Robotic vision systems can assist in increasing plant productivity, safety, and quality. Vision systems offer a critical use of technology for robotic applications. With the increased use of vision technology in manufacturing, production economies of scale have helped reduce the prices of essential components that integrate vision systems, making them more available and affordable.

Achieve dramatic improvements in robotic performance using these integrated vision systems, locating required parts, welding accurately, and inspecting the final assembly and replacement of parts. In addition, vision systems include capabilities for parts sortation, flexible parts feeding, presence/absence, error proofing, visual servoing, and environmental perception. When used in dispensing applications, vision systems ensure the correct locations of the dispensed liquids.

2D Vision Systems

For standard 2D vision systems, cameras can be mounted up, down, horizontally, or at angles within the robotic workspace. Alternatively, cameras can be permanently affixed above the robotic workspace or flexibly moving with end-of-arm tooling. Flexible mounting provides higher-resolution imagery and allows six degrees of freedom within the workspace. Still, there are advantages to both mounting configurations. These cameras are available in IP67 rating and provide additional protection against dust and liquids in industrial environments, designed to withstand shock and vibration during robotic uptime.

3D Vision Systems

For applications requiring more sophisticated vision systems, 3D cameras provide three-dimensional vision across the X, Y, and Z axes. 3D vision assists with the correct placement of randomly placed parts. Specific 3D software can even be “taught.” It can easily handle extreme part variability, making random depalletization, bin picking, and deformable objects ideal applications. While 3D vision software offers more features than the 2D variety, 2D vision systems serve most application needs.

With proper set up, spatial-type vision software achieves 3D vision using a standard webcam. However, when using multiple images, be sure to calibrate when necessary. Keep in mind that standard CAD files of parts track data after being imported into the software. Additionally, spatial vision software is accurate up to 1/10th of a pixel, making it incredibly reliable.

Robotic Vision Techniques

The robotic vision system compares the images captured by 3D cameras and those stored within the software template. The two popular techniques used for robotic vision applications include PBVS (Position-Based Visual Servoing) and IBVS (Image-Based Visual Servoing). Adequate lighting is crucial for applications calculating object depth with the PBVS method. Vision tools of varying performance and price are available to assist in the quick and easy programming of vision applications, depending on your vision system’s requirements.

Augmented Sensing Technologies

Vision systems can also use other augmented sensing technologies, allowing for accurately detecting size variation and parts location. When the vision system camera captures an image, it sends it to the processor. The processor converts that image to a digital signal. The software then interprets the digital signal.

Once this occurs, the vision software can sort through geometry, color, barcode, markings, and other pre-defined characteristics.

Additionally, high-speed Ethernet connections control cameras. The Ethernet connections provide enough bandwidth for image processing. GigE Vision, for example, is a popular standard used for industrial cameras, which runs on UDP protocol and PoE (Power-Over-Ethernet), simplifying the amount of cabling used. The development of mobile vision applications coincides with the emergence of mobile technology. They can be connected through wireless Ethernet as well.

Benefits of Robotic Vision Systems

Robotic vision systems can track and trace parts from the start to the final assembly of a product. The robotic vision system traces defective parts across the assembly process.

Moreover, better analytics can be generated by tying the vision system information to your company’s MES and ERP systems for SKU, shift, and vendor analysis. These analytics can provide real-time data to your server or cloud computing system, tying together production, order processing, and inventory management.

Notably, barcode scanning vision systems compare across databases, eliminating the selling and production of counterfeit goods.

These characteristics lead to increased quality of a final product due to the rejection of defective parts, increased throughput of parts manufactured, increased productivity through reduced usage of resources, and increased output. Vision systems marginally impact cycle times. But, increased productivity decreases the payback period for an installed system. Accurate distance measurement with automatic focus, increased mean time between failures (MTBF), and reduced setup time with robot vision systems also benefit vision system usage.

In hazardous locations, use robotic vision systems to reduce industrial accidents in an industrial environment. It also reduces costs associated with the overuse of materials, making production processes leaner.

To learn more about implementing robotic vision systems, contact a Motion Automation Intelligence Specialist today.