Quality January 2011

January 2011, Volume 50/Number 1 www.qualitymag.com

V I S I T J O E G I B B S R A C I N G | S E E p . 8 0 F O R D E TA I L S

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CONTENTS

JANUARY 2011 VOLUME 50/NUMBER 1

DEPARTMENTS 6

From the Editor 50 Years in the Making

8

Industry News

Source: Mahr Federal Inc.

ASQ 2011 Manufacturing Survey Reveals Brighter Outlook  X-ray Inspection Systems Markets Increasingly Diverse

28 FEATURES

 PMA Report Forecasts Few Economic Changes in Coming Months

18 Face of Quality 50 YEARS OF QUALITY

26 The Pros and Cons of Optical Comparators The reason comparators have not changed much in 85 years is because the fundamental technology behind an optical comparator is elegantly simple, and it simply works.

QUALITY MEASUREMENT

28 Driving to the Finish The automotive industry has special needs that make dedicated surface finish gages a necessity.

QUALITY TEST & INSPECTION

38 Data Leads to Good Leak Test Decisions Through the adoption of new leak testing approaches that provide comprehensive data about the entire leak test cycle, manufacturers can get more out of their leak test.

44 Laser Doppler Vibrometers Rewrite the Book Laser vibrometry is rewriting how today’s engineers measure vibration in the lab, on the production floor and in the field.

52 Spectroscopy Simplified Advances in FT-IR spectrometers and software enable improved sample verification and increased confidence in QA/QC testing.

QUALITY MANAGEMENT

56 The Need for ISO 13485 The increasing need for quality medical devices is matched by the need for compliance with ISO 13485: 2003.

The Quality Profession Continues to Evolve

20 Other Dimensions Certificates of Confusion

22 Quality 101 CAD Overlay Inspection Basics

24 Quality Innovations 3-D Inspection in Color

58 Case Study  Accuracy in Production  An Upgraded Inspection Process

66 Quality Products 78 Classifieds 79 Advertising Index

NEXT MONTH  Noncontact Inspection  Machine Vision  Enterprisewide Software  Quality Leadership 100

ABOUT THE COVER The fact is that nothing is 100% sealed; everything leaks, whether it is supposed to or not. The challenge for manufacturers is to determine whether the leakage is acceptable from product quality and regulatory compliance perspectives. Source: Sciemetric Instruments

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QUALITY | January 2011

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Measurably Different Fetura® Vision Metrology Systems set the new benchmark for throughput and precision Fetura Vision Metrology Systems combine the world’s fastest optical zoom technology with powerful software and precision mechanics to offer a notable advantage in offline inspection and quality control productivity. • Image Navigator streamlines maneuvering around complex parts • Color edge detection finds edges that grayscale cannot • Intelligent lighting automatically cally sets intensity for optimal imaging aging Discover the Q! • Visual Basic scripting speedss customized programming WEST • Optional laser autofocus and d scanning for surface analysiss Booth 2273 • Multipoint autofocus streamlines mlines detailed surface topography • Optional PowerMatch software compares direct to CAD

MD&M

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O N L I N E TA B L E O F C O N T E N T S

JA N UA R Y 2011

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QUALILITT YMAG.COM February 23, 2:00 p.m. ET A Streamlined 3-D Approach A municipal ice rink recently contracted an engineering firm to install new cooling equipment in the mechanical room. The challenge for the engineers was to limit the downtime while updating the old cooling unit. The firm was able to quickly perform updates with minimal disruption of the structures’ functions through 3-D laser scanning. Becoming a Lean Machine IBM is transforming its manufacturing into a leaner, more efficient operation. By using deep business analytics, simplifying its offerings and product development and implanting test clouds, the company is cutting costs and getting products to market more quickly. Quality Bingo A twist on the classic game, Quality Bingo is meant to enhance employee productivity by educating its players. The game encourages workers to improve metrics and meet goals to support continuous improvement efforts.

Introduction to Precision Ultrasonic Thickness Gages and Applications

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QUALITY | January 2011

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Look closer.

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F RO M T H E EDI TOR

B Y GIL L IA N C A MP B E L L

50 Years in the Making W

Gillian Campbell is editor of Quality Magazine. Gillian can be reached at [email protected].

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elcome to our golden anniversary. Quality Assurance, as we were originally known, launched in 1962, back at the early stages of the space exploration program and the dawn of man in space. As people watched a space capsule take off, many wondered: will it work? Then, upon re-entry, when the astronaut was fished from the ocean, one thought dominated: what if the cable snaps? As W.F. Schleicher, the magazine’s first publisher and editor, pointed out, “The prayer and hope that the thing and all its parts will work is the culmination of many long nights of work; the finale to a monumental formula of quality assurance, men and natural laws. By the innocent phrase, ‘will it work?’ dangles life—and liberty.” While, at the time, the space exploration program was an extreme example of all things coming together to prove its weight in quality, today we rarely wonder “will it work?” We just assume that whatever we buy—a car, computer, cell phone, lamp or tape dispenser—will work, rarely giving quality a second thought unless there’s a recall. In 2010 there were various recalls because quality standards weren’t met, but many of those recalls were because corners were cut, and quality standards were glossed over or ignored altogether. It sent a loud and clear message to everyone from management to consumers that quality is a necessity and in place for a reason. As I look back at the magazine’s original mission statement, the message we sent 50 years ago still resonates today. Take a look at this passage from our inaugural issue.

Quality Assurance believes: …nothing is more important to America than the quality of its products. …a sound quality assurance program increases efficiency, decreases costs, meets competition, increases sales and reduces the profit squeeze. …quality is management’s concern, with which it must live, think and sleep. From management it must permeate every corner of the plant. …quality assurance people are the fastest growing group of professionals in industry—and none in industry is more important. To unify all aspects of quality assurance; to broaden knowledge and understanding of management and quality assurance professionals; to continually reiterate the importance of quality to America; to oppose and perversion of the quality assurance function; and to continually champion new techniques, greater efforts and always superior products… With the exception of the number of people involved in the quality field and the fact that we now reach a global audience, the message remains very much the same. What’s your take on how quality has changed—or stayed the same—over the years? Send along your thoughts to [email protected], or share with other members of the Quality community at the Quality Magazine LinkedIn Group page, the Quality Facebook page and on Twitter at http://twitter.com/QualityMagazine.

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QUALITY | January 2011

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CORPORATE DIRECTORS Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Information Technology: Scott Kesler Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec

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TOUGH

DITTO

Engineered to get its hands dirty Different people have different uses for force measurement equipment, but durability is a universal requirement. Consider the all-new Series 5 digital force gauge from Mark- 10. With key design features such as an overload-protected load cell, shock-resistant circuit board mounting, and narrow gaps in the all-aluminum housing, this gauge is engineered for your toughest jobs. Add to this an industry-leading sampling rate of 7,000 Hz, USB data output, 1,000-reading memory with statistics, ±0.1% full scale accuracy, and a rugged allaluminum housing. The Series 5 – engineered to be tough enough for anybody’s toolbox. To learn more, visit us at www.mark-10.com or call us at 888-MARK-TEN.

FORCE & TORQUE MEASUREMENT

INDUSTRYNEWS | Business News | Coming Events | People News | Mergers |

COMING EVENTS FEBRUARY 8-10 MD&M WEST Anaheim, CA Canon Trade Shows (310) 445-4200 www.canontradeshows.com 28–3/1 2011 LEAN AND SIX SIGMA CONFERENCE Phoenix, AZ (800) 248-1946 sixsigma.asq.org

APRIL 5-7 AERO DEF Anaheim, CA SME (800) 733-3976 aerodef.sme.org 11-13 QUALITY CONFERENCE Charlotte, NC Quality Magazine (888) 530-6714 www.qualitymagconference.com 19-21 FUNDAMENTALS OF RANDOM VIBRATION AND SHOCK Testing College Park, MD Equipment Reliability Institute (805) 564-1260 www.equipmentreliability.com/ vibration_course1.html

ASQ 2011 MANUFACTURING SURVEY REVEALS BRIGHTER INDUSTRY OUTLOOK

• 73% expect no mandatory furlough days. In 2010, 72% indicated they did not have to take furlough days.

MILWAUKEE, WI—The second annual American Society for Quality (ASQ) Manufacturing Outlook Survey shows a majority of manufacturers are optimistic about an economic uptick in 2011 at their organizations. The survey conducted by ASQ reveals 68% of respondents employed in the manufacturing sector predict their organizations will experience revenue growth. Despite the economic landscape, a year ago 64.7% of respondents predicted that revenue would grow in 2010. This year 67% indicated that their organizations experienced revenue growth in 2010. More than 1,200 manufacturing professionals from the United States and Canada responded to the online survey. The two areas from the survey that showed the most promise were in the area of payroll and operational budgets. Eighteen percent expect a pay freeze in 2011, compared to 44.8% in 2010 at their organizations. In addition, 18% predict mandatory budget cuts in 2011, whereas 35.2% did in 2010. Other findings include: • 48% expect of a salary/merit increase • 47% expect organizations will continue to create processes to reduce costs, down from 61.3% in 2010 • 42% expect their organizations to maintain current staff levels • 42% expect that additional staff will be brought on in their companies

As organizations made sacrifices to survive a down economy, the survey inquired whether staff reductions or other cutbacks implemented in 2010 negatively impacted the quality of the products and services delivered. Thirty three percent of respondents believed that the quality of their products and services was negatively impacted, and 32% believed that the quality did not suffer. Respondents also were asked what one tip they would give to manufacturers to ensure revenue growth in 2011. The top four tips, similar to the 2010 outlook, from respondents were: • To continue to participate in continuous improvement practices and increase use of quality processes • To increase customer satisfaction • To implement more lean processes • To reduce costs and eliminate waste.

