Clear view guaranteed with vision sensors

Technology report

Three aspects of sensor technology are particularly important in image processing for industrial automation: performance, flexibility and usability. Simple Vision sensors meet these requirements. They are as easy to operate as optical sensors, plus they are as powerful as camera systems. The Sensor People from Leuze offer this concept as a quick and straightforward introduction to vision technology.

Vision sensors are the ‘eyes of industrial automation’. That is because these little marvels enable machines to see and interpret their surroundings. They are easier to integrate and operate than camera systems. The devices are suitable for many different tasks: They are used for presence or absence detection, parts detection, inspection, code reading, measuring or counting tasks, as well as print quality verification. When selecting the optimum sensor technology, it is worth considering performance in the corresponding detection, identification and inspection tasks. In addition, sensor configuration and parameterization must be as simple as possible to save time and money. The Sensor People at Leuze provide a product portfolio that meets these requirements with their Simple Vision concept.

simple-vision-product-highlights_500x700 — The devices are used for presence or absence detection, parts detection, inspection, measuring or counting tasks, as well as print quality verification.

Simple setup, efficient detection

The image processing tools from Leuze are powerful: They combine image acquisition, processing and communication functions in one device. A common sensor application is detecting the presence or absence of objects. In filling systems, for example, caps, labels or imprints on bottles or flacons must be reliably detected. Sensors can also be used to check how an object is aligned – regardless of its format, material, color or dimensions. Users must ensure that the device performs well. The IVS 108 Simple Vision Sensor from Leuze, for example, has a consistent response time of just 50 milliseconds – even with changing objects, ambient or application conditions. This makes it very easy for system operators to decide whether the sensor meets their production process requirements. A quick sensor setup is also important. The IVS 108 requires neither programming nor lengthy configurations. All you need to do is position ‘GOOD’ and ‘NOT GOOD’ objects in front of the sensor and confirm by pressing the teach button.

APIC_DCR_OCV_Kontrolle MHD_neu_(1) — The DCR 1048i OCV identifies a 1D/2D code and also compares the imprint of the best-before date with a taught-in reference image. This involves assessing whether or not the print has the required quality. The threshold value for this is easy to set.

Code reading made easy

Vision sensors can also be used to read 1D or 2D codes. Practical: Sensors such as the DCR 1048i from Leuze read single or multiple codes simultaneously. This is relevant for packages containing several secondary packaging units, for example. Multicode decoding makes this possible. If DPM codes printed on the packaging need to be detected, a sensor such as the DCR 1048i DPM is recommended. This is equipped with an optimized reading algorithm for reliable decoding. Anyone looking for a particularly powerful sensor for print quality verification will find what they need in the DCR 1048i OCV: It can read 1D/2D codes within one application and also check print quality (e.g. best-before date, batch and others) using the OCV process. OCV stands for “Optical Character Verification”. The vision sensor can be taught in particularly easily, quickly and without any complex parameters: all you need to do is present it with a reference image of the optimum print. The DCR 1048i OCV then reliably detects defective printing – for example, clogged print heads, low ink cartridges, or adhesion problems.

APIC_PA_IVS108_Presence-detection-for-printed-information-on-bottle_wl — The IVS 108 from Leuze is suitable for any application that requires checking the presence or absence of objects. For example, bottle caps, labels or imprints on bottles or flacons in filling systems. It can also be used to check the correct alignment of objects, regardless of their shape, material, color or dimensions.

All-rounder application

Depending on the application and system design, an all-rounder vision sensor can prove worthwhile. This enables system operators to respond quickly to market requirements and product changes. The all-rounder vision sensors such as the IVS 1048i from Leuze are recommended for detection, inspection and identification tasks. For example, checking whether labels or adhesive have been applied correctly on a packaging line. Another possible use is checking whether bottles are sealed correctly in a beverage-filling system. Some manufacturers offer devices with different resolutions. The IVS 1048i is available with a lower (736 x 480 pixels) or higher resolution (1,440 x 1,080 pixels). This allows very flexible sensor use. There is also a choice of four interchangeable S-mount lenses with variable focus adjustment. This means that the reading distance, field of view and depth of field can also be adapted to each system’s requirements.

Flexible configuration

No vision sensor without software: The usability of the associated image processing program must be a decisive factor when selecting the sensor technology. Time and effort can be saved in system operation with software that includes powerful tools and also provides statistics for image processing and inspection that can be used offline. Common interface protocols such as TCP/IP, PROFINET, FTP and SFTP (Secure File Transfer Protocol) are integrated into the device. This facilitates communication and data acquisition. Leuze provides PC-based configuration software that fulfills all these requirements with its Leuze Vision Studio. It is suitable for the IVS 1048i and DCR 1048i Simple Vision sensors. The Leuze Vision Studio offers the option of configuring the various sensors virtually using an emulator and testing the applications with real images without a device being physically present.

Abfullprozess — Vision sensors are recommended in many cases for image processing in industrial automation. Leuze’s Simple Vision product portfolio has the right solution for almost any application.

Summary

It can be beneficial for system operators to focus on vision sensors that can be set up and operated without any specialist knowledge. This makes integration and ongoing operation easier, even if production process requirements change. The system sensors can thus be designed cost-effectively with minimal effort. It is also important to choose a device with a powerful performance. The sensors in the Simple Vision concept from Leuze Vision combine all of this. This enables the efficient use of image processing technology in industrial automation.

More than 60 years of experience have made Leuze a real expert in innovative and efficient sensor and safety solutions for automation technology. Today there are more than 1600 Sensor People around the world who are working with curiosity, passion and determination for progress and transformation. Their motivation is the continued success of their customers in an ever-changing industry. Leuze offers its customers a tailored competitive advantage through intuitive, reliable solutions for safe and non-safe position detection. For example, switching and measuring sensors, identification systems, solutions for data transmission and image processing. As a safety expert, the family business also focuses on components, services and solutions for occupational safety. Thanks to their broad and in-depth application expertise in the machine and system construction, the Sensor People are a competent and flexible partner for customers with a wide range of industrial requirements. www.leuze.com

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