vision systems and 3D sensors, Leuze Electronicsare in the unusual position of being able to discuss andadvise on both technologies. 3D sensor systems are rapidly increasing in importance inthe automation sector. In particular, they are movingfrom having previously been high-priced to a point nowwhere they are affordable for general automation.Millions of optical sensors are used in measuring orswitching systems, determining the distance or thepresence of an object by emitting a single beam of light.Various forms of light are used dependent upon theapplication, with red light the most common, beingeconomical and easy to use, because of it being easilyvisible. Ultra-violet light is used in sensing UV colouring.Contrast sensors, which are also called contrast scanners,use red, green, or blue light or indeed all of these in theform of white light, to look for specific colours such asprint registration marks. Laser light being highly energeticis suitable for sensing over a greater distance. It alsoprovides a finer resolution and hence accuracy for sensingedges, for example delicate cogs, or holes in a PCB.More recently camera-based vision systems which usesurface illumination have become more common. Thesevision systems analyse the light/dark distribution ofelements (pixels) within a 2 dimensional surface, usually
at a high resolution. If this 2D data is combined withdistance information from an energetic single-beamsystem, this additional depth information provides a thirddimension.An alternative technology to combining a camera imageand a sensor is to project a laser line across a section,which provides not only the location of each pixel in anx/y-coordinate system and its brightness value, but alsothe distance in the z-coordinate. For example, Leuzeelectronic’s recently launched line profile sensor, theLPS36, projects a line up to 600mm long, which isequivalent to using a chain of 376 laser distancemeasurement sensors working together. The LPS sensorbenefits from being perfectly calibrated the moment it isswitched on and is used to take cross-sectional profiles orslices. An example system is Faude’s "Flexvision" whichgives a robot the ability to automatically detectcomponents and pick from a tray. The sensor provides 2Dcross-sectional profiles or slices across the tray, which thevision system constructs into a 3D image of the tray andits contents.
COGNEXVision system assists blind workersBosma Enterprises, an Indianapolis-based organisationserving the blind and visually impaired with employmentopportunities, has for many years employed blind workersto package and ship surgical gloves from manufacturersto Veterans Administration hospitals around the U.S.Bosma has a contract from the VA Hospitals prohibitingthe use of the corrugated cardboard packaging suppliedby the manufacturer, because that material can harbourbacteria and parasites. Workers would now need to packgloves in generic chipboard boxes, and create new labelsthat identified the product. In addition to themanufacturer’s name and product type, the new labelshad to contain the lot number, part number, size, and abarcode from the original boxes shipped by themanufacturers in order to comply with themanufacturer’s product traceability requirements.
To keep the VA contract, Bosma needed to find a way toenable blind operators to read and enter informationprinted on the package shipped by the manufacturer sothat new labels could be created for the contract-compliant chipboard boxes. Bosma worked with the EMP Technical Group, a systemsintegrator that specialises in data collection equipmentand labelling systems, to develop a system that blindworkers could use to accurately recreate the correct labelsfor each manufacturer’s box. The system combines a PCthat contains a database of manufacturer names, glovetype and model number, a Cognex In-Sight® Micro 1403vision system to read and transmit the date/lot/batchinformation from the packaging supplied by themanufacturer, and a Continued on back page >
Machine Vision courses from Leuze electronic½ day workshops - Introduction to MachineVision – FREE at St Neots13th AM or PM or 14th September AMAn introduction to machine vision & 3Dmeasurement. Topics will include:• Sensors, Smart Cameras, Vision systems• The importance of focus & lighting• Vision vs 3D measurement systems• Vision combined with barcode & 2D code
reading• Application examples• Resources from Leuze electronic
½ day workshop - Machine VisionApplications – FREE14th September PMThis session is an extension of the introductionsessions and will discuss in more depthapplications and challenges in more detail:• Application examples• Challenges found in the real-world & tips on
solving them
http://www.leuze.com/uk/offers.html
UKIVAnews • 15
MULTIPIX LAUNCH ‘INFOPACKED’ WEBSITE
Multipix Imagingannounce the launch oftheir new websitewhich has been indevelopment for sixmonths. Packed withthe latest machinevision products, newsand industry views, thiswebsite has been
design to harness the power of .com communication.Interactive links with Facebook and Twitter ensures thelatest news is shared quickly and efficiently. In additionalto product related contents there is also an emphasis onwhite paper’s and case studies, with the aim of being aresource centre for all levels of machine vision users. www.multipix.com
Leuze Electronic is the newest member of the UKIVA, being better knownacross the packaging and process industries as being ‘the sensor people’.
Leuze has joined the UKIVA because it has recently launched three newproduct ranges covering smart cameras, 3D measurement sensors and 2Dprofiling sensors.
Mark Weymouth, MD of Leuze electronic in the UK, explained: ‘Leuzeelectronic differentiate ourselves by providing excellent service and supportand therefore whilst Leuze has sold PC based vision systems within theGerman market for many years, machine vision is not an area we promotedin the UK because we did not feel we could support it well enough.However, with the launch last year of our LSIS400 family of smart visioncameras, and more recently the LPS 2D profiling sensors and LRS 3Dmeasuring sensor families, we are able to provide excellent products andsupport within the UK.’
Leuze Electronic frequently runs free-of-charge training workshops andinvites people to check their website www.leuze.co.uk for details of the nextworkshop, or to come along to one of the lectures it is giving for localregions of the IET, or at the Photonex exhibition.
• Very High Resolution Imaging(Stemmer Imaging)This technical tip looks at veryhigh resolution imaging andcovers a number of differentcamera types, including linescan,and CCD and CMOS area scancameras as well as noveltechniques for obtaining highresolution such as ‘pixel shifting’.www.stemmer-imaging.co.uk/en/pages/service/download.php?file=en_GB-TechTip-Very-high-resolution.pdf
• Code Reading: DecodingBarcode and DataMatrix marks(Stemmer Imaging)This technical tip looks at theprocesses involved in reading,decoding and grading 1D and 2Dcodes using machine visiontechniques. Some of the differenttypes of codes and their uses in avariety of industries are alsoreviewed.www.stemmer-imaging.co.uk/en/pages/service/download.php?file=en_GB-Code-Reading.pdf
• What is sensitivity and whyare sensitivity statements oftenmisleading? (Multipix Imaging) This document explains howsensor sensitivity is just one ofthe factors involved in theoutput signal from a camera.Electronic devices in the camerasuch as Analogue to Digitalconverters and amplifiers alsoinfluence the output signal. Itcould be said that a camera's"responsivity" is a better measureof performance.http://multipix.com/wp-content/uploads/2011/07/Sensitivity.pdf
Originally, EMP had tested asystem that simply captureda photo image of the label,but that did not reproducethe label in a high enoughresolution. The Cognexsystem produced a muchmore accurate and highquality label that met all of
the manufacturers’ requirements for traceability. Without the Cognex camera,the visually impaired operator would need to read each character from theoriginal packaging under high-powered magnification, taking a significantamount of time. The new system eliminates the need for this process, as wellas reduces processing time and eliminates keystroke errors. In addition, totallyblind operators would not be able to use the magnification system at all. Thenew system has increased productivity and allowed the company to workthrough a large backlog of orders.
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