X-RAY INSPECTION SYSTEMS MARKETS INCREASINGLY DIVERSE MOUNTAIN VIEW, CA—According to a recent Frost & Sullivan report of the X-ray inspection systems market for nondestructive testing applications, the evolution to new applications has driven the uptake of X-ray inspection systems. While advancements in technology and emergence of new application areas are making a strong case for X-ray inspection systems, it is the

MAY 1-5 ANTEC 2011, Boston, MA Society of Plastics Engineers (203) 740-5452

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QUALITY | January 2011

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ASSOCIATION NEWS  The National Tooling and Machining Association (NTMA) and Precision Metalforming Association (PMA) appointed new leaders and announced a convention in March 2011 that will mark one of the largest gatherings of small- and medium-sized manufacturing executives in recent history. NTMA appointed David Tilstone as its new president. Tilstone brings more than 35 years of metalworking experience to the role. He previously held leadership positions with Kennametal and Extrude Hone, where he focused on developing and implementing growth strategies and improving operating results. NTMA and PMA will join the Association for Manufacturing Technology (AMT) and the American Machine Tool Distributors’ Association (AMTDA) to co-host the Manufacturing for Growth (MFG) Meeting March 3-6, 2011, in Chandler, AZ. The convention brings together business owners and executives from around the country to combine resources and explore opportunities to reestablish manufacturing as a primary engine driving the U.S. economy.

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rising standard of quality and safety of critical structural components that is expected to bring in the revenues. Recent industrial disasters, such as the oil spill in the Gulf of Mexico, have placed the spotlight on the need for stringent quality control programs. Reacting to such incidents, governments across the globe have announced plans to strengthen laws to prevent industrial debacles. The aerospace industry, in an effort to fulfill high standards of safety and quality, has traditionally been the first to adopt the latest advances in X-ray technology intended for the field of medicine, said the analyst of this research. Examples of these advances are high volume, safety critical inspection applications, repair and maintenance applications, and precision 3-D material analysis. Apart from rising usage in key enduser industries such as aerospace, oil and gas, and automotive, new applica-

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BUSINESS NEWS  Nikon Metrology Inc. (Brighton, MI) opened a Western regional sales office in Irvine, CA. The facility will serve as a sales and demonstration center for current and potential Nikon Metrology customers in California, Arizona, New Mexico, Utah, Colorado, Nevada, Idaho, Wyoming and Texas. The office will be home to nearly a dozen Nikon Metrology employees who will provide customer support and sales demonstrations for customers.  The more than 300 employees who work at Eriez headquarters (Erie, PA) have set a safety record after instituting a companywide employee awareness program. According to president and CEO Tim Shuttleworth, Eriez employees have worked at least 730 days straight without a lost-time accident, surpassing the old mark of 259 days.  QMI-SAI Global (Cleveland, OH) announces the release of a new training course, Understanding and Transitioning to AS 9100 Rev C. This new course is designed to identify the differences between AS 9100’s Revision B and Revision C, and provide the necessary guidance for companies to make the transition between the two. It also will prove valuable to

those organizations seeking initial certification to AS 9100C. Attendees will experience practical workshops and simulations to develop the proper understanding of the material and enable an efficient implementation within their organizations.  Geomagic’s (Research Triangle Park, NC) reverse engineering and 3-D inspection software has been validated by the National Institute of Standards and Technology (NIST). The test verifies accuracy of features in the company’s software for a geometry used in Geomagic Studio 12 and Geomagic Qualify 12. NIST is accepted and recognized as an indicator of accuracy for technology and in setting and testing technological standards. The evaluation covers least-squares fitting methods in both Geomagic Studio and Geomagic Qualify. It was tested on 240 datasets representing geometry types including lines, circles, spheres, cylinders and cones.  Restor Metrology (Leesburg, FL) has achieved accreditation to ISO/IEC 17025 and ANSI/NCSL Z540.3-2006 for calibration services. Restor Metrology provides test equipment calibration and repair services to companies in Florida and across the United States. The company produces covers thousands of products from hundreds of manufacturers. Its capabilities include RF and microwave to 50Ghz, EMI/ EMC, general purpose electrical, mechanical, physical/ dimensional and fiber optics.

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QUALITY | January 2011

tion areas such as food safety inspection hike the demand for X-ray equipment. However, despite the increasing applications and growing need for greater productivity, quality and accuracy of inspection, the global economic downturn has caused end users to scrutinize maintenance and inspection budgets. Although there are numerous advantages offered by digital X-ray, customers’ unwillingness to move away from triedand-tested techniques such as filmbased inspection restrains short-term market growth potential and leads to limited investment in new technologies. Although the transition to a filmless future is a continuous and ongoing trend in the X-ray inspection market, film continues to play a crucial role in meeting the nondestructive testing needs of customers, notes the analyst. Particularly, in such trying economic conditions, companies with lower financial resources are unwilling to make large investments in digital radiographic technology. To attract higher investments, X-ray inspection vendors have to work closely with standards bodies and customers to understand their specific needs while leveraging advancements in technology to provide easy-to-use solutions.

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A New Name. A New Dawn of Innovation. Our name is now Bruker. The Veeco Metrology Business; AFM, Optical Profiler and Stylus Profiler product lines have successfully become part of the Bruker family. And, while our name has changed, the team, commitment and dedicated support for our full line of solutions remain. Our current facilities and worldwide team are now supplemented by Bruker’s 50 years of scientific instrumentation leadership, vast resources, over 4500 employees and 90 locations across the world. We are excited at the new possibilities, the continued commitment to our customers and the dedication to advancing the tools and solutions for the measurement and collection of nanoscale information. We are Bruker.

For more information visit www.bruker.com, email [email protected], or call +1.520.741.1044 / 800.366.9956.

Innovation with Integrity

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BUSINESS NEWS CONTINUED  CIMx Software (Cincinnati, OH) and Dynafact Software Inc. (Parry Sound, Ontario, Canada), announced a strategic technology partnership. Dynafact is integrating its finite capacity scheduling engine with CIMx’s Manufacturing Execution Software (MES) suite. The CIMx Interax suite controls the production process, from the creation of routings, quality control plans and work instructions through the execution and management of orders on the shop floor.  Illinois Tool Works Inc. (Glenview, IL) has acquired North Star Imaging Inc. (NSI, Rogers, MN). The terms of the transaction were not disclosed. NSI is a developer and manufacturer of nondestructive testing systems and software for industrial and research applications. NSI develops computed tomography and digital radiography imaging systems technologies. NSI’s systems are used in life sciences, military/defense, aerospace, security, research/education, industrial and electronics markets.  Objet Geometries Ltd. (Rehovot, Israel), the 3-D printing for rapid prototyping and additive manufacturing company, announced today that it has achieved ISO 13485: 2003 certification for medical devices. ISO 13485 specifies requirements for a comprehensive quality management system for the design and development, production, installation and servicing of medical devices. This international standard confirms Objet’s ability to provide the medical industry with 3-D printers and related services that meet the regulatory requirements applicable to medical devices.

Ultimate Gauging Freedom M1 Multi Wave is the MOST ADVANCED manual bore gauge available • Uses latest Bluetooth® Wireless transmission technology • Repeatability of 0,5 micron (0.000020 inch) guaranteed • IP67 shop floor protected • Communicates with Marposs Bluetooth® electronic devices • Communication range 10 meters (33 feet) • Ultimate quality and precision guaranteed • Marposs reliability and cost effectiveness always • Instantly measure up to 7 diameters – with one click! • Cable free & powered by Li-ion cells with inductive recharging

www.marposs.com • Toll Free 1.888.MARPOSS Bluetooth® wireless technology The Bluetooth® word mark and logos are owned by the Bluetooth SIG, Inc. and any use of such marks by Marposs is under license. Other trademarks and trade names are those of their respective owners.

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QUALITY | January 2011

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VISION & SENSORS

TA B L E O F C O N T E N T S

January 2011 18VS

DEPARTMENTS 3VS Editor’s Note Technology Drives Growth 4VS Industry News 6VS Integration Corner

Machine Vision: Back to Basics 8VS Machine Vision 101

Image Processing Broken Down 20VS Case Studies • Sensing with Robotics • Vision Sensors Improve

Wheel Fastener Productivity 25VS Advertising Index THERMAL IMAGING

12VS SEEING HEAT WITH IR Infrared cameras improve quality assurance, process monitoring and control in industrial applications. LIGHTING

16VS GAIN CONTROL OF LIGHTING Unless light is controlled, it is impossible for a vision system to perform reliably.

