EXPERT

VISION SYSTEM
TECHNIQUES
1. THREE DIMENSIONAL INSPECTION Using a Laser Line

CONFIGURATION Example of inspection images

Laser line

Target gap Camera

Left: Raw image Right: Processed image

OUTLINE
Apply a laser line to the surface of the target and capture the image using machine vision equipment. When the target surface
is flat, the laser is reflected in a straight line. However, when the target surface is curved or uneven, the reflection of the laser
will be warped as shown on the upper right. By inspecting the image using the Trend Edge tool, deviations in the straightness
of the laser line can be detected based on minimum/maximum positions of the edges created by the laser's reflection. This
inspection method is generally called the “lightsectioning method" and can be used for simple measurement applications.

2. DETECTING SURFACE WARPAGE Using Stripe Pattern Illumination

CONFIGURATION CONFIGURATION EXAMPLE

Stripe pattern lighting

Camera

Inspection image

Inspection target

OUTLINE
Arrange the lighting unit and camera so that they form a V-shape to
the target in a specular direction from each other. A dent on the target
will result in distortion of the stripe as shown in the image on the right.
Detection can be performed by scanning the image in the X-direction.

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3. THREE SURFACE INSPECTION Using Prisms

CONFIGURATION Example of inspection images

Camera

Prism Prism

OUTLINE
Place reflective prisms or mirrors to the sides of the inspection target and capture the image with a camera located directly
above the target in order to simultaneously inspect both the top and side surfaces of the target. In the example shown above,
the Trend Edge tool is used to detect the position of IC leads on the sides, and the Stain tool is used to detect imperfections on
the molded portion on the top surface. This technique is effective for applications in a limited space where two or more cameras
cannot be installed. However, attention is required for mirror angle adjustment, and other installation conditions.

4. Colour-COMPONENT EXCLUSION Using Infrared Illumination

Colour camera image with Monochrome camera image with Monochrome camera image with
white-colour illumination white-colour illumination infrared illumination

Stain inspection - stability screen

OU T L INE
When a target has multicoloured patterns, applying infrared
light may eliminate gradation of colour components as shown
in the upper right image. Eliminating the colour components
of the image causes flaws to stand out as dark stains. This
technique is effective for emphasizing stains, flaws, dates,
lot numbers, etc. The inspection image on the right shows an
example of stain detection implementing the use of infrared
illumination.

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5. ULTRA HIGH-SPEED INSPECTION 2 Camera Split Imaging Inspection

Image from Camera 1 Image from Camera 2

CONFIGURATION

Camera 1 Camera 2

OU T L INE
To accelerate the machine vision equipment processing time, two
cameras can be used to capture a horizontally-split image of a single
target. Reducing the imaging area by half will decrease the time
needed to transfer images. This will also decrease the processing
time required to inspect the same area using one camera. The
example to the right shows the detection of black spots on a target.
With one camera, the detection takes 12ms; but with two cameras,
inspection time is reduced to 10ms. (Camera: CV-H035C) Camera 1 & 2 composite inspection image

6. IMPROVING MEASUREMENT ACCURACY Using Transmitted Illumination

CONFIGURATION A Cylindrical
Bar light column
Illumination
width A

Accurately detecting the

CORRECT CONFIGURATION outer diametre of the
Distance A cylindrical column
(EXAMPLE)

CONFIGURATION B

Illumination
width B
Distance B
Inaccurate edge position due
INCORRECT CONFIGURATION to incorrect configuration.
(EXAMPLE)

OUTLINE
When inspecting the outer diametre of a cylindrical target by applying backlight illumination, it is important to set the position,
size, and brightness of the light to optimal conditions in order to ensure accuracy. Configuration A shows an example of a
correct arrangement, and Configuration B shows an example of an incorrect arrangement.
The following three points are important for accurate measurement inspection:
(1) Place the light as far away from the target as possible to obtain the most accurate results.
(2) Minimize the width and brightness of the light to reduce diffraction.
(3) Select a lens with a long focal distance or a telecentric type lens to reduce errors in measurement position.

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7. Eliminate the influence of uneven lighting on cylindrical targets

CONFIGURATION Configuration example

Camera

Diffuse-reflective object

OUTLINE
With a diffuse-reflective object
mounted over the cylindrical target
surface, the camera captures an
image of the target surface through
a hole cut out of the diffuser. Light
is uniformly applied to the cylinder's
Cylinder
mirrored surface, and the camera
can capture a clear image of the
target surface without irregular
reflection. The camera should be Observation hole
Ring installed at an angle, so that the
illumination observation hole is not reflected in
the target surface image.

INSPECTION IMAGE

Image captured with ordinary illumination Inspection image with diffuse reflected light

Stain mode stability screen Stain mode stability screen

INSPECTION
As shown above, the stray reflected light creates an image that is unsuitable for inspection. Using the advanced lighting
technique shown above, glare from the illumination source is eliminated and the flaw is clearly visible.

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8. Eliminate the influence of background characters

CONFIGURATION Configuration example

Camera

Cylindrical target

LED backlight
OUTLINE
Install an LED backlight under the cylindrical target so that
the light is emitted uniformly across the front of the cylindrical
target. Since the camera is installed at an angle, it can only
receive specular reflections from the target's surface. With this
configuration, the camera can detect an unsecured or creased
part of a glossy sticker label, without influence from printed
characters and patterns on the cylindrical target surface.

INSPECTION IMAGE

Image captured with ordinary illumination Image captured using the above lighting technique

Image after filter processing Image after filter processing

INSPECTION
As shown above on the left (standard configuration), the camera cannot stably detect an improper label placement because
of the influence of the printed characters and patterns in the background. However, by using specular reflection, a label that
is not applied correctly to the target can be stably extracted.

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9. Inspect the entire surface of cylindrical targets with one camera

CONFIGURATION OUTLINE
With two mirrors placed at 120° angles behind the cylindrical target (as
Camera
Mirror shown above), the camera can simultaneously capture images of both the
front side and the back of the cylinder.

INSPECTION
The mirrored image allows for inspection of the target from three angles,
Target covering the entire surface of the object.

Ring illumination

Configuration example Raw image Inspection image after processing

10. Stable detection of defects on glass surfaces

CONFIGURATION Inspection target Inspection using backlight illumination

Camera

Glass tube
Backlight with a Inspection using striped pattern
stripe pattern illumination

OUTLINE
Attach a film with a striped pattern to the front surface of an LED backlight. When
a glass tube is set in front of the camera and the illumination placed behind the
target, the camera can capture an image of a defect (flaw, dent, etc.) on the glass
tube as warpage of the stripe pattern.

Filtered image

INSPECTION
With the above configuration, the stripe pattern will show a break in the pattern or
warpage if there is a defect on the target surface. Furthermore, if composite filters
are provided to detect warpage, the camera can stably extract the defect, while
filtering out the striped pattern.

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The information in this publication is based on KEYENCE’s internal research/evaluation at the time of release and is subject to change without notice.
Copyright (c) 2010 KEYENCE CORPORATION. All rights reserved. CVExpert-WW-EN0803-E 1080-1 E 600858 Printed in Japan
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