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In Focus - Archive October 2009
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More and more industries tap the full potential of machine vision systems
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02.10.2009 -
Whether in the supermarket, on the highway, at the airport, or in the factory; pictures are being taken by a camera system and are evaluated with a computer, in order to make a fully-automatic, quick and safe decision. What is the price for a pound of butter? Did the truck pay its toll? Does the suitcase contain dangerous objects? Did the robot install the right component in the correct place of the car? No other industry advanced so quickly in the last few years as machine vision. The aptitude of modern computers to process information within the shortest possible time opens up possibilities, which even today cannot be judged completely. Today the trend goes to more compact, efficient, and easy to handle components. In the future, they will provide quality and efficiency in many branches of industry.
In 1979, a German manufacturer presented a first industry-standard machine vision system called "Intellect". With a weight of ten kilograms it belonged to the first generation of machine vision systems, used in the manufacturing industry for controlling the product quality. At a converted price of 87,000 Euros, the "Intellect" cost a bit much.
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Beady-eyed the vision sensors take care for perfect quality around the clock. Faulty components are gripped at lightning speed and separated.
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Highest aim: Perfect Quality
In the 90’s, progress in the field of quality management supported the demand of the industry for systems used for automatic quality control. Here the precursors were the automobile manufacturers and their suppliers. No matter of qualification and motivation of the worker at the assembly belt, the quality of each production step needed to be controlled and documented. A second incitement was the booming semi conductor industry. For being able to control smaller structures faster and faster, the development of efficient hardware and software was necessary. At that time the "grip of the robot to pick items from a box" symbolized the imagination of leading managers, of how industry should look in the future: humans would be relieved from monotonous and dangerous jobs. The robot will take over all of these jobs.
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A vision solution combined with the suitable gripping systems is the pacemaker for salami handling.
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Targeted seeing, gripping and sorting. A typical task for vision sensors.
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For every application the suitable system
The times where machine vision systems were considered to be complicated and expensive now belong to the past. In the meantime, technically sophisticated and user-friendly components open new fields of application for automation. Since the millennium change three main tendencies with different strengths have been established in the field of machine vision. For choosing the matching system a detailed analysis is helpful. What will be the task? What are the inspection characteristics? How are the lightning conditions? Do the objects move? And if this should be the case, how fast does it move? These and many other questions are keys for successfully, safely and efficiently solving problems such as the aforementioned "gripping from the box" for our colleague the robot.
The most efficient systems are still the computer-based systems. Optimized for the unique tasks, experts select and program the individual components. Anything that can be programmed and displayed efficiently is possible. However even today, the maintenance costs for such a system are rather high. For example, a vision system determines position and orientation of miniature salamis on an assembly belt and this information is transferred to the robot controller. The robot finally grips with a special gripper and places the delicate food into the correct position.
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Modern machine vision solutions are easy to handle
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The vision sensor SVS-VC from SCHUNK is suitable for manifold applications.
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A second segment is the intelligent camera systems: The so-called "smart camera systems", which were already designed in the mid 80’s as intelligent cameras and are continuously improving. In the camera housing of these systems optical systems and evaluation electronics are integrated. Picture recording and evaluation are carried out immediately; this means without the need of an additional PC. After adjustment, the systems are working automatically and issue the results. Even here, a minimum of expert knowledge is necessary, which can be acquired during trainings.
The third branch is composed by vision sensors. These efficient and small machine vision systems provide a higher functionality than conventional sensors, such as laser sensing devices. Vision sensors are functional machine vision systems with integrated illumination and pre-adjusted optics. Hereby the complexity, which steadily increases inside the system, is further reduced for the operator. The simple system eliminates complexity at the same efficiency. From a market for exotic special applications a mass market develops, which in the meantime reaches different industries.
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SVS-VC from SCHUNK combines in a compact housing beside the camera and the object lens, the LED illumination and evaluation unit including the software and interface.
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All-in-one sensors belong to the future
All necessary system components are integrated inside the compact units. By pressing the teach button or at a low parameterization they can be operated easily and intuitively. Installation and initial operation is possible in a short period of time. Simple integration possibilities into the controller equipment are important. Standardized protocols thereby simplify the exchange of information between the actuator and sensor. High efficiency is the result of a streamlined, intuitive and operable self-learning parameterization software as well as the reliability of the system which is achieved by integrated and effective illumination.
Operation of compact modules is pretty simple: With the object size the user adjusts the camera of the vision sensor. By simple parameterization, the program is adjusted and generates the desired result.
Generally the functionality of the sensors is adapted to special applications. They are suitable for simple tasks, which have to be carried out completely and at low cost. Where complex vision systems are too big and expensive, vision sensors are the first choice. Basically they are used where mass-produced goods are produced at high cycle times - from electronics to automotive industry up to packaging, food processing industry, pharmaceuticals and medical industry. The control of components and the determination of the rotational position of objects on the assembly belt as well as their alignment are typical applications.
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SVS-VC from SCHUNK combines in a compact housing beside the camera and the object lens, the LED illumination and evaluation unit including the software and interface.
