Endüstriyel Görüntü İşleme Nedir?

Endüstriyel Görüntü İşleme Nedir?

Üretilen ürünlerin görsel kontrollerini gerçekleştirmek için; endüstriyel kamera, lens ve uygun aydınlatmaların kombinasyonuyla oluşturulan görüntü işleme sistemleri kullanılır.

KEYENCE görüntü işleme sistemleri gömülü yazılım sistemli bir kontrolörden oluşmaktadır. Bu özelliği sayesinde donanım ve yazılım birbirleriyle uyumlu çalışmaktadır. Bu da onları piyasadaki en hızlı ve en kullanışlı görüntü işleme sistemi yapmaktadır.

Görüntü işleme sistemleri; endüstriyel robot konumlandırma, ürün üzerinde kusur tespiti, montaj, varlık/yokluk kontrolü, karakter ve kod okuma gibi çeşitli uygulamalarda kontrolleri sağlayabilmektedir.

Çalışma Prensibi ve Bileşenleri

Görüntü işleme sistemleri, belirli uygulama ihtiyaçlarına uyacak şekilde özelleştirilebilir ve her sistem genellikle bir kamera, aydınlatma ve görüntü işleme için bir kontrol ünitesinden oluşur.

Bu bölüm, kalite kontrol için bir endüstriyel kamera kontrol sistemi kullanma ilkelerini anlatır ve bir görüntü yakalamanın başlangıcından algılama sonuçlarının çıktısının sonuna kadar olan süreci açıklar.

1. Görüntü yakalama

Bir görüntü yakalamak için ışık bir hedefi aydınlatır ve bu ışık bir lens aracılığıyla kameranın görüntü sensörüne odaklanır. Bu yakalamadan toplanan görüntü verileri daha sonra görüntü işleme ve değerlendirme için kontrol ünitesine aktarılır.

2. Ön işleme

Ön işleme işlemleri, görüntüleri analiz etmeden önce görüntü verilerinde istenen özellikleri vurgularken, istenmeyen/gürültülü nitelikleri ortadan kaldırır. Bu işlemler, inceleme için özelleştirilmiştir ve örnekler arasında görüntü filtreleme ve renk çıkarma yer alır.

3. Ölçüm işleme

Bir görüntü, ön işlemeye tabi tutulduktan sonra ölçüm, pozisyonlama, varlık/yokluk, sayma, karakter/kod okuma ve leke tespiti, renk kontrolü ve robot ile haberleşme gibi kontroller gerçekleştirilebilir. 

4. Sıralama/Çıktı

İşlenen görüntü verileri, OK/NG kararı vermek, ölçülen sonuçları kaydetmek veya parçaları sınıflandırmak için kullanılır. Hem görüntü hem de veri çıkışı ve diğer cihazlarla iletişim kurulabilir. (PC-PLC vb… ) 

Çeşitli endüstrilerdeki uygulamalar, görsel kontroller ile çözülebilir. KEYENCE’in görüntü işleme sistemleri, güçlü yazılım ve özelleştirilebilir donanım sayesinde doğru sonuçlar veren ve kullanımı kolay ara yüzler sağlar. Doğru kamera, aydınlatma ve kontrolör seçimi, hat içi denetimleri uyarlamak ve optimize etmek için çok önemlidir. Ek olarak, uygun kriterlerin karşılandığından emin olmak için denetimler her uygulamaya göre özelleştirilir.

Parça tanımlama, leke algılama ve doğrulamaya ek olarak, görsel denetimli robot teknolojisine yönelik artan ihtiyaç için endüstriyel kamera sistemleri kullanılabilir. KEYENCE görüntü işleme sistemleri, global robot kontrolör markalarına doğrudan bağlanacak şekilde tasarlanmıştır. Her üretici için sağlanan robot programları, son kullanıcı için karmaşık robot programlamasını ortadan kaldırır. DENSO, Toschiba, FANUC, Yaskawa, ABB, KUKA, Epson, Kawasaki, Mitsubishi, Staubli, Yamaha, Universal Robots gibi markalar tarafından desteklenir. 

