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Radiant Vision Systems | A Konica Minolta CompanyRadiant Vision Systems | A Konica Minolta CompanyPresented By Davis Bowling | November 17, 2017
INSPECT.assembly: ADVANCED VISION SYSTEM FOR IN-LINE ASSEMBLY VERIFICATION
Global SupportAutomated Visual InspectionLight & Color
3Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
TODAY’S TOPICS
• Assembly Verification Challenges
• The Trouble with Current Methods
• The Solution: INSPECT.assembly
• Fully-Integrated Solution
• Production Line-Ready
• Advanced Imaging Capability
• Specially-Configured Software
• Application Examples
• System Specifications
• Summary
4Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
ASSEMBLY VERIFICATION CHALLENGESTHE TOUGHEST INSPECTION PROBLEMS
5Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
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© Radiant Vision Systems, LLC.
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© Radiant Vision Systems, LLC.
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© Radiant Vision Systems, LLC.
9Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
THE TROUBLE WITH CURRENT METHODS
10Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
CURRENT INSPECTION METHODS
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© Radiant Vision Systems, LLC.
HUMAN VISION IS REQUIRED
EXAMPLES:
Display appearance
Surface cosmetics for consumer products
Particulates in parenteral preparations
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© Radiant Vision Systems, LLC.
HUMAN VISION IS MORE ACUTE
EXAMPLES:
Electronic assembly inspection
Surface cosmetics for consumer products
Glass quality inspection
13Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
MACHINES ARE MORE REPEATABLE
EXAMPLES:
Multi-part manufacturing processes
Operational standards across branches
Testing consistency from supplier to OEM
14Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
MACHINE DATA IS QUANTIFIABLE
EXAMPLES:
Process control
Vendor management
“Big data”
15Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
CAMERAS NEED TO SEE MORE DETAIL
• Resolution – The number of pixels in an image translates into spatial resolution, which determines the ability to distinguish fine detail within an image.
1MP Resolution 29MP Resolution
16Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
THE IMPACT OF RESOLUTION
• Higher-resolution CCD imaging enables:
• Easier detection of contrast variations
• Pixel-level defect detection and correction (displays)
• Detection of subtle defects
17Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
CAMERAS NEED TO SEE MORE CONTRAST
• Dynamic range:
The ratio between the
maximum possible signal and
the “noise” level at the
minimum signal of one
measurement
• Measured in dB (decibels)
• Calculates a signal-to-noise ratio
(SNR)
WHAT WE SEE:SIGNAL
NOISE
18Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
THE IMPACT OF DYNAMIC RANGE
• Dynamic range - Larger dynamic range yields greater
measurement precision and enables higher contrast ratio
measurement.
Low Dynamic Range High Dynamic Range
19Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
CAMERAS NEED TO BE CALIBRATED TO THE IMAGING ENVIRONMENT
20Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
A CAMERA DOESN’T CUT IT
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© Radiant Vision Systems, LLC.
SOLUTION COMPONENTS
Imaging System Analysis Software Automated Test Stations
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© Radiant Vision Systems, LLC.
THE SOLUTION: INSPECT.assembly
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© Radiant Vision Systems, LLC.
INSPECT.assembly
Lighting
Fixture
Computer
AdvancedImaging System
Inspection ResultSystem Components
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© Radiant Vision Systems, LLC.
FULLY-INTEGRATED SOLUTION
INSPECT.assembly is a turnkey Assembly Verification
product, that can be installed over a moving conveyor belt
or a non-moving test station
Components
• ProMetric® Y29 Imaging System
• INSPECT Software
• Fixture (including lighting)
These components combined make up the INSPECT.assembly.
25Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
PRODUCTION LINE-READY
26Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
WHAT DOES INSPECT.assembly DO?
Engineered for Assembly Verification
INSPECT.assembly inspects for the following:
• Component presence• Connectors• Cable routing• Screws
And it does all of this on a moving conveyor.
• Batteries• Labels & their location• Fasteners• Missing components
27Radiant Vision Systems | A Konica Minolta Company
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ADVANCED IMAGING CAPABILITY
Radiant’s advanced imaging systems provide the visual sensitivity to replicate and quantify human
perception of and color
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© Radiant Vision Systems, LLC.
INSPECTION METHOD COMPARISON
Typical machine vision struggles to distinguish black screw from hole
Advanced imaging system with high-resolution and dynamic range detects the missing screw
29Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
INSPECTION METHOD COMPARISON
• Measures relative contrast/color
• Speed favored over resolution (limited detail
inspection); small CCD pixels, noisy images
• Low repeatability for applications that
normally require human inspection
• Poor contextual evaluation
• Measures absolute luminance/chromaticity
• Extremely high resolution, low noise, and
broad dynamic range imaging system
• Detect minute visual differences in a way that
replicates human visual perception
• Detect and classify defects by severity
Machine Vision Camera Advanced Imager
30Radiant Vision Systems | A Konica Minolta Company
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INSPECTION METHOD COMPARISON
• When Human Visual Judgement is the evaluation
standard, INSPECT.assembly…
• Improves Consistency
• Captures
Quantifiable Data
• Reduces Labor Cost
• Reduces Latent
Failures
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© Radiant Vision Systems, LLC.
