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File Name: Fiatpowertrain_Project Book_Omronvisionsystem_2013_Final.Doc Version: 1.1 Original Date: May 2011 Revised Date: January 2013 Page No.: 1 of 22

Fiat Powertrain

Joint Project Book for

Omron System Vision

Document Name.: Project Book for Omron Vision Systems

Version 1.1

Release Date: May 2011


Any questions or comments with respect to this specification should be directed to the project engineer for the specific project in question.

Revision Date Version No.

Description Section Affected

Revised By

May 2011 1.0. First release New document Antonio Paglino January 2013 1.1. Update from FZ-3 to FZ-4 and FJ

Introduction of FQ-2 vision sensors All section Antonio Paglino


CONTENTS

1. INTRODUCTION ............................................................................................................................................................. 4

2. CONTACT & SUPPORT ................................................................................................................................................. 5

3. PRODUCT OVERVIEW ................................................................................................................................................... 7

4. ADDITIONAL INFORMATION ...................................................................................................................................... 11


1. INTRODUCTION This document contains product information to be used for the selection of components for FP programs. This document provides a basic guide to selecting the correct type of vision system for the correct application. It also provides the necessary contact information to assist in application engineering, program management review, and stocking locations for ease of purchasing.

All information contained in this document is superceded by the requirements of the FP Global Specification.


2. CONTACT & SUPPORT Fiat Powertrain Europe (Italy) North America

Address Corso Settembrini, 167 10135 Torino (Italy)

Website Project Contact Mauro Falletti

Company FGA S.p.A.

Office +39 0110033099 Mobile Fax

E-Mail [email protected]

Omron Electronics Spa

Europe (Italy) North America

Address Viale Certosa 49 20149 Milano, Italy

Website http://industrial.omron.eu http://industrial.omron.it

Project Contact

Antonio Paglino Account Manager Automotive Market

Company Omron Electronics SpA

Office +39 02 3268 829 Mobile +39 335 56 88 752 Fax +39 02 325154


Omron Electronics Spa

Europe (Italy) North America

Address Viale Certosa 49 20149 Milano, Italy

Website http://industrial.omron.it Project Contact

Mauro Tarantino

Company Omron Electronics SpA

Office +39 02 3268 1 Mobile +39 346 1330780 Fax +39 02 325154


3. PRODUCT OVERVIEW

Picture Symbol Model Description Notes Doc #

FJ Vision Camera System

Real Color Sensing, up to 5 Million-pixel Camera, High Grade

Processing Items, Panorama Image Processing, High Dynamic

Range Function, Trapezoidal Distortion Correction, Dual Mega ARCS Engines, Hard disk less,

Ethernet / IP, Macros and programmable HMI

FZ4-605

Xpectia Series, two/four-camera controllers.

Real color Sensing, up to 5 Million-pixel Camera, High Dynamic Range Function, Ethernet / IP

n.a.

FJ-H3 Series Two/four-camera controllers. High Grade, High Speed

Controllers. Real Color Sensing, up to 5 Million-pixel Camera, High Dynamic Range Function,

Ethernet / IP, The Industry’s fastest CPU, Trapezoidal

Distortion Correction, Hard disk less, Dual Mega ARCS Engines,

Panorama, Macros and programmable HMI, Windows XP

embedded.

n.a.

FZ-SC5M

Digital Camera. 5 million-pixel.

Color

n.a.

FZ-S5M

Digital Camera. 5 million-pixel. Black & White

n.a.

FZ-SC2M

Digital Camera. 2 million-pixel.

Color

n.a.

FZ-S2M

Digital Camera. 2 million-pixel. Black & White

n.a.

FZ-SC

Digital Camera. 300,000-pixel.

Color

n.a.

FZ-S

Digital Camera. 300,000-pixel. Black & White

n.a.


FZ-SFC Small digital Camera.

300,000-pixel flat type. Color

n.a.

FZ-SF

Small digital Camera. 300,000-pixel flat type. Black &

White

n.a.

FZ-SPC Small digital Camera. 300,000-pixel pen type. Color

n.a.

FZ-SP

Small digital Camera. 300,000-pixel pen type. Black &

White

n.a.

FZ-SLC15

Intelligent camera (autofocus, auto-lighting, auto-zoom), narrow

field of vision

n.a.

