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2017-11-06
: Microscan Assembly Presentation Assembly_Presentation
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Ensure 100% Traceability and Quality of Your Products using Omron Microscan Automatic Identification and Machine Vision Systems Presenter: Steven J. King – Machine Vision Product Manager Date: Oct 26, 2017 © Microscan Systems Inc. Agenda ▪ Automatic Identification and Machine Vision Tool Set ▪ Traceability ▪ ▪ ▪ ▪ Automatic ID Code Types Code Marking Methods Code Reading Code Verification ▪ Machine Vision Inspection ▪ ▪ ▪ ▪ ▪ ▪ Presence/Absence Color ID/Color Match Count Measurement/Gauging Assembly and Assembly Verification Defect Detection © Omron Microscan Systems Inc. 2 AutoID and Machine Vision Basic Toolset Presence/ Absence Read Codes Verify Code Quality Locate Read Text Verify Text Quality Count Color Detect Measure Logic © Omron Microscan Systems Inc. 3 Traceability Blade Runner Trivia – Who made the Replicant snakes? ▪ Strategy • Mark all parts with codes • Enables automation • Build a complete manifest of what goes into a product • Track from cradle to grave ▪ Requirements • • • • Marking Mark quality verification Reading Data recording Abdul Ben Hassan © Omron Microscan Systems Inc. 4 Code Marking Types ▪ Human Readable Codes ▪ Machine Readable Codes Highest read reliability • 1D Bar Codes • 2D Symbologies © Omron Microscan Systems Inc. 5 Traceability © Omron Microscan Systems Inc. 6 Traceability ▪ Track ▪ In house ▪ Part tracking ▪ Process control ▪ Process optimization ▪ Trace ▪ Part Genealogy ▪ Defective Part Tracking ▪ Spill Containment ▪ Selective Recalls ▪ Anti Diversion ▪ Counterfeit Prevention ▪ Nabbing replicants © Omron Microscan Systems Inc. 7 Code Marking Methods ▪ Labels – Ink Jet, Laser, Thermal ▪ Direct Part Marks – Laser, Dot Peen, Ink Jet © Omron Microscan Systems Inc. 8 Direct Part Mark Application Examples © Omron Microscan Systems Inc. 9 Automotive Applications ▪ Engine component traceability • Head and block traceability • Assembly error proofing • Selective pairing of components ▪ Transmission components traceability ▪ Fuel injector traceability ▪ Catalytic converter traceability ▪ PCB traceability ▪ Final assembly and WIP verification © Omron Microscan Systems Inc. 10 Code Readers ▪ ▪ ▪ ▪ Handheld label reader – HS 21 Handheld DPM (Direct Part Mark) reader – Mobile Hawk Fixed mount label and DPM reader – MicroHAWK ID20, ID30, ID40 Fixed mount vision system with reading – MicroHAWK MV, HAWK MV HS-21 Mobile Hawk MicroHAWK ID Reader MicroHAWK/HAWK MV © Omron Microscan Systems Inc. 11 AutoID and Machine Vision Basic Toolset Presence/ Absence Read Codes Verify Code Quality Locate Read Text Verify Text Quality Count Color Detect Measure Logic © Omron Microscan Systems Inc. 12 Code Verification – Check the handwriting Frequency ▪ Marking processes drift from nominal settings ultimately leading to unreadable marks ▪ Verification allows adjusting of marking process before unreadable marks are made ▪ Verification is metrology tool to ensure consistent mark quality ▪ Verifier can tell not only that mark is readable but also how close it is to edge of readability that it is Measurement value © Omron Microscan Systems Inc. 13 Code Verification ▪ Offline or Inline symbol verification ▪ Verify or validate the symbol immediately after printing ▪ Deviate from the standards if process or circumstances require ▪ Provide results that correlate directly with ISO standards ▪ Verification ensures that EVERY product ships with a good quality symbol despite the fact that every marking system will degrade over time Without verification, some “bad” parts escape into the process With verification, we prevent bad marks from ever being made. © Omron Microscan Systems Inc. 14 ISO15416 - 1D Label Verification ▪ ISO 15416 • 1D on Labels • Requires even illumination • Requires good lens with high MTF © Omron Microscan Systems Inc. 15 ISO15415 - 2D Label Verification ▪ ISO 15415 • 2D on Labels • Requires even illumination • Requires good lens with high MTF ▪ Modulation © Omron Microscan Systems Inc. 16 ISO 29158 - 2D DPM Verification ▪ ISO 29158 • Direct Part Marks • More forgiving spec • Requires application specific lighting © Omron Microscan Systems Inc. 17 Verification Example: Inkjet on cartons ▪ Direct inkjet printing is economical ▪ But the results are not always pretty ▪ No reads at big retail customers result in fines for each unreadable code ▪ Inline verification after printing ensures NO bad symbols ship © Omron Microscan Systems Inc. 18 Code Verifiers ▪ Offline • Handheld label and DPM verifier –LVS-9580, LVS 9585 • Desktop Verifier – LVS-9510 ▪ Inline • Fixed mount inline verifier – MicroHAWK MV, HAWK MV-4000 LVS-9580, LVS 9585 LVS-9510 MicroHAWK, HAWK MV © Omron Microscan Systems Inc. 19 Code Verification at the printing source © Omron Microscan Systems Inc. 20 Optical Character Verification ▪ Show and Go Tool - Validate printed text by training on a good sample ▪ Detects common printing problems and provides pass/fail output ▪ Symbols are compared against trained golden symbol ▪ Symbols are rejected if the total residue exceeds the set tolerance ▪ Optional tests for Largest single defect, character breaks, contrast, and blurriness © Omron Microscan Systems Inc. 21 Optical Character Verification - Example Pad Printing OCV on ICs © Omron Microscan Systems Inc. 22 AutoID and Machine Vision Basic Toolset Presence/ Absence Read Codes Verify Code Quality Locate Read Text Verify Text Quality Count Color Detect Measure Logic © Omron Microscan Systems Inc. 23 Full Machine Vision Smart Cameras – MicroHAWK MV © Omron Microscan Systems Inc. 24 Brand New High Performance Camera HAWK MV-4000 ▪ 8 Models ▪ MV-4000-03, Mono, 0.3 MP ▪ MV-4000-03C, Color, 0.3 MP ▪ MV-4000-13, Mono, 1.3 MP ▪ MV-4000-13C, Color, 1.3 MP ▪ MV-4000-20, Mono, 2.0 MP ▪ MV-4000-20C, Color, 2.0 MP ▪ MV-4000-50, Mono, 5.0 MP ▪ MV-4000-50c, Color, 5.0 MP © Omron Microscan Systems Inc. 25 HAWK MV-4000 Light Kits © Omron Microscan Systems Inc. 26 Presence/Absence of Critical Parts and Features ▪ Count Pixels • Within range of grayscale intensity • Edge pixels (brightness invariant) ▪ Tolerance • Compare count to min and max values ▪ Output • Pixel count • Pass/Fail © Omron Microscan Systems Inc. 27 Presence/Absence using Color ▪ Color ID • Determine color from library of colors ▪ Color Check • Compare color to one specific color ▪ Tolerance • Compare pixel count to min values ▪ Output • Color • Count of pixels • Pass/Fail © Omron Microscan Systems Inc. 28 Count ▪ Locate features • Shape based ▪ Tolerance • Compare count to min and max allowed values ▪ Output • Count • Locations © Omron Microscan Systems Inc. 29 Count ▪ Locate features • Blob based • Select based on min and max size of blob ▪ Tolerance • Compare count to min and max values ▪ Output • Count • Locations © Omron Microscan Systems Inc. 30 Measurement ▪ Locate features • • • • Lines Points Circles Patterns ▪ Measure • Line to Line • Point to Point • Point to Line ▪ Calibration • Convert pixels to real world units ▪ Tolerance • Compare to min and max values ▪ Output – OK/NG © Omron Microscan Systems Inc. 31 Location and Guidance ▪ Train a pattern ▪ Return X, Y, Theta ▪ Add encoder based offset for “pickup down the belt” ▪ Intellifind Tool • • • • • Edge Based Pattern Matching Allows 360 degree rotation Allows scale changes Lighting invariant Finds patterns amongst clutter © Omron Microscan Systems Inc. 32 Assembly ▪ Train pattern of points on each part ▪ Compute offset of part 1 to blueprint ▪ Compute offset of part 2 to blueprint ▪ Compute offset part 1 to part 2 ▪ Output X, Y, Theta to assemble part 1 onto part two ▪ Uses “rigid body fit” algorithm © Omron Microscan Systems Inc. 33 Defect Detection ▪ Often difficult – Defects similar in size and shape to allowed features ▪ Highly dependent on lighting to create contrast © Omron Microscan Systems Inc. 34 Defect Detection – Lighting Dependency © Omron Microscan Systems Inc. 35 Defect Detection – Using OCV ▪ OCV is not just for characters ▪ OCV can be used for individual shapes or symbols ▪ OCV computes difference between trained and inspected shape ▪ OCV combined with color checks is very powerful © Omron Microscan Systems Inc. 36 Wrap Up ▪ Modern Machine Vision Systems contain tools for • Automatic Code Identification • Code Verification • Machine Vision ▪ Traceability is a Strategy that involves • • • • Picking the correct code types Picking the correct code marking methods Code Reading Code Verification ▪ Traditional Machine Vision is used for • • • • • • Presence/Absence Color ID/Color Match Count Measurement/Gauging Assembly and Assembly Verification Defect Detection © Omron Microscan Systems Inc. 37 Last Trivia Question ▪ What is a Machine Vision Engineer’s favorite quote from Blade Runner? HAWK MV-4000 Coming in Dec 2017! ▪ I just do eyes! © Omron Microscan Systems Inc. 38 Thank you! For more information… visit booth number www.microscan.com Manuals, Software, Drivers, Technical Publications, Knowledge Base MicroscanCommunity Blogs, Videos, Photos helpdesk@microscan.com Technical support © Omron Microscan Systems Inc. 39 Thank You! Any Questions? Contact: Steven J. King sking@microscan.com www.microscan.com © Microscan Systems Inc.
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