VISIONARY INSIGHTS: REVOLUTIONIZING MANUFACTURING WITH MACHINE VISION LENSES

 

In the fast-paced world of manufacturing and production, efficiency reigns supreme. The relentless demand for high-quality products delivered promptly has forced businesses to continually seek innovative solutions to enhance their production processes. One such revolutionary solution is the use of machine vision lenses, a critical component of automated inspection systems. These lenses play a pivotal role in optimizing manufacturing efficiency, precision, and quality control. In this article, we will delve deep into the world of machine vision lenses, exploring their significance, benefits, and the transformative impact they have on modern production processes.

THE ROLE OF MACHINE VISION LENSES IN AUTOMATION

Machine vision lenses, also known as industrial lenses, are indispensable in automated inspection, measurement, and identification processes within manufacturing industries. They are designed to capture high-resolution, precise images of products and components, providing the necessary data for machine vision software to analyze and make informed decisions. This automation reduces the reliance on manual inspection, resulting in a substantial increase in the speed of production lines.

1. Precision and Accuracy
   
   One of the most significant advantages of machine vision lenses is their unparalleled precision. Traditional manual inspections are susceptible to human error and can often yield inconsistent results. In contrast, machine vision lenses ensure consistent, accurate inspections, leading to a reduction in errors and less waste. The enhanced precision directly translates to an improvement in the overall quality of the end product, meeting and often exceeding customer expectations.
   
   Machine vision systems equipped with advanced lenses can detect even the slightest defects or deviations from specifications, ensuring that every product meets the required quality standards. This level of accuracy is difficult to achieve through manual inspection processes and underscores the value of machine vision lenses in quality control.


2. Continuous Operation
   
   Machine vision lenses possess a unique advantage over human inspectors – they can operate continuously without fatigue. While human workers may need breaks and rest periods, machine vision systems can tirelessly inspect products around the clock. This capability not only increases production uptime but also allows for 24/7 manufacturing, a crucial factor in meeting the demands of today's globalized markets.
   
   Moreover, these lenses can simultaneously inspect multiple product features, further amplifying inspection speed and efficiency. This multitasking ability ensures that no detail is overlooked and that production lines can maintain peak performance at all times.


3. Predictive Maintenance
   
   Machine vision lenses contribute significantly to predictive maintenance strategies in manufacturing. By identifying minute defects or changes in the production line, these lenses can alert operators to potential issues before they escalate into costly repairs or unplanned downtime. This proactive approach to maintenance saves both time and money while minimizing resource wastage, further enhancing production efficiency.

INVESTMENT IN EFFICIENCY

It is understandable that some manufacturers may initially view the integration of machine vision lenses as a substantial investment. However, it is crucial to consider the long-term benefits these lenses bring to the table. Increased efficiency, reduced waste, improved product quality, and minimized downtime are just a few of the advantages that make this investment not only worthwhile but essential for modern manufacturing operations.

CONCLUSION

In conclusion, machine vision lenses have ushered in a new era of production efficiency, revolutionizing manufacturing processes across industries. As businesses continue to seek ways to improve productivity and product quality, the adoption of machine vision lenses in production lines is no longer merely beneficial but essential. In an age characterized by automation and Industry 4.0, machine vision lenses will undoubtedly continue to play a pivotal role in enhancing production efficiency.

As you embark on your journey to harness the full potential of machine vision lenses, we invite you to explore COMPUTAR'S collection of revolutionary machine vision lenses. Discover how they can be seamlessly integrated into your operations to improve efficiency, reduce waste, and elevate the quality of your products. Embrace the future of manufacturing with machine vision lenses, and watch as your production processes evolve into streamlined, efficient, and highly competitive operations.

FOR MORE INFORMATION ON COGNEX MACHINE VISION SYSTEMS INDIA CONTACT US AT MVASIA INFOMATRIX PTE LTD +65 6329-6431 OR EMAIL US AT INFO@MVASIAONLINE.COM

GIGABYTE'S INNOVATIVE 3D SENSING TOF SOLUTIONS: TRANSFORMING INDUSTRIES WITH ADVANCED TECHNOLOGY

 

In today's rapidly evolving technological landscape, GIGABYTE stands out as a pioneer in providing cutting-edge solutions that cater to diverse industries. With a commitment to enhancing lives through innovation, GIGABYTE has developed a comprehensive product lineup that spans consumer electronics, gaming, business systems, and cloud solutions. Renowned for its award-winning products such as motherboards, graphics cards, laptops, mini PCs, and various PC components and accessories, GIGABYTE has firmly established itself as an industry leader. This article explores GIGABYTE's groundbreaking contributions to the field of 3D sensing Time of Flight (TOF) technology, particularly in applications such as 3D sensing cameras and people counting solutions.

