Vision Systems
KEYENCE is constantly developing advanced, proprietary vision system technology. With such a range of innovative products, this lineup provides solutions to numerous problems that occur every day at manufacturing sites. These products include all-in-one smart cameras as well as modular high-speed controllers for 2D, line scan, and 3D cameras. When building vision inspections, AI and rule-based vision tools provide options for any application. In addition to worldclass hardware and powerful software, this lineup extends to lenses, lighting, and peripheral equipment for simple optimal image creation with all necessary equipment.
Recommended Items
Products Lineup : Vision Systems
The VS Series delivers rapid machine vision solutions for a wide range of applications at any experience level. This smart camera includes the industry’s first optical zoom function to create optimal images with a single click. The simple-to-use software also enables quick setup of a variety of inspections for both AI and rule-based vision tools. With this simplified setup and ease-of-use interface, the VS Series provides optimised vision solutions as quickly as possible.
High Performance, Icon-driven system with easy-to-use tools for simple setup by any user.
Flexible programming interface with 3D and linescan capabilities for high-quality, high-speed inspection and control.
High-speed cameras for inspection and defect analysis on large parts, continuous webs, and cylinders.
Vision Systems for pick and place applications, with direct connection and automatic calibration for most major robot manufacturers.
Products Lineup : Other Accessories
High-intensity lighting to ensure high quality images are captured every time.
Ultra high-resolution, low distortion lensing for area and line scan cameras.
A vision system combines industrial cameras, lenses, and lighting to automate visual inspections of manufactured products. KEYENCE vision systems are controller based, which enables them to be the fastest and most versatile systems on the market. Vision systems can be used in a wide range of applications, such as defect detection, assembly checks, character and code reading and positioning for industrial robots.
Vision system principles and mechanisms
Vision systems can be customised to fit specific application needs, and each system generally consists of a camera, lights and a controller (image processing unit). This section introduces principles of using a vision system for inspections and explains the process from the beginning of capturing an image to the end of outputting inspection results.
1. Image capturing
To capture an image, light illuminates a target and this light is focused back through a lens onto the camera’s image sensor. The gathered image data from this capture is then transferred to the vision controller for image processing and judgement.
2. Pre-processing
Pre-processing operations remove unwanted/noisy qualities while emphasising wanted features in the image data before analysing the images. These operations are customized for the inspection and examples include image filtering and colour extraction.
3. Measurement processing
After an image has been pre-processed, inspections like measurement, positioning, counting, OCR/code reading and defect detection can take place.
4. Sorting/Output
Processed image data is used to perform OK/NG judgement, record measured results or categorize parts. Both images and data output, and communication with other devices can be established.
Diverse applications within various industries can be solved with visual inspections. Vision systems from KEYENCE provide easy to use interfaces with powerful results thanks to intuitive software and customisable hardware. Proper selection of cameras, lighting and controllers is essential to tailor and optimize inline inspections. Additionally, inspections are customized to each application to ensure proper criteria are met.
In addition to part identification, defect detection and verification, vision systems can be used for the growing need of vision-guided robotics. KEYENCE vision systems are designed to connect directly to all major brands of robot controllers. Provided robot programs for each manufacturer eliminate complicated robot programming for the end user. Supported brands include FANUC, Yaskawa, ABB, KUKA, Denso, Epson, Kawasaki, Mitsubishi, Staubli, Yamaha, Universal Robots and more.
Benefits of Vision Systems
Adopting a vision system makes it possible to perform 100% inline inspection automatically for items that would otherwise need to be inspected manually. No additional costs are needed after the vision system is installed and variation in judgement results between operators can be eliminated.
Improvements in vision system technology have enabled advanced, automated inline inspections for any level of user. It’s now possible to inspect 100% of products on high-speed manufacturing lines, so defective parts can be identified before additional processing or release. If similar inspections were done manually by operators, this process would be slower and less reliable.
Thanks to high-speed cameras and image processors, multiple images can be taken under different lighting conditions fast enough for 100% inline inspection. This makes it possible to complete multiple inspections at the same time using variable lighting to pull out complex or low-contrast features and defects.
Using a vision system to act as the "eyes" of an industrial robot can significantly improve the accuracy and efficiency of advanced picking operations. The vision system detects a product’s position in the robot's coordinate system and outputs these measurements directly to the robot controller for dynamic adjustment.
Conventional industrial robots require operators to specify coordinates manually using a teaching pendant. This manual operation can be time consuming and accuracy may vary between operators. KEYENCE vision systems can communicate directly with many robot manufacturers, allowing for easy connection and efficient programming of the robot. This connection automates the cumbersome tasks of calibration and calculation which stabilises inspections and reduces the time required for integration.
