8/8/2019 Resubmit Group Project-Final Report
1/32
1
INFO 6240Group Assignment
Emerging Technology
1.0 INTRODUCTION
1.1 Definition
Computer vision is the science and technology of machines
that see, where see in this case means that the machine is able to
extract information from an image that is necessary to solve some
task. As a scientific discipline, computer vision is concerned with the
theory behind artificial systems that extract information from images.
The image data can take many forms, such as video sequences,
views from multiple cameras, or multi-dimensional data from a
medical scanner.
1.2 Concept
Computers do not 'see' in the same way those human beings are
able to. Cameras are not equivalent to human optics and while
people can rely on inference systems and assumptions, computing
devices must 'see' by examining individual pixels of images,
processing them and attempting to develop conclusions with the
assistance of knowledge bases and features such as patternrecognition engines. Although some machine vision algorithms have
been developed to mimic human visual perception, a number of
unique processing methods have been developed to process images
and identify relevant image features in an effective and consistent
manner.
Machine vision and computer vision systems are capable of
processing images consistently, but computer-based image
processing systems are typically designed to perform single,
repetitive tasks, and despite significant improvements in the field, no
machine vision or computer vision system can yet match some
capabilities of human vision in terms of image comprehension,
8/8/2019 Resubmit Group Project-Final Report
2/32
1
INFO 6240Group Assignment
Emerging Technology
tolerance to lighting variations and image degradation, parts'
variability etc.
Two important specifications in any vision system are the
sensitivity and the resolution. Sensitivity is the ability of a machine to
see in dim light, or to detect weak impulses at invisible wavelengths.
Resolution is the extent to which a machine can differentiate
between objects. In general, the better the resolution, the more
confined the field of vision. Sensitivity and resolution are
interdependent. All other factors held constant, increasing the
sensitivity reduces the resolution, and improving the resolution
reduces the sensitivity.
1.3 General Application
All machine vision systems are designed to reduce or eliminate
the need for human observation of a particular task, and as their
price drops, the number of potential users that purchase a system
will increase. Machine vision applications generally fall into three
categories: measurement, inspection, and guidance. Measurement
systems determine the dimensions of an object in a camera's field ofview. Inspection systems determine whether an object matches a
predetermined description. Guidance systems cause a machine to
take certain courses of action based on visual queues.
Machine vision is used in various industrial and medical
applications. Examples of applications of computer vision include
systems for:
Controlling processes (e.g., an industrial robot or an autonomousvehicle).
Detecting events (e.g., for visual surveillance or people counting). Organizing information (e.g., for indexing databases of images and
image sequences). Modeling objects or environments (e.g., industrial inspection,
medical image analysis or topographical modeling).
8/8/2019 Resubmit Group Project-Final Report
3/32
1
INFO 6240Group Assignment
Emerging Technology
Interaction (e.g., as the input to a device for computer-humaninteraction).
2.0 TECHNOLOGIES USED/COMPONENTS OF MV SYSTEM
What is Machine Vision?
Machine vision (MV) is the application ofcomputer vision to industry
and manufacturing. It is an automated extraction of useful
information from digital images in an industrial setting. Examples of
useful information:
1. Confirmation of fill level
2. Confirmation that all components are assembled correctly
3. Part location and orientation for robot pickup
4. Part identification reading human or machine readable codes
2.2 About Machine Vision
100% quality control in manufacturing reduces costs and ensures a
high level of customer satisfaction. Machine vision inspection plays
an important role in achieving this goal. While human inspectors
working on assembly lines visually inspect parts to judge the quality
of workmanship, machine vision systems use cameras and image
processing software to perform similar inspections.
Machine vision system inspection consists of narrowly defined tasks
such as counting objects on a conveyor, reading serial numbers, and
searching for surface defects. Manufacturers often prefer machine
vision systems for visual inspections that require high speed, high
magnification, around-the-clock operation, and/or repeatability of
measurements.
For example, semiconductor fabrication depends greatly on vision
inspection technology, without which yields for computer chips would
be significantly reduced. Machine vision systems inspect silicon
wafers, processor chips, and sub-components such as resistors and
capacitors at high speeds with precision and accuracy.
http://en.wikipedia.org/wiki/Computer_visionhttp://en.wikipedia.org/wiki/Computer_vision8/8/2019 Resubmit Group Project-Final Report
4/32
1
INFO 6240Group Assignment
Emerging Technology
2.3 Components of a Machine Vision System
Machine Vision is a subfield of engineering that is related to computer
science, optics, mechanical engineering, and industrial automation.
One of the most common applications of Machine Vision is the
inspection of manufactured goods such as semiconductor chips,
automobiles, food and pharmaceuticals.
While machine vision is best defined as a process of applying
computer vision to industrial application, it is useful to list commonly
utilized hardware and software components.
A typical machine vision solution will include several of the following
components:-
1. One or more digital or analog cameras (black-and-white or color) with
suitable optics for acquiring images.
2. Camera interface for making the images available for processing. For
analog cameras, this includes digitization of the images. When this
interface is a separate hardware device it is called a "frame grabber".