THE EVOLUTION OF GIGABYTE: A LEADER IN TECHNOLOGICAL ADVANCEMENTS

GIGABYTE's journey as a developer of PC and server hardware solutions has been marked by a commitment to continuous innovation. The brand's reputation for excellence has been built upon its ability to anticipate industry trends and customer needs. With a focus on catering to a wide range of sectors, including consumer electronics, gaming enthusiasts, and businesses, GIGABYTE has consistently delivered products that elevate user experiences.

3D SENSING TIME OF FLIGHT (TOF) SOLUTIONS

GIGABYTE's foray into 3D sensing TOF solutions has opened up new avenues for industries to harness the power of advanced technology. TOF technology utilizes the principle of measuring the time taken for light to travel from a source to an object and back to the sensor, enabling highly accurate depth perception. This technology has found applications in various sectors, including automotive, industrial automation, security, and more.

1. T01-NP / 3D TOF Sensing Camera Ethernet Version
   
   One of GIGABYTE's pioneering offerings is the T01-NP 3D TOF Sensing Camera Ethernet Version. This advanced camera leverages TOF technology to capture precise depth information, enabling applications such as object detection, gesture recognition, and spatial mapping. With the ability to integrate seamlessly into different environments, the T01-NP empowers industries to enhance their processes and functionalities.


2. M03-U3 / 3D TOF VGA Sensing Camera
   
   GIGABYTE's M03-U3 3D TOF VGA Sensing Camera exemplifies the brand's commitment to pushing the boundaries of technology. This camera offers high-resolution depth sensing, making it a valuable tool for industries that require accurate spatial understanding. From robotics to augmented reality, the M03-U3 plays a pivotal role in enabling machines to interact intelligently with the world around them.


3. E02-U3 / 3D TOF Outdoor Sensing Camera
   
   The E02-U3 3D TOF Outdoor Sensing Camera showcases GIGABYTE's versatility in catering to various environments. With rugged construction and advanced sensing capabilities, this camera thrives in outdoor settings, making it an ideal solution for industries such as agriculture, construction, and surveillance.

PEOPLE COUNTING TOF SOLUTION

GIGABYTE's 3D sensing TOF solutions extend beyond object detection and spatial mapping. The brand's expertise has led to the development of people counting solutions that offer insights into crowd management and behavior analysis.

1. M03-U3 / 3D TOF VGA Sensing Camera for People Counting
   
   The M03-U3, already known for its high-resolution depth sensing capabilities, finds a unique application in people counting. In retail, events, and public spaces, this solution aids in understanding foot traffic patterns, optimizing space utilization, and enhancing security measures.


2. T01-NP-PC / 3D TOF People Counter
   
   The T01-NP-PC is a specialized people counting solution that capitalizes on GIGABYTE's advanced TOF technology. Its ability to accurately track individuals in dynamic environments makes it an indispensable tool for businesses and institutions seeking data-driven insights into customer behavior and space usage.

TRANSFORMING INDUSTRIES THROUGH INTEGRATION OF AI AND ALOT APPLICATIONS

GIGABYTE's commitment to innovation extends beyond hardware solutions. The brand's vision includes integrating Artificial Intelligence (AI) and the Internet of Things (IoT) to unlock new possibilities for industries. By harnessing AI and AloT applications, GIGABYTE enables customers to gather, analyze, and convert digital information into valuable economic data. This approach not only streamlines processes but also accelerates business success from the edge to the cloud.

DRIVING PROGRESS IN THE AUTOMOTIVE SECTOR: A SINGAPOREAN PERSPECTIVE

GIGABYTE's impact is felt globally, including in Singapore's automotive industry. As an automotive system dealer in Singapore, staying ahead of technological advancements is imperative. GIGABYTE's 3D sensing TOF solutions offer transformative possibilities for the automotive sector, from enhancing driver assistance systems to enabling more accurate object detection in autonomous vehicles. The precision and reliability of GIGABYTE's TOF solutions align with Singapore's commitment to cutting-edge automotive technologies.

CONCLUSION

In an era where technology is the driving force behind progress, GIGABYTE emerges as a beacon of innovation. With a diverse product lineup that caters to consumers, businesses, gamers, and cloud systems, the brand's contributions have left an indelible mark on various industries. GIGABYTE's 3D sensing TOF solutions, coupled with its integration of AI and AloT applications, exemplify its commitment to pushing the boundaries of what's possible. As a renowned automotive system dealer in Singapore, GIGABYTE's technological prowess resonates deeply with the nation's drive toward a technologically advanced future. With each innovation, GIGABYTE reaffirms its position as a leader, dedicated to upgrading lives through transformative technology.