IN THE NEXT ISSUE GigE Interface Industrial Machine Vision Software CCD vs. CMOS ABOUT THE COVER January 2011

www.visionsensorsmag.com

SMART CAMERAS

18VS SMART CAMERAS GO MOBILE A smart camera that uses mobile computing technology has a number of advantages.

SENSING WITH

GAIN CONTROL ON

ROBOTICS

LIGHTING

p. 20VS

SEEING HEAT WITH IR p. 12VS

p. 16VS

SMART CAMERAS

GO MOBILE p. 18VS

C Cameras and power ssensors enable tthis robot to detect what it touches with w hhumanlike sensitivity. SSource: Allied Vision TTechnologies

VISIT VISION & SENSORS ONLINE AT

www.visionsensorsmag.com Vision Blogs by Ned Lecky, John Nagle and Norman Axelrod

2VS

VISION & SENSORS | January 2011

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VISION & SENSORS

FROM THE EDITOR

Technology Drives Growth Welcome to 2011! With the New Year comes new beginnings and a chance to set new resolutions and, in my case, finally use that dusty gym pass that hasn’t seen the light of day for months (real original, I know). While it’s a time to start off fresh, it also is important to look back and reflect on the things we want to change. Perhaps quality procedures in your plant need some fine-tuning or you need to take steps toward improving your manufacturing process. Maybe you’d like to invest in more technology or update your equipment. When looking back on last year, I was glad—as I’m sure most of you are—that things were not as bleak as 2009 and that we saw some momentum in the market. Quarterly reports from the Automated Imaging Association (AIA) show that starting in the first quarter of 2010, sales increased by 34.4% compared to results from the same quarter the previous year. This was the beginning of what some would say is a recovery. While this is encouraging, experts say the industry isn’t completely back to prerecession numbers. “Despite the impressive growth we are experiencing now, the fact that our industry has not yet returned to the turnover levels of 2008 should not be overlooked. If we have predicted the situation correctly, it will be 2012 at the earliest before we are back on top,” says Dr. Olaf Munkelt, chairman of the board of German Engineering Federation (VDMA)

Machine Vision, speaking at the Vision 2010 press lunch last year in Stuttgart, Germany. However, a strong indicator that the market is picking up is the number of companies that exhibited at the Vision 2010 show. Some 323 companies purchased exhibition space, up from 293 in 2009, and there were 6,200 attendees, while the previous year there were only 5,700 visitors due in part to the economic climate. The final report showed that 83% of visitors came with specific investment and purchasing intentions, while 60% surveyed said that they looked to invest within the first half of 2011. What’s partially driving this growth is the spur in new technologies across all machine vision markets as the need for it continues to grow in existing industries, as well as branching out to new ones—biometrics, advanced traffic management, laboratory automation, medical imaging, high-end surveillance and the solar market. On top of that, there is a significant technological shift to threedimensional (3-D) camera technology and improved standardization.

One company that has jumped on the 3-D technology wave is Sick AG (Waldkirch, Germany). They were presented with the prestigious Vision Award for Applied Machine Vision for their ColorRanger E color camera. This multi-imaging solution combines color and 3-D capabilities in one high-speed camera, eliminating the need for multiple cameras and reducing the overall cost of hardware and integration. The calibrated 3-D data provides measurements in real-world units such as millimeters, which alleviates much of the complexity of calibrating the system in the field. The jury members selected the winner from a total of 28 submissions. Other technologies exhibited included recent advancements in cameras, such as smart, line scan, high-speed and infrared. Also, attendees were able to check out the latest in frame grabbers, software tools, lighting and optics. With the New Year comes new prospects. Mark your calendar for the upcoming Quality Conference in Charlotte, NC, April 11-13. The Quality Conference will provide an exclusive behind-the-scenes tour of the Joe Gibbs Racing facility and show attendees how cars are built from the ground up and prepared for each race track. For more information, visit www. qualitymagconference.com.

Kari O’Rourke, Managing Editor

Vision & Sensors Editorial Advisory Board David Dechow Aptura Machine Vision Solutions

www.visionsensorsmag.com

Ned Lecky Lecky Integration

Perry West Automated Vision Systems Inc.

January 2011 | VISION & SENSORS

3VS

VISION & SENSORS

NEWS

Vision 2010

Shows Strength of Industry Recovery STUTTGART, GERMANY—After the largest economic crisis in 60 years, Vision 2010 is now benefiting from a sharp upturn in the economy, mainly in Germany. The willingness of the industry to invest is currently exceeding even the most confident expectations of economic forecasters. Many exhibitors are reporting a marked improvement in orders booked. According to the VDMA Machine Vision (German Engineering Federation for Machine Vision), many companies report increasing orders from user industries, including machinery and plant engineering, the plastics and rubber industry, robotics and the electronics industry. For the first time more than 300 exhibitors have registered. Last year the number was 293; this year it is 323 exhibitors. At the same time, the amount of international exhibitors has grown from 42% to 44% in 2010. An accompanying program provides multiple perspectives on machine vision applications and solutions. Twenty-seven countries were represented, including the United States (32 exhibitors), Japan (14), Great Britain (13), the Netherlands and Switzerland (10 exhibitors each). The exhibitors showcased machine vision and identification components, including smart, matrix and line scan camera systems, high-speed and infrared cameras, vision sensors, frame grabbers, software tools and libraries, lighting, objectives and optical filters, as well as accessories and application solutions and services for complete systems.

VISION AWARD GOES TO SICK WALDKIRCH, GERMANY— The Vision Award—the Award for Applied Machine Vision—was presented to Sick for the 3-D color camera ColorRanger. The jury included Dieter-Josef Walter, Daimler AG; Don Braggins, Machine Vision System Consultancy; Hermann Tropf, Vision Tools, and Martin Wäny from Awaiba Lda. The jury members chose from a total of 28 submissions.

NAVITAR AWARDED CONTRACT FOR ASSEMBLY TO BE USED BY NAVY ROCHESTER, NY—Navitar Inc., a manufacturer of precision optical and electro-optic systems, was recently awarded a contract with the Defense Supply Center in Columbus, OH, (DSCC) for a multi-element lens assembly to be used by the Naval Air Warfare Center Aircraft Division (NAVAIR). The lens assembly requested by the DSCC has been approved for use in the Aircraft Launch and Recovery Equipment of U.S. Navy aircraft carriers, specifically within the optical landing system. The origins of the lens assembly lie with Buhl Optical, an optics

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company previously based in Pittsburgh, PA, that was acquired by Navitar in 1997. Buhl fi rst manufactured the lens assembly for the Navy in 1989. Navitar engineers worked with NAVAIR to make slight modifications and improvements to the specifications and updated the lens design to meet today’s standards.

LUMENERA SHIPS 125,000TH DIGITAL CAMERA OTTOWA, ONTARIO, CANADA—Lumenera Corp., a manufacturer and developer of high-performance digital cameras and custom imaging solutions for scientific, industrial and surveillance markets, has sold 125,000 digital cameras since its inception in 2002. To date, more than 1,250 camera variants have been designed, including USB, Ethernet, GigE, custom and OEM solutions.

PHYSICAL OPTICS CELEBRATES 25TH YEAR TORRANCE, CT—Physical Optics Corp. (POC), a system integration company for military, aerospace,

VISION & SENSORS | January 2011

homeland security and avionics markets, marks its 25th year in business serving advanced technology communities. POC, founded in 1985 by Dr. Joanna Jannson and Dr. Tomasz Jannson, began as an R&D company focused on holographic technology and laser optics. POC serves the private sector in applied technologies, electro-optic systems, information technology, avionics, wireless communication, software and advanced sensor systems. The privately-held company has grown in revenue and personnel each consecutive year as a self-funded, employee-owned business. This year’s consolidated revenues have topped $45 million and the company now employs 225 people. POC holds 91 U.S. patents and has introduced 100 new products to worldwide markets since the company’s inception. During the past 12 months, POC has created 16 new, high level technical jobs.

EDMUND OPTICS INCREASES FOCUS ON TAIWAN SINGAPORE—Edmund Optics (EO), the premier provider of optical components, continues its expansion across Asia with the opening of an office in Taichung City and appointment of Mr. Johnson Chang to lead its Taiwan Sales operations. “We are extremely pleased to welcome Johnson Chang to our Asia Sales team. This is an exciting time for us as we continue to see rapid growth in the demand for our products across the region, especially in Taiwan,” commented Vincent Thong, director, Asia Sales. “Chang’s knowledge and experience in vision integration systems and imaging lenses adds tremendous strength to our Asian team.” In his role as Sales Manager, Johnson Chang will spearhead further development of EO’s Taiwan presence. Chang joins EO after having worked in precision optics for more than 12 years at one of Taiwan’s most established lens manufacturing businesses.