3. A processor (often a PC or embedded processor, such as a DSP).
4. Machine Vision Software which provides the tools to develop the
application-specific software program.
5. Input/Output hardware (e.g. digital I/O) or communication links (e.g.
network connection or RS-232) to report results.
6. A Smart Camera, a single device which includes all of the above
items.
7. Lenses to focus the desired field of view onto the image sensor.
8. Suitable, often very specialized, light sources (LED illuminators,
fluorescent or halogen lamps etc.).
9. An application-specific software program to process images anddetects relevant features.
10.A synchronizing sensor for part detection (often an optical or
magnetic sensor) to trigger image acquisition and processing.
11. Some form of actuators used to sort or reject defective parts.
2.4 Machine Vision for Camera
http://en.wikipedia.org/wiki/Digital_Camerahttp://en.wikipedia.org/wiki/Camerahttp://en.wikipedia.org/wiki/Personal_computerhttp://en.wikipedia.org/wiki/Digital_signal_processorhttp://en.wikipedia.org/wiki/Ethernethttp://en.wikipedia.org/wiki/RS-232http://en.wikipedia.org/wiki/LEDhttp://en.wikipedia.org/wiki/Sensorhttp://en.wikipedia.org/wiki/Digital_Camerahttp://en.wikipedia.org/wiki/Camerahttp://en.wikipedia.org/wiki/Personal_computerhttp://en.wikipedia.org/wiki/Digital_signal_processorhttp://en.wikipedia.org/wiki/Ethernethttp://en.wikipedia.org/wiki/RS-232http://en.wikipedia.org/wiki/LEDhttp://en.wikipedia.org/wiki/Sensor8/8/2019 Resubmit Group Project-Final Report
5/32
1
INFO 6240Group Assignment
Emerging Technology
The sync sensor determines when a part (often moving on a
conveyor) is in position to be inspected. The sensor triggers the
camera to take a picture of the part as it passes beneath the camera
and often synchronizes a lighting pulse to freeze a sharp image. The
lighting used to illuminate the part is designed to highlight features of
interest and obscure or minimize the appearance of features that are
not of interest (such as shadows or reflections). LED panels of
suitable sizes and arrangement are often used to this purpose.
The camera's image is captured by the frame grabber or by computer
memory in PC based systems where no frame grabber is utilized. A
frame grabber is a digitizing device (within a smart camera or as aseparate computer card) that converts the output of the camera to
digital format (typically a two dimensional array of numbers,
corresponding to the luminous intensity level of the corresponding
point in the field of view, called pixel) and places the image in
computer memory so that it may be processed by the machine vision
software.
The software will typically take several steps to process an image.
Often the image is first manipulated to reduce noise or to convert
many shades of gray to a simple combination of black and white.
Following the initial simplification, the software will count, measure,
and/or identify objects, dimensions, defects or other features in the
image. As a final step, the software passes or fails the part according
to programmed criteria. If a part fails, the software may signal a
mechanical device to reject the part; alternately, the system may
stop the production line and warn a human worker to fix the problem
that caused the failure.
Though most machine vision systems rely on "black-and-white" (gray
scale) cameras, the use of colour cameras is becoming more
http://en.wikipedia.org/wiki/Conveyor_belthttp://en.wikipedia.org/wiki/LEDhttp://en.wikipedia.org/wiki/Digitizinghttp://en.wikipedia.org/wiki/Smart_camerahttp://en.wikipedia.org/wiki/Digitalhttp://en.wikipedia.org/wiki/Pixelhttp://en.wikipedia.org/wiki/Computer_storagehttp://en.wikipedia.org/wiki/Conveyor_belthttp://en.wikipedia.org/wiki/LEDhttp://en.wikipedia.org/wiki/Digitizinghttp://en.wikipedia.org/wiki/Smart_camerahttp://en.wikipedia.org/wiki/Digitalhttp://en.wikipedia.org/wiki/Pixelhttp://en.wikipedia.org/wiki/Computer_storage8/8/2019 Resubmit Group Project-Final Report
6/32
1
INFO 6240Group Assignment
Emerging Technology
common. It is also increasingly common for Machine Vision systems
to include digital camera equipment for direct connection rather than
a camera and separate frame grabber, which reduces cost and
simplifies the system.
"Smart" cameras with built-in embedded processors are capturing an
increasing share of the machine vision market. The use of an
embedded (and often very optimized) processor eliminates the need
for a frame grabber card and external computer, thus reducing cost
and complexity of the system while providing dedicated processing
power to each camera.
Smart cameras are typically less expensive than systems comprising
a camera and a board and/or external computer, while the increasing
power of embedded processors and DSPs is often providing
comparable or higher performance and capabilities than conventional
PC-based systems.
2.5 Machine Vision in the Industry
Cognex is a manufacturer & supplier of machine vision systems &
vision inspection systems that are used to automate a wide range of
manufacturing processes where accurate visual inspection is
required. They offer vision sensors, modular vision systems &
camera-based surface inspection systems. Their vision systems
optimize product quality & control traceability while driving down
manufacturing costs.
