Full Spectrum Illumination and Powerful Algorithms VISION ... · • With 1 ms (1/1000 sec) of...
Transcript of Full Spectrum Illumination and Powerful Algorithms VISION ... · • With 1 ms (1/1000 sec) of...
Multi-Spectrum Vision SystemCV-X/XG-X Series
NEW
Full Spectrum Illumination and Powerful Algorithms
VISION SYSTEM WITH UNLIMITED FLEXIBILITY
CV-X Series | XG-X Series
Multi-Spectrum Vision SystemCV-X/XG-X Series
NEW
For Colour, Shape, Gloss, and Target Variability
All-In-One Illumination Outstanding ControlMulti-Spectrum lighting incorporating LEDs in eight colours
and a dedicated control circuit.
Synchronised lighting, colour control, segmented lighting,
and high-speed image capture without complicated PLC integration.
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LumiTraxTM MODE P. 6
MULTI-SPECTRUM MODE P. 4
Accurate Sorting, Even between Slight Colour Differences
NORMAL ILLUMINATION MODE P. 7
Simple Selection of Optimal Lighting
Detect Height Changes While Removing Glare
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MULTI-SPECTRUM MODE
Accurate Sorting Even between Slight Colour Differences
CONVENTIONAL COLOUR CAMERA MULTI-SPECTRUM MODE
Completely New Colour Inspection AlgorithmUsing a high-speed monochrome camera in combination
with 8-wavelength lighting provides vastly superior
capabilities compared with colour inspection
with conventional colour cameras (RGB).
This allows users to achieve accurate sorting,
even of the slightest differences in colour.
Inspection of Various Types of Plastic Caps
With conventional models, distinguishing between similar targets
with little noticeable colour difference was difficult.
Multi-Spectrum Mode analyses information using eight different wavelengths,
allowing for easy distinction between similar colours.
Although some differences are noticeable, the extracted colours are largely the same.
Differences in colour are clearly defined.
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Easy Configuration Enables Powerful Colour Differentiation
Colour-Separation Method
Packing Presence Detection
Colour-Separation
Method
Detection of Foreign Particles in Instant Food
Products
Registration of Excluded Colours
Colour extraction is performed just by clicking the inspection location. The colour information excludes any areas with ambiguous colour differences, such as blown-out highlights or crushed shadows, allowing users to extract only areas where colour differences are clear.
Perform separation over a specified range according to differences in colour.
Register the detection target colour as the “Extracted Colour”.
Register a similar detected colour, such as a background colour, as an “Excluded Colour”. Easily separate the detection target colour
from the other colours.
Intuitive configuration of colour settings is accomplished by simply selecting the image with the desired colour separation from multiple choices generated by the system.
Registering colours to exclude from detection
Capturing Images with Colour Cameras vs. Multi-Spectrum Mode
In addition to the conventional “Eyedropper Method”, the Multi-Spectrum Mode includes a Colour-Separation Method for analysis of only a specific area and group of specified colours.With this method, users have only to choose the colour required for inspection from the ones automatically separated. This new method of colour-based analysis solves the problem faced with conventional methods for specifying a colour, which leads to varying results depending on who is setting the colour or where the mouse is being clicked.
Colours that should not be included in detection can be registered as “Excluded Colours”. This feature is capable of reliably distinguishing between colours, eliminating the need for complicated fine adjustment of the extracted colour when colours similar to that of the detection target exist, such as similar background colours.
The imaging element receives white light reflected from the target through a colour filter. This data is then used to create a colour image.
Colour analysis is performed for every pixel based on eight grey-scale images taken at different wavelengths.
Colour camera
Multi-Spectrum Image Capture
R
R
R
R
G
G
G
G
G
G
G
G
B
B
B
B
UV
AM
IR
B
R
W
G
FR
Wavelength characteristics for multi-spectrum lighting
Rel
ativ
e em
issi
on in
tens
ity
[%]
Wavelength [nm]330 380 430 480 530 580 630 680 730 780 830 880 930
100
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20
0
Features of Multi-Spectrum Image Capture Easy detection of subtle differences using wide wavelengths
Multi-Spectrum imaging uses wavelengths covering both visible and invisible light for powerful colour discrimination capabilities. This enables both easy configuration and stable operation.