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S E E I N G

I S

B E L I E V I N G

VISION & SENSORS

I N T E G R AT I O N C O R N E R

Machine Vision:

thermore, the more sensor types that are added to a system, the flakier the system often will become. However, by going back to the basics, we were able to create a simple solution. We took the demo PROGRAMMERS ARE MAKING USE OF TOOLS THAT HAVE BEEN programs supplied by each vendor AROUND FOR DECADES. By Ned Lecky for his own camera interface and wrapped each one of these into its own thread. A thread is a lightweight process that coexists with many other threads as part of the same application. They run independent of one another, each waiting, in the appropriate way, for an image from the desired camera. By adopting this approach, we were able to rapidly create independent camera interface The UI-1008XS from IDS is a programs based on the 8-megapixel color camera that camera vendors’ own weighs only 12 grams and fits in a volume less than a code—a safe and risk1-inch cube. Source: Imaging averse approach that Development Systems (IDS) is almost certain to speed deployment. It turns out that modern multicore processors and big 64-bit operMy company spends its days building and deploying ating systems—including Linux and 7—can actually manage machine vision applications for factory automation, Windows all of the memory and library interOEM machinery, transportation and security applications actions required to support armies requiring faster, accurate, real-time image analysis. Some of threads for cameras with very effort. The threads are autoof these applications involve 10-camera simultaneous little matically distributed across all of the processor cores to allow for true simultaneous execution, making use Our application, however, also acquisition, mixed line scan and area of all of the hardware that is availrequired more standard machine scan cameras and combinations of able for processing. vision cameras with GigE interfaces, other specialty cameras. In our typical applications, each and needed the option of adding Not long ago, we discovered an camera has its own grab thread, Camera Link or analog cameras to application for a camera from Imagwaiting patiently for the next support some legacy hardware preing Development Systems (IDS) image. In addition, each camera has installed on older machines. Some called the UI-1008XS. This 8-megaa processing thread that analyzes of the cameras required could only pixel color camera weighs only 12 the data most recently received be purchased from other camera grams, fits in a volume less than from its camera. vendors including Basler, Dalsa, Pixa 1-inch cube—including built-in Finally, we add multiple acceleLink and Point Grey. auto-focus lens—and has trigger erator threads for hard operations, Putting such an integrated imagcapability and a USB 2.0 interface such as OCR, a processor-intensive ing solution together in the past was that powers the camera, as well as activity that benefits from the subnearly impossible due to the lack of provides data connectivity. At less division of the image into separate imaging software that could support than $500, it is a capable addition regions to allow parallelizing of the these types of devices simultaneously. to many a machine vision system. character recognition tasks. To this day, none of the off-the-shelf We have used these for general Tricky programming? Sure. But imaging software packages are likely inspection, optical character recogreally, this is all just back to basics to handle such a mix of sensors seamnition (OCR) and security applicafor programmers, making use of lessly and at high performance. Furtions with great success.

Back to the Basics

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VISION & SENSORS | January 2011

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tools that have been available for decades. The camera-specific interface code, often a real bear to write and debug, can be extracted from the vendors’ own example programs, often in just a few hours. Image processing and feature extraction is designed by the machine vision expert and can be performed by the expert’s tool or library of choice. The thread boundaries even ease the chore of using different libraries with different cameras using a custom OCR library, for example, on one camera, while using a general-purpose machine vision library on all of the others. Ned Lecky, Ph.D., is the owner of Lecky Integration (Little Falls, NY). For more information, call (518) 258-5874, e-mail ned.lecky@ lecky.com or visit www.lecky.com or his blog at www.visionsensorsmag.com.

www.visionsensorsmag.com

Shown here is a programming screen capture in Windows 7. Source: Lecky Integration

January 2011 | VISION & SENSORS

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VISION & SENSORS

M A C H I N E V I S I O N 10 1

Image Processing

cameras. OIP is routinely done with handheld cameras using a suitable color filter, polarizing filter, numerical aperture, lighting angle or sensing direction. Appropriately used, DETERMINE WHEN TO APPLY DIGITAL VS. OPTICAL IMAGE these all can increase the signal-toPROCESSING TECHNIQUES. By Dr. Norman N. Axelrod noise ratio or optical contrast by altering the light before the light strikes the photosensitive surface. In vision systems, OIP enhances the optical signal before the light reaches an electronic camera or photodetector, before electronic or digital signal processing, and before control decisions. OIP uses variations in the light, due to changes in materials, structure and processing, to improve signal-to-noise or optical contrast. It produces signals from critical features only and suppresses background images. This has the An integrated circuit on silicon without (right) and with (left) optical image processing before any digital obvious virtues processing is shown here. The defect can be easily of improving the detected in the area marked on left: the image intensity of the integrated circuit features has been significantly imaging and posreduced so that there is a large signal-to-noise ratio sibly simplifying between the light intensity from the defect compared software and with the light intensity from the circuit features. The high signal-to-noise ratio permits detection with hardware. It also reduced resolution. Source: Norman N. Axelrod Associates is fast. Simple applications of more complex optical pheIn a vision system, light is collected from an object nomena also are common to increase and made incident onto an array of photosensors in a the signal-to-noise ratio. Some of these provide outstanding results video camera, for example, a charged-coupled device without even forming an image. (CCD) or complementary metal-oxide semiconductor For example, to gage a small diameter cylindrical object such as a wire or fiber, the diffraction pattern of a laser beam from very small radii (CMOS), or a scanned analog phoassociated with it that represents the object will provide simple informatosensor surface in a video camera. intensity of light incident onto it. tion to gage the diameter. Even more All of the information from the Image processing is typically remarkably, the smaller the diameter object, contained in the light intensithought of as the digital image proof the object is, the more spread out ty variations, is in the light incident cessing (DIP), by a computer, of an the diffraction pattern will be and onto the photosensors. image in order to enhance the image the more accurate the measurement Not only is information from the or to extract information of interwith no image will be. feature of interest contained in the est. This DIP is done by a computer Optical spatial filtering—or 2-D light, but also light from possible after the light has been incident onto optical fourier transforms—has been other sources—reflected and scatthe camera’s photosensitive surface. used to eliminate background when tered light, room and sunlight—that Optical image processing (OIP) is the geometry of the defects is differwill interfere with the digital image done on the light before the light ent from that of the background. processing of the photodetected sigstrikes the photosensitive surface. This has been used in defect nals. The smallest area of the phodetection on complex integrated tosensing surface that is accessible OPTICAL IMAGE PROCESSING circuits (on both photomasks and by the computer is a pixel. Each The simplest tools of OIP are familon silicon wafers) when the circuit illuminated pixel provides a number iar to all operators of still and video

Broken Down

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VISION & SENSORS | January 2011

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VISION & SENSORS

M A C H I N E V I S I O N 10 1

USEFUL FEATURES FOR IMAGE PROCESSING Features

Possible Applications • Area: Small vs. large • Shape: Regular, irregular, directional • Texture differences and texture axes • Optical properties of different materials (UV, visible, IR) • Processing changes in materials • Asymmetries in stresses as with extrusion • Suppressed reflections as with polarized sunglasses • Non-uniform stresses from pressure, temperature, etc.

Source: Norman N. Axelrod Associates

COMPARISON OF O.I.P. AND D.I.P. Optical Image Processing

Digital Image Processing

• Processing BEFORE light incident onto photo-sensor

• Processing AFTER light incident onto photo-sensor

• Higher S/N, reliability, speed

• More complex programs

• Photodetected OIP uses DIP

• D.I.P. programs available

images consist of straight edges. Since the optical fourier transform is the same as the Fraunhofer diffraction pattern, the straight edges provide a diffraction pattern perpendicular to the edges along and near the X and Y axis (perpendicular to the Y and X edges as with a single slit). The use of an opaque cross in the plane of the diffraction pattern results in the reformed image showing only the image of the irregularly shaped defects. A seemingly remarkable feat is the use of optical spatial filtering to optically filter the image of a 2-D rectangular grid of perpendicular (vertical and horizontal) identical lines. The final image after filtering and reimaging contains only vertical or horizontal lines, depending on the optical filter orientation used. The filter, in the diffraction (or transform) plane, contains only a vertical or horizontal slit oriented perpendiculalry to the lines reimaged.

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OIP is preferable to DIP if it can significantly improve the amount of information from the objects of interest (the signal) and/or decrease the amount of information from objects or sources that do not contain information on features of interest (the noise).

