Auto-Teach. Vision Inspection that Learns What a Good Part Is

Transcription

1 Auto-Teach Vision Inspection that Learns What a Good Part Is Jeff Johnson National Product Sales Director- Machine Vision Keyence Corporation of America

2 Keyence Corporation Global Headquarters: Osaka Japan Founded: May 1974 Worldwide Employees: 4,450 Over 200,000 customers in 70 countries Factory automation products Sensors Safety Equipment Barcode Readers Measuring Instruments Vision Systems Laser Markers Digital Microscopes

3 Keyence Innovation Forbes' "World's Most Innovative Companies" Business Week's "1000 Best Valued companies. Top 50 in Newsweek's Electronic Industry Ranking Featured on Discovery Channel s Automation World First Team - Leadership in Automation

4 Keyence Vision System Innovations From introducing the world s first vision sensor in the1980 s, to manufacturing today s 21 Megapixel high-resolution cameras and powerful multi-camera & 3D vision systems, Keyence has been a global leader in vision system innovation.

5 Keyence Vision System Innovations Vision Systems Design Innovator Awards: 2015 Innovators Gold Award for: LumiTrax TM 2016 Innovators Gold Award for: Auto-Teach 2017 Innovators Silver Award for: Complete Line Scan / 3D Solution

6 Why Auto-Teach? Average Vision system novices Presence / Absence Defect detection Complex Shapes Small Defects Unique Benefits Not sure what defects may occur Prevent adjustment errors in the future -3σ Range of quality 99.7% +3σ

7 Vision System Novices Don't understand complex vision algorithms Don t know which algorithm to choose Easy, intuitive set-up Just teach Good Parts! Automatically rejects Bad Parts Good introduction to vision systems Frequent addition of new parts Copy program & reteach

8 How does it work? Teach a large set of GOOD parts Statistical analysis of the RGB values for every pixel Pass or Fail based upon +/- 3 Sigma (Standard Deviation) of good samples

9 How does it work? Four easy steps 1) Locate Part 2) Inspection Region 3) Auto Teaching 4) Verify / Judge

10 1) Locate Part Critical for pixel alignment Position Gap confirms stability Green Area Too Bright Red Area Too Dark Gray within pattern region = OK Red & Green within pattern region = NG 2) Inspection Region Where to inspect Multiple regions possible Individual pass/fail within one tool

11 Quality image Quality image Quality image 3) Auto Teaching Teach Good Parts Average composite image Variability image - visualize the variability level of each pixel During the inspection, the full RGB data for each pixel is compared to the data cloud from the taught images for that same pixel Sets a tolerance of ±3σ of the averaged data for each pixel NG Parts closer to the mean than parts within the ±3σ range will still fail

12 4) Verify / Judge Pass / Fail limits are set automatically Can be adjusted, if necessary Teaching bad parts is never required Bad parts can be registered To confirm that test parts are NG Registered NG parts can be used to prevent future adjustment errors

13 Auto-Teach Example Application Teach Good Parts Composite image shows Variability Light areas have more variability Dark area have less variability Actual RGB data distribution from low variability pixel on the cap

14 Auto-Teach Example Application Test Good Parts Test Bad Parts Puncture Double label Foreign object Print defect Wrinkled label Torn label

15 Auto-Teach Navigator Adding good parts at a later date can be VERY DANGEROUS Navigator verifies that registered NG parts won t pass Select images from archive to add Click NG Verification Warning allows you take back your adjustment Prevents bad parts being sent to the customer!

16 Auto-Teach - Summary Auto-Teach Major Benefits Auto-Teach Easy programming for vision novice Presence / absence for complex parts Small defects relative to large featues Find random defects unknown at the time of installation Protection against sending defective parts to a customer

17 Jeff Johnson National Product Sales Director- Machine Vision Keyence Corporation of America 500 Park Boulevard Itasca, Illinois USA Telephone: KEYENCE