National Instruments is a leading machine vision and scientific
imaging hardware and software tools provider. From inspecting
automotive parts to researching advanced medicines, engineers and
http://en.wikipedia.org/wiki/Digital_camerahttp://en.wikipedia.org/wiki/Smart_camerahttp://en.wikipedia.org/wiki/Smart_camerahttp://en.wikipedia.org/wiki/Digital_signal_processorhttp://en.wikipedia.org/wiki/Digital_camerahttp://en.wikipedia.org/wiki/Smart_camerahttp://en.wikipedia.org/wiki/Smart_camerahttp://en.wikipedia.org/wiki/Digital_signal_processor8/8/2019 Resubmit Group Project-Final Report
7/32
1
INFO 6240Group Assignment
Emerging Technology
scientists use NI vision software and hardware to solve a diverse set
of application challenges, faster and at a lower cost.
Microscan holds one of the world's most robust patent portfolios for
machine vision systems technology, including hardware design,
software algorithms and machine vision illumination. Their
Visionscape brand of machine vision hardware and software is an
industry pioneer, improving automated technical inspection, gauging
and measurement capability to the benefit of manufacturers
worldwide.
Microscan is in continual development of their Visionscape hardware
and software as well as the NERLITE machine vision lighting
products, to ensure provides cutting edge technology and the most
complete offerings for machine vision applications.
Visionscape is a comprehensive line of machine vision system
solutions, with total scalability from smart camera systems to PC-
based solutions. Visionscape software provides all the elements
required for fast and efficient development and deployment ofadvanced machine vision applications in any industrial environment.
VIMATIC develop and build machine vision solution cater to the
semiconductor and electronic manufacturing industry. They welcome
enquiry from any companies that have requirement to integrate
vision system to their existing machines, or to replace existing
obsolete vision system. They are keen to joint venture with OEM
companies to incorporate vision system into their machines.
VIMATIC vision systems are installed to inspect a wide range of
packages like 2pSSP, 2pUSMM, 3pSSP, 3pUSMM, 3pMM, QFP, SOIC,
http://www.microscan.com/en-us/Products/ProductCategory.aspx?id=263http://www.microscan.com/en-us/Products/ProductCategory.aspx?id=2563http://www.microscan.com/en-us/Products/ProductCategory.aspx?id=263http://www.microscan.com/en-us/Products/ProductCategory.aspx?id=25638/8/2019 Resubmit Group Project-Final Report
8/32
1
INFO 6240Group Assignment
Emerging Technology
BGA, FlipChip and among others. The systems are checking products
for:
Leads quality and dimensional measurement.
Pads quality and dimensional measurement.
Marking specification.
Mold package quality.
Dye attach placement.
Dye wire bond placement.
Optical Character Recognition.
Machine vision software application development is carried out in-house by a team of experience engineers.We have products that cover the following market segment.
Vision System Integration
OEM Vision System
Stand Alone Vision System
2.6 Examples of Common Application
1. Colour matching
2. Sub Assembly verification
3. Die attach bond inspection
4. Location & alignment for pick and place
5. Ball grid array inspection
6. Measures solder paste levels
7. Wafer positioning
8. Robotic guidance
8/8/2019 Resubmit Group Project-Final Report
9/32
1
INFO 6240Group Assignment
Emerging Technology
2.7. Machine Vision Applications
Inspection
Gauging
Guidance
Identification
2.8 Component of Machine Vision
8/8/2019 Resubmit Group Project-Final Report
10/32
1
INFO 6240Group Assignment
Emerging Technology
Barcode Scannerand Reader
Camera Encoders
Filters Indicator LightsIndustrial Computers
Label Printers Lenses Lighting & Illuminations
Machine Safety
Measuring Solutions Sensors
Smart Camera Software
Support Systems
UID Vision Sensors Vision Systems
3.0 HOW THE MV WORKS/PROCESSING METHODS
8/8/2019 Resubmit Group Project-Final Report
11/32
1
INFO 6240Group Assignment
Emerging Technology
During the last 15 years, machine vision technology has matured
substantially, becoming a very important and in some cases,
indispensable tool for manufacturing automation. Today, machine
vision applications crop up in many industries, including
semiconductor, electronics, pharmaceuticals, packaging, medical
devices, automotive and consumer goods.
Machine vision systems offer a noncontact means of inspecting and
identifying parts, accurately measuring dimensions, or guiding robots
or other machines during pick-and-place and other assembly
operations.
Historically, machine vision has been most successful in applications
where it was integrated into the production process. For example,
guiding machines or closing a control loop. But, while vision guidance
has proved its worth in placing surface-mount components on printed
circuit boards, most users would hesitate before investing in a
machine vision inspection station to catch defective parts on an
existing production line.
However, continuous improvements in cost, performance, algorithmic
robustness and ease of use have encouraged vision systems' use in
general manufacturing automation. Further advances in these areas
will characterize the future of machine vision and result in more
vision systems on manufacturing floors during the next few years.
What characteristics will describe future vision systems? They must
include three characteristics in order to be useful in most
manufacturing industries. First, they must be fast enough to keep up
with ever-increasing production rates. Second, they must be intuitive
8/8/2019 Resubmit Group Project-Final Report
12/32
1
INFO 6240Group Assignment
Emerging Technology
and easy to use. Finally, they must be intelligent enough to deal with
part-to-part or other process variations.
