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Technologie von Machine Vision Cameras

Ma­chi­ne Vi­si­on Ca­me­ras spie­len eine ent­schei­den­de Rolle in Vision-​Anwendungen, ins­be­son­de­re bei der au­to­ma­ti­sier­ten Qua­li­täts­kon­trol­le. In Kom­bi­na­ti­on mit Ma­chi­ne Vi­si­on Con­trol­lern und 2D-​Bildverarbeitungssoftware, wer­den die hoch­auf­lö­sen­den Bild­da­ten ana­ly­siert und Feh­ler als auch Un­re­gel­mä­ßig­kei­ten in Pro­duk­ti­ons­pro­zes­sen iden­ti­fi­ziert.

Was ist eine Ma­chi­ne Vi­si­on Ca­me­ra?

Eine Ma­chi­ne Vi­si­on Ca­me­ra, auch In­dus­trie­ka­me­ra ge­nannt, ist wich­ti­ger Be­stand­teil eines 2D-​Bildverarbeitungssystems. Ihre Haupt­funk­ti­on be­steht darin, Bil­der auf­zu­neh­men, die an­schlie­ßend durch eine Kom­bi­na­ti­on aus Hard­ware und Soft­ware ver­ar­bei­tet wer­den. Die ge­won­ne­nen In­for­ma­tio­nen wer­den für ver­schie­de­ne An­wen­dun­gen auf­be­rei­tet.

Ein ty­pi­sches Bei­spiel für eine Bild­ver­ar­bei­tungs­an­wen­dung in einem Fer­ti­gungs­sys­tem ist die Qua­li­täts­kon­trol­le, An­we­sen­heits­kon­trol­le und Voll­stän­dig­keits­kon­trol­le. Hier­bei wird ein be­stimm­tes Merk­mal eines Teils ana­ly­siert, das auf einem Fließ­band pro­du­ziert wird. So kann über­prüft wer­den, ob das Teil den Qua­li­täts­kri­te­ri­en ent­spricht oder ge­ge­be­nen­falls aus­sor­tiert wer­den muss.

Die Ka­me­ra ist ein Be­stand­teil des Bild­ver­ar­bei­tungs­sys­tems. Die­ses be­steht aus fol­gen­den Kom­po­nen­ten:

Haupt­kom­po­nen­ten von 2D-​Bildverarbeitungssystemen

Aus­wahl­hil­fe für das pas­sen­de Ob­jek­tiv

Pas­sen­des Ob­jek­tiv für die In­dus­trie­ka­me­ra ein­fach und au­to­ma­tisch über den Vi­si­on Cal­cu­la­tor er­mit­teln las­sen:

Der Un­ter­schied zwi­schen Ma­chi­ne Vi­si­on Ca­me­ras und Smart Ca­me­ras

Ma­chi­ne Vi­si­on Ca­me­ras

  • Bild­aus­wer­tung er­folgt über den Ma­chi­ne Vi­si­on Con­trol­ler und die Bild­ver­ar­bei­tungs­soft­ware

  • An­schluss meh­re­rer Ka­me­ras an einen ein­zi­gen Ma­chi­ne Vi­si­on Con­trol­ler mög­lich

  • Schnel­le­re Pro­zess­zei­ten durch hohe Re­chen­leis­tung des Ma­chi­ne Vi­si­on Con­trol­lers

  • Für In­spek­ti­ons­auf­ga­ben mit sehr hoher Auf­lö­sung ge­eig­net

  • Kom­pak­te Ka­me­ra­bau­form



 

Smart Ca­me­ras

  • Bildaufnahme-​ und aus­wer­tung er­folgt in der Smart Ca­me­ra über die Bild­ver­ar­bei­tungs­soft­ware

  • Da­ten­aus­ga­be über in­te­grier­te Schnitt­stel­len

  • Be­leuch­tungs­tech­nik op­tio­nal in­te­griert

  • Kein zu­sätz­li­cher Con­trol­ler er­for­der­lich



 

