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Machine Vision Controller Technology

Machine vision controllers are analysis modules for data processing and result output. Due to their robust and fanless housing, they can be used in various industrial environments.

Operating Principle

Structure and Components

Interfaces

2D Image Processing System

Applications

What Is a Machine Vision Controller?

Machine vision controllers are computers used in demanding and industrial environments. Unlike traditional office computers, machine vision controllers offer high uptime, fail-safe continuous mode, higher IP ratings, robustness against vibration, dust, or extended operating temperature ranges. Applications include production facilities in a wide range of industries such as automotive, metal, logistics, food, pharmaceuticals and energy.

The Difference Between Machine Vision Controllers and Smart Devices

Machine Vision Controllers

Suitable for applications where multiple cameras or profile sensors are required for evaluation
Shorter process times due to higher computing power
Image and profile evaluation takes place on the controller
Suitable for very high resolution inspection tasks

Smart Devices

Suitable for applications where only one camera or profile sensor is required for evaluation
Image and profile evaluation takes place on pre-installed software in the camera or in the profile sensor
Result output via integrated interfaces
No additional machine vision controllers required

Structure and Components of a Machine Vision Controller

CPU (Processor)

The CPU is the heart of the machine vision controller and provides the computing power. The appropriate processor is selected depending on the application. wenglor’s machine vision controllers have powerful i7 processors.

Mainboard

All components required for the operation of an industrial PC are installed on the mainboard. This includes the processor, the RAM, the mass storage, the chipset, the graphics, as well as modules for interfaces and other essential components.

Memory (RAM and Hard Disk)

The RAM (Random Access Memory) stores the data the processor needs for fast and short-term processing. The RAM can be compared with the displacement of a combustion engine: A sufficiently large RAM allows the processor to unfold its full power.

Interfaces

The controllers have some interfaces to communicate with the cameras and other devices, including

RTE
- PROFINET
- Ethernet IP
- EtherCAT
Ethernet TCP/IP
UDP
Digital I/O
SFTP

Cooling System

Many industrial PCs are installed in places where it is hot, such as foundries. For this reason, the cooling system must be efficient to keep temperatures under control. A distinction is made between passive and active cooling.

Graphics Card

Depending on the application, a graphics card may be required in the machine vision controllers. A graphics card in an industrial PC plays an important role in the processing and presentation of data.

The Differences Between the Interfaces

Ethernet TCP/IP

Ethernet TCP/IP stands for “Transmission Control Protocol/Internet Protocol” and is a data transmission protocol that makes it possible to reliably address data broken down into packets and transfer them to the subscriber devices connected to the network. It ensures that every data packet arrives. If this is not the case, it is sent again.

UDP

UDP (User Datagram Protocol) is a network protocol that enables the wireless transmission of data in IP-based computer networks. Connectionless means that the data is sent without mutual authentication between the emitter and receiver. UDP focuses on speed.

SFTP

SFTP (Secure File Transfer Protocol) is a file transfer protocol for IP-based networks that is used for encrypted data transfer. Typically, data is uploaded from the client to the server and downloaded from the server to the client.

DIO (Digital Input/Output)

DIO (Digital Input/Output) transmit digital signals from e.g. sensors or cameras efficiently and directly to other controllers (PLC). For example, a sequence of pulses triggers an image capture via a digital input. At the same time, illumination can be triggered via a digital output.

RTE (Real-Time Ethernet)

RTE (Real Time Ethernet) is a real-time Ethernet environment based on IP protocols, mainly used in automation technology to connect decentralized peripherals to a controller. These include PROFINET, Ethernet IP, EtherCAT. In factory automation, real time refers to cycle times in the single-digit millisecond range.

Flexible Use of Machine Vision Controllers

A machine vision controller is a component of an image processing system. In addition to the machine vision controller, a complete image processing system includes the following components, which wenglor offers:

Illumination Technology

Lenses

Lens Filters

uniVision Image Processing Software

2D/3D Profile Sensors

Machine Vision Cameras

Illumination Technology

Lenses

Lens Filters

uniVision Image Processing Software

2D/3D Profile Sensors

Machine Vision Cameras

How Is the Evaluation of the Machine Vision Camera Carried out Via a Controller?

Data recording: Image captured by camera
Data processing: Evaluation of the image captures by the software
Data transfer: Result transfer via interface to higher-level control

Applications of Machine Vision Controllers

Machine Vision Controller with Machine Vision Cameras

Visual “End of Line” Quality Inspection of Engine Blocks

Engine manufacturing in the automotive industry requires a visual, fully automated end-of-line quality control at the end of each production line. This prevents faulty engines from leaving the production line.