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Compact, autarkic and intuitive operation
An example for modern solutions in the field of machine vision is the SVS-VC. The intelligent sensor of SCHUNK, the leading expert in automation, is able to fulfill a multitude of image processing tasks without the need of peripheral equipment. It can inspect mechanic components such as pencils, rings, nuts, and screws on completeness and presence and carries out controls on assembly and characteristics. It recognizes edge disruptions, registers position of locks and etiquettes, separates wrong parts or makes sure in pick & place applications, that the components with different rotational positions and even flexible objects such as cables and hoses can be gripped safely.
The compact housing of the vision system SVS-VC combines beside the camera and object lens, also the LED illumination and the evaluation unit including software and interfaces. In the simplest case it is enough to connect the sensor with the power supply and to teach it in via two keys. After the teach-in, the sensor puts out a signal via the signaling line and shows, if a part is present or missing. It is not necessary for the operator to program an application on a computer first and then transfer it onto the sensor. He can start working immediately. This way, even unpracticed operators intuitively achieve a machine vision solution quickly. For demanding tasks, an adjusted software is available for object and position recognition, which is designed for highest ease of use.
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Where does the development go to?
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Since some years applications with stereoscopic pictures and stereo cameras are becoming more and more important in the industrial environment. New technologies such as highly integrated laser distance sensors at small semi conductor sensors open new fields of application in future, e.g. the control of robot systems. Heat images in the production process using machine vision algorithms will allow online quality controls in future.
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Conclusion:
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Vision systems are the eyes in automation. Where optical controls were carried out by humans in the past, vision systems will increasingly carry out these tasks - faster, precise, safe, and available around the clock. The trend for standard tasks increasingly goes to vision sensors. The low-priced and nevertheless efficient units are suitable for numerous applications and disposes of an excellent cost/performance ratio.
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11.2009
Straightaway micron-precise
In addition to a high repeat accuracy, in modern machine tools, positioning-, measuring- and handling the accuracy of the axial movement is now playing an important role. In this way, precise parts for the production or electronic industry, can be designed with a micron-precise guidance along the complete axis.
 more...
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10.2009
How Machines Can Learn To See
More and more industries tap the full potential of machine vision systems. Whether in the supermarket, on the highway, at the airport, or in the factory; pictures are being taken by a camera system and are evaluated with a computer, in order to make a fully-automatic, quick and safe decision.
more...
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09.2009
Hydraulic expansion technology for workpiece clamping
Hydraulic expansion toolholders for tool clamping (milling cutter, drills, taps and reamers) are known on the market for a long time and are appreciated for their technical advantages. They combine powerful, centric clamping with a high internal dampening. The result is an excellent surface at high machining speeds.
more...
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08.2009
Gripping - checking - measuring - preventing from damage
Intelligent sensors transform actuators to sensitive helpers in automation
Sensors used in automation are essential organs of machines and plants. While gripping modules and other actuators performed pre-defined tasks in the past, today, they are intelligent and flexible helpers in the manufacturing process due to the use of intelligent sensors. They provide the plant with important information on the process, products or components as well as plant functions. This increases flexibility, shortens manufacturing time, ensures product quality, avoids plant failures, and prevents the automation systems from damage.
more...
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07.2009
The trend towards precision toolholders
For many years, collet chucks have been popular because of their low pricing and have been the established toolholders for many machining applications. Unfortunately, the same scenario happens in many companies: Because of worry over loose tools, many machine operators are tightening the coolant tube nut of the collet mountings with oversized extensions.
more...
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06.2009
Always up-to-date with the standards - The new machinery directive in the EC
The safety of products and systems traditionally tops the priority list at SCHUNK. Since we want to partner with our customers, we are exclusively offering top-of-the-line products in quality and safety.
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05.2009
Highly economical due to performance in toolholding and workholding
5-axis machines offer an enormous potential for efficiency in modern production. With sturdy machine kinematics, high axis accelerations, short chip-to-chip times, fast tool magazines and finely tuned controllers, you have all kinds of production power in a very small space.
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04.2009
Microvalve Technology
- Small component handling and assembly
Anyone who wants to handle or assemble small, light parts can really get a move on with electromagnetic microvalves. These energy-efficient valves are screwed directly onto the pneumatic actuator and thus eliminate the need for long wires. They make the tempo significantly faster and thus save compressed air, complicated wiring, and a lot of assembly time.
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03.2009
Reliable precision for the most well-hidden corners
Regardless of their design sophistication, it is sometimes impossible to avoid cre-ating hard-to-reach points on workpieces. All of these cases require slim toolholder systems with minimized interference contours. They have to penetrate into the most well-hidden corners, transmit sufficient torque and guarantee high precision at the same time.
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02.2009
The foundry sector: a red-hot key industry
With 87,000 employees and sales of around €14 billion in 2007, the foundry sector is one of German industry's smaller branches. Its economic significance is large.
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In Focus - 2013
In Focus - Archive 2012
In Focus - Archive 2011
In Focus - Archive 2010
In Focus - Archive 2009
In Focus - Archive 2008
In Focus - Archive 2007
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