DIGITAL IMAGE PROCESSING DIP is done by computer after the light has been incident onto the camera’s photosensitive surface. After the light has been incident onto an array of photosensors (or photodiodes) as with a CCD or CMOS camera, all of the information is now contained in an array of numbers: each number corresponds to the intensity of the light that was incident onto that photodiode. So how can one get information from an array of numbers? A simple example is that of locating the edges of the image of a vertical wire. The numbers corresponding to the areas outside the wire will ideally be zero

VISION & SENSORS | January 2011

(black). The numbers corresponding to the areas inside the wire will ideally be 255 (white) Note that with a common 8-bit binary-intensity scale: 28 = 256 so that there are 256 levels from 0 to 255 including zero. To detect the location of an edge of a vertical wire, the computer looks at the numbers representing pixel intensities in the image along a horizontal line through the wire. The computer then subtracts adjacent numbers. The difference of all adjacent numbers on the line inside the wire is zero. The difference of all adjacent numbers on the line outside the wire is zero. The difference of adjacent numbers on the horizontal line, when one number is from inside the wire and one number is outside the wire, will be 255. That is the location of the edge. This method takes the mathematical derivative along the line, point by point. If the edge is not completely sharp, then the same approach will still work but there will be more non-zero differences between adjacent numbers. This new array can be used to systematically compute the location of the edge. The image processing that is used to detect a defect depends strongly on the properties of the defect and of the background behind the defect. The simplest case is where the intensity of the defect is very high (say 156) and the intensity of the background is very low (say 34). Then, the computer can use a simple thresholding function: if the pixel intensity was initially greater than a chosen value of 60, then set all pixels to 255 (white); if the pixel intensity was initially less than 60, then set all pixels to 0 (black). This eliminates background signals. The resulting all-white pixels would then represent defects. If the intensity of the defect is initially in the middle of the intensity numbers from the background, then the simple threshold operation by itself will not work. OIP often can be used to obtain high optical contrast between defects and background.

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For example, use of near-infrared pass filters—eliminating visible light—for defects on sutures to sew up surgery on an eye has been used to change the signal-to-noise ratio from about 1 to about 7. The signal-to-noise ratio of 7 provided much more reliability against possible interferences than the signalto-noise ratio of 1. This simple threshold method depends on either the natural high optical contrast between defect and background, or the high optical contrast obtained by use of optical methods. However, if the signal is smaller than the background noise optical signal (and the background is repeatable), then defect signals can be detected by subtracting a defectfree image from an image with a defect. For example, this method

has been used to detect defects on magnetic memory disks for computers where the background signal is from repeatable scattered light from the disk. OIP can be applied to information containing light before the light is incident onto the photosensitive surface of the video camera. DIP is then necessarily used to determine action for diagnostics, detection, recognition, gaging and other functions. DIP is applied to the numericalintensity pattern recorded by the photodiode array of the video camera. This can be used without OIP for diagnostics, detection, recognition, gaging and other functions.

systems. For more information, call (212) 7416302, www.axelrodassociates..com or e-mail [email protected].

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VISION & SENSORS

THERMAL IMAGING

Seeing Heat with IR INFRARED CAMERAS IMPROVE QUALITY ASSURANCE, PROCESS MONITORING AND CONTROL IN INDUSTRIAL APPLICATIONS. By Kari O’Rourke, Managing Editor

targets. These quantitative measurements can be used in a variety of monitoring and control applications in industrial and manufacturing environments. Essentially, if you need to see what a target or product looks like from a heat or temperature perspective, a thermography camera for automation is a valuable and efficient option. Compared to a spot radiometer, which is limited to a single spot reading and requires precise aiming at the point being measured, thermography cameras produce thousands of temperature measurement points.

Q: Who is using thermal imaging? A: Thermal imaging has a wide and growing number of valuLike visible light cameras, thermographic able applications: military, cameras and their associated software security, predictive maintecan recognize the size, shape and relative location of target objects. Source: Flir Inc. nance, building diagnostics, law enforcement, search and rescue, medical, science, research development (R&D), maritime Manufacturing engineers are constantly looking for and navigation, automation and condisolutions to improve production quality in their auto- tion monitoring. Consumer-based cameras also are mated processes. By using infrared cameras in autobeing designed and manufactured mated systems, there is the opportunity to improve for recreational boaters, outdoors process monitoring and control, quality assurance, enthusiasts and for automobile thermal night vision applications. For automation, infrared variations across an object or scene. asset management and machine conmachine vision is being used in a Some IR cameras are designed only dition monitoring. Jason Styron, busivariety of manufacturing environfor qualitative uses, providing relaness development manager, Flir Inc. ments, including food production, tive temperature differences. These (North Billerica, MA) addresses the iron and steel works, automobile are used in IR cameras for law key components of thermography. component manufacturing and enforcement, maritime thermal night testing, critical vessel monitoring vision navigation, in automobiles Q: What is thermal imaging? and predictive maintenance for and for monitoring applications A: Thermal imaging sees heat within mechanical equipment and electriwhere thermal images are interpretthe infrared (IR) spectrum—radiation cal systems within those environed based on temperature contrast. not detectable by the human eye, ments, among other uses. But cameras designed for therdigital (visible light) video or still mography application not only capcameras. An IR camera can convert Q: How do thermal cameras work? ture thermal images of objects, they the radiation it detects into a visual A: In many ways, thermal cameras also provide accurate noncontact image that depicts temperature operate similarly to digital video temperature measurements of those

tech tips

 An IR camera can convert the radiation it detects into a visual image that depicts temperature variations across an object or scene.

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 While the digital camera relies on a CCD detector to see light within the visible spectrum, an IR camera uses a resistive detector.

VISION & SENSORS | January 2011

 With GigEVision protocol, a near real-time IR vision system can be created in which almost all of the CPU time can be dedicated to processing images.

www.visionsensorsmag.com

and still cameras. While the digital camera relies on a charged-couple device (CCD) detector to see light within the visible spectrum, an IR camera uses a resistive detector. Each pixel on a thermal camera is a resistor, allowing the pixels to be sensitive to heat instead of light, which is how they pick up temperature differences and radiation within the infrared spectrum. A variety of components and features determine the sophistication, image detail and level of functionality of thermal imaging cameras. The camera’s centerpiece is its infrared detector. Resolution, thermal sensitivity, lenses and other features contribute to what makes a particular IR camera appropriate for a specific application and/or environment. Some are handheld models with viewfinders and liquid crystal display (LCD) screens, while others are fixed mounted (or mounted on pan/tilt devices) and operated by remote control. Lenses determine the field of view and clarity relative to distance from the object. The resolution affects the number of pixels and spot measurements. Finally, the detector sensitivity determines the range of temperature differences that the camera can capture to create the thermal image, the detail within that image and the data that complements it.

A generalized IR machine vision system and its communications network. Source: Flir Inc.

1 Computer, PLC and/or transaction manager server

5 Wireless access points

2 CAT-6 Ethernet cable with RJ45 connectors

Q: How is thermal imaging applied to machine vision applications in automation? A: It may sound cliché, but it is true: thermal imaging provides a whole new set of eyes in industrial, manufacturing and automation applications—environments where the ability to see and measure temperature differences provides critical data that helps monitor and improve quality assurance, uniformity and safety, among other benefits. Because of their combined imaging and temperature measurement capabilities, IR cameras can be cost-effective for noncontact obser-

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3 Industrial Ethernet switches with fiber optic ports 4 Fiber optic cable

6 CAT-6 Ethernet cable with RJ45 connectors. Powering the camera using PoE (Power over Ethernet) 7 Industrial Ethernet switch 8 ThermoVision A320 cameras monitoring a process or other target objects

Shown here is production testing of car seat heater elements. Source: Flir Inc.

January 2011 | VISION & SENSORS

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VISION & SENSORS

THERMAL IMAGING

the environment/conditions that the camera would need to withstand and how the camera needs to interface to other software, hardware and systems. In simple examples, if a customer needs to monitor a warehouse to prevent fires, machine vision would not be an appropriate solution where a smart camera would. If the customer needed to identify an anomaly in a manufacturing process, then machine vision IR cameras would be the best route. IR image of a circuit board indicates three spot temperature readings. Image colors correspond to the temperature scale on the right. Source: Flir Inc.

vation. Like visible light cameras, thermographic cameras and their associated software can recognize the size, shape and relative location of target objects. The electronics in newer IR cameras provide fast signal processing that allows high video frame rates to capture relatively fast-moving parts on a production line. Their analog-todigital (A/D) converters combine short integration times with 14- to 16-bit resolution, which is essential for properly characterizing moving targets or objects that change temperature rapidly. Q: How are signal and image processing techniques used to solve machine vision applications involving thermography? A: With GigEVision protocol, a near real-time IR vision system can be created in which almost all of the computer central processing unit (CPU) time can be dedicated to processing images. Making sure the IR camera also is GenICam compliant makes it easier for developers to integrate cameras in their IR vision systems. Common tasks associated with IR cameras in machine vision systems include configuration settings, command and control, image processing and appending temperature measurement results to the image data stream. In addition, the