While vision technology might not have reached this point yet, recent
advances in the vision industry have helped facilitate and accelerate
vision applications in manufacturing for the near future.
3.1 Faster hardware
Since its inception, the machine vision industry has been
characterized by continually improving price and performance ratios.
This trend has followed a similar one in the semiconductor industry,
which has seen desktop PCs move from yesterday's 8 MHz 8086 CPUs
to today's 300+ MHz Pentium IIs. The industry projects future 64-bit
processors that will run at clock rates in the gigahertz range.
Higher vision-processing hardware speeds have been key to both
faster parts-per-minute throughput and greater robustness in
individual vision tools. Even in manufacturing processes wheremechanical considerations limit production rates, higher-speed vision
processing means more processing power reserve. More reserve
means more intelligent vision tools that can help deal with process
variations and simplify a system's programming.
Formerly, machine vision systems allowed only binary processing of
low-resolution, black-and-white images. Today, sophisticated image
processing and analysis performed on high-resolution, grayscale
images is commonplace. Computationally intensive image-
preprocessing operations such as mathematical morphology are
widely used. In addition, vision hardware now allows not one but
8/8/2019 Resubmit Group Project-Final Report
13/32
1
INFO 6240Group Assignment
Emerging Technology
many processing passes through an image during a single frame
time.
Other advances have brought about process improvements. For
example, older systems' slow hardware couldn't rotate images to
compensate for part rotation. This could be performed only in very
expensive hardware or else required approximations that introduced
artifacts. State-of-the-art vision-processing hardware permits full-
frame image rotation within less than a frame time, which in turn
supports additional processing in real time.
Until recently, the standard broadcast TV frame rate of 30 Hz was
considered "real time." However, digital machine vision cameras,
which run at higher rates, require processing at a faster real-time
rate than conventional video. New vision-processing hardware readily
supports image acquisition from such nonstandard cameras. This
nimble hardware also can process the increased data contained in
higher-resolution images as well as conventional resolution images
that are acquired much faster.
Continuing advances in semiconductor technology during the last
decade have enabled custom vision-processing systems to shrink
continuously -- from board-filled cabinets to single boards to custom
silicon chips. In fact, during the last few years, VLSI design tools and
processes have matured to the point where vision vendors can
develop truly high-performance vision hardware.
Today, users perform vision-processing tasks at substantially faster
rates, using hardware that requires far less electrical power, while
paying a much lower unit cost than what conventional PC CPUs offer.
Custom vision-processing hardware also allows robust vision
8/8/2019 Resubmit Group Project-Final Report
14/32
1
INFO 6240Group Assignment
Emerging Technology
functionality, in less complex and lower cost configurations, closer to
the manufacturing process.
3.2 PC-based vision
During the last 10 years, PC-based vision systems have become more
widely accepted due to the ever-increasing speed of standard PC
CPUs.
Key advantages of PC-based vision systems include both the vision
supplier's and the user's abilities to leverage third-party hardware
and software. Also important is the PC's wide acceptance for both
desktops and factory floors. Today, PCs running under the Microsoft
Windows NT operating system are becoming a dominant platform for
delivering factory-floor monitoring and control applications.
Numerous low-cost frame grabbers and image-processing software
packages allow individual users to build vision applications
themselves. Although feasible, this option is not without potentialproblems, which include conventional multimedia frame grabbers'
limitations, nondeter-ministic performance and, occasionally,
excessive development, installation and support costs.
New technology that addresses current PC-based vision systems'
limitations includes next-generation, single-board, PC plug-in vision
engines and powerful, component-based software environments for
vision application development and deployment.
Plug-in vision engines
This latest generation of vision engines incorporates a complete
vision system in a single PCI board. Users can thus offload all vision-
8/8/2019 Resubmit Group Project-Final Report
15/32
1
INFO 6240Group Assignment
Emerging Technology
related processing from the host PC and use it for other tasks such as
production monitoring, control or user interfacing. Because all high-
bandwidth, image-capture operations are internal to the board, this
vision engine configuration offloads the host PCI bus in addition to
freeing up the CPU.
Furthermore, because the vision board fits completely inside a host
PC used for other purposes, plug-in vision engines offer a zero-
footprint solution -- a key consideration in many original equipment
manufacturer or clean-room applications. By plugging multiple boards
into a single PC, users can further leverage the single PC host over
multiple vision-engine boards, each dedicated to different inspection
tasks.
In addition to on-board, high-performance CPUs and custom vision-
processing hardware, such next-generation vision engines typically
run under a real-time multitasking operating system, which allows
deterministic performance in all image-acquisition, vision-processing
and input/output operations. This offers a distinct advantage over
conventional PC-based systems, which run under a nonreal-timeWindows operating system.
In contrast to multimedia frame grabbers, vision engine boards
support machine-vision input devices ranging from conventional
analog video to nonstandard digital cameras. Designed specifically
for machine vision applications, these products offer options such as
strobing and channel-switching between successive frames, which
conventional multimedia frame grabbers don't always do. On-board
display capabilities present images and graphics in a dedicated
optional display or in a picture-in-picture fashion on the host
PC/Windows display.