Also Read: TIRE PROFILE DETERMINED WITH DEEP LEARNING

BASLER BLAZE TIMEOF FLIGHT CAMERA – FREQUENTLY ASKED QUESTIONS (FAQ)

HERE YOU’LL FIND ANSWERS TO THE MOST COMMON TECHNICAL QUESTIONS CONCERNING TIME-OF-FLIGHT CAMERAS.

1. WHAT IS TIME OF FLIGHT?

Time of Flight is a method for distance measurement--the time it takes for light to travel from the light source to the object then return to the sensor is measured and used to calculate a distance.

2. HOW ACCURATE IS THE MEASUREMENT OF A TOF CAMERA?

ToF cameras are accurate to a few millimeters, depending on the situation. Basler’s user manual contains a graphic with detailed accuracy measurement data.

3. WHAT RESOLUTION DOES THE BASLER BLAZE CAMERA OFFER?

ToF cameras have lower resolutions than modern 2D cameras due to the complexity of the ToF pixel design. The Basler blaze-101 camera offers a state-of-the-art resolution of 640 pixels (horizontal) x 480 pixels (vertical).

4. WHICH SENSOR IS USED IN THE BASLER BLAZE-101 CAMERA?

The Basler blaze camera uses the latest ToF-specific Sony DepthSense™ IMX556PLR sensor.

5. DOES A TOF CAMERA NEED TO BE CALIBRATED IN THE FIELD?

Every ToF camera requires calibration to achieve a reasonable accuracy. The Basler blaze-101 camera comes pre-calibrated ex-works. In-field calibration or re-calibration of the sensor is not necessary. Each blaze-101 camera has an individual calibration for lens distortion, distance error and thermal drift compensation.
However, you can configure the camera parameters further with the blaze-101 API based on the scene and object.

6. WHICH APPLICATIONS ARE SUITABLE FOR THE TOF CAMERA?

The Basler ToF cameras are used in a variety of applications in the fields of logistics, factory automation, robotics, AGV, agriculture and medicine.

7. WHAT IS THE FRAMERATE OF TOF CAMERAS?

The Basler blaze-101 camera runs at up to 30 fps.

8. HOW DOES THE OPERATING TEMPERATURE AFFECT THE ACCURACY OF A TOF CAMERA?

Due to the high demands on the precision of light pulses and shutter speeds, ToF cameras are sensitive to temperature fluctuations. The Basler blaze-101 has several temperature sensors, which are used for individually calibrated compensation of possible signal shifts. Thus, the influence of temperature on a blaze-101 camera is negligible.

9. CAN I CHANGE THE LENS OR BUY A TOF CAMERA WITH ANOTHER LENS?

A ToF camera is a calibrated system. If focus, aperture or lens are changed, the calibration is lost. Furthermore, the illumination and lens are optimally tuned to each other in wavelength and field of view. Thus, it is not advisable to modify the lens.

10. WHAT IS THE FOV OF THE LENS?

It depends on the camera model. The field of view of the Basler blaze-101 camera is 67° x 51° (H x V). This large measuring range can cover approximately two Euro pallets or a small car at 5 m distance.

11. WHAT KIND OF LIGHT SOURCE IS USED IN TOF CAMERAS?

ToF cameras typically use LED or laser diodes. The Basler blaze-101 camera uses four VCSEL laser diodes as its light source.

12. ARE THE INBUILT LASER DIODES EYE-SAFE?

Eye safety is very important to us and we make high demands on the safety of our products.
Basler blaze-101 is classified as a Class 1 laser product according to EN/IEC 60825-1:2014 Edition 3. This classification means the camera is eye safe under all reasonably foreseeable conditions of normal use. The Basler blaze includes technical safety elements that ensure that the accessible emissions--e.g. via the electrical power control (electronic safety circuitry), the optical diffusor and the cover glass on the illumination--stay within safe limits. Correct functioning is guaranteed by quality management measures that include a 100% test after assembly.

13. WHAT IS THE WAVELENGTH SPECTRUM OF TOF CAMERAS?

In principle, a ToF camera can work at any wavelength as long as the illumination and sensor operate in the same spectrum. For practical reasons, the near infrared is preferred because the photoelectric effect works well in that range, but people are not disturbed because they cannot perceive the light.
The Basler blaze-101 camera works with a wavelength spectrum of 940nm. When comparing the 940nm ToF cameras with the 850nm cameras it is important to know that 940nm is completely invisible for humans, so it is a better choice in situations involving illumination of a person’s face or deployment close to humans. At 850nm, human eye sensitivity is very low but 850nm light can still be seen, especially in dark conditions. This can be uncomfortable and or confusing.

14. WHAT IS THE MODULATION FREQUENCY OF THE TOF CAMERAS?

A typical modulation frequency for a ToF camera is between 10 and 100Mhz.
In default mode (20 fps) the Basler blaze-101 camera operates at two different frequencies: 15 MHz and 100 Mhz. In fast camera mode (30 fps) the modulation frequency is 15 MHz for long range and 100 MHz for short range.