FZ-SLC100

Intelligent camera (autofocus, auto-lighting, auto-zoom), wide

field of vision

n.a.

FZ-SQ Intelligent compact camera, integrated light and lens

n.a.

FZ-SZC15 Autofocus, auto-zoom camera,

narrow field of vision n.a.

FZ-SZC100 Autofocus, auto-zoom camera,

wide field of vision n.a.

FZ-LEH Series Lenses, high resolution, Low

distortion lenses

n.a.

3Z4S-LE

Lenses, focal length: 5-8-12-16-25- 35-50-75 mm

n.a.

FZ-LES Series Small lenses

n.a.

3Z4S-LE ML-EXR

Extension tubes. Thickness: 40mm, 20mm, 10mm,

5mm, 2.0mm, 1.0mm, 0.5 mm. Max outer diameter: 30 mm dia.

n.a.

FZ-VS Camera cables. Length: 2m, 5m,

or 10m n.a.

FZ-VSB Bend resistant camera cables,

ideal for Robot application. Length: 2m, 5m, or 10m

n.a.

FZ-VSL Right-angle camera cable. Length:

2m, 5m, or 10m n.a.


FZ-VS2 Long-distance camera cable.

Length: 15m. n.a.

FZ-VSL2

Long-distance right-angle camera cable. Length:

15m.

n.a.

HPD Series Dome Lights

Brighter, more uniform, easy-to-use, high-power

n.a.

TH Flat Lights

Silhouette inspection using high intensity chip LED arrays

n.a.

LFV/LFV2 Series Coaxial Lights

Even illumination on reflective object surfaces

n.a.

FL Series

Bar Lights High-intensity LED arrays in a

rectangular oblique illumination unit

n.a.

FL Series Ring Lights

High-intensity light output, creating crisp vivid images

n.a.

FZ-M08 LCD monitor

n.a.

FZ-VM Monitor cable. Lenght: 2m or 5m

n.a.

FZ-VP Parallel cable. Lenght: 2m or 5m

n.a.

FZ-MEM1G USB memory

n.a.

FZ-VESA VESA attachment

n.a.

FZ-DS Desktop controller stand

n.a.


FQ-2 Vision Sensors

Real Color Sensing, VGA, wide VGA and Mega-pixel

Camera, Sub-pixel processing, High Dynamic Range Function, Ethernet /

IP, High power lighting integrated, 360°

positioning compensation, OCR, 1D code, 2D code

n.a.

Touch screen FQ2-D30 Touch screen monitor

FQ-WN FQ Ethernet cable. Length 2m, 5m, 10m, 20m

FQ-WD I/O cable. Length 2m, 5m, 10m, 20m.


4. ADDITIONAL INFORMATION

4.1. Corporate information OMRON is one of the great innovative companies that have their roots in Japan’s Kansai region. Established in Osaka in 1933, Omron’s headquarters shifted to Kyoto in the early 40’s. Omron Corporation, with over 36.300 employees at almost 200 sites in 34 countries (as of March 31, 2010), is today an undisputed global leader in the areas of industrial automation, electronic components, automotive electronic components, social systems and healthcare. Much of Omron’s most significant growth in the short and medium term will come from rapidly evolving technologies of information sensing, from single control components to total solutions. Our strengths The core competency of Omron is sensing and control technology. About 39% of the revenue is from the area of industrial automation that includes PLC’s and terminals, industrial and advanced sensors, switches, relays, temperature and process controllers, motion and drives, safety, vision systems. About 13.5% of revenue is derived from sales of electronic components and more than 14% of revenue comes from sales of automotive electronic components. Other key revenue sources include medical equipment and services (Omron is active in the production of healthcare products, including digital blood pressure monitors, electric digital thermometers, body fat monitors), while the social systems business is about 11% of the revenue.

