Increased throughput, higher quality, and lower costs are the main drivers for using automated testing in production. Manual testing as in the past can slow down the process, be error prone, and often inefficient considering product size, lighting conditions, or line speeds. Most manufacturers use automated machine vision because it is more suitable for repetitive inspection tasks. Machine vision is faster, more objective, and continuous. The system can test hundreds or even thousands of parts per minute and provide more consistent and reliable test results – 24 hours a day, 7 days a week. Machine vision can also collect data for downstream process control and improvement.
So while the business need for machine vision may not be a difficult decision, choosing the correct components for a machine vision platform can be. Choosing the right machine vision platform often depends on the requirements of the application, including development environment, capabilities, architecture, and cost. Machine vision implementation platforms can vary, including PC-based systems, vision controllers designed for 3D applications and multiple 2D cameras, stand-alone vision systems, vision sensors Simple and image-based barcode reader .
In this article, we’ll explore the many components of a machine vision system — from lights, lenses, image sensors, controllers, vision tools, and communication protocols — to help buyers make informed choices.
Lighting: Illuminates the part under test, allowing its features to stand out so that they can be clearly seen by the camera.
Lens: Take a picture and display it to the sensor as light.
Image sensor: Converts light into a digital image, which is then sent to a processor for analysis.
Vision processing engine: Processing and optimizing images for analysis; review the image and extract the necessary information; use algorithms to run necessary checks and make related decisions.
Communication: Discrete I/O signal or data sent over a serial connection to a device that is recording information or using it.
Most machine vision hardware components, such as lighting modules, sensors, and processors are commercially available (COTS). Machine vision systems can be assembled from COTS or purchased as an integrated system with all components in a single device.
Source: Cognex