Ein­satz­mög­lich­kei­ten von Ma­chi­ne Vi­si­on Ca­me­ras

Po­si­ti­ons­kon­trol­le

Po­si­tio­nie­rung Ro­bo­tik

Tei­le­ver­mes­sung

Qua­li­täts­kon­trol­le

An­we­sen­heits­kon­trol­le

Pro­zess­über­wa­chung

Code Rea­ding

Zu­ver­läs­si­ge Lö­sung für bran­chen­über­grei­fen­de An­wen­dun­gen

Au­to­mo­bil­in­dus­trie

  • Qua­li­täts­in­spek­ti­on von Pkw-​Innentüren

  • Qua­li­täts­in­spek­ti­on von Mo­tor­blö­cken

  • Po­si­ti­ons­er­ken­nung für au­to­ma­ti­sier­tes Ver­schrau­ben

Elek­tro­in­dus­trie

  • La­ge­kon­trol­le von Pla­ti­nen

  • Kon­trol­le der Aus­rich­tung von Bau­tei­len

  • In­spek­ti­on von Steck­ver­bin­dern und Ka­beln

Ver­pa­ckungs­in­dus­trie

  • Über­prü­fung von Ver­pa­ckun­gen auf Be­schä­di­gun­gen, Ver­schmut­zun­gen oder feh­len­de Eti­ket­ten

  • La­bel­kon­trol­le von Ver­pa­ckun­gen

  • Min­dest­halt­bar­keits­prü­fung auf PET-​Flaschen

Food In­dus­try

  • Ori­en­ta­ti­on of be­verage cans 

  • Label check on packa­ging

  • Te­the­red cap in­spec­tion

This Is the Dif­fe­rence Bet­ween Sur­face and Line Ca­me­ras

The fol­lo­wing table sum­ma­ri­zes the main dif­fe­ren­ces bet­ween sur­face and line ca­me­ras:

Sur­face ca­me­ras

Image cap­tu­re of com­ple­te 2D sur­faces (with one cap­tu­re)
High image qua­li­ty
Ideal for sta­tio­na­ry ob­jects
Sui­ta­ble for ge­ne­ral image proces­sing



Line Ca­me­ras

Image cap­tu­re takes place line by line (mo­vement is ne­cess­a­ry to cap­tu­re the ob­ject)
Image qua­li­ty de­pen­dent on mo­ti­on and time of image cap­tu­re
Ideal for ap­pli­ca­ti­ons with mo­ving ob­jects and end­less ma­te­ri­als 
High speed

Ope­ra­ting Orin­ciple of CMOS Sen­sors with Glo­bal or Rol­ling Shut­ter

CMOS image sen­sors have two ex­posure me­thods that con­trol how an image is cap­tu­red and read. These pro­ce­du­res de­ter­mi­ne the ex­posure time and thus the amount of light that is con­ver­ted into elec­trons as a value in the ca­me­ra sen­sor. A di­s­tinc­tion is made bet­ween glo­bal shut­ter and rol­ling shut­ter:

Glo­bal Shut­ter

En­ti­re image area is ex­po­sed si­mul­ta­neous­ly 
Sui­ta­ble for sta­tic as well as dy­na­mic ap­pli­ca­ti­ons
No image dis­tor­ti­on on mo­ving ob­jects

Rol­ling Shut­ter

Lines are ex­po­sed with a time off­set
For sta­tic ap­pli­ca­ti­ons
Image dis­tor­ti­ons due to fast ob­ject mo­vements (rol­ling shut­ter ef­fect)
Cap­tu­ring still images 

The Rol­ling Shut­ter Ef­fect

With the rol­ling shut­ter, the ex­posure time is the same for all pi­xels of the sen­sor, but the ex­posure of the in­di­vi­du­al lines takes place one after the other with a time delay. The rol­ling shut­ter ef­fect oc­curs when an ob­ject moves fas­ter than the ex­posure and read time, caus­ing the image to be dis­tor­ted due to ex­posure.

Left: Glo­bal shut­ter, Right: Rol­ling shut­ter

Mo­no­chro­me or Color Ca­me­ra? Which Do I Use When?

Ac­tu­al Image

Image Cap­tu­re with a Mo­no­chro­me Ca­me­ra

A mo­no­chro­me ca­me­ra can di­stin­guish ob­jects from the back­ground.

Image Cap­tu­re with a Color Ca­me­ra

A color ca­me­ra is able to di­stin­guish ob­jects from each other and from the back­ground.

In in­dus­tri­al image proces­sing, a di­s­tinc­tion is made bet­ween mo­no­chro­me and color ca­me­ras. Mo­no­chro­me ca­me­ras cap­tu­re grays­ca­le and focus on the dif­fe­ren­ces in bright­ness in the image. This makes them par­ti­cu­lar­ly sui­ta­ble for ap­pli­ca­ti­ons that re­qui­re fine con­trasts and de­tails, such as when in­spec­ting sur­faces or mea­su­ring ob­jects.

