Machine vision systems are programmed to perform narrowly defined tasks such as counting objects on a conveyor, reading serial numbers, and searching for surface defects. Though machine vision systems have neither the intelligence nor the learning capability of human inspectors, they are considered useful in many applications. Manufacturers favor machine vision systems for visual inspections that require high speed, high magnification, 24-hour operation, and repeatability of measurements.
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The optical sensor determines when a part moving on a conveyor is in position to be inspected. The optical sensor triggers the camera to take a picture of the part as it passes beneath the camera and lighting. The lighting used to illuminate the part is designed to highlight features of interest and obscure or minimize the appearance of features that are not of interest.
The camera's image is captured by the framegrabber. A framegrabber is a computer card that converts the output of the camera to digital format and places the image in computer memory so that it may be processed by the machine vision software.
The software will typically take several steps to process an image. Often the image is first manipulated to reduce noise or to convert many shades of gray to a simple combination of black and white. Following the initial simplification, the software will count, measure, and/or identify objects in the image. As a final step, the software passes or fails the part according to programmed criteria. If a part fails, the software signals a robotic device to reject the part; alternately, the system may warn a human worker to fix the production problem that caused the failure.
Though most machine vision systems rely on black-and-white cameras, the use of color cameras is becoming more common.
In most cases, a machine vision system will use a combination of these processing techniques to perform a complete inspection. A system that reads a barcode may also check a surface for scratches and measure the length and width of a machined component.
In the automotive industry, machine vision systems are used to guide industrial robots, gauge the fit of stamped metal components, and inspect the surface of the painted vehicle for defects.
Though machine vision techniques were developed for the visible spectrum, the same processing techniques may be applied to images captured using imagers sensitive to other forms of light such as infrared.
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