8/8/2019 Resubmit Group Project-Final Report
16/32
1
INFO 6240Group Assignment
Emerging Technology
With on-board input/output communications controlled by the on-
board, real-time operating system, plug-in systems also allow
straightforward integration with other equipment as well as control of
peripherals such as lighting without relying on the host PC and its
nonreal-time behavior.
Finally, on-board network connectivity simplifies deployment and
ensures participation in factory-floor networks and intranets. It also
supports innovative remote monitoring and diagnostics options.
3.3 Ease of use and deployment
Many users might be involved with the development, deployment and
day-to-day support of vision applications. Users range from factory-
floor operators and engineers -- who typically would set up, install or
modify vision applications -- to system integrators or OEMs, who
would create custom vision applications or even develop new vision
tools.
Ease of use no longer implies just a top-level, point-and-click
graphical user interface but also multilevel, comprehensive access for
all expected system users and skill levels. Newer systems'
intelligence reduces the need for inordinate vision-processing
expertise and minimizes application development and deployment
time.
Most state-of-the-art vision systems include built-in graphical user
interfaces and comprehensive run time or monitoring environments.
These allow systems to select jobs, start and stop inspections, adjust
inspection parameters, access reports and statistics, and capture and
log failed-part images or other data.
8/8/2019 Resubmit Group Project-Final Report
17/32
1
INFO 6240Group Assignment
Emerging Technology
At one level down, manufacturing engineers who set up or configure
vision applications do so in an intuitive environment, using high-level
tools as opposed to low-level image-processing and analysis
operations.
Describing a vision application program as a sequence of steps and
using high-level, application-oriented tools -- as opposed to low-level,
image-processing or analysis operations in a conventional
programming language -- is now a widely accepted approach.
Implementing such tools on high-performance platforms has
increased these tools' robustness and intelligence, while limiting the
need for users' vision expertise. This trend certainly will continue in
the future.
At the system's lowest level, system integrators or OEM users can
develop customized user interfaces quickly and, in some cases, add
to the system's functionality by working in industry-standard,
software-development environments. One recent development in this
area, which promises faster application deployment for system
integrators as well as faster time to market for OEMs, is component-based software. Such software encapsulates core vision system
functions required to develop and deploy vision applications.
In a Microsoft Windows environment, these components are
developed as ActiveX controls (formerly OCXs or OLE custom
controls). A vision application deployment component, for example,
would encapsulate all functions related to training or trying out a job.
Another deployment component would encapsulate all functions
related to loading a job, and starting, stopping and monitoring an
inspection. It's now possible to create or customize vision applications
without knowing much about vision system internals by dropping
8/8/2019 Resubmit Group Project-Final Report
18/32
1
INFO 6240Group Assignment
Emerging Technology
such basic building blocks inside a custom graphical user interface
developed using Visual Basic or Visual C++.
3.4 The future is now
The hardware and software trends highlighted above will continue
and even intensify in the future. Faster hardware, more intelligent
tools and better application software development and deployment
environments all will enable a broader and deeper proliferation of
machine vision in manufacturing.
However, through recent positive advances in price, performance,
robustness and ease of use, vision technology now has reached a
point very close to what the vision industry and marketplace
projected as a distant promise a few years ago.
At the same time, the last 15 or 20 years of vision applications on the
factory floor has educated manufacturers about optimal vision-
system uses, and these application boundaries continue to moveoutward. Manufacturers now consider machine vision not as a
research curiosity but rather a mature tool for manufacturing
automation.
Although potential users may want to wait for the future's inevitable
new technology -- including faster hardware and more intelligent
software -- the recent vision technology developments mentioned in
this article imply that the future is now, and it's an exciting time for
vision users and suppliers
8/8/2019 Resubmit Group Project-Final Report
19/32
1
INFO 6240Group Assignment
Emerging Technology
APPLICATIONS OF MACHINE VISION
4.0 Introduction
The applications of machine vision (MV) are diverse, covering areas
of endeavor including, but not limited to:
Large-scale industrial manufacture
Short-run unique object manufacture
Safety systems in industrial environments
8/8/2019 Resubmit Group Project-Final Report
20/32
1
INFO 6240Group Assignment
Emerging Technology
Inspection of pre-manufactured objects
Visual stock control and management systems
Control of automated guided vehicles
Quality control and refinement of food products
Retail automation
Machine vision systems are widely used in semiconductor fabrication
semiconductor fabrication indeed, without machine vision, yields for
computer chips would be significantly reduced. Machine vision
systems inspect silicon wafers, processor chips, and subcomponents
such as resistors and capacitors.
In the automotive industry, machine vision systems are used to guide
industrial robots, gauge the fit of stamped metal components, and
inspect the surface of the painted vehicle, weld seams, engine blocks
and many other components for defects.
Though machine vision techniques were developed for the visible
spectrum, the same processing techniques may be applied to images
captured using imagers sensitive to other forms of spectra such asinfrared light or x-ray emissions.
