Turnkey Machine Vision: Ready to Go - Feature Article - Vision and Sensors

From QUALITY Magazine's Vision & Sensors section, here is an article I was interviewed in regarding Turnkey Machine Vision Systems and the need to custom-tailor solutions to the specific application:

Turnkey Machine Vision: Ready to Go - Feature Article - Vision and Sensors

Why the need to use an experienced Systems Integrator in Machine Vision?

To me, this is like asking the question: Do you want the system to be successful? The obvious answer is YES! The less fortunate part is that success will mean cost. Granted in this case, cost = value!

Deploying a successful Machine Vision Inspection System requires a variety of knowledge and skills that an experienced Systems Integrator holds:

1. Knowledge of Cameras, Lights, and Optics

• Camera Sensor requirements
• Smart Camera? Smart Sensor?
• Camera Processing Requirements
• Field of View requirements
• Lens requirements
• Application - color vs monochrome
• Linescan vs Area-Scan cameras
• Image Resolution
• Choice of Lighting? (lighting can easily "make or break" a machine vision application). Dome light? DOAL Light? Indirect/direct? Low Angle? Spot/Brick? Backlight? Structural Lighting?Mechanical constraints?

2. Knowledge of Image Processing Algorithms and Techniques

• Blob Inspection, Filtering, and Analysis
• Pattern Matching (2D/3D)
• Image Filters
• Former Application Experience

3. Knowledge of System Integration

• Communication to existing controls (Ethernet TCP/IP, EthernetIP, Profibus, Modbus, Serial, etc.), and understanding various communication protocols
• Is a separate PLC required? If so, knowledge to choose an appropriate processor
• Is product reject required? If so, programming of product tracking & reject
• How will the camera be triggered? Photoeye? Encoder?
• Data Recording Required? Where will data be stored?
• Use of an HMI?

4. Mechanical & Electrical Design Knowledge

• Electrical Design - ACAD Drawings, Power requirements, I/O requirements
• Mechanical Design - (note - there are many "flimsy" systems out there! Don't let your project become one of them!) "Centerlining", experience in mounting requirements, positional tolerances per the application, etc.

5. Experience in System Maintenance Requirements & End-User Training

• This is important. Once a system is installed - who will maintain it? Often this falls to the end-user. But has the end-user received training? An experienced Systems Integrator in Machine Vision technology has the ability to properly train the end-user (Plant/Factory) on the "How To" of the vision system; and can provide recommendations on preventative maintenance, system maintenance, product setup, alignment, calibration, and troubleshooting, etc.

6. Previous Application Experience

• Right away, an expert in Machine Vision integration will be able to point out a variety of potential pitfalls, mechanical or electrical issues/constraints, application feasibility, product fixturing problems, and many other "unexpected" problems.

Experience equals Value to the customer and success for the project!