Vision System Case Studies
Case studies of vision systems in the automotive industry
In the automotive industry, even a small defect can result in a serious accident. To mitigate this potential risk, strict inspection requirements ensure rigorous quality and safety standards. Vision systems allow users to meet quality specifications, increase efficiency, reduce costs, improve accuracy and ensure traceability of component inspections. Application examples include:
- Presence detection: moisture-proofing agents on ECU's and fuse assembly checks
- Appearance inspections: DPF, oil seal, engine valve, piston coating and differential gears
- Measurement/alignment checks: battery positioning, bent connector terminals, spark plug dimensions and gather positional data for robotic pick and place applications
Case studies of vision systems in the food and medicine industries
In the food and medical industries, inspection standards are regularly strengthened and traceability is required to ensure safety. A vision system makes it possible to automate inspections and easily store image/result data. Application examples include:
- Presence detection: ensure proper case count, multiple components such as straws adhered to drink cartons
- Appearance inspections: character recognition (OCR) for lot codes, proper forming and no defects in food trays, shrink wrap, blister packs and cans
- Measurement/alignment checks: label placement, seal width and position, needle dimensions and gather positional data for robotic pick and place applications
Case studies of vision systems in the electronic devices industry
As electronics such as smartphones, gaming consoles and PC's become smaller and thinner, their semiconductors and other electronic components need to be even more compact and accurate. KEYENCE vision systems improve inspection accuracy to meet the growing needs of these precise assemblies. Additionally, 3D vision systems bring ultimate stability to these inspections to identify height changes despite low contrast in materials. Application examples include:
- Presence detection: pins, connectors, solder
- Appearance inspections: crystal oscillators, IC molds, LEDs
- Measurement/alignment checks: Connector pin co-planarity, tray orientation, PCB warpage, terminal heights
Case studies of vision systems in the resin and container industries
Vision systems are used in the moulding and resin industries to automate inspections and ensure defective products are not released. These inspections are necessary to detect any mishaps in processes such as injection moulding, plastic forming, laminations, and product labeling. Application examples include:
- Presence detection: resin coatings, cap presence, proper labeling
- Appearance inspections: container inner surface inspection, product flash, resin scratching/chipping, foreign particles, pin holes
- Measurement/alignment checks: gasket centre misalignment detection, label misalignment detection, bottle opening dimensions
Vision systems rely on a combination of cameras and software to inspect objects automatically. The system would use one or more high-resolution cameras to capture the images and data of the object being inspected in real time. This image capture is also incredibly accurate, granting these systems levels of accuracy in single-digit microns.
Once the images and other data have been captured and collected, they’re relayed to a computing unit for processing by dedicated software solutions. This could potentially involve techniques like filtering, edge detection, pattern recognition or even colour analysis to identify different properties associated with an observed object and various inspection requirements. Once the image is processed, the processing software extracts relevant information, including measurement, presence or absence of different components, defects, etc. These metrics are then compared against pre-set standards or criteria, leading to subsequent decision-making based on the results of the comparison.
Decision-making could be as simple as a pass-fail outcome or as complex as the location of a specific defect. Vision Inspections systems can be further programmed to either alert the operator, trigger automated actions, or gather data for QA. What’s great about these systems is that they’re fully customisable and they often use machine learning to adapt to new patterns for greater efficiency.
The most cutting-edge features associated with vision solutions mostly depend on the applications of such systems. Generally speaking, the integrability between vision systems and other automated machinery is perhaps the most cutting-edge feature associated with vision solutions.
The same applies to wireless connectivity implementations, especially 5G connectivity options, as these allow for quick transfers of large amounts of data, thus allowing for faster decision-making on the part of the system’s machine learning or artificial intelligence. While on the subject of AI, these particular implementations revolutionised various industries, and vision systems are no different. The improved AI implementations allow vision systems technology to better interpret the data and solve difficult applications.
These systems can be used for colour and product type inspections, measurement applications, character recognition, defect detection and more.
These systems can subsequently be used for the following:
- Connector cable colour difference check
- Front/Back differentiation for pressed metal parts
- Product type differentiation of injectors
- Sealing tape presence detection
- Identifying groove detection in gear assembly processes
- Coating inspection on ECU
- Lead frame plating inspection
- Presence inspection for seasoning packets
- Screw processing presence detection
- Part mounting confirmation
- Hot melt presence detection
- Detection of remaining moulded products
- Retaining ring detection
- Bottle count in cases
- Product type differentiation/2D identification of IC packages
- Chip count
- Various part inspection inside tray
- PCB solder appearance inspection
- Transmission assembly and sealant inspection
- Busbar flatness measurement
- Inspection of connector housing and pins
- Lithium-ion battery sealing plate top surface welding inspection
- Torque converter assembly inspection
- ECU PCB solder inspection
- Alignment for mounting of camera module
- Electronic PCB laser alignment
- Wafer alignment
- Battery lamination layer alignment
- ECU sealant coat inspection
- Electronic component inspection
- Appearance inspection - printed surface of batteries
- Differential gear appearance inspection
- Black rubber sheet appearance inspection
- Inspection for foreign particles in jelly after filling
- O-ring burr inspection
- Appearance inspection of battery housing
- Wound coil appearance inspection
When using a vision system, the hardware will be selected based on the application specifications and desired inspection details. This section outlines how to select the best camera, lens, lighting, controller and any other accessories needed.
Selecting a Camera
Area cameras are categorised into four main groups: high-resolution models, high-speed models, standard models and compact models. Each model has the ability to be colour or monochrome. The correct camera is dependent on the application, which is outlined below.