The following examples of specific applications indicate the diverse
nature to which machine vision technology can be applied. These
examples fall under the ambit of one of the above mentioned areas
4.2 Examples of MV Applications
Synergy between Solar Cell And Machine Vision Technologies
Machine vision inspection has been used to provide real-time process
feedback in the manufacture of solar cells, while solar cell technology
8/8/2019 Resubmit Group Project-Final Report
21/32
1
INFO 6240Group Assignment
Emerging Technology
has been used to develop a machine vision sensor which offers
exceptional dynamic range for demanding vision applications.
Machine Vision Gives Optometrists a Clear View
The international glasses manufacturer Rodenstock, Germany, has
developed an optometrist service terminal called ImpressionIST that
enables the adaptation of glasses regarding the individual
parameters and center data in an absolutely unstrained atmosphere.
Innovative 3D images (MV application) determine the facial
measurements, comfortably and accurately giving the optometrist
the information they require and the customer a view of themselves
in their new glasses.
Placing Of Foldable Plastic Spoons in Convenience Snacks
A specialist supplier of plastic injection moulded components for the
food industry approached RNA Automation Ltd. to automate a
production line for disposable plastic spoons. Some of the industries
largest food and snack manufacturers use this type of spoon in ready
meals and convenience snacks. For this particular project a foldable
spoon needed to be placed into a cap, the cap is supplied to a
manufacturer of milk based fast foods. A disposable plastic spoon is
very difficult to orient due to the design of the moulding especially at
120 parts per minute. The solution chosen was a vision guided
robotic system equipped with an RNA step feeder, (MV application) a
bulk storage hopper and a 6 axis robot.
Vision-Guided Robots Help Automate Vial and Syringe FillingAutomated Systems of Tacoma, Inc. (AST) was asked by a life science
research company to develop an alternative to conventional
pharmaceutical filling machinery having the capability to fill and
finish all their small-scale clinical trial products with a single flexible
platform. To solve this problem, AST had to develop a machine with
8/8/2019 Resubmit Group Project-Final Report
22/32
1
INFO 6240Group Assignment
Emerging Technology
the flexibility to be able to handle various sizes of prefilled syringes,
vials, cartridges and IV bags with minimal product changeover times.
The basic concept is a system that positions ready-to-use nests of a
particular container within the operating envelopes of two robots, the
Cognex In-Sight Micro vision system is used to precisely locate each
container and stopper and provide the robots these locations prior to
processing.
The Power in the Wind Using MV Technology
Larger and larger wind power turbines are bringing the forces of
nature under control. The main structures, the powerful tower and
rotors, are supported by parts that play a less obvious, but no lessimportant role: bolts. As simple as it may look, precision tightening of
bolts is an art form of its own. Intellifast GmbH is now ensuring
perfect support in any weather using ultrasound permanent sensors
and Data Matrix codes and reading the codes with the DataMan 100
from Cognex.
360 View Provides Extremely Fast Surface Check
In a strained economic situation, it is more important than ever to be
able to optimise processes and make them more efficient. The Expert
ETK inspection system, integrated with Cognex OmniView
technology, combines many different quality control requirements
into just one compact system.
There have been two key challenges to implementing machine vision
to aid in the quality control of labels on cylindrical objects. First,
vision systems require the bottles be consistently aligned within the
labelling machine, and second, labelling machines offer unfavourable
ambient conditions and lack appropriate space within to contain the
vision system. But now, the innovative OmniView vision technology
8/8/2019 Resubmit Group Project-Final Report
23/32
1
INFO 6240Group Assignment
Emerging Technology
from Cognex integrated in the Expert ETK inspection system from
Syscona Kontrollsysteme and Weber Systemtechnik has a 360
complete view of the bottle surface which provides new potential for
the inspection of bottle features with much greater reliability.
Vision Sensor Helps Automate High-Speed Loading Of
Transparent Cartons
A major beverage manufacturer uses transparent cartons to package
its bottled drinks so that their distinctive branded labels are visible to
consumers. However, the need to orient the bottles so that the right
part of the label is visible makes automated packaging a challenge. In
the past, bottles were filled on an automated line, and a team of 15
people were tasked with manually loading and orienting the bottles
into the transparent cartons. Recently, this beverage producer
became the first to successfully automate high-speed carton loading
with the use of a bucket autoload cartoner from AFA Nordale
Packaging Systems, which uses Cognex Checker vision sensors to
orient the bottles before they are placed in the cartons.
Cameras Sort Rice and Beans
A vision system will trigger air-jets at specific points to blast out the
unwanted beans or rice, broken beans or rice, or extraneous items
such as rocks or bugs. Since rice or beans are a consumable product
quality sorting is very important. Accuracy is paramount as no one
wants to bite into a rock or consume any bugs. Speed is very
important also since large volumes of product must be sorted
efficiently.