Endüstriyel Görüntü İşleme Sistemlerinin Avantajları
1. Otomatik %100 Denetim ve Artan Verim

Bir endüstriyel görüntü işleme sisteminin benimsenmesiyle birlikte, manuel denetlenmesi gereken ürünler için %100 otomatik hat içi denetimi gerçekleştirmeyi mümkün kılar. Görüntü işleme sistemi kurulduktan sonra ek maliyet gerekmez ve operatörler arasındaki farklı sonuçlar ortadan kaldırılabilir.

Görüntü işleme sistemi teknolojisindeki iyileştirmeler, her düzeydeki kullanıcı için gelişmiş, otomatik hat içi denetimleri mümkün kılmıştır. Yüksek hızlı üretim hatlarındaki ürünlerin %100’ünü denetlemek artık mümkün, böylece hatalı parçalar ek işleme veya serbest bırakmadan önce belirlenebilir. Benzer denetimler operatörler tarafından manuel olarak yapılsaydı, bu süreç daha yavaş ve daha az güvenilir olurdu.

2. Gelişmiş Denetim Öğelerinin Otomasyonu

Yüksek hızlı kameralar ve endüstriye görüntü işleme sistemleri sayesinde, farklı aydınlatma koşulları altında %100 sürekli inceleme için yeterince hızlı, birden fazla görüntü alınabilir. Bu, karmaşık veya düşük kontrastlı özellikleri ve hataları ortaya  çıkarmak için değişken aydınlatma kullanarak aynı anda birden fazla kontrolün tespitini mümkün kılar.

Geleneksel kamera sistemlerinde, parlak, metal yüzeylerdeki kılcal çizikler ve lekeler yalnızca belirli aydınlatma koşullarında görülebilir ve bu koşullar genellikle karakterleri ve barkodları okumayı inanılmaz derecede zorlaştırır. Bu yaygın sorunla mücadele etmek için KEYENCE, her bir özelliği ve kusuru “LumiTrax™ ” görüntülemeyle çıkarmak için birden fazla aydınlatma koşulunu otomatik olarak birleştirerek gelişmiş donanım kullanan LumiTrax™ teknolojisini geliştirdi.

3. Kamera Destekli Robotlar ile Önemli Derecede İyileştirilmiş Doğruluk

Bir endüstriyel robotun “gözleri” olarak hareket etmek için bir görüntü işleme sistemi kullanmak, gelişmiş alma/bırakma  işlemlerinin doğruluğunu ve verimliliğini önemli ölçüde artırabilir. Görüntü işleme sistemi, robotun koordinat sistemindeki bir ürünün konumunu algılar ve bu ölçümleri dinamik ayar için doğrudan robotun kontrol ünitesine gönderir.

Geleneksel endüstriyel robotlar, operatörlerin özel bir hesaplama metodu kullanarak koordinatları manuel olarak belirlemesini gerektirir. Bu manuel işlem zaman alıcı olabilir ve doğruluk operatörler arasında farklılık gösterebilir. KEYENCE endüstriyel görüntü işleme sistemleri, birçok robot üreticisiyle doğrudan iletişim kurarak robotun kolay bağlanmasına ve verimli programlanmasına olanak tanır. Bu bağlantı, denetimleri stabilize eden ve entegrasyon için gereken süreyi azaltan hantal kalibrasyon ve hesaplama görevlerini otomatikleştirir.

İlginizi çekebilir..
Görüntü işleme sistemleri için uygulama örnekleri
Endüstriyel kamera seçiminde sıkça sorulan sorular
Endüstriyel Kamera Seçimi
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Endüstriyel kamera seçiminde sıkça sorulan sorular

Görüntü İşleme Sistemleri için Uygulama Örnekleri

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Ölçüm Nedir?

Webinar: Sensörler gelişen performanslarıyla büyülüyor

2D Profilers give width, height, and volume of sealant beads inline without touching a part.

2D/3D Laser Profiler
LJ-X8000 series

Conventionally, a vision sensor was used for OK/NG judgment based on the area. Since the LJ-X8000 Series can measure the volume and position of paste application, it can reduce material costs and support higher component densities.