Our Corporate Philosophy The OMRON Group corporate motto, "At work for a better life, a better world for all" was conceived by founder Kazuma Tateisi as a means of communicating the idea that a company should work for the benefit of society. It was designed to express that idea in a concise, clear phrase for employees. The motto is now positioned as a simple and clear statement describing the underlying concept for the OMRON Principles. "Working for the benefit of society", the credo of OMRON founder Kazuma Tateisi, serves as the core value that underlies the OMRON Group's corporate activities. Our founder believed that the real purpose for a company to exist is to serve society, and that only when this is accomplished should the company earn profits and enjoy sustainable growth. He also believed that only companies that add value and meet social needs can earn trust and respect from society as good corporate citizens, and thus successfully continue to exist as businesses. At the OMRON Group, this spirit has been preserved and consistently maintained over the years. 4.2. Omron Europe As part of the Omron Corporation, Omron Industrial Automation is a global manufacturer of technologically advanced products and a leading provider of application expertise. From its European headquarters near Amsterdam it operates locally in every European country and it is dedicated to provide unrivalled automation products and customized expert solutions for any industries. Omron Europe was founded in 1974, and it now counts over 2,200 employees working in 19 national sales companies at 39 locations. The net annual sales have been approximately 600 million Euro in 2008. In Europe Omron IAB takes advantage of 3 production facilities, 4 R&D centers and 3 application centers devoted to


Sensing, Motion and Automation. The real strength of Omron Europe is its over 800 Field Engineers working in a very close contact to our customers. Omron Europe is a well-recognized expert in machine automation and we can:

Bringing you the latest machine automation technology; Providing you with the best support to operate globally; Enabling you to operate more quickly, more efficiently and more smartly than your competitors Offering you sensing, motion and control competence.

4.3. Omron Italy Omron Italy was established in 1986 and it counts 3 Regional offices located in Milan, Bologna and Terni. The Italian structure is based on over 200 employees, 40 of them, called Field Application Engineers, are completely devoted to support our customers in developing solutions that meet their customers’ needs. Omron Italy has acquired in 25 years of activity a deep experience and expertise in all the main Italian industries such as Automotive, Ceramics, Food and Beverage, Packaging, Textile, Wood, Lift, Plastics and Metal. Moreover, in the last few years we acquired a good knowledge of non-industrial markets such as Public Utilities, Water Treatment, Energy Management, Recycling. To ensure a complete and widespread coverage of the territory we take advantage of a strong network composed of more than 100 distributors, with over 700 point of sales, and 14 Omron Solution Partners (OSP) dedicated to applications for specific markets.

4.4 FJ Vision Camera System technologies – going deeply One of the most difficult image processing task is the generation of images more appropriate for individual inspections. Believing that the mastering of image processing is the key to solve inspection challenges for factory automation, Omron has put a number of new technologies into practical use. Going deeply:

Close to the Human Eye

Real Color Sensing

Processing 256 gradations of each of the RGB colors as it is Different colors are represented as different positions in the 3D RGB space. Subtle variations in color can be recognized by representing them as distances between different color pixels comprising this space. Thus, scratches and dirt can be detected accurately even in the images with low contrast.

Industry-Leading Resolution


5 Million-pixel Camera

Achieving high-precision measurement never before possible It enables more precise inspection by measuring high-resolution images taken by camera with an advanced image-processing algorithm.

Optimum performance for each application

High Grade Processing

Items Ex: High-speed Halation Prevention Filter

Cutting-edge Image Processing FJ features a set of “high grade” processing items that solves inspection/measurement challenges requiring difficult setting and many man-hours.

Landscape formal (5200-pixel length)

Panorama Image Processing

The Vision Sensor’s wider fields of view enable inspections for whole workpieces Wider fields of view can be achieved by synthesizing the images of two or more cameras. Each synthesized image can be inspected as a single image.

5000 times Dynamic Range


High Dynamic Range Function

Fundamental solution for difficult lighting settings The conventional difficulty in setting and adjusting lighting conditions is ascribed to the limited dynamic ranges of cameras. FJ has achieved a high dynamic range, 5000:1 maximum. This HDR function solves existing problems in settings for lighting.

Image Distortion Correction

Trapezoidal Distortion Correction

Correcting distorted images shot from an angle High-precision inspections are ensured even when images are taken from an angle or the carrying process is unstable.

Parallel processing of measurement, adjustment and logging tasks


Dual Mega ARCS Engines

(ARCS stands for Advanced Real Colour Sensing)

Industry’s fastest Inspection & Measurement Processing The FJ series is equipped with Dual Mega ARCS Engines to process data twice as fast as when one Mega ARCS Engine is used. This engine achieves multi-task, high-speed processing not heretofore possible.

Parallel processing of measurement, adjustment and logging tasks

Highly reliable hardware

Hard disk less

Highly robust controllers The FJ Series controllers use Flash memory – not hard disc drives. That’s why they are highly robust and can take a few knocks in the factory environment. Even sudden power outages and strong vibration will not affect them. Choose either the compact controller when space is limited, or the touchscreen-integrated model for optimised ease of use.