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camera’s digital I/O can be used to control other hardware, as well as triggering and synchronization functions that go with real-time data acquisition. GigEVision makes hardware independence possible, while GenICam creates software independence. In a system with IR cameras compliant in both and connected to a GigE network, virtually any application program can command a camera to send a 60 hertz (Hz) stream of images without losing important data. The information can then be processed for alarm functions, trend analysis and statistical process control. GigEVision and GenICam compliant cameras make it easier for thirdparty developers to integrate cameras into vision systems with a broad array of functions and includes the ability to define complex pass/fail decisions, control digital I/O, and communicate with serial or Ethernet devices, such as programmable logic controllers (PLCs), personal computers (PCs) and human machine interfaces (HMIs). Q: How should customers go about choosing a thermal camera? A: The most efficient path is for the customer to consult with their representative who can customize the best recommendation based on what the customer needs to accomplish,

VISION & SENSORS | January 2011

Q: What types of applications are ideal for industrial thermography? A: Applications ideal for industrial thermography include: • Noncontact diagnosis of mechanical equipment/motors • Electric utility equipment monitoring • Gas leak monitoring • Boiler and furnace inspection with through-flame cameras • Part production and assembly lines • Building inspection and energy auditing • Slag monitoring and ladle inspection • Casting, soldering and welding of metals and plastics • Product packaging • Nondestructive testing • R&D, prototyping and production in the electronics industry Q: What are the advantages of using thermal imaging? A: Some advantages of using thermal imaging include: • Nondestructive testing • Noncontact temperature measurement/analysis • Improved quality and uniformity • Reductions in wasted materials during manufacturing • Maximum uptime • Predictive and preventative maintenance • Improved safety in the work environment. V&S Jason Styron is business development manager at Flir Inc. (North Billerica, MA). For more information, call (866) 477-3687, e-mail info@flir. com or visit www.flir.com/thermography.

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VISION & SENSORS

LIGHTING

Gain Control on

Lighting

trolled, it is essentially impossible for a vision system to perform reliably.

BEST PRACTICES

Light is the most critical tool for creating adequate contrast for a successful and reliable machine vision application. Quite simply, contrast is the delta between the light levels on the feature of interest and every other feaUNLESS LIGHT IS CONTROLLED, IT IS IMPOSSIBLE FOR A VISION ture visible to the imager. The total SYSTEM TO PERFORM RELIABLY. By Jeff Schmitz scope of the area seen by the imager, or field of view, is divided between the feature of interest and the background of these features. Illumination, or lumen levels, from the feature of interest are differentiated from all other elements of a field of view. In the case of front lighting— lighting from the top—the lumen level on features of interest is maximized. In the case of backlighting, the light level is minimized or completely blocked. Choices for lights to create and amplify contrast are nearly infinite. Lights are available in difLighting is the first tool fering photon producers, for building a stable consuch as halogen, incandestrast foundation for vision systems. Source: PPT Vision cent, light-emitting diode (LED), and also differing shapes—spot, area blocks—or evenly illuminated backlights, for When machine operators are polled about the most example, linear, diffused, reflective challenging aspect of applying vision systems, the over- domes, coaxial, and all in differing colors or wavelengths. To cut whelming majority have a single word answer: lighting. through the cacophony of options, What makes lighting such a critical component when the best advice is to backlight the application, if possible. applying a vision sensor? Backlighting entails placing a light opposite the smart camera to maximize contrast. This results Each pixel’s light level—in the The heart of a machine vision in creating a silhouette. Opaque 300,000 to 5 million pixels typically application is light. Essentially an objects are dark, whereas more present in a machine vision system— image processor, the digital imager translucent or empty air spaces in is processed in a machine vision used in both machine vision and conthe rest of the field of view are conalgorithm. The only other pixel data sumer digital cameras is a light coltrastingly bright. This is the most is its X-Y address—its location—on lector. Each tiny imager component, ideal method of applying machine the image processor grid. picture element or pixel is a microvision for opaque object presence, Unless light—both applied light scopic light measurement sensor. shape and measurement. and ambient light noise—are con-

tech tips

 Light is the most critical tool for creating adequate contrast for a successful and reliable machine vision application.

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 When backlighting for gaging a part, it becomes critical to collimate the backlight as it shines on the part, silhouetting the part from the camera.

VISION & SENSORS | January 2011

 Maximized contrast is a requirement for all successful vision system applications.

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Sophisticated image filtering algorithms, such as edge enhancement, Gaussian, meridian, average and binary filtering, light leveling, morphing and erosion controls, maximizes contrast for marginal contrast images. Source: PPT Vision

When backlighting a part for gaging it becomes critical to collimate the backlight as it shines on the part, silhouetting the part from the camera. Incoherent light will wrap around the silhouetted part, distorting its measurement. Collimation can be achieved with a collimating filter on the surface of the light, or more simply by increasing the distance between the light, the part and the camera. When deploying either method, its cost is less lumens from the light shining on the camera and being blocked by the part, lessening contrast. However, the contrast from this method has such a significant margin that the light loss from increasing the distance of or filtering the backlight greatly benefits both the accuracy and repeatability of the measurement without compromising required contrast. Often backlighting is not feasible because the mechanical space to fit the part between the camera and light is unavailable, or the feature of interest is on the surface of an opaque background. Then the art of optimal lighting for creating contrast becomes more complex. Significant arrays of lighting options become available for surface lighting an object. To build adequate lighting with top or low angle surface lighting requires experimentation— often very time-consuming trials— with the part, the camera and various lighting options. Shortening this time-extensive experimentation is to see if a ring light surrounding or an

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area light closely adjacent to the camera creates adequate contrast levels. The simplest way of selecting front or dark angle lights is to contract a professional vision integrator. After the lighting method is determined, a critical practice is to make the controlled light used to create contrast in the application free of light noise from ambient factory light. The best ways to eliminate ambient light from affecting robust contrast include: • Mechanically shroud the part being inspected and its lighting— build a chamber isolating the application from outside light. • Build a cave for the vision application for the vision application is at most ideal for the vision system design engineer, but often is not practical on the factory floor. • Use high-powered lights for the application. Flood the inspection with many photons so that ambient lighting has very little effect on the strong contrast levels created for the application. • Progressing LED brightness levels are making this achievement more and more achievable every year. • Use infrared light and filters to optically shroud the application from visible light. Most commonly, this is done with infrared light wavelengths and matching wavelength infrared band-pass lens filters.

SMARTER VISION ALGORITHMS Sometimes, light-engineered contrast seems too minimal for an application to succeed. Contrast, even

with optimal lighting, is imperfect and not perfectly consistent. This is where smart camera image preprocessing tools come into play. Software delivers scores of tools for extrapolating better contrast. Sophisticated image filtering algorithms, such as edge enhancement, Gaussian, meridian, average and binary filtering, light leveling, morphing and erosion controls, maximizes contrast for marginal contrast images. Image geometry tools use image sampling, line-profiling and other algorithms to further interpolate data from images with less-thanideal contrast. Lighting is the first tool for building a stable contrast foundation for vision systems. Image filtering and geometry are the next steps for robust contrast and reliable vision sensing. Controlled light creates contrast. Maximized contrast is a requirement for all successful vision system applications. The brighter LEDs continually being developed make contrast control better and better. V&S Jeff Schmitz is smart camera marketing director at PPT Vision (Bloomington, MN). For more information, call (952) 996-9500, e-mail info@ pptvision.com or visit www.pptvision.com.

VISION & SENSORS ONLINE For more information on lighting, visit www.visionsensorsmag.com for the following: • “Fiber Optics: Beyond Simple Light Pipes” • “Lights, Camera and Special Effects” • “Sensors See the Light”

January 2011 | VISION & SENSORS

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VISION & SENSORS

SMART CAMER AS

Smart Cameras

Go Mobile A SMART CAMERA THAT USES MOBILE COMPUTING TECHNOLOGY HAS A NUMBER OF ADVANTAGES. By Ben Dawson A smart camera combines a digital camera, processing, software and communications in a small package. Source: Dalsa Corp.

Smart cameras combine a digital camera, processing, software and communications in a small package. They are an excellent choice for a machine vision system to do tasks such as gaging or visually detecting part defects. Currently, there are several types of machine vision systems that are commonly used for quality control.

THREE TYPES OF MACHINE VISION SYSTEMS A vision sensor is appropriate for simple vision tasks, such as detecting when a part is present. Vendors such as Banner, Omron and Keyence offer a variety of sensors that

tech tips  Smart cameras are appropriate for the many machine vision tasks that require two- or three-dimensional imaging and have moderate computation and speed requirements.

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measure things such as International Commission on Illumination (CIE) color or depth at a point on an object. Sensors make one type of measurements at one or a few points. They require little or no programming so are easy to setup. Most machine vision tasks require multiple measurements on two- or three-dimensional images and so require significantly more intelligence

 Easy-to-use software is required for rapid and successful development of a machine vision application.