2D/3D Laser Profiler
LJ-X8000 series

Check the tilt of the elements after bonding. The CL-3000 Series uses the multi-color confocal method that enables coaxial measurement. No matter whether the target surfaces are specular or rough, they can be measured in the same setting, which achieves easy and highly accurate inspection.

Ultra Confocal Displacement Sensor
CL-3000 series

High-speed sensors can measure runout of brake discs, regardless of surface finish.

Confocal Displacement Sensor
CL-3000 series

Measure the extent of foil vibration just before the slit. Even if the target is tilted due to vibration, the good angle characteristics of the CL Series enable stable measurement.

Confocal Displacement Sensor
CL-3000 series

A sensor is placed above and below a target to measure the thickness of anything in-between. This non-contact method can be used for measuring the thickness of any material and can be used in process or for offline inspection.

Confocal Displacement Sensor
CL-3000 series
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Ultra-compact ø8 mm heads make it possible to install multiple heads in narrow spaces. This reduces the amount of work spent designing equipment and the number of parts that need to be purchased to measure multiple points in close proximity.

Confocal Displacement Sensor
CL-3000 series

Check step heights on machined parts without influence from oil or other surface contamination.

High-Accuracy Digital Contact Sensor
GT2 series

Measure many points on an engine with a multi-point laser system for accurate characterization of engine vibration. With ultra-highspeed sensors, even the smallest vibrations can be detected.

Ultra High-Speed/High-Accuracy Laser Displacement Sensor
LK-G5000 series

Measure the position and edge flutter of a belt with two 2D laser profile sensors for stable measurement.

2D/3D Laser Profiler
LJ-X8000 series

Residual vibration measurement is used to determine how much a robot shakes after stopping. When working with a welding torch or other tool, the measurement location may not always have a flat surface. Using a 2D laser profiler enables accurate measurement on a wide range of surface shapes.

2D/3D Laser Profiler
LJ-X8000 series

Opposing 2D profilers can scan multiple points of thickness over a part. This allows stable thickness measurement even on rough surfaces.

2D/3D Laser Profiler
LJ-X8000 series

High-speed thrubeam sensors can measure runout and ovality of rotors accurately and repeatably.

High-speed optical micrometer
LS-9000 series

Measure roller runout using confocal sensors for high stability on reflective surfaces.

Confocal Displacement Sensor
CL-3000 series

Thrubeam micrometers allow for high-speed measurement of wire OD without being affected by vibration.

High-speed optical micrometer
LS-9000 series

2D thrubeam sensors can measure hole diameter after stamping inline.

Telecentric Measurement System
TM-X5000 series

The Telecentric Measurement System uses 2D images of a target's silhouette to measure diameter. Target misalignment or tilt is automatically corrected for, making it simple to get accurate measurement without perfect fixturing.

Telecentric Measurement System
TM-X5000 series

Compressible or rough surfaces can be accurately measured using the 2D image generated by the Telecentric Measurement System. Implementing non-contact measurement eliminates error due to part deformation and any variation in diameter due to surface texture can be averaged over to stabilize results.

Telecentric Measurement System
TM-X5000 series

Compressible or rough surfaces can be accurately measured using the 2D image generated by the Telecentric Measurement System. Implementing non-contact measurement eliminates error due to part deformation and any variation in diameter due to surface texture can be averaged over to stabilize results.

Telecentric Measurement System
TM-X5000 series

Using 2D measurement systems makes it possible to measure the minimum and maximum diameter on a target from a single captured image. The TM-X Series works by capturing the silhouette of a target using a telecentric optical system, so it can accurately measure objects of any material (including clear vials).

Telecentric Measurement System
TM-X5000 series

With an exposure time of just 100 µs, the Telecentric Measurement System can capture clear images of targets moving at high speed. This makes it an ideal solution for accurately measuring diameter inline.

Telecentric Measurement System
TM-X5000 series

With small sensor heads and a mirror fixture, confocal sensors can give an accurate measurement of pipe ID.

Confocal Displacement Sensor
CL-3000 series

High-speed laser displacement sensors can check for valve float without touching the valve head.