15. CAN I SET THE MODULATION FREQUENCY OF THE CAMERA MYSELF? IF I WANT TO MEASURE UP TO 15 M, CAN I SET 10 MHZ?

The camera performance is optimized for two modulation frequencies (15 MHz and 100 MHz) and factory-calibrated, so it is not possible to change it.

16. CAN I USE A TOF CAMERA FOR OUTDOOR APPLICATIONS AS WELL?

Ambient light does not help with distance measurement. In fact, it fills the sensor with photons from random directions not related to the distance which thus have to be considered as a noise source.
Basler’s blaze-101 camera works under sunlight conditions. Compared to a ToF camera working at 850 nm, a ToF camera working at 940 nm is more daylight robust as at this wavelength the sunlight is strongly absorbed by the atmosphere. Also, modern artificial light sources do not emit NIR light for efficiency reasons. Please check the user manual for details.

17. IS A TOF CAMERA WORKING AT 940NM (BASLER BLAZE) LESS SUITABLE FOR INDOOR USE THAN A TOF CAMERA WORKING AT 850 NM?

The quantum efficiency (QE) of a typical sensor at 850 nm is indeed higher than at 940 nm. However, the maximum permissible light exposure at 940 nm permits a 1.5X higher lighting output for cameras working at 940 nm. This compensates for the disadvantages of QE to a large extent. Furthermore, the properties of camera illumination, ambient light and other sensor properties such as dynamic range must also be considered. For indoor use of a ToF camera we recommend uniform DC lighting such as high-quality LEDs.

18. IS THE BASLER TOF CAMERA SUPPORTING THE GIGE VISION INTERFACE STANDARD?

Basler blaze-101 is compatible with GigE Vision standard. However, if you want to access all four streaming formats (point cloud, range map, intensity image, confidence map) and have usage of the full range of functions available, we highly recommend the Basler GenTL producer, provided with the Basler blaze SDK.

19. WHAT IS THE PROTECTION CLASS RATING FOR THE TOF CAMERA?

If you put a ToF camera into an external enclosure, you have to make sure that the cover protection glass does not interfere with the ToF measurement.
The Basler blaze-101 camera is already rated to protection class IP67; thus, it is completely dustproof and can withstand submersion in water down to 1m for 30 minutes.

20. CAN A TOF CAMERA SURVIVE VIBRATION AND SHOCKS?

Due to their design principle, ToF cameras are fundamentally more robust than structured light or stereo cameras, which must maintain a precise basic length.
The Basler blaze-101 camera is shock- and vibration-proof according to EN60068. The cameras were submitted to an independent mechanical testing laboratory and subjected to specific stress tests. After mechanical testing, the cameras exhibited no detectable physical damage and produced normal images during standard operational testing. Please check the user manual for test details.

21. I'D LIKE TO USE THE CAMERA IN AN OUTDOOR SETTING AND WANT TO PUT IT INTO A HOUSING. WHAT FACTORS REQUIRE SPECIAL CONSIDERATION? CAN I SIMPLY PUT THE TOF CAMERA INTO A STANDARD PROTECTION HOUSING?

Cooling is a primary consideration before mounting into a protective housing, as well as avoidance of stray light (no reflecting housing parts near the lens).
The protective glass must be translucent in the required wavelength, must be of high quality with no scratches and must not cause reflections. Ideally, the lens and the LEDs will have separate protective glasses.

22. I'D LIKE TO USE MULTIPLE TOF CAMERAS IN MY APPLICATION.

Operating multiple ToF cameras extends your field of view and allows you to capture objects from every angle. However, the light pulse of one ToF camera can disturb the sensor of a second camera, leading to false distance measurements.
In case of Basler’s blaze-101 camera, you have several options to minimize camera interference for reliable multi-camera operation:

• 1. Use the software trigger over Ethernet. You can synchronize the cameras such that two cameras never illuminate the scene at the same time. Trigger one camera after another.
• 2. Use the Precision Time Protocol (PTP) to synchronize the timing. Instead of issuing the trigger via software (1.), you can configure the cameras to trigger themselves based on a common clock. This clock is synchronized over the network automatically (PTP protocol) down to a microsecond precision which allows very tight timing in the trigger sequence.
• 3. Use the multi-camera feature of Basler blaze. For each camera, select a slightly different modulation frequency, which yields almost no interference.

You can also combine the methods. For example, you can configure PTP so that all cameras trigger at exactly the same time, but also use multi-camera feature to minimize the interference. This is the recommended method to capture objects in motion.

23. CAN I USE A 2D AND A 3D BASLER CAMERA WITHIN ONE SYSTEM?

Yes, you can install the blaze SDK and the pylon SDK on one computer. The blaze SDK comes with samples; one shows the use of a blaze-101 and an ace camera in combination.