1) Determine the number of pixels necessary to meet accuracy requirements.
2) Select the transfer speed based on the needs of the application.
3) Select a camera size based on installation space.
4) Select either a colour or monochrome camera based on what kind of inspection is needed.
Advanced Inspections: Line scan cameras and 3D cameras
KEYENCE offers other camera solutions as well, including line scan cameras that can detect subtle or minute defects. Additionally, KEYENCE offers cameras with 3D capability that can also accomplish 2D and 3D simultaneous inspection on a single vision system.
Selecting a Lens
When choosing the right lens for the vision system, there are a variety of factors to consider. Both the field of view (FOV) and working distance (WD) of the inspection will determine the right lens focal distance for image capture. The depth of field (range of the depth of focus) and contrast are other important considerations when selecting a lens. A general selection procedure is outlined below.
(1) Determine the focal distance based on image capture size (FOV) and installation distance requirements (WD).
(2) Determine the depth of field needed based on the height and shape of the target. Targets with varying height surfaces and features will require a greater depth of field. The depth of field will increase as working distance increases, as focal length decreases and as the aperture becomes narrower.
(3) Select a high-resolution lens or standard lens according to the necessary inspection accuracy and contrast of the target.
Selecting lighting
The lighting direction, colour, and type will be determined by a combination of target characteristics, inspection needs and the surrounding environment. Outlined below is a general lighting selection process:
(1) Decide the direction of the lighting: Depending on the material and shape of the target along with the inspection purpose, select one of the following illumination types: specular reflection, diffuse reflection or transmission.
(2) Decide the lighting shape and size: If choosing specular reflection in Step 1, select either coaxial lighting, ring lighting or bar lighting. If choosing diffuse reflection, select either low-angle lighting, ring lighting or bar lighting. If choosing transmission, select either surface lighting or ring lighting.
(3) Decide the colour (wavelength) of the lighting: For colour camera inspections, white lighting is standard. For monochrome camera inspections, coloured lighting can help enhance image contrast using complementary colours and wavelengths.
Advanced Inspections: Multi-functional, high-performance lighting units
Using new inspection algorithms with a multi-functional, high-performance lighting unit that can project light in multiple directions, multiple wavelengths, various patterns and other ways can solve a variety of problems experienced with conventional single-function lighting. Advanced lighting can be used to meet challenging inspection requirements such as glare removal, extraction of only irregularities on a patterned background, differentiation of subtle colour differences, 3D inspections and efficient performance with multiple inspection items.
Frequently Asked Questions About Vision Systems
A colour camera is generally preferred when inspecting for changes or irregularities in colour. Each pixel of a colour image holds RGB information, which is three times the data of a monochrome pixel. Because there is more data per pixel, extraction and differentiation is easier.
Monochrome cameras are preferred for measurement type inspections, where strong edge extraction is needed. Monochrome cameras are also commonly paired with coloured lighting to aid in inspection. Examples include mitigating ambient light, causing a UV-dyed material to fluoresce and emphasising surface scratches.
Traditionally, coloured lighting is paired with a monochrome camera, and the colour (wavelength) of light will vary depending on the desired inspection. Colours which closely match a given target or are complementary to the target colour can strategically manipulate and stabilise the image. To differentiate subtle differences in surface characteristics and further stabilise inspections, an intelligent lighting method called Multi-Spectrum uses eight different colours of light to gather more pixel data per pixel. Having data from multiple wavelengths creates more contrast between like-colours, and a true colour image can be shown on the operation screen despite using a monochrome camera.
KEYENCE vision systems can perform appearance inspections on a variety of target surfaces. Sophisticated inspection algorithms, such as the defect tool, can detect localised changes in contrast to identify scratches and stains. Because the inspection looks for localised changes, external influences like ambient light do not disrupt the inspection. In addition to robust inspection tools, 24 image enhancement filters are available to reduce the effects of uneven lighting, rough surfaces or variation among products. Two noteworthy filters are the scratch defect extraction, which enhances linear flaws on rough targets, and the shading correction, which emphasises sharp changes in contrast while eliminating gradual ones.
Stable detection of burrs and chips relies on the accuracy of edge extraction. KEYENCE vision systems include profile defect tools which precisely extract lines, circles, ovals and free form curves to detect any sections which stray too far from the expected shape. The user can specify thresholds to control the size and severity of considered flaws.
All KEYENCE vision systems include a wide range of measurement and dimension tools which make finding intersections, midpoints, and distances very simple. For example, simply click anywhere along an edge to auto-extract that line, or refer to line results from a tool which has already been configured. This intuitive interface allows users to easily create complex inspection settings while combining several measurements and dimensions.
Vision systems are used for a variety of applications, including quality control and inspection in manufacturing, automated guidance in robotics and even security surveillance.
They utilise advanced vision systems technology such as image processing algorithms and artificial intelligence to accurately identify and analyse images or objects. With their high-speed capabilities and precision, vision systems have become an essential tool in many industries, providing reliable and efficient solutions for a wide range of tasks.
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