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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

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.



 

Ma­chi­ne Vi­sion Con­trol­ler with 2D/3D Pro­fi­le Sen­sors

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