Open Network

Open Network

Ethernet/IP, a global standard for factory automation data networking, is supported or seamlessly integrated into a production line or machine. This allows users to easily connect to any manufacturer. Further communication is possible via TCP/IP, serial and parallel interfaces.

Customization - Macros


Time-saving Macros

Time-saving Macros We also offer a wide range of Macros to further accelerate your development process – especially for your calculation functions. Simply drag and drop the required Macro into your flow.

Customization – Programmable HMI

Free HMI programming

Create the HMI to fit your needs You can create original HMI and GUIs quickly with Visual Studio®, rich customisable control units and program samples in the FJ “Application Producer”.

4.5. FlexXpect vision platform


FlexXpect is a modular Vision platform featuring industry specific functionality. In combination with the powerful Xpectia-hardware, the FlexXpect software modules take you into a new dimension of specialization. FlexXpect is simple to use and can be customized easily, to focus on your individual needs. The combination of Xpectia’s real colour sensing, high resolution and intuitive user guidance combined with the FlexXpect value added tools represents an unbeatable duo. 4.6. FlexXpect - Glue Bead

The FlexXpect - Glue Bead enables to inspect the complete sealing of automotive parts in one shot. Driven by the real color functionality, any sealing can be identified and checked, independent how visible it is. Featuring a simple set-up procedure and automatic calculation of the path, it represents a powerful and straight forward solution for any glue application. Features of FlexXpect-Glue Bead:

o One shot inspection of the complete path; o Easy set-up (no expert knowledge of the user is required); o Automatic path calculation; o Real colour glue extraction.

Glue Bead inspection:

Correct path;


Thickness; Interrupt.

FlexXpect – Glue Bead features an intuitive and easy set-up procedure. No expert knowledge of user required.

Code Description


FLEXXPECT-GLUE BEAD FlexXpect-Glue Bead software module

4.7. FQ-2 Vision Sensors - Going deeply

The compact design of the FQ2 means that it fits easily into confined spaces. Furthermore, unlike conventional vision sensors with multiple components, it comes in a single, all-in-one package.

Real Color Sensing

Processing 256 gradations of each of the RGB colors as it is Different colors are represented as different positions in the 3D RGB space. Subtle variations in color can be recognized by representing them as distances between different color pixels comprising this space. Thus, scratches and dirt can be detected accurately even in the images with low contrast.

Resolution

VGA: 350.000 pixels Wide VGA: 760.000 pixels Mega-pixel Camera: 1,3 Million pixels Sub-pixel processing


High Dynamic Range Function

Typical automotive industry: shiny and reflective

HDR sensing Variations in lighting conditions can cause unwanted glare or halation. HDR minimizes these effects, maximizing the stability of inspection results, even countering piece-to-piece variation or misalignment.

Open Network

This widely used communication interface enables simple and easy connections to a wide range of EtherNet/IP devices.

High power lighting

A new DR optical system has been developed for the FQ vision sensor. This system effectively uses all of the LED light to maintain consistent brightness across the field of view at twice the brightness of previous models. The FQ vision sensor also has a polarisation filter, to cut off the specular reflection light which can result from highly reflective objects, resulting in reliable and consistent inspections.


360° rotational position

compensation

The correct position of workpieces with an inconsistent orientation can be measured through automatic detection of the offset of the workpiece in relation to a registered standard model.

OCR

Unique OCR technology character verification

Omron’s unique recognition technology enables stable recognition of worn or distorted characters and requires no setting of parameters to compensate for character contrast or positional offsetting. No character registration is required because Omron’s new OCR algorithm matches the characteristics of each character with structural models.

1D code

Where reliable verification of barcodes and characters is required on paper labels, the FQ2 is the perfect choice. All commonly used types of barcodes can be handled. And only one code reader is required, even when different types of code have to be processed.


2D code

2D codes printed directly on many materials, including metals, substrates, glass, can be difficult to read with good stability. No problem for FQ2, which is equipped with filters designed specifically for DPM and allows easy and stable reading. Unique, Omron-developed filters remove printing irregularities and noise, while erosion and dilation can be combined to connect dots on 2D codes without changing the dot thickness.

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