When an inspection application requires more sophisticated data acquisition than that provided by a traditional photoelectric sensor many application engineers will choose a vision system. Through it, they can obtain image-based data and identify label orientation, part presence and arrangement, and other features. But for some of these applications a full vision system may not be required. Instead, a compact touch screen image sensor with no PC or additional electronics can be used.
A touch screen image sensor can combine the capabilities of three separate sensors in the same housing. One sensor is a match sensor. It compares the target object to a stored reference point, identifying parts of irregular shape, alphanumeric characters, etchings and labels at rapid production speeds. An area sensor identifies target features within a region of interest, ideal for detecting drilled holes on a metallic component or inspecting blister packs, and verifies that all features are correctly sized and located. The third sensor has a similar purpose – examining an area for specific features – but offers tools that adjust for motion.
These tools allow the sensor to detect objects of varying position and orientation on the production line. The image sensor also incorporates integrated lighting and adjustable lenses to optimise image contrast, as well as accommodate changing plant conditions.
The sensor’s touch screen LCD display is used for setting up an inspection and modifying parameters. Once users select the sensor type (match, area, or area with motion), it captures a sample image. From this point, the sensor is configured by adjusting the region of interest, setting inspection parameters, and designating the minimum and maximum pass count. The final setup configuration and logged inspection results can be downloaded from the sensor to a USB drive through the sensor’s USB port. To minimise system downtime, users can set new application parameters offline through the sensor’s software emulator and then upload these new configurations onto the sensor using the USB drive.
Figure 1 – Label orientation: The touch screen image sensor allows users to set inspection parameters on the spot and then examine a target object, such as a salad dressing bottle, to verify label placement and orientation.
Figure 1
Figure 2 – Drilled hole inspection: The image sensor features integrated lighting to create contrast between target features (drilled holes) and their background (metal plate), allowing any reject parts to be readily identified.
Figure 2
Figure 3 – Injection moulding verification: Once the sensor is programmed, it compares the obtained image – in this case a plastic container – to a reference pattern, confirming the size and shape match to the parameters set. If the target object fails this inspection, it is rejected from the production line.
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