introduction
With reliable, discrete logic and simple analog I / O, programmable logic controllers (PLCs) have dominated the production and automation industries for decades. Although these properties of PLC can well meet the requirements of most industrial applications, the ever-evolving industrial machines continue to push the performance of traditional PLCs to a wider direction.
For some product defects that cannot be detected by traditional measurement sensors, in the past few years, machine vision has gradually become an important tool for identifying such product defects. Adding machine vision to existing industrial control and automation systems can help you monitor various safety hazards and necessary maintenance packages in industrial equipment, track product development processes in real time, help product quality control to reduce scrap and ensure customer satisfaction .
Integrate machine vision into existing systems
NI vision products can be easily integrated into programmable logic controllers (PLCs), programmable automation controllers (PACs), and human-machine interface (HMI), and can work in conjunction with a large number of camera and image processing standards on the market, so , NI vision products can choose the sensor type, resolution and bandwidth that meet your application needs.
Figure 1 NI provides a variety of hardware platforms and software tools for vision applications
To implement inspection applications, NI provides a series of hardware platforms, ranging from rugged and reliable smart cameras, to embedded systems for integrated cameras that can operate independently, to high-performance frame grabbers based on PC systems. Users can connect these systems to PLCs through digital I / O, analog I / O, and industrial communication protocols including Ethernet protocols Modbus / TCP, EtherNet / IP, TCP / IP, RS232, and Modbus serial protocol.
To enhance the functionality of the hardware platform, NI provides 2 optional software tools that you can use on various NI vision hardware devices. The NI Vision Generator (VBAI) for automatic detection is a machine vision software that can be easily operated and can run independently. NI Vision Development Module (VDM) integrates image processing and machine vision functions and is suitable for multiple programming languages. You can use VBAI to configure your system, or use VDM to program the system. Because you can use a unified software development kit on the entire NI vision hardware product platform, you can easily migrate existing code between multiple application platforms, thereby reducing system development time and maintenance costs.
Case study: cosmetic packaging production line integrating vision and robotics
You can integrate a visual inspection system with a PLC or even an industrial robot to achieve complete automation of the product production process. The following case is a good example.
Vetraco is a recognized leader in the complete assembly and packaging production line of cosmetics. The company needed a system that could put the paint brush into the powder container accurately. Since the shapes of the paint brush and the powder box are not fixed, this system must be flexible and easy to operate.
Vetraco contacted ImagingLab. ImagingLab is an Italian company that helps equipment manufacturers and users adopt innovative machine vision and robot technology. They use NI vision tools to propose solutions. The product quality control is performed by detecting the product defects of the paint, and at the same time, the rate of putting the paint into the powder box reaches 80 pieces per minute. In this system, a vision system with a PC-based image acquisition card with IEEE1394 interface is integrated into the feed conveyor of the brush. At the same time, the system also integrates the DENSO robotic arm. Load the brush onto the programmable feeder and vibrate the brush to transfer it separately. The vision system collects the image of the stucco, determines its position and the coordinate points that can pick up the parts, and transmits them to the robot. Guided by the vision system, the robot picks up and places the paint to the corresponding position to help the classification and assembly tasks of the paint. The vision system provides quality control of components by measuring dimensions and verifying integrity.
Figure 2. Cosmetic packaging production line developed by ImagingLab and Vetraco
in conclusion
Whether it is to ensure the correct assembly of automated components, or to detect label defects in medical product packaging, machine vision has played a great role. In many areas of automation, machine vision has proven to be a very valuable component.
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