8/8/2019 Resubmit Group Project-Final Report
24/32
1
INFO 6240Group Assignment
Emerging Technology
Custom Cameras Classify Plastic Pellets Precisely
In the recycling of plastic products, incoming plastic is ground into
flakes, washed and dried, and, converted into pellets. These pellets
are manufactured by melting the plastic and then extruding and
cutting the plastic material into small, uniform pieces. Once
manufactured, these plastic pellets must be sorted before they are
sold to manufacturers to be made into new products, such as bottles
and trash bags.
Vision System Measures Scallops
Between July and August each year, the US National Oceanic and
Atmospheric Administration (NOAA) Fisheries Service conducts
surveys to determine the abundance and size distribution of deep-sea
scallops. To do this, sample height measurements from 125,000
scallops are taken from approximately 500 randomly selected
locations. To increase the accuracy and speed of these
measurements over current methods, William Kramer, an IT specialist
at the NOAA Woods Hole Laboratory on Cape Cod, obtained a Pioneer
Funding grant from the Chesapeake Bay Trust to develop a prototype
machine-vision system.
Inspecting Turbine Blades In Aircraft Engines
Turbines that are housed in aircraft engines are subjected to pretty
tough conditions. They must perform at speeds of 30 thousand rpm in
temperatures greater than 800C for hours at a time. The engine
manufacturers fully understand that even small surface defects can
reduce performance, increase maintenance costs, and reduce the
useful life of an aircraft engine. They need to inspect turbine blades
8/8/2019 Resubmit Group Project-Final Report
25/32
1
INFO 6240Group Assignment
Emerging Technology
very carefully to maintain the efficiency and reliability that the air
transport industry requires. One particular North American
manufacturer inspected its blades by hand and human eye. The
highly-trained inspectors measured hundreds of features and
checked for surface defects at depths in the order of thousandths of
an inch. Manual inspection was not only costly in terms of time and
labour, but subjective as well. Results were variable and even
differed between inspectors. Finally, because manual inspection was
so time consuming, there was no systematic inspection of every
blade; only a sampling of blades was inspected. The manufacturer
required an approach that would allow systematic inspections of the
blades, save time, and yield consistent and repeatable results.
Vision Automates Parking Surveillance
Instead of looking on parking fees and fines as a cash cow, some
enlightened cities attempt to balance their needs with those of
business owners and residents. Fredericksburg, VA is one city that
revolutionized the way it manages parking. By adopting an
automated parking system using a vehicle mounted vision system,
the city has enjoyed greater revenues, improved efficiency, and far
fewer complaints and repeat offenders.
Laser Marking and Image-Based Industrial ID Reader
An electronics manufacturer produces thousands of different part
numbers of electronic products intermixed on the same assembly
line. The difficulty in identifying parts, combined with the fast pace of
the line, resulted in a large amount of rework or scrap. The
manufacturer had experienced several hundred thousand dollars a
year in losses when incorrect parts were added to, and/or the wrong
operations were performed, on assemblies. The manufacturer asked
Claire Lasers for a solution. The manufacturer developed an
8/8/2019 Resubmit Group Project-Final Report
26/32
1
INFO 6240Group Assignment
Emerging Technology
application of the companys ClearMarka laser marking system that
added a motorized platform to move the Cognex DataMan ID reader
into position based on the location of the assembly.
5.0 CONCLUSION
Machine vision proves most successful in the controlled environment
of the factory floor, offering some important advantages over human
vision in terms of cost, speed, precision and physical demands.
Systems can:
Determine location or the position of an object.
Measure dimensions within thousandths-of-an-inch accuracy.
Count items such as pills in a bottle or cells in a petri dish.
8/8/2019 Resubmit Group Project-Final Report
27/32
1
INFO 6240Group Assignment
Emerging Technology
Identify or recognize an object.
Inspect objects and identify flaws in manufactured goods.
Verify that an object's quality meets standards.
Machine vision excels at locating and examining objects with hard,
well-defined edges and regular patterns. And its high-speed
processing capability gives it unquestioned superiority when it comes
to looking at parts on today's fast-paced production lines. Although
human inspectors can keep pace with visual inspection demands at a
rate of a few hundred items per minute, they also tend to get
fatigued and miss flaws. With machine vision, thousands of parts
often run past a camera per minute and resolve a dozen features on
each piece for product conformance -- all in a matter of milliseconds.
Machine vision systems ensure repeatable results and can run
continuously 24 hours a day, seven days a week.
The potential applications for machine vision reach far beyond even
those areas where human vision can be applied. These include
conditions where light levels are too low or too bright for human
vision, or where nonvisible electromagnetic radiation such as X-rays
or infrared is required. Machine vision systems can be applied in
manufacturing clean rooms and can survive environments too
hazardous for humans.
5.1 Cost Make or Buy Decision
Once manufacturers determine that machine vision can be an
effective tool for their application, they must decide the best path to
take in configuring a system. Larger companies with skilled
engineering staffs may pursue their own solution, assembling
components purchased from various vendors or even using new
technology. However, a steep learning curve, lack of industry
8/8/2019 Resubmit Group Project-Final Report
28/32
1
INFO 6240Group Assignment
Emerging Technology
standards and time-to-market pressures make the in-house approach
largely impractical. The vision system meant to add value to a
product can become a serious drain on time, energy and resources.
Expert help must be called in to solve the problem.