Real-time processing of eight images with different wavelengths
Eight images are captured at eight different wavelengths. This not only allows for improved colour sorting capabilities but also more complex processing using only images for a specific wavelength.
Same ease of handling as colour cameras
Multiple images are captured and analysed with a single trigger input. Imaging and lighting control are automatically synchronised through the vision system, eliminating the need for complex hardware integration.
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Using optimal wavelengths
LumiTraxTM MODE
Detect Height Changes While Removing Glare
CONVENTIONAL IMAGING PROBLEMS
SOLUTIONS WITH LumiTraxTM
Difficult imaging conditions require trial and error for selecting the optimum light.
Various surface conditions Influence from surrounding environment (ambient light)
Target vibration caused by transfer conditions
Stamped Character Inspection on Metal Casting
Printed Character Inspection on Film Surfaces
Chip Inspection on Metal Surfaces
Tape Presence Inspection
Extraction of only shape (irregularity) information regardless of surface conditions
Suppressing glare and ambient light to extract only textures (pattern)
Same colour Noise Pattern Gloss
Eliminating the Problems of Conventional Image CreationLumiTraxTM is a vision system solution where analysis is
performed using multiple images taken with lighting
from different directions in order to generate shape
images and remove glare. This allows users to
effortlessly create images that would conventionally
require a great deal of time and experience.
Glare is eliminated through LumiTraxTM, but no contrast between the background and the characters is produced.
White LED
A slight difference between the background and the characters is produced, but glare also occurs.
Normal Image
Background intensity is reduced and glare is eliminated.
Infrared LED
Application examples 2
Application examples 1
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NORMAL ILLUMINATION MODE
Simple Selection of Optimal Lighting
Optimum Colour Selection from among Multiple Images
Excellent Flexibility for Future Inspections
Select the image with the best contrast from among the 8 colour lighting images. Stable detection is possible!
When configuring the lighting colour, images for each of the eight lighting colours are displayed allowing for quick determination of which lighting provides the best inspection results.
Colours used for lighting are memorised for each set product type, so users need only switch the setting during operation. This eliminates the need for cumbersome external control.The eight coloured LEDs cover both visible and invisible light, providing maximum flexibility even when adding product varieties in the future.
Appropriate Lighting Colour Usage According to Inspection Items
A red ink stain appears on a printing with a blue background.
2nd image capture: Blue LED1st image capture: Red LED
Illumination using a red LED capable of clearly viewing the pattern is performed for position shift correction.
To erase the printed pattern for defect inspection, illumination using the same blue colour is performed.
The combination of multiple images and lighting colours enable the optimum lighting colour for each inspection item.
Ink spot detection
Multi-Capture Imaging
(Lighting Colour Variation)
Easy Inspection Stability and Responsiveness ImprovementMulti-Spectrum lighting utilises eight built-in colour LEDs in
order to illuminate targets in a variety of colours for
inspection. With the ability to remember illumination
colours for every program or product type,
multi-spectrum lighting provides the optimum colour for
inspection even with multiple items and various product types.
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❚ 3D Display Function for Registered Colours
Powerful LEDs with a wide illumination range
(from visible to invisible light) for detecting targets
Lighting Equipped with 8 High-Brightness LEDs of Different Wavelengths
Real-time intensity feedback circuit for even
brightness between images
Photodiode and Real-Time Intensity Control Circuit
Stable vision system inspection depends not only on the capabilities of hardware, such as cameras and lighting,
but also on software capable of controlling these devices according to the application requirements.
By developing both hardware and software, KEYENCE is able to commit fully to inspection stability as only a
comprehensive manufacture of vision systems can.