24. I HAVE TO DOWNLOAD A GENTL PRODUCER COMPLIANT WITH THE GENICAM STANDARD TO OPERATE THE BASLER BLAZE CAMERA. WHAT EXACTLY IS THAT STANDARD AND WHY DOES BASLER USE THIS PROCESS?

GenTL is the third module of GenICam. While GenApi and SFNC are more oriented toward the camera's settings, GenTL regulates the transport of the image data. GenTL is the latest module.

25. WHERE DOES ALL THIS INTENSE PROCESSING HAPPEN? ON THE CAMERA OR THE HOST? WHAT KIND OF CPU/GPU COMBINATION WOULD YOU NEED?

It depends on the specific camera model you use. For example, stereo cameras often load the host processor with the depth calculation. The Basler blaze-101 camera has a very powerful NXP processor that does all the work, so the host requirements are relatively low.

26. DOES THE BASLER BLAZE SUPPORT ROS?

Yes, the blaze SDK comes with a driver and sample for ROS under Linux.

27. DOES USING POLARIZING FILTERS HELP WHEN WORKING WITH STRONG REFLECTIVE SURFACES?

For this setup you would need an especially strong, polarized light source. This is unusual for ToF cameras.

28. HOW DOES YOUR CAMERA MANAGE SCATTERED LIGHT?

Scattered light occurs due to unwanted reflections within the lens or behind it. Even for the most carefully engineered setup, scattered light cannot be completely eliminated. Bright surfaces located very close to the light source quickly scatter too much light into the lens. This can cause measurement errors (measured distance too short). In the intensity image, scattered light leads to a washed-out image with poor contrast. The Basler blaze-101 camera has an inbuilt lens that is optimized for Time-of-Flight cameras and reduces stray light effects as much as possible. You should also remove specular objects from the scene, if possible.

29. IS IT POSSIBLE TO INSTALL THE CAMERA BEHIND A PROTECTIVE GLASS?

It is possible, but you have to choose a protective glass as transparent to 940nm light as possible. The protective glass must not cause reflections. Please also consider that the latest model blaze-101 is rated to protection class IP67, so it is splash water and dust resistant.

30. DO YOU HAVE ANY PLAN TO SELL HIGH RESOLUTION VERSIONS OF THIS TOF SENSOR?

Currently VGA resolution is state-of-the-art for ToF cameras. But across the product life cycle, we closely observe innovations in the ToF sensor market, and newer sensor models will be taken into consideration for future camera models as they are released.

WHAT’S THE DIFFERENCE BETWEEN VISIBLE AND SWIR LENSES?

 Short-wave Infrared (SWIR) lenses are designed to operate in the 0.9-1.7 µm wavelength region. SWIR is close to visible light in that photons are reflected or absorbed by an object, providing the strong contrast needed for high-resolution imaging. 

SWIR is great for the Machine Vision and the Health & Sciences Industries because water vapor, fog, and certain materials such as silicon are transparent. SWIR imaging is also helpful because similar-looking colors visible to the human eye are easily differentiated using SWIR lenses.

HOW DOES IT WORK?

SWIR lenses are like visible cameras in the way they detect reflected light. Photons in the SWIR wavelength are reflected or absorbed by objects, allowing for high-resolution imaging with a strong contrast. This kind of technology is the only wavelength technology that can pierce through cloud coverage and capture a well-defined image.

For our ViSWIR series, according to Mr. Katsuya Hirano, Chief Optical Designer, CBC Group, for fully-corrected focus shift in visible and SWIR range (400nm-1,700nm): “By using ultra-low dispersion glass and low partial dispersion glass paired with superior design technology developed from Computar’s extensive optics experience, the focus shift is minimized within a few micron mm at a super wide range of wavelengths. With this, spectral imaging is achievable with a single sensor camera by simply syncing the lighting.”

With Computar's ViSWIR HYPER-APO lens series, it is unnecessary to adjust focus for differences. By adopting an APO floating design*, the focus shift is reduced at any wavelength and any working distance. This function makes SWIR lenses ideal for multiple applications, including machine vision, UAV, and remote sensing.

WHICH LENS IS THE BEST FOR MY INDUSTRY?

For the Machine Vision Industry as well as the Life Sciences Industry, we recommend our ViSWIR Series. These lenses achieve a clear and precise image visible to the SWIR range by applying a multilayer coating to absorb the specific light. A higher-resolution lens gives you greater specificity in designing and implementing the most efficient vision solutions. So, for medical devices and robotics, this is great for detail work and other short-range imaging.

For the Intelligent Transport Systems Industry and Government and Defense, a blend of visible and SWIR would be most helpful—visible imaging for distance and SWIR for detailed imaging.