Outsourcing is a megatrend seen across all market segments as
companies find that purchasing a custom-engineered machine vision
system entails less risk than designing and manufacturing it
themselves. System integrators and value-added resellers have the
integration expertise necessary to provide application-specific
solutions based on a thorough review of the requirements. Many
specialize in serving a particular market niche such as foodprocessing or pharmaceutical manufacturing. This allows them to
focus their attention on a smaller range of needs.
Even then, putting together puzzle pieces from a variety of
component vendors remains a costly, time-consuming task, mainly
due to a lack of industry standards. According to industry analyst
Nello Zeuch of the Automated Imaging Association, the cost of
components accounts for less than one-third the cost of a machine
vision system. The rest goes toward custom development, system
integration and installation.
Moreover, the real costs of product development often hide in the
lost opportunity cost of not getting a product to market on time.
Studies show that, in today's fast-paced markets, the opportunity
cost of a six-month delay in product development can far exceed
both a 50-percent development cost overrun and a 10-percent
increase in manufacturing costs. With the help of an experienced
system integrator or VAR, schedules are more likely to be met.
8/8/2019 Resubmit Group Project-Final Report
29/32
1
INFO 6240Group Assignment
Emerging Technology
Having the support of an outside source -- long after a product
delivers -- adds another advantage. Many companies don't have the
in-house support required to get a system back up and running
should problems arise. Nor do they have the expertise necessary to
upgrade the system later with newer technology. A capable third-
party supplier may willingly take responsibility for the whole system,
providing an invaluable source of technical assistance and advice.
5.2 Future of MV
Historically, machine vision has been most successful in applications
where it was integrated into the production process. For example,
guiding machines or closing a control loop. But, while vision guidance
has proved its worth in placing surface-mount components on printed
circuit boards, most users would hesitate before investing in a
machine vision inspection station to catch defective parts on an
existing production line.
However, continuous improvements in cost, performance, algorithmic
robustness and ease of use have encouraged vision systems' use ingeneral manufacturing automation. Further advances in these areas
will characterize the future of machine vision and result in more
vision systems on manufacturing floors during the next few years.
What characteristics will describe future vision systems? They must
include three characteristics in order to be useful in most
manufacturing industries. First, they must be fast enough to keep up
with ever-increasing production rates. Second, they must be intuitive
and easy to use. Finally, they must be intelligent enough to deal with
part-to-part or other process variations.
8/8/2019 Resubmit Group Project-Final Report
30/32
1
INFO 6240Group Assignment
Emerging Technology
While vision technology might not have reached this point yet, recent
advances in the vision industry have helped facilitate and accelerate
vision applications in manufacturing for the near future.
The hardware and software trends highlighted above will continue
and even intensify in the future. Faster hardware, more intelligent
tools and better application software development and deployment
environments all will enable a broader and deeper proliferation of
machine vision in manufacturing.
However, through recent positive advances in price, performance,
robustness and ease of use, vision technology now has reached a
point very close to what the vision industry and marketplace
projected as a distant promise a few years ago.
At the same time, the last 15 or 20 years of vision applications on the
factory floor has educated manufacturers about optimal vision-
system uses, and these application boundaries continue to move
outward. Manufacturers now consider machine vision not as a
research curiosity but rather a mature tool for manufacturingautomation.
Although potential users may want to wait for the future's inevitable
new technology -- including faster hardware and more intelligent
software -- the recent vision technology developments mentioned in
this write-up imply that the future is now, and it's an exciting time for
vision users and suppliers.
8/8/2019 Resubmit Group Project-Final Report
31/32
1
INFO 6240Group Assignment
Emerging Technology
6.0 REFERENCES
http://whatis.techtarget.com/definition/0,,sid9_gci212508,00.html
http://www.answers.com/topic/computer-vision
http://en.wikipedia.org/wiki/Machine_vision
http://www.vimatic.com.my/machinevision
http://www.microscan.com
http://www.ni.com/vision
http://whatis.techtarget.com/definition/0,,sid9_gci212508,00.htmlhttp://www.answers.com/topic/computer-visionhttp://en.wikipedia.org/wiki/Machine_visionhttp://www.vimatic.com.my/machinevisionhttp://www.microscan.com/http://www.ni.com/visionhttp://whatis.techtarget.com/definition/0,,sid9_gci212508,00.htmlhttp://www.answers.com/topic/computer-visionhttp://en.wikipedia.org/wiki/Machine_visionhttp://www.vimatic.com.my/machinevisionhttp://www.microscan.com/http://www.ni.com/vision8/8/2019 Resubmit Group Project-Final Report
32/32
INFO 6240Group Assignment
Emerging Technology
http://www.cognex.com
Article from: Product Line Card 2009 Microscan Systems, Inc. ML006A
05/09
Article from: Mechanical Engineering-CIME, Article date: July 1, 1992, Author:
Puttre, Michael, see http://www.highbeam.com/doc/1G1-12525307.html
http://www.cognex.com/http://www.highbeam.com/doc/1G1-12525307.htmlhttp://www.cognex.com/http://www.highbeam.com/doc/1G1-12525307.html