HARDWARE AND SOFTWARE THAT SUPPORTS INSPECTION STABILITY
Automatic wavelength and directional control
according to the inspection settings
Multi-capture imaging even on high-speed lines
Built-In Dedicated Illumination Control Circuit
Ultra, High-Speed CMOS camera and Dedicated Control Circuit
HARDWARE
SOFTWARE
P. 10
Greater Inspection Stability
❚ Registration of Multiple Colours
❚ Brightness/Colour Range Function ❚ Ambient Light Elimination
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P. 12
Improved Application-Specific Inspection Capabilities
❚ Colour Distribution ❚ Fine Colour Processing
❚ Colour Extraction Guide ❚ Custom Menu Registration
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Simply select the column where the detection location appears the clearest. This eliminates the need to adjust the parameters based on the users’ perception.
Stability Consistent Inspection Capabilities through Dedication to Stability
The distribution of registered colours can be displayed in 3D, indicating how different the registered selected and excluded colours are and allowing visualisation of whether the inspection is stable and free from interference from other colours.
The range of every extracted colour is displayed as an oval. This allows users to ensure that extracted colours and excluded colours do not overlap.
: Extracted colour : Excluded colourGreen Oval Grey Oval
3D Display Function for Registered Colours
Adjust the brightness ranges so that the ovals do not overlap
The extraction status does not change even if the brightness changes.
ExampleIncreasing responsiveness to brightness changes without changing the extraction status
This function adjusts the brightness and colour range for each registered colour. Analysis is performed beforehand using simulations for factors that may cause unstable inspection, such as changes in the surrounding environment and variations in the target, ensuring stable inspection over a longer period within the actual environment. This allows users to obtain the optimal settings for the best results.
Brightness/Colour Range Function Brightness Variation Adjustment ScreenCreation of simulated images with ±20% brightness within the controller allows the device to immediately display multiple colour extraction results using varying brightness parameters.
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The photodiode and real-time intensity control circuit within the lighting is used for feedback control of the LED light intensity. Setting the current brightness to the regularly used brightness prevents drops in inspection capabilities due to deterioration caused by LED ageing.
Photodiode and correction circuit within the lighting
Real-Time Intensity Feedback Function
Multi-Colour Registration
(Support for Invalidation and Integration)
Addition And Invalidation
Up to 32 individual colours can be stored. This makes it possible to perform adjustment even during operation without sacrificing colour information.
Added colourExisting colour
Multi-Colour Registration: Caulking amount inspection
Good parts with different colours are produced.
Detection is made possible through additional registration of the unregistered colours.
The effects of the ambient light generated from the left are eliminated.
Ambient light is analysed using an image captured without the use of the lighting (ambient light image) in order to remove the ambient light from the inspection image. This removal is performed for capture, reducing the effects of unexpected ambient light changes that may occur.
Ambient Light Elimination FunctionAmbient Light Elimination Function OFF
Ambient Light Elimination Function ON
Registration of up to 32 extracted colours and 32 excluded colours is possible. This makes it possible to handle a variety of inspection targets through added colour extraction without losing existing colour information. In addition, the ability to integrate or invalidate colours later allows for optimisation while always checking results.
Colours can not only be removed but also invalidated. This provides flexible testing without having to redo inspection.
Invalidated colours are not used for inspection, but the colour information is saved.
• With 1 ms (1/1000 sec) of illumination
Illumination Time Chart
For every illumination, monitoring and feedback are performed every 20 μs to adjust the brightness to a consistent intensity.
20 μs × 50
1 ms
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Inspection/Operation
Colour SortingColour
DistributionThis mode determines which colour group the current inspection target belongs to.
This mode calculates how distributed a colour group is within a target.
Product Differentiation
The group to which the current target belongs to is displayed.
Distribution Checking for Air Fresheners
The mixing ratio of an air freshener is determined.
Fine Colour Processing enables detection of scratches and dirt by measuring grey-level differences within the measurement area using images for each of the eight wavelengths and identifying any differences above the threshold. This function captures changes in background colour, making it effective for cases when the occurrence of scratches and dirt cannot be predicted. In addition, by using an algorithm that captures colour changes that occur within the detection region, this function is also useful for easily identifying changes in background colour.