Some lenses, such as ours, are designed to perform well with for both visible and SWIR, enabling cost-effective and performance imaging systems for a range of applications.

FOR MORE INFORMATION ON MACHINE VISION LENSES DEALERS IN SINGAPORE CONTACT US AT MVASIA INFOMATRIX PTE LTD +65 6329-6431 OR EMAIL US AT INFO@MVASIAONLINE.COM

3 WAYS TO LEVERAGE 3D TECHNOLOGY IN LOGISTICS

 In logistics, the demand for automation is rising due to growth in e-commerce and changing customer expectations. For companies to keep up with these conditions, they need to incorporate the latest innovations that will help them deliver to customers faster.

This is where 3D technology comes into play. 3D machine vision, such as Cognex’s 3D-A1000, is a camera system that captures and processes data from all three dimensions.

Within logistics, 3D can not only automate processes such as dimensioning, item detection, and presence/absence, but it can also increase throughput, improve process efficiency, and ensure order accuracy. In addition, unlike 2D, 3D technology is adaptable to ever-changing packaging, graphics, and artwork.

Here are 3 innovative ways to leverage 3D technology in logistics.

1. SIDE-BY-SIDE DETECTION:

This feature of 3D technology detects when items are unintentionally placed next to each other or on top of each other, and accidentally counted as one item instead of two. This can cause a customer to receive multiple items or no order at all, which can be extremely costly. Detecting side-by-side situations is important for ensuring no inventory is lost, preventing mis-sorts and incorrect or delayed shipments, and reducing manual rework. This type of detection can also correctly identify multi-packs such as a pack of soda bottles or a split-top box containing multiple items.

2.TOTE FILL:

This application tracks and measures tote fill height and volume, which allows customers to maximize the usage of their totes, ensure no products or equipment is damaged, and verify the contents of totes. Totes are useful for order fulfillment, to move goods around facilities, or for storage. However, many logistics companies need to automate the use of totes to ensure they’re used properly, which is why they rely on 3D technology.

3.LABEL PLACEMENT VERIFICATION:

Ensuring that labels are properly placed on packages is crucial to accurate order fulfillment. 3D technology can measure where a label or marking is placed on a package and detect where the label is overhanging. Accurate label detection and verification allows logistics companies to ship readable labels, avoid production line delays, and reduce manual work.

FOR MORE INFORMATION ON 3D MACHINE VISION SYSTEMS VISIT MVASIAONLINE.COM OR CONTACT US AT MVASIA INFOMATRIX PTE LTD +65 6329-6431 OR EMAIL US AT INFO@MVASIAONLINE.COM

IMPROVING VISION WITH SHORTWAVE INFRARED LINE-SCAN CAMERAS

 Makers of machine vision systems have long relied on visible light cameras when building systems to give their customers the ability to perform quality control in all sorts of production environments. Recently, another type of sensor, the short-wave infrared (SWIR) linescan camera, has improved in resolution and come down in price enough that system integrators have started to develop new inspection systems that take advantage of the unique advantages offered by such cameras.

LOOKING WITH NEW EYES

The SWIR part of the spectrum, which is generally considered to be wavelengths between 900 and 2500 nm, can pick out features that are not immediately obvious in visible light. For instance, it’s excellent at sorting fruits and vegetables and detecting foreign objects, such as packaging, mixed in with the food.

Say the customer is a produce distributor who needs to inspect frozen peas, to make sure there’s no debris among them. If there’s a small piece of plastic, similar in shape, size, and color to the peas, machine vision using visible light might not notice it. SWIR light, however, is strongly absorbed by water, so frozen peas with their high water content would be very dark in the image. A piece of plastic, which has little or no water content, would instead reflect the light and stand out sharply from the peas, and the sorting machine could use an air jet to blow it out of the pile (see Fig. 1).

In a very different example, the photovoltaic industry can also benefit from the properties of SWIR. Inspecting the silicon wafers that go into solar cell arrays is crucial, as defects within them can severely impair their efficiency at converting sunlight to electricity. Visible light, however, can only look at the surface of the wafers. But at SWIR wavelengths, the wafers are transparent. That makes it possible to find cracks inside them that wouldn’t be apparent in a normal visual inspection.

HYPERSPECTRAL IMAGING – BASED ON AREA SCAN CAMERAS

SWIR cameras can also play a role in hyperspectral imaging, which relies on multiple wavelengths of light in applications ranging from inspecting food to sorting different types of plastic waste to characterizing different materials. Hyperspectral imaging includes both visible and SWIR wavelengths, and sometimes, depending on the application, goes further into the infrared to include midwave and longwave infrared wavelengths as well.

