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Motion and Vision Convergence
Introduction
Presenters:
David Kaley
Commercial Marketing Manager
Jonathan R. Schroeder
Business Development Manager
Moderator:
Miles Budimir
Senior Editor
Agenda
• Introduction
• MOVI as a concept
– Elements
– Typical Applications
– Challenges
• Application 1 – Bottle Inspection
• Application 2 – Inspection In Motion
• Application 3 – Automated Storage & Retrieval
Inspection History
• In the past:
– Inspect & Reject
• Today:
– Vision Guided Motion
– Cameras In Motion
= Motion + Vision
• Taking Vision beyond Inspect and Reject
• Integrating Motion and Vision
– Move, Inspect and Reject
– Move, Inspect and Orient
– Inspection in Motion
– Storage and Retrieval
Not A New Concept
• Critical Inspection of precision
products like Circuit boards and
Semi Conductor Wafers
• Either the camera or the product
is moved for precise inspection
Automated Optical
Inspection (AOI)
3 Key Elements
• Controller
• I/O
• Drives
• Motors
• Actuators
• Gear boxes
• Couplings
• Sensors
• Cable carriers
• Mounting Hardware
• Controller
• Cameras
• Lighting
• HMI
Motion Control Mechanical Vision
Challenges
• Speed
• Accuracy
• Communication
• Selection
• Software
• Speed
• Accuracy
• Selection
• Torque Calculations
• Wear
• Environment
• FOV
• Triggering
• Color Discrimination
• Communication
• Selection
• Environment
Speed
• Network data
• Processing
• Measured in
uSec update
cycles
• Acceleration
• Deceleration
• Function of load
•Measured in
meters per
second
• Trigger time
• Processing time
•Measured in mSec
Accuracy
• Overshoot
• Hysteresis
• Settling time
• Backlash
• Repeatability
• Rigidity
• Color
discrimination
• Resolution
Not every company does it all
Many only do 1 of the 3 disciplines
Collaboration Is Key
• Companies are beginning to leverage each other’s
strengths
– Customers receive products designed to work together
• Omron Industrial Automation and PBC Linear
collaboration
– Omron controls and PBC Linear mechanicals
• By combining strengths, it is easier for customers
– This focus on strength helps each company to reduce energy
spent on non-core products
Why Customers Want Convergence
• Reduced selection time
– Shorter design cycles
• Fewer technical support conflicts
– Less finger pointing between vendors
• Common communication protocols
– Faster communication between devices
• Vision systems that speak directly to the motion
controller
– Easier to program and less hardware
BOTTLE INSPECTION
The Application
• Bottle filling
• Cap inspection
• Varying bottle sizes
Static Mount, Manual Adjust
Manual Adjustment
w/set screw
The Problem
• System used manual adjustments for change-over
– Time consuming
– Inaccurate
– Enclosure integrity
– Limited space
The Solution
Linear Actuator with built in motor and coupling
MLB Series by PBC Linear
Dynamic Mount, Automatic Adjust
Upper
Position
Lower
Position
Dynamic Mount, Automatic Adjust
The Result
• Eliminated errors during change over
• Reduced change over time from 10 minutes or
more to roughly a minute
• Improved water ingress resistance resulting in
fewer moisture related repairs
• Smaller footprint for total enclosure
• Parts count reduction by 40%, justifying the
added cost
Another Actual Application
INSPECTION
IN MOTION
The Application
• Lab automation
• Inspecting cultures
• Logging the data
– Date & Time
– Color
– Physical Size
• Diameter
• Area
– Change from previous size
Sample Culture
The Problem
• Manual process
• 24/7 human monitoring
– One hour increments
• Manual measurements
– Subjective measurements, not typically repeatable from
one person to the next (due to frequent odd shape/size)
• Image logging data base manually input
– Time intensive & data entry error prone
Inspection In Motion
The Solution
• Cartesian robot
• Trajexia controller
• X and Y planes
• Low profile, high precision linear actuators
• FZ Vision System
• Vision system can auto guide motion controller to
ensure optimal image capture (offset move)
Vision Capture
The Result
• Automatic Process
• Eliminated 24-hour staff
– Reduced Cost
• Auto measured culture size and color
– Improved accuracy
• Auto logged images
– Reduced data entry errors
Inspection in Motion
AUTOMATED STORAGE
& RETRIEVAL
The Application
• Automated pharmaceutical dispensing machine
• Robot picks drug to be dispensed
• Vision system records bottle barcode, locates edge
and calculates offset movement distance
The Problem
• Incorrect dispensing is a major liability
Complicated by…
• Mechanical Tolerances
– Inexpensive frame creates
huge tolerance stack up
• Recording Barcodes
• Label Verification
The Solution
• The Cartesian Robot was installed with a home
sensor located on a sheet metal component
• The vision system provided final move
coordinates to the controller
• The vision system reads the barcode which is
then verified against the order
• The vision system also verifies the printing
on the label
• The vision system stores applicable images/data
using onboard PC (for liability reasons)
The Result
• The vision system’s ability to do edge detection and
calculate offset moves reduced assembly tolerances
and decreased assembly cost
• The motion and vision interface ensure accuracy of
the medicine picked
– Allows for minimized levels of liability
• Fast, accurate medicine dispensing without the
need for costly pharmacist staff
Other Storage & Retrieval Systems
• Automated Parking System
• High Bay Storage
SUMMARY
3 Key Elements
• Controller
• I/O
• Drives
• Motors
• Actuators
• Gear boxes
• Couplings
• Sensors
• Cable Carriers
• Mounting Hardware
• Controller
• Cameras
• Lighting
• HMI
Motion Control Mechanical Vision
Challenges
• Speed
• Accuracy
• Communication
• Selection
• Software
• Speed
• Accuracy
• Selection
• Torque Calculations
• Wear
• Environment
• FOV
• Triggering
• Color Discrimination
• Communication
• Selection
• Environment
Benefits Of Convergence
Better Communications = Faster Machines
Easier Selection = Faster Design
Unified Tech Support = Less Wasted Time
Networked Cameras = Less Hardware
Stay Tuned
Motion + Vision + Safety
S
QUESTIONS
www.pbclinear.com
1.800.962.8979
Jonathan R. Schroeder
Business Development
www.omron247.com
1.800.556.6766
David Kaley
Commercial Marketing Manager
Thank you for attending!
