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These 6 Common Process Features Account for Nearly All Vision Sensor Problems

July, 2020

Most customers purchase vision sensors to simplifiy or automate their production processes. However, nearly 50% of customers have experienced problems with vision sensors, claiming that they do not work well for their processes. Although each individual process is different, all of these problems can be sorted into 6 distinct Vision Sensor Problems.

Since vision sensors are low-cost solutions, many vision sensor users consider these problems to be problems with all vision sensors. But these problems can be solved without upgrading to a high-end vision system or measurement product.

With the right product and features, these vision sensor problems can be solved easily.

6 Common Vision Sensor Problems and How to Solve Them

1 Ambient Light

Throughout the work day, lighting may change around a production process. In addition, if the vision sensor is mounted far away from the target, nearby lighting can also interfere with the consistency of the inspection. For vision products, slight changes in lighting can result in major problems with the inspection.

The IV2-vision sensor uses artificial intellegence to identify the primary differences between OK parts and NG parts and ignores minor image changes caused by ambient lighting.

2 Individual Differences Between Products

No process is ever perfect. For many manufactured parts, there will be minor, insignificant differences between products. For example, if the lot is changed then there may be slight differences between one lot and the next. Or if there can be oil, water, or other types of contamination on the target, the target seen by the vision sensor may be slightly different each time. Since most vision sensors match on a pixel-by-pixel basis, these slight inconsistencies can result in major stability problems.

The IV2-vision sensor uses artificial intellegence to identify the primary differences between OK parts and NG parts and ignores minor inconsistencies between parts.

3 Position of Part Changes

Consistency of part shape and of lighting are very important to the stability of vision sensors. However, as a part moves in the field of view, the shape of the target may distort. In addition, if the lighting is inconsistent across the field of view, changes in position can result in the part being in a spot of different lighting. These distortions can have major impacts on stability.

The IV2-series vision sensor uses a quad-lens to prevent visual distortion as the part moves and Hi-R Illumination lighting so that lighting is consistent across the entire field of view.

4 Low Contrast Between Target and Background

Vision sensors work by detecting visual aspects of a target. If there is low contrast between the target and the background, a vision sensor may misdetect. For example, this occurs when detecting black-on-black parts or when detecting metal-on-metal parts.

The IX-series image-based laser sensor uses height inspection to detect targets so products with low contrast can be inspected stably no matter what.

5 Unable to do "Seating" Or Applications with Raised Parts

Vision sensors can detect the presence/absence of multiple points on a target. However, since a vision sensor is only doing visual inspection, it cannot detect if parts are seated, raised, or have some other height change. This means that other sensors will need to be added to perform all relevant inspections.

The IX-series image-based laser sensor can easily check the height of multiple points at once, meaning only a single sensor can solve multiple different types of inspection, including targets with raised parts.

6 Operator Cannot Adjust Vision Sensor Settings

When initially installing conventional vision sensors, the engineer must carefully consider what kind of tools should be used for the application. For more complex applications, multiple edge, outline, color, or width tools must be used to accurately solve the application. Since the settings are highly specialized, an operator or another user will struggle with adjusting the settings of the vision sensor.

The IV2-series will automatically learn what is OK and NG so changing settings is so easy that anyone can do it.

If problems happen with your vision sensor, it is necessary to check the cause of the problem and to improve sensor settings, mounting, lighting, or other conditions.

In many cases, the settings, mounting, and lighting conditions of the vision sensor are complicated and difficult to adjust. This can take a very long time and if you cannot solve the problems, it may be necessary to ask a vision sensor expert to improve the setup.

By using the IV2-series vision sensor or IX-series image-based laser sensor, solving these vision sensor problems is quick and easy.

Please download the catalog below or contact your local representative for more information on how to solve your vision sensor problems.