Hyperspectral imaging systems add a dimension to the images they collect. Though they are used in line scan setup, they rely on area (two-dimensional) detectors. That’s because the scans are passed through a prism, diffracting the light, with different wavelengths falling on different parts of the detector to create a layered image. Individual wavelengths supply different information about the objects being imaged.

Often, hyperspectral systems are used in research to develop applications. Then, once the best wavelengths for detecting what’s sought have been determined, they’re replaced with simpler line scan systems that only look at a limited number of wavelengths, for example by using pulsed LEDs.

A NARROWER VIEW

The major difference between a line scan camera and an area camera is apparent in the name. A line scan camera consists of a single row of pixels that image a narrow line across the object being scanned, whereas an area camera captures a much larger area in each frame. Each pixel absorbs light from the object and converts it into a charge, and adjacent lines add up to an image of the whole object. In order to do that, either the scanner or the object must move so that different sections are within the sensor’s field of view.

That movement makes a line scan camera well suited to a production environment, where parts being inspected often move along a conveyor belt, or where objects being sorted drop into a bin. Fruits and vegetables, for instance, typically fall past the detector. Because these applications already involve motion, they fit naturally with line scan cameras, while avoiding the risk of blurring the image that the motion might produce in an area camera. A line scan image is also less likely than an area image to contain faulty pixels that can hide the defects being sought, and they provide good resolution at an affordable price.

HOW TO SELECT AN INFRARED LINE SCAN CAMERA

THE WAVELENGTH

In deciding whether to turn to SWIR imaging for your application, it is important to know whether there is some aspect of the objects being viewed that stands out at SWIR wavelengths. In applications such as inspection of markings—labels and bar codes, for instance— there is no reason to use IR light, as visible imaging does a much better job, at a much lower cost.

Knowing the SWIR wavelength you need is often critical to the success of the setup. Which wavelength is best depends on the intended application. For food sorting based on moisture content, the typical wavelength used is 1450 nm, which is very strongly absorbed by water (see Fig. 2). Other food inspection applications might require different wavelengths. SWIR can be used to identify different aspects of food, such as the fat content in meat or a bruise in an apple, that reflect or absorb light differently from the area around them. It can measure how fresh a fish is. Or it can look for impurities.

Melamine, an industrial chemical that has been found to be contaminating powdered milk, stands out in SWIR light, for instance.

Nowadays, the typical SWIR camera uses a detector built from indium-gallium-arsenide, which is sensitive to light from 900 to 1700 nm. Some applications, however, require wavelengths as long as 2000 or 2500 nm, which is sometimes referred to as extended SWIR. The mining industry, for instance, sometimes turns to those wavelengths, which require a different or modified material in the detector.

No one specific wavelength is used for silicon wafer inspection. The silicon is transparent at wavelengths above 1200 nm, so anything beyond that works. Of course, finding small defects requires high resolution and often large magnification, and the shorter the wavelength is, the higher the resolution and the smaller the defect it can detect.

RESOLUTION

If the user wants to build a megapixel image from the camera— that is, an image with a million pixels—he can achieve that by scanning 1,000 lines that each have 1,024 pixels. So, a system that scans at a relatively low line rate of 1 kHz—1,000 lines per second—can capture a megapixel in one second. In order to achieve that without significant overlaps or gaps between the lines, the speed of the conveyor belt has to match with the line rate and the camera’s field of view.

The resolution of the system should also match the application, and system designers can figure that out by considering the field of view of their scanners and the size of the particle or defect they’re trying to find. Generally, people looking for foreign matter in fruits and vegetables are interested in macroscopic objects, so it’s easy to achieve the necessary resolution. Depending on the setup, the field of view may be up to one meter. So, a 512-pixel camera may be sufficient.

For silicon wafer inspection, the defects being sought are smaller, so the resolution needs to be higher (see Fig. 3). Such a system might call for a 2,048-pixel camera. One relatively new technique for finding smaller defects in wafers is an approach called “transflection,” a combination of transmission and reflection. Light that has transmitted for a short distance inside the wafer is then reflected, and any crack in the way will cast a shadow, which tends to be bigger than the crack itself and therefore easier to spot. Transflection systems require careful optimization by the system designer.

NOISE

Noise is also important in these systems. The main contributor is the detector’s read noise and it defines the limits of detection. As the line rate increases, the exposure time, and thus the number of photons reaching the detector during the exposure time, decreases. At a rate of 1,000 lines per second, for instance, the exposure time can be a maximum of 1 ms. Increasing the line rate shortens the exposure time even more, so it becomes crucial that the noise doesn’t overwhelm the light signal collected by the detector. Of course, it is possible to increase the light intensity in the system so that more photons per second reach the detector, but that’s not always easy; it drives the cost of the system up and can create problems with heat. For this reason, detectors with low noise levels are desirable.