SPECIALLY-CONFIGURED SOFTWARE
http://www.szxmsck.com/
32Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
SPECIALLY-CONFIGURED SOFTWARE
• Multiple software functions are
combined to perform the exact
inspection needed.
• The “Screw Tool” combines a
number of tools to meet precise
tolerances of the component
features.
http://www.szxmsck.com/
33Radiant Vision Systems | A Konica Minolta Company
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SPECIALLY-CONFIGURED SOFTWARE
• Each software recipe is configured
exactly to the requirements for a
given part.
• Multiple recipes are supported by a
single system, to accommodate
multiple products on the line.
34Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
APPLICATION EXAMPLESINSPECT.assembly IMAGES AND ANALYSIS
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© Radiant Vision Systems, LLC.
LET’S TAKE A CLOSER LOOK…
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© Radiant Vision Systems, LLC.
EXAMPLE: CABLE ROUTING
Pass
Fail
System checks for appropriate channels. Routing over guides or too close to other components will be flagged as a failure.
Improper cable routing can lead to electrical failures due to shorts or breaks.
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EXAMPLE: CONNECTOR ALIGNMENT
Pass
Fail
System checks for connector alignment and gaps for various connector types. Misalignment or an out-of-spec gap will be flagged as a failure.
Connector misalignment can cause failures because of poor or lost connections once the system is in regular use (e.g., due to vibrations).
38Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
EXAMPLE: SCREW PRESENCE
Pass
Fail
System checks for screw presence. Missing screws will be flagged as a failure.
Missing screws can cause failures because of sub-assembly / component movement when in use.
39Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
EXAMPLE: LABEL PLACEMENT
System checks for label placement and position. Labels and logos that fall outside of tolerances are flagged as a failure.
Skewed or missing labels and logos can have obvious negative impact for a manufacturer’s image.
SOFTWARE EXAMPLE
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© Radiant Vision Systems, LLC.
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© Radiant Vision Systems, LLC.
44Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
SYSTEM SPECIFICATIONS
45Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
INSPECT.assembly SPECIFICATIONS
• Computer: Typical workstation w/ Intel Core i7, 32GB RAM, 1 TB Hard Drive, Windows 10.
• Monitor: Full HD, 1920x1080, Touch Screen.
• Camera: ProMetric® Y Imaging System, 29MP
• Illumination: Super bright, white LED lamps (x4, adjustable location and brightness)
• Part-in-Place Sensor: 1 operator-driven trigger device, and 1 smart camera-based
trigger device.
• Software: Radiant INSPECT Software with INSPECT.assembly configuration
• Test Housing: Fixture size 1200mm height x 890mm depth
• Installation time required: 2 Days of onsite installation time will be required for
software and hardware configuration.
• Delivery Schedule: 4 weeks from receipt of PO.
46Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
WHAT DOES INSPECT.assembly DO?
Inspect components
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© Radiant Vision Systems, LLC.
WHAT DOES INSPECT.assembly DO?
Auto Registration
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© Radiant Vision Systems, LLC.
WHAT DOES INSPECT.assembly DO?
Results/Data Reporting
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© Radiant Vision Systems, LLC.
WHAT DOES INSPECT.assembly DO?
Accommodating 2nd Sourced Components
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WHAT DOES INSPECT.assembly DO?
Model Selection via Image
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© Radiant Vision Systems, LLC.
WHAT ARE THE SYSTEM OPTIONS?
Shop Floor Communications
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WHAT ARE THE SYSTEM OPTIONS?
Barcode Reading
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© Radiant Vision Systems, LLC.
WHAT ARE THE SYSTEM OPTIONS?
2nd Monitor for Operator Station
54Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
WHAT ARE THE SYSTEM OPTIONS?
Typical Field of View Options (560mm working distance):
• 35mm lens – 550mm x 370mm• 50mm lens – 370mm x 245mm
Working distance has some adjustment, so FOV can be increased/decreased approx. 15%. This version supports single part only.
55Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
WHAT WE NEED FROM YOU:
• Part Samples
• Set Line Speed
• Minimum Indexing Time
• Space on the Line
• Barcode (if required)
• Product Model Mix
• Component Mix per Part (2nd Sources)
56Radiant Vision Systems | A Konica Minolta Company
© Radiant Vision Systems, LLC.
SUMMARY
✓ Human inspectors and machine vision systems have unique advantages and disadvantages for visual inspection. Neither offers the ideal solution.
✓ Advanced imaging systems from Radiant combine human visual acuity with consistent, quantifiable data acquired by machines for true automation.
✓ INSPECT.assembly integrates this advanced imaging with specially-configured software and fixturing into an inspection station that easily rolls up to existing lines.
Radiant Vision Systems | A Konica Minolta CompanyRadiant Vision Systems | A Konica Minolta CompanyQuestions? Contact [email protected]
THANK YOU!
mailto:[email protected]