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
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:
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
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
In the automotive industry, the quality of individual components of passenger car interior doors, such as window controls or armrests, must be visually checked for different types of door. For this purpose, a vision system consisting of several cameras, lenses, illuminations and a control unit is installed.
Machine Vision Controller with 2D/3D Profile Sensors
When producing baked goods with chocolate glaze, the exact height and width of the baked goods must be determined for quality control purposes. For this purpose, a 2D/3D profile sensor with a large measuring range is installed above the conveyor belt, which measures all cookies with micrometer precision over the entire width of the line.