VISION & SENSORS | January 2011

than a simple sensor. These tasks are typically solved by a combination of vision processing functions and therefore require some programming. Machine vision tasks that are difficult, fast or require significant computational power are best done by a PC-based machine vision system. An example of a difficult task is detecting low-contrast defects such as scratches, bubbles, discolorations, burn marks or contamination. These types of defects are poorly defined so extensive computation is required to detect them. Smart cameras are appropriate for the many machine vision tasks that require two- or three-dimensional imaging and have moderate computation and speed requirements. Dimensional gaging, verifying a part’s outline, barcode or optical character recognition (OCR), defect detection and locating parts (perhaps to guide a robot), are examples of tasks that can be done quickly and inexpensively by a smart camera. Some vendors call their smart cameras “sensors” perhaps to emphasize that they have limited programmability and thus should be easy-to-use. An example of a smart camera often called a sensor is a dedicated barcode reader.

RIDING THE MOBILE COMPUTING CURVE Most smart cameras use a digital signal processor (DSP) for their intelligence. Some smart cameras also use processing elements similar to that in advanced cell phones or other mobile computing devices. These processing elements include a standard central processing unit (CPU), hardware image processors and a capable DSP. A smart camera that uses mobile computing technology has a

 The convergence of smart mobile devices and machine vision allows small, fast and inexpensive machine vision systems that are perfect for many machine vision tasks.

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number of advantages. per week for automoFirst, the demand for tive, aerospace and other smarter mobile devices industries. Defective with ever-better features parts cause expensive drives increases in proreturns and hurt customcessor performance. The er relations. Using smart smart camera can ride cameras, Prime is doing the mobile computing 100% quality inspection performance curve for with nearly zero part increased speed or to defect escapes. take on more demanding One Prime facility manvision applications. ufactures mostly screw Second, the inclusion machined parts—parts of a standard CPU means with grooved patterns familiar operating syssuch as threaded anchor tems and machine vision bolts. Critical dimensions software can be used. for these parts include the If more performance minimum and maximum is needed, it is easy to dimensions of the threads. PC-based machine vision systems and smart cameras require programming migrate to a PC-based To measure these dimenbecause they are general-purpose tools. Source: Dalsa Corp. system running the same sions, the parts are fed by machine vision software. a vibratory feeder into slots Third, mobile computing devices on an index wheel. The wheel turns on the part to be measured. There is are very low power and fit into to position the part in front of the no programming in the usual sense. small packages. smart camera and a caliper tool meaVision operations are presented in Some smart phone applications sures the thread dimensions. familiar terms, rather than the terms have a machine vision compoDefective parts are manually of machine vision algorithms. For nent. For example, one can get an removed from the product stream. example, the caliper tool is presentappplication for a smart phone It might seem odd to have automated as if it was a mechanical gage so that reads a bar code which coned the handling and visual inspecthere is no need to understand subnects to reviews of that product. tion of the parts but not defect pixel edge detection algorithms. Also, some cell phone cameras sorting, but the defect New smart cameras locate faces in an image to set rate is low and Prime are designed to be the color balance and exposure. examines defective servers on an Ethernet However, industrial machine parts to correct the network and have no vision requires hardware and softproduction process. way to display images ware not found in a smart phone. Once again, easy-tothemselves. Instead, Besides, who would want to washuse software for the images are sent over down their smart phone? smart camera was the Ethernet to a clithe key to getting this ent PC. Here a techni- Parts from a vibratory bowl go into an index wheel that rotates inspection task built. cian can set up and IT’S THE SOFTWARE to show the part to the smart camera for dimensioning. Note The convergence of program the smart PC-based machine vision systems protective enclosure around smart mobile devices camera from the client the and smart cameras require prothe smart camera’s lens. Source: and machine vision PC and then log off of Prime Engineering gramming because they are generalallows small, fast the smart camera and purpose tools. If the programming and inexpensive machine vision let it run independently. Results takes too much time, the need and systems that are perfect for many are reported over Ethernet using money for a machine vision project machine vision tasks. How about standard industrial protocols or evaporates. Easy-to-use software is having the smart camera e-mail or via digital input/output lines from therefore required for rapid and suctweet your smart phone when there the camera. One client PC can cessful development of a machine is a problem? V&S manage many smart cameras. vision application. Modern machine vision software allows you to program your vision A WORKING EXAMPLE Ben Dawson is director of strategic developapplication graphically—pointPrime Engineered Components ment at Dalsa Corp. (Billerica, MA). For more and-click to select a tool, such as a (Watertown, CT) manufactures information, call (978) 670-2002, e-mail ben. caliper, and then position that tool 800,000 precision-turned parts [email protected] or visit www.dalsa.com.

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January 2011 | VISION & SENSORS

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VISION & SENSORS

CASE STUDY

Sensing with Robotics

on many simple, unrefi ned tasks which previously had to be done by humans. The pi4_workerbot has been conceived to learn new Cameras and power sensors enable tasks or to change from one job this robot to detect what it touchto another with little retraining, es with humanlike sensitivity. Source: Allied Vision Technologies much like a human colleague. Even though the pi4_workerbot is no humanoid robot, it does possess certain similarities to humans: its size—just less than 2 meters—and proportions approximate those of a human so that it needs about as much space as a person. Like a human, it has two highly movable arms, a head and eyes. It has no legs, precluding independent movement, but instead stands with full steering technology on a rolling platform, allowing it to be easily moved from one workstation to the next. The pi4_workerbot does require a power supply at its new workstation; otherwise, it brings everything else along. Thanks to cameras and power sensors being built into its arms, the pi4_workerbot can see and feel what it grasps and manipulates. Thus, it is equipped to take on sensitive joining Robots are nothing new in industrial assembly. For tasks and to self-monitor the quality example, everyone has heard of the heavy yet highly pre- of its own work.

cise one-armed soldering or painting robots of the auto industry. Such systems take over laborious and repetitive tasks, raising production quality and productivity. Still, most industrial robots have the disadvantage of being very capital-intensive and reprogrammable only with great effort. For that reason, they are only profitable when used for large serial-capacity production, and they are not particularly known for their flexibility. The trend of today’s fast-moving economy, however, lies more along the lines of shorter product life cycles, greater product variety and

benefits  Allied Vision Technologies’ sensors and functions can be switched in and out of the robot system with ease.

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SUPERHUMAN POWERS

faster adaptation to new market requirements. More flexibility is the Holy Grail of industrial production. Pi4_robotics GmbH (Berlin, Germany), a robotics and imaging specialist, has developed within the framework of the EU-aided research project Assembly System Integrated Project (PiSA), a new type of robot that brings human flexibility to industrial automation. The so-called pi4_workerbot is a compact robot that can take

One feature of the pi4_workerbot is its extensive configuration of industrial imaging technology. Depending on the execution and formulation of tasks, it makes use of up to three digital cameras. For applications requiring spatial perception of the workspace, an optional time-of-fl ight camera is mounted in the middle of the head. For inspection tasks, two additional digital cameras from Allied Vision Technologies (AVT) with different illumination units can be attached to the head. The cameras in question are area scan cameras with FireWire IEEE

 The FireWire interface’s integrated power supply allows for an operator-friendly plug-and-play functionality.

 Thanks to cameras and power sensors being built into its arms, the pi4_workerbot can see and feel what it grasps and manipulates.

VISION & SENSORS | January 2011

www.visionsensorsmag.com

1394 interface, such as the little AVT Guppy or the high-performance AVT Stingray. The importance of easily integrated cameras cannot be understated. AVT’s FireWire digital cameras’ versatile selections of sensors and functions fulfill this need because they can be switched in and out of the robot system with ease. The FireWire interface’s integrated power supply is particularly convenient and easy to switch out, allowing for a operator-friendly plug-and-play functionality. The pi4_ workerbot is not fixed to a particular interface, however. For example, digital cameras with Gigabit Ethernet interface also can be integrated.

ABLE TO LEARN Crucial to the pi4_workerbot’s flexibility is its intelligent software. Pi4_control is a software solution that combines imaging with machine control. Thus, inspection tasks can be programmed particu-

larly easily and efficiently, such as having the robot grasp objects and move them within the camera’s field of view to achieve optimal test quality. pi4_robotics and Allied Vision Technologies demonstrated the pi4_ workerbot application at the Vision 2010 show in Stuttgart, where the robot inspected chrome-plated Peugeot emblems for an automotive component supplier. The chromeplated surface generates mirroring effects and light reflections that pose a challenge for testing with machine imaging. Moreover, the complex, angular form of the lion on the emblem requires that the part be turned to capture every edge and surface. Exactly as a human would, the pi4_workerbot holds the product in front of its camera eye and moves it to search for surface defects from all sides. The pi4_control software coordinates not only the machine controls and the imaging, but excels as well with an particularly simple

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operator surface, thanks to which the pi4_workerbot can be reprogrammed to a new task quickly and without complication, even by trained personnel without extensive robot programming experience. The pi4_workerbot’s potential range of applications is vast. For example, it can execute assembly, testing or packaging tasks that could not have been automated before and were handled by unskilled workers. Thanks to the pi4_workerbot, such personnel-intensive tasks that for cost reasons would have previously been outsourced to low-wage countries can be kept on location in higher wage countries. Alternately, for workstations that place workers in peril—such as those involving the manipulation of chemicals or laser beams—the pi4_workerbot offers an interesting alternative. Allied Vision Technologies GmbH (604) 875-8855 ext. 123 www.alliedvisiontec.com

