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

80

60

40

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