Vision Sensors

Vision sensors detect the shape of a target by capturing the surface of the target as an image. This eliminates the need to align the position and angle of the target, which eliminates the need for a positioning device and enables detection of targets in motion. With no need to stop the conveyor carrying the targets, stable detection is possible even with high-speed lines.

Contact-type displacement sensors and laser displacement sensors capture information from a specific point on the target, so as many sensors as detection points are required. This results in significant effort installing a large number of sensors and positioning them to the desired locations. In addition, detection is only possible while the target is stopped.
Vision sensors, on the other hand, determine the target shape based on the image captured by the camera. The detection location is then specified using the image, eliminating the need for positioning equipment or for stopping the target. Moreover, the ability to perform detection of multiple points within the camera’s field of view at the same time means there is no need for a large number of sensors as with contact-type displacement sensors and laser displacement sensors. Being able to keep the number of necessary sensors to a minimum significantly reduces the work required for product changeovers.

Vision sensors are capable of accurate color difference checking. Their design also makes them less susceptible to glare caused by reflected light. This enables stable detection even if the target color is uneven or if there are glossy spots in the detection area.

The most common use for color sensors is color differentiation. However, small color differences and color irregularities in the detection area frequently cause false detections with some color sensors. Glare caused by light reflected off metal parts can also cause false detections. Lighting equipment can help reduce the effects of glare, but configuring the lighting conditions requires skill, and changeovers take a lot of time.
Vision sensors, however, can automatically configure settings for color differentiation, glare, and other factors. This means stable detection is possible at all times even without separate lighting equipment, and even subtle color differences are detected. The sensors are also able to automatically detect when the target changes to reconfigure detection conditions and lighting settings as necessary.

With a vision sensor, detection conditions such as contour, color, and area can be configured for multiple locations, and detection is possible for all locations at the same time. This eliminates the need to install numerous sensors. These various detection conditions can also be saved.

In a conventional system, performing various detections such as presence, contour, color, and area means installing color sensors, photoelectric sensors, or laser displacement sensors according to the desired detection.
Vision sensors, however, can be used to use different detection conditions at different locations all at once. The ability to perform detection using the various configured settings all at once means differentiation that conventionally required several sensors can be done with just one device. Also, the ability to save the detection conditions means they can be easily retrieved as needed. This helps significantly reduce not only the number of sensors needed but also the time required for changeovers.

When using a contact-type displacement sensor, laser displacement sensor, or color sensor to detect multiple weld nuts on automobiles or clips securing interior components, a large number of sensors must be used, and a lot of time is needed for installation and setup. Accurate positioning is also required.
A single IV2 Series vision sensor with built-in AI, however, can perform detection over an area as large as 550 × 412 mm (21.65" × 16.22"). This area is large enough to include up to 16 installed nuts or interior clips all at once, reducing the overall number of sensors that need to be installed. Moreover, because detection is not affected by glare from reflected light, stable detection is possible even for glossy targets.

More details

Using a vision system to check the connection of cables for electrical components and circuit boards, the wide field of view eliminates the need for positioning, and the system’s high resolution ensures stable detection even for thin cables with small components. However, installation and configuring such a system takes a lot of time, and the system itself is expensive.
Meanwhile, the IV2 Series vision sensor with built-in AI comes equipped with automatic focus and brightness adjustment functions. This means detection of missing or incorrect wiring can be performed with the optimal focus and brightness. Also, because a single device can cover a wide detection area, even large PCBs can be inspected easily. The built-in AI can also perform the necessary settings for battery wire detection such as color differentiation and edge detection.
This makes the IV2 Series the ideal choice in terms of functionality, ease of use, and price.

More details

Various types of sensors can be used to detect molding remaining on molded products, including photoelectric sensors. However, the number of sensors required depends on the number of detection points. With large molds, the detection area also becomes wider, making it necessary to align numerous sensors.
KEYENCE’s AI Series of pattern matching sensors is able to capture surfaces as an image, and AI is used to position targets automatically. This makes positioning easier than photoelectric sensors and other sensors that detect only points on a target, while also enabling stable detection. The AI Series can also be used in presence check mode or difference check mode. Enjoy convenient functionality with the same ease of use as a general-purpose sensor.
Unlike point-based detection sensors such as photoelectric sensors, the AI Series enables stable detection and offers all the necessary functions with easy setup and operation.

Misaligned products can cause false detections with sensors that detect points on a target, such as photoelectric sensors. This means positioning devices are required to ensure accurate positioning.
Vision sensors detect the shape of a target by capturing the surface of the target as an image. The target’s features are then analyzed to determine the position and orientation of the detection target. This ensures accurate differentiation even if the position of the passing target is misaligned.
In addition, with the IV2 Series, the detection area is wide (550 × 412 mm 21.65" × 16.22"), and accurate detection and differentiation are possible anywhere within the area even for misaligned targets.

Photoelectric sensors and contact-type displacement sensors capture information from a specific point on a target, requiring the same number of sensors as detection points. All of these sensors must be installed and configured before performing detection. Moreover, if the product type changes, a significant amount of time is required for changeovers.
The IV2 Series, however, captures the surface of the target, enabling detection of up to 16 different points within the field of view. This includes not only presence checking and shape analysis, but also color, pitch, and various other differences. Up to 32 different detection setting configurations can also be saved (for 32 different products), and changing the settings is as easy as loading the configuration for the specific target.
This means the number of sensors required for difference checking as well as the time spent on installation, setup, and changeovers can be significantly reduced.

Glare caused by the strong reflected light from polished metal surfaces can cause false detection with conventional systems. With photoelectric sensors and color sensors, color is detected at a single point, making stable detection difficult.
The IV2 Series vision sensor with built-in AI, however, features automatic focus and brightness adjustment functions that enable stable detection by determining the optimal focus and brightness without separate lighting equipment even if glare is present. Detection settings for color differentiation, contours, and other factors are also configured automatically by the AI.
The IV2 Series uses AI to ensure differentiation even with glossy surfaces by determining the ideal detection conditions, allowing users to construct inspection systems with superior detection stability.