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VISION & SENSORS

CASE STUDY

Vision Sensors Improve

to locate the edge of the part. Then he picked a brightness tool to look for the light reflecting off the threads. He then set up the vision sensor to interface with the programmable logic controller (PLC) that operates the assembly machine. The PLC provides a static output that indicates when a fi xture is in position with two new parts. When the vision sensor Cognex Checker 101 vision sensors receives this signal, it captures are looking down at a 45-degree an image and inspects the part. angle about 5 inches from the two parts in the inspection station The vision sensor then sends an of the assembly machine. Source: output to the PLC indicating Maclean Vehicle Systems that the part is either good or bad. Based on the inspection results, the PLC determines whether to send the part to the pass or fail bin. Most recently, MVS has standardized new applications on the Cognex Checker 232 vision sensor that One of Maclean Vehicle Systems’ (MVS; Royal Oak, provides high resolution and a wide MI) many automotive fastener products is stainless field of view to inspect small features up to 1,600 parts per minute. steel capped wheel nuts. The nuts are assembled on The ability of the vision sensor to an index machine that processes two parts simultane- determine the position of the part ously at each station. The fasteners must be inspected to and evaluate the brightness of the entire opening of the nut, as opposed to an individual point evaluated by a traditional sensor, has eliminated and pick tools off a menu that inspect verify the nuts are properly threadincorrect pass/fail decisions. The the critical features of the part.” ed. MVS previously performed this elimination of sorting costs quickly Konieczke mounted two Cognex fastener inspection with an eddy paid for the new vision sensor. The Checker 101 vision sensors looking current sensor whose accuracy was vision sensor also has increased down at a 45-degree angle about less than desirable, at times resulting confidence that not a single bad part 5 inches from the two parts in the in expensive over-sort. will be shipped to the customer. inspection station of the assembly “We looked at a number of differ“The latest generation of vision machine. The parts are presented to ent vision sensors,” says TJ Koniecsensors is much more reliable and the inspection station in a fi xture zke, manufacturing controls engineer accurate while being just as easy to and held in position by a springfor MVS. “Some were sensitive, set up and operate and not much loaded keeper, so there is some variintimidating and had a high learning more expensive than traditional senability in the height at which they curve like the vision systems that we sors,” Konieczke concludes. are positioned. have used in the past. We selected Konieczke set up the vision senCognex Checker vision sensors sor by dragging inspection tools and because they are very easy to program Cognex Corp. dropping them onto the features and operate. We simply put them in One Vision Drive that he wanted to inspect. First, he place, connect a PC to the USB port, Natick, MA 01760 addressed the variable placement of train them on the part to be inspected (508) 650-3000 the part by using an edge finder tool www.cognex.com

Wheel Fastener Productivity

benefits  The ability of the vision sensor to determine the position of the part and evaluate the brightness of the entire opening of the nut as opposed to an individual point evaluated by a traditional sensor has eliminated incorrect pass/fail decisions.

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VISION & SENSORS | January 2011

 The elimination of sorting costs quickly paid for the new vision sensor.  The vision sensor also has increased confidence that not a single bad part will be shipped to the customer.

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VISION & SENSORS

PRODUCTS

HIGH-SPEED CAMERA The Phantom v341 is a high-speed camera tailored to military, scientific, research and range applications. It has a light sensitivity rating of 4000 ISO and a 4-megapixel, 35-millimeter format sensor. It has 1 microsecond shutter speeds and a global electronic shutter. It has range data input and a 2560 by 1600 pixel complimentary metal-oxide semiconductor (CMOS) sensor. Vision Research (866) 450-7426 www.visionresearch.com

SAFETY CABLES Breakaway safety cables are designed to protect technicians and their equipment from being pulled into rotating machinery during route-based vibration monitoring. The safety cables disconnect in the event that a sensor or analyzer cable becomes accidentally entangled when collecting data. They are designed to interface directly with handheld data collectors and to withstand harsh industrial environments. They have EMI/RFI shielding and multiple connector configurations including 2-pin MIL style, BNC plugs or jacks that are compatible with most major data collector manufacturers. IMI Sensors (800) 959-4464 www.imi-sensors.com

LINE SCAN CAMERAS The uEye 1.3-megapixel line scan cameras with complementary metaloxide semiconductor (CMOS) have global shutter readout, high sensitivity and high color fidelity. The CMOS technology includes a fast line scan mode to camera models UI-1240 and UI-5240. The technology will then read it out with a rate of up to 64 kilohertz. In the USB version, the e2v sensor reads out with a line rate of 20 kilohertz. The models with GigE interface. IDS Imaging Development Systems Inc. (781) 787-0048 www.ids-imaging.com

CCD CAMERA

SWV TECHNOLOGY Super Wide View (SWV) is a technology for thin-film-transistor liquid crystal displays (TFT-LCDs). It is designed to solve the color shifting problems inherent in traditional twisted nematic (TN) and vertical alignment (VA) type displays and provides a viewing angle of greater than 170 degrees.

The VA-29MC-M4 is a 29 million pixel, 12-bit charged-coupled device (CCD) digital camera. It has an electronic shutter and four frame-persecond readout speed in a 35-millimeter optical format. It measures 68 by 68 by 83 millimeters and weighs 460 grams. It has a programmable lookup table, flat-field correction, exposure control and many more features make it easy to use. Vieworks +82-70-7011-6161 www.vieworks.com

Optrex America Inc. (734) 416-8500 www.optrex.com

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January 2011 | VISION & SENSORS

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VISION & SENSORS

PRODUCTS

FIXED FOCAL LENGTH LENSES

CCD SENSORS

Compact fixed focal length lenses provide transmission out to 1,000 nanometers and are designed for factory automation, inspection or qualification applications that require near infrared (NIR) or visible and near-infrared reflectance (VIS-NIR) performance. The lenses take into consideration the working distances and requirements of factory automation and inspection. They have large maximum apertures and a broadband anti-reflective coating.

Charged-coupled device (CCD) sensors for the AviivA 2 camera range extends from 512 pixels up to 4096 pixels, with Camera Link and GigE Vision interfaces. They have 68 dB dynamic range, responsitivity of 164 DN/(nJ/cm2) at minimum gain, and can be operated through a camera link interface at a pixel rate of 80-megahertz using 2 taps or at a pixel rate of 160-megahertz using 4 taps. A GigE Vision interface is also available with advanced generalpurpose input/output (GPIO) and features the fastest line rates on the market at a given number of pixels per line.

Edmund Optics (856) 573-6250 www.edmundoptics.com.tw

e2v (800) 342-5338 www.e2v.com

EMBEDDED VISION SYSTEM The high-resolution M-390 smart cameras is a single system with four independently operating cameras running distinct inspection, guidance or identification programs. Operators can mix and match camera resolutions for all points of inspection. It can differentiate parts, locate defects and gage features on four sides of a part. It has an optional right angle view and operators can perform up to four separate inspections with one vision processor. PPT Vision (919) 341-5425 www.pptvision.com

STROBE SPOTLIGHT

INDUSTRIAL VISION SOFTWARE

The ODS30 OverDrive Prox light is a strobe-only spotlight in a 30-millimeter sensor housing that includes an integrated strobe driver for light-emitting diode (LED) light control. Its driver monitors the strobe operation. The light has SafeStrobe technology, which applies safe working parameters to ensure the LEDs are not damaged.

Scorpion Basic is a product in the Scorpion Vision Software family; an independent and open software tool for industrial vision. The rapid machine vision framework speeds up the development by a factor of 10 compared to a standard library approach. The software is designed for robot vision, robot inspection and in identification systems.

Smart Vision Lights (231) 722-1199 www.smartvisionlights.com

Scorpion Vision Software +47 2315 8700 www.scorpionvision.com

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VISION & SENSORS | January 2011

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VISION & SENSORS

AD INDE X

ADVERTISER

PAGE

PHONE

WEB ADDRESS

Allied Vision Technologies

5, BC

(877) USA-1394

www.alliedvisiontec.com

Cincinnati Automation Ltd.

11

(859) 371-5070

www.cincinnatiautomation.com

Dalsa

9

Edmund Optics

1

(856) 547-3488

www.edmundoptics.com

Matrox Imaging

IFC

(800) 804-6243

matroximaging.com/mil

7

(613) 247-1211

www.pixelink.com

Pixelink

www.dalsa.com/boa/vs1

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Value packed

The Manta is a perfect balance of quality and affordability. Because reducing cost required more than just trimming a little fat, we developed a new, optimized platform featuring a compact cast housing, single board architecture, and our enhanced GigE Vision interface. Which means you don’t have to settle for anything less than a grade-A quality Sony ICX CCD sensor for images up to 5 megapixels, and up to 88 fps. If your application calls for a rugged, low cost camera, serve up the Manta. Learn more at www.AlliedVisionTec.com/ValuePacked

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