BEYOND CAMERAS

An inspection system includes several components that work in conjunction with the SWIR line scan camera. One key component is the light source, which can consist of LEDs, lasers, or halogen lamps. Of course, the source has to provide the right wavelength for the application, but there are other considerations as well. For instance, in order to get uniform illumination along the whole line of pixels, it might be best to match the camera with a line of LEDs. And the setup might be arranged in a number of different ways. For food sorting, perhaps the best place to locate the source would be next to the camera, while for semiconductor inspection it might make more sense to put the source on one side of the wafer and the camera on the other. Users might also want to look at a silicon wafer at an angle to see reflected light inside it, the better to notice small defects.

Another consideration is synchronizing the camera with the light source. As the objects move past the camera, the camera snaps individual frames. It’s important that the light be illuminating the objects at the moment the camera fires. The standard method is to send a triggering pulse to the camera and the light source at the same time, using an external trigger connector or something like the CameraLink data and control interface. That functionality is standard on any commercial machine vision camera. In some applications, users might look for different characteristics with two or three wavelengths. Triggering different sources, for example LEDs with different wavelengths, at different times allows the system to sort the wavelengths temporally.

AN EVOLVING FIELD

While machine vision systems based on visible light have been widely used for years, SWIR line scan imaging is relatively new and not as widespread. In part, that is due to the lower resolution of the IR systems, with maximum pixel counts of 2,048 as compared to 16,000 for visible.

But in recent years, the noise and resolution of SWIR cameras have improved at the same time the cost has come down. That has led to their adoption in high-volume applications such as food sorting and semiconductor inspection. Making higher resolution cameras will require building smaller pixels, and there are technological challenges that must be overcome to achieve that. The main focus of camera manufacturers today is in reducing the noise in the system and increasing the scanning speed.

THE RIGHT ANSWER

System integrators who build machine vision setups for their customers can benefit by using SWIR line scan cameras in their systems. For the right application, IR light provides the ability to see things that visible light does not. It can peer beneath the surface of a silicon wafer to look for cracks, for instance, or make inedible material stand out sharply from food items that in visible light may look very similar.

Machine vision integrators have several factors to consider when incorporating a SWIR line scan camera into their systems. Which wavelength is right for the application? Which light source works best? What level of resolution is necessary? Does the scanning speed match the speed at which the inspected objects are moving? Is the noise low enough to get a readable signal with that light source and scanning speed?

If these questions have the right answers, system integrators may find that SWIR line scan cameras provide the capabilities to give their customers the machine vision that they’re looking for.

TO KNOW MORE ABOUT LINE SCAN CAMERAS IN SINGAPORE CONTACT MVASIA INFOMATRIX PTE LTD AT +65 6329-6431 OR EMAIL US AT INFO@MVASIAONLINE.COM

HOW WILL THE LATEST IMAGE SENSORS IMPACT THE FUTURE OF MACHINE VISION?

 

WHAT IS AN IMAGE SENSOR?

An image sensor is a device that allows the camera to convert photons (light) into electrical signals. They are composed of millions of pixels on a single chip. The image sensor measures light intensity – but light's angle, spectrum, and other characteristics are also extracted.

For simple applications like photography, the intensity information of three-color bands (RGB) is adequate. However, for advanced sensing applications, such as autonomous vehicles, biomedical imaging, and robotics, extracting more information from the incident light could help machines to make better decisions.

SIZE MATTERS

The bigger, the better when it comes to image sensors. Because the sensor is the part of the camera capturing the image, it is critical to the quality of the resulting image. Sensor size and megapixel count are very closely connected. A larger camera sensor will give you better image quality because it gathers more light and delivers a higher megapixel count than a smaller sensor.

IMPROVING IMAGE SENSORS FOR MACHINE VISION

In the future, it is predicted that more cameras will be built for machines than people. This will be further accelerated by the rapid progress in machine learning and artificial intelligence. In addition, it is predicted that machine vision applications will substantially benefit from the multimodal measurement of light fields by advanced imaging sensors.

Some of the latest advances in image sensing have significantly impacted 3D imaging, event-based sensing, and nonvisible image sensing. According to innovations-report.com , the latest developments could enable autonomous vehicles to see around corners instead of just a straight line, biomedical imaging to detect abnormalities at different tissue depths, and telescopes to see through interstellar dust.

Optics play a major role in the performance of any imaging system. For optimal performance, it is critical to choose a lens that can accommodate the latest sensor technology. Computar's MPT 1.4" 45 Megapixel Series is engineered to optimize the capabilities of the latest industrial CMOS sensors.

TO KNOW MORE ABOUT MACHINE VISION DEALERS IN SINGAPORE CONTACT MVASIA INFOMATRIX PTE LTD AT +65 6329-6431 OR EMAIL US AT INFO@MVASIAONLINE.COM