Validating a vision system

Source: Radix Today’s integrated machine vision systems can range from a very simple single camera to an array of multiple cameras at one operational cell inspecting hundreds of features on a single part.Often these systems are created after the development and execution of the assembly process and core automation.With the proliferation of vision system hardware and software, today solving vision related problems has become much more economically feasible and achievable.

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As a machine vision system integrator providing an effective solution to address the quality issues affecting the part, it is often a challenging endeavor to inject automation after the fact.

These turnkey machine vision systems need to integrate within the existing physical and control logic structure of the current operational cell.

Often times a customer expresses to the machine vision integrator the specific quality issues that are affecting the part with no regard for the process and constraints imposed while the part is being manufactured.

It is good practice to video the station in question to permit the entire integration team to review all aspects of the existing cell to ensure a good understanding of the cell prior to the final design phase.

This approach ensures that only the light provided by the vision integrator is what is seen within the vision application.

Once the physical aspects of the cell and solution become clear the customer must be engaged in regards to the points of interest on the part that will dictate the “PASS” or “FAIL” state of any one part during manufacturing.Source: Radix This is a multiple camera system used to validate the fit and correct assembly of a fastener and clip assembly.There are three assembly steps for this part and after each step the part is inspected.Statistically speaking this would mean an infinite number of each to ensure the set points for each measured feature can be calculated.Without this collection of parts it is impossible to create an effective vision solution.The use of smart cameras makes economic sense when the camera count to solve the problem is low, as these systems are much more costly than PC systems.The smart camera does have some advantages in that they tend to be industrially hardened with ratings of up to IP67 (dust tight and submersible to one meter), an ability to connect to various programmable logic controllers (PLC) types and perform native IO operations and thus not require a control panel.What can be a surprising aspect of machine vision to a new vision system customer is the concept of having a few false reject events to occur to ensure that no false accepts take place.During the design phase of the vision algorithms it is required that a customer provide a collection of “Good” parts as well as a pool of “Bad” parts.This large inspection station (this is only a small portion) is used to check over 100 features and measurements on an aluminum engine head. Source: Radix This turnkey vision system uses six Gig E cameras with a custom written application to validate the correct assembly and dimensional fit of two subassemblies on a clip assembly just prior to the mounting onto an automotive cross member.Source: Radix If the data does not have two mutually exclusive distributions of results there will thus be a need to reject some good parts to ensure no faulted parts are passed and allowed to continue to the customer.

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