Color ca­me­ras, on the other hand, can cap­tu­re color in­for­ma­ti­on, al­lo­wing them to cap­tu­re sur­faces more ac­cu­ra­te­ly. They ana­ly­ze the en­ti­re color spec­trum, pro­vi­ding more de­tail­ed and ver­sa­ti­le image re­pro­duc­tion. This makes them ideal for ap­pli­ca­ti­ons where color plays an im­portant role, such as in pro­duct qua­li­ty con­trol, where color dif­fe­ren­ces can in­di­ca­te ma­te­ri­al de­fects.

What to Con­sider When In­stal­ling Ma­chi­ne Vi­si­on Ca­me­ras

To en­su­re re­lia­ble image cap­tu­re, the fol­lo­wing in­struc­tions must be ob­ser­ved when ad­jus­ting the in­dus­tri­al ca­me­ra.
In ad­di­ti­on to the op­ti­mal ori­en­ta­ti­on of the ca­me­ra, the po­si­tio­ning of the il­lu­mi­na­ti­on plays an im­portant role. The shape of the ob­ject to be ex­ami­ned is key for how the light re­a­ches the ca­me­ra to crea­te the hig­hest pos­si­ble con­trast. It is im­portant to note, for ex­ample, the angle and the re­sul­ting re­flec­tions. 

The Ma­chi­ne Vi­si­on Ca­me­ra In­ter­face

An Ether­net in­ter­face for in­dus­tri­al ca­me­ras al­lo­ws image data to be trans­fer­red over a net­work. This in­ter­face is com­mon­ly used in in­dus­tri­al image proces­sing to con­nect ca­me­ras to ma­chi­ne vi­si­on con­trol­lers or other de­vices.

Gi­ga­bit Ether­net (GigE)

Gi­ga­bit Ether­net (GigE) is an Ether­net tech­no­lo­gy that en­ables data trans­fer rates of up to 1 Gi­ga­bit per se­cond (1 Gbit/s). The main fea­tures of Gi­ga­bit Ether­net in con­nec­tion with in­dus­tri­al ca­me­ras are:
 
  • Fast trans­fer of large amounts of image data

  • Easy in­te­gra­ti­on thanks to pro­to­col stan­dard

  • Mul­ti­ple ca­me­ras can be ope­ra­ted in a net­work


It is also pos­si­ble to con­nect the ma­chi­ne vi­si­on ca­me­ra via a cable using PoE (Power over Ether­net), which means that both power sup­ply and data trans­fer take place via a sin­gle con­nec­tion.


Re­so­lu­ti­on

The spa­ti­al re­so­lu­ti­on of a sen­sor in­di­ca­tes the num­ber of pi­xels: the hig­her the re­so­lu­ti­on, the smal­ler the pixel size and the finer the de­tails that can be de­tec­ted. Sen­sors can have dif­fe­rent re­so­lu­ti­ons with the same di­men­si­ons be­cau­se the pixel size can vary. 

Frame Rate

The frame rate in­di­ca­tes the num­ber of com­ple­te frames a ca­me­ra cap­tu­res per se­cond. A hig­her frame rate en­ables many images to be cap­tu­red in fast-​paced ap­pli­ca­ti­ons.

Ex­posure Time

The ex­posure time de­ter­mi­nes how much light falls on the CMOS sen­sor and thus af­fects the bright­ness and sharp­ness of the re­cor­ded image. A lon­ger ex­posure time leads to brigh­ter images, but can also cause mo­ti­on blur and in­cre­a­sed image noise. A short ex­posure time en­ables fast ap­pli­ca­ti­ons and re­du­ces the as­so­cia­ted mo­ti­on blur. 

The Right Re­so­lu­ti­on for Every Ap­pli­ca­ti­on

Re­so­lu­ti­onAc­cu­ra­cyEx­amp­les
1.6 MPAp­pli­ca­ti­ons that do not re­qui­re ex­tre­me­ly high re­so­lu­ti­onOp­ti­cal cha­rac­ter re­co­gni­ti­on, as­sem­bly con­trol, pre­sence check
5 MPAp­pli­ca­ti­ons re­qui­ring me­di­um level of de­tailIn­spec­tion of packa­ging
12 MPAp­pli­ca­ti­ons re­qui­ring high pre­cisi­onIn­spec­tion of fine me­cha­ni­cal parts
24 MPAp­pli­ca­ti­ons re­qui­ring very high re­so­lu­ti­on and at­ten­ti­on to de­tailChe­cking PCBs for faul­ty com­po­n­ents
Produktvergleich
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