Ensuring the Maximum Inspection Capabilities According to the Situation
The distinctive colours from each product type are registered in a colour group (16 groups maximum).
Registered colours can be combined together as customisable colour groups. These colour groups allow for differentiation of various products according to colour and for inspection of the distribution ratios for each group. Whereas, conventional inspection methods required a combination of multiple tools. Colour Distribution enables inspection with higher accuracy using only a single tool.
The set group name is displayed on the operation screen.
Colour distribution is displayed according to the index colours of the registered group. Upper and lower area and ratio (%) limits can be configured for each group.
Colour changes in the background or from defects are analysed to ensure changes in colour are properly ascertained.
Colour Distribution
Fine Colour Processing
Group No. 02
Group No. 00
Group No. 01
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With absolutely no numerical adjustment of parameter values, users are able to extract colours intuitively, just by selecting an image.
Configuration is performed simply by selecting which tool to use as a reference for the colour information.
A step-by-step guide walks users through the necessary steps for extracting a colour. Simply select the optimal parameters from among multiple screens.
Custom menus allow users to create shortcuts to a selected area within the tool. This creates a menu with only those items required for operation being registered, providing a way to quickly call up frequently used items.
Information on configured extracted colours can be shared between tools. This enables synchronisation of colour information between shared tools simply by changing the original colour extraction setting.
Open only a specific point within a registered area.
Colour information shared as a reference
Colour Extraction Guide Custom Menu Registration
Sharing of Extracted Colours
Select the area to extract
Select the optimal setting from the images presented
Click on the colour to be extracted
Select a colour range
STEP 1
STEP 2
STEP 3
STEP 4
Colour extraction complete
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SYSTEM CONFIGURATION DIAGRAM
PRODUCT LINEUP/OPTIONS
* Fan units are not included with CV-X400/X420/X450 and XG-X2000/X2200/X2500 products. The CV-X480 and XG-X2800 have no camera connection port. Use in combination with a camera input unit or similar device.
PLC
PC
Touch panel
Sensors, etc.
SD card
RS-232C
Multi-Spectrum lighting
RGB monitor CA-HX camera
CA-HX camera
CA-HX camera
CA-HX camera
Mouse
USB
USB
CV-X400 Series*XG-X2000 Series* CA-E100 CA-DC60E
USBHDD
PLCPCNetwork-
compatible HDD
Ethernet
❚ Multi-Spectrum Lighting
❚ Multi-Spectrum Lighting Dome Attachment ❚ Multi-Spectrum Lighting Polarisation Attachment
❚ Lighting Power Supply ❚ Lighting Cables
50 mm type CA-DRM5X
LED light control expansion unit CA-DC60E
100 mm type CA-DRM10X
50 mm type CA-DRM5DA100 mm type CA-DRM10DA200 mm type CA-DRM20DA
50 mm type CA-DRM5PA100 mm type CA-DRM10PA200 mm type CA-DRM20PA
Lighting cables Lighting extension cables
200 mm type CA-DRM20X
Cable length (m) Model
3 CA-D3MX
5 CA-D5MX
10 CA-D10MX
Cable length (m) Model
5 CA-D5MXE
10 CA-D10MXE
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DIMENSIONS
90°
ø145.0
ø60.0ø30.0
42.0
76.8
ø100.0
(70.7)
(70.7)
(82.0)4 × M4Depth: 8 max.
ø145.0
ø50.042.0
49.8
(70.7)
(70.7)
ø100.0
(82.0)90° Depth: 8 max.4 × M4
(99.0)
(99.0)
(82.0)
90.0
ø195.0
ø100.0ø50.0
67.0
ø140.0
90°
Depth: 8 max.4 × M4
(99.0)
(99.0) ø140.0
50.0
67.0
ø195.0
ø100.0
(82.0)90°
4 × M4Depth: 8 max.
(82.0)
(221.7)
(221.7)
(91.8)
(91.8)
ø240.0
117.0
ø295.0
ø200.0
139.0
ø100.0
45°8 × M4Depth: 8 max.
Multi-Spectrum Lighting (50 mm type) CA-DRM5X
(When CA-DRM5DA is attached)
(When CA-DRM10DA is attached)
(When CA-DRM20DA is attached)
(When CA-DRM5PA is attached)
Multi-Spectrum Lighting (100 mm type) CA-DRM10X (When CA-DRM10PA is attached)
Multi-Spectrum Lighting (200 mm type) CA-DRM20X (When CA-DRM20PA is attached)
45° (82.0)
(91.8)
(221.7)
117.0ø295.0
ø200.0(91.8)
(221.7)
ø240.0
8 × M4Depth: 8 max.
61.8
4 × M4Depth: 8 max.
ø100.0
(70.7)
(70.7)
90° (82.0)
ø145.042.0
70.1
(82.0)
67.0
ø195.0
71.6
ø140.0
(99.0)
(99.0)
90° 4 × M4Depth: 8 max.
8 × M4Depth: 8 max.
(91.8)
(221.7)
(221.7)
(91.8) ø240.0
45° (82.0)
ø295.0
117.0
83.7
Unit: mm
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CVXMSL-WW-C-GB 1077-1 600N10 Copyright (c) 2017 KEYENCE CORPORATION. All rights reserved.
www.keyence.com
Model CA-DRM5X CA-DRM10X CA-DRM20X
Illumination method
Ring illumination (with support for optional CA-DRM (DA) Series dome attachment and CA-DRM (PA) Series polarisation attachment*1)
Multi-Spectrum lighting / LumiTrax lighting / Normal lighting (single-colour lighting in all directions)*2
Constant current control mode (1024-step digital gradation: With CA-DC60E connected / Adjustable per wavelength*3)
Response speed 1 ms or less
LED Peak wavelengthUltraviolet: 405 nm / Blue: 457 nm / Green: 527 nm / Orange: 600 nm / Red: 660 nm /
Far red: 730 nm / Infrared: 860 nm / White: 600 nm (All values approximate)
Controller connection Dedicated cable (3 m / 5 m / 10 m), Max. 30 m (with extension cables*4)
I/F input 12-pole connector (dedicated cable)
Power consumption51.4 W
(during normal light emission)71.0 W
(during normal light emission)71.0 W
(during normal light emission)
Environmental resistance
Operating ambient temperature
0 to 40°C
Operating ambient humidity
35 to 65% RH (No condensation)
Weight(With dome attachment /
With polarisation attachment)
Approx. 560 g (Approx. 680 g/Approx. 690 g)
Approx. 600 g (Approx. 820 g/Approx. 810 g)
Approx. 1080 g (Approx. 1730 g/Approx. 1570 g)
*1 The UV and IR wavelengths cannot be used when the polarisation attachment is attached.*2 Continuous lighting can only be set during normal lighting when brightness value control is set to ON.*3 Simultaneous lighting of multiple colours is not supported.*4 Connection of up to two dedicated extension cables is allowed.
Model CA-DC60E
Output
Light control method Constant current control mode
Gradation 1024-step digital gradation (switchable settings using controller)
Connection points 2ch (Dedicated 12-pole connector)
Synchronisation Camera trigger and shutter synchronisation*1
Response speed 1 ms or less
Display LED display Power / Lighting status (2ch each)
RatingVoltage 24 VDC ±10%
Current consumption 5.1 A (incl. supply to light emitter for lighting)
Environmental resistance*2
Operating ambient temperature
0 to 45°C (DIN rail-mounted) / 0 to 40°C (bottom-mounted)
Operating ambient humidity
35 to 85% RH (No condensation)
Weight Approx. 500 g
*1 Continuous lighting (single-colour lighting in all directions) can only be set when the brightness value control is set to ON.*2 Environmental resistance for lights includes an operating ambient temperature of 0 to 40°C and an operating ambient humidity of 35 to 65% RH (with no condensation).
Multi-Spectrum Lighting
Lighting power supply
SPECIFICATIONS