Ultra High-Speed/High-Accuracy Laser Displacement Sensor
LK-G5000 series

Measure fine details on touch panels regardless of surface finish with confocal sensors. With a beam spot of 3.5μm, even the smallest features can be measured.

Confocal Displacement Sensor
CL-3000 series

Check outer diameter on machined parts without influence from oil or other surface contamination.

High-Accuracy Digital Contact Sensor
GT2 series

High-speed laser displacement sensors can check for valve float without touching the valve head.

Ultra Confocal Displacement Sensor
CL-3000 series

Profile tire treads and sidewalls with multiple 2D laser profilers.

2D/3D Laser Profiler
LJ-X8000 series

Inspect for lamination misalignment after winding. With a minimum X-resolution of 2.5 μm 0.000098", the LJ-X8000 Series accurately measures the profile of each electrode.

2D/3D Laser Profiler
LJ-X8000 series

Provide feedback about disconnected locations in electrodes before lamination. Accurately acquire the profile of electrode terminals to perform high-accuracy inspection of edge locations.

2D/3D Laser Profiler
LJ-X8000 series

Measure the profile of a wafer edge. By selecting one of the inspection tools such as Height Difference/Width or Angle, users can start measurement easily. The high-resolution image capturing using 3200 points/profile achieves highly accurate profile measurement that was impossible with conventional methods.

2D/3D Laser Profiler
LJ-X8000 series

Film curvature and wrinkling measurements are performed using a blue laser with a maximum width of 720 mm. Measurement is possible even for transparent targets thanks to the wide dynamic range of the CMOS sensor.

2D/3D Laser Profiler
LJ-X8000 series

Measure the step height of features on a wafer after etching. With 3D interferometry, mirrored surfaces can be measured accurately.

3D Interference Measurement Sensor
WI-5000 series

Unlike triangulation sensors, interferometers can measure small parts in confined spaces without blind spots or unstable data.

3D Interference Measurement Sensor
WI-5000 series

Using 2D thrubeam sensors, medical balloons can be inspected inline at high-speed.

Telecentric Measurement System
TM-X5000 series

Measure small part dimensions inline with pattern projection measurement heads. Projection from both sides reduces dead zones.

Inline 3D Inspection
3D Vision series

With two thrubeam micrometers installed on either side of a film, we can get a width measurement and give film position, regardless of color or material.

High-speed optical micrometer
LS-9000 series

2D thrubeam sensors can measure the step height between a roller and a sheet to get a thickness measurement. Additionally, A second sensor can be added to get a width measurement.

Telecentric Measurement System
TM-X5000 series

A displacement sensor with an extremely small beam spot of just 3.5 µm can be used for accurate profile measurements of roughness and subtle shapes. 3D shape measurements are also possible through detailed scanning synchronized with the X-Y stage. Measurements with impressive angle characteristics are possible not only for opaque targets but also transparent targets and 3D shapes with mirrored surfaces.

Confocal Displacement Sensor
CL-3000 series

Confocal sensors do not have the dead zones characteristic of triangulation sensors, and can therefore measure into smaller and deeper holes more reliably.

Confocal Displacement Sensor
CL-3000 series

Measure the height of the equipment when adhesive is applied to glass. Utilizing the multi-colour confocal method measurement principle enables high-precision measurement whether the glass is transparent or opaque.

Confocal Displacement Sensor
CL-3000 series

2D Profilers can measure width, height, and volume of sealant beads inline, regardless of surface finish or color.

2D/3D Laser Profiler
LJ-X8000 series

Detect burrs arising on terminals after electrode slitting. With ultra-high-resolution 3200 points/profile measurement, the LJ-X8000 Series produces stable detection even for minute burrs.

2D/3D Laser Profiler
LJ-X8000 series

Profile measurement can be continuously performed on captured 3D shapes. This allows pass/fail criteria to be applied to maximum and minimum values over an area or period of time, making it possible to catch small defects in continuous processes.

2D/3D Laser Profiler
LJ-X8000 series

Free-form planes allow the system to pick up on deviations from the typical contour of a surface.This makes stable defect detection possible, even for targets with complex shapes.

2D/3D Laser Profiler
LJ-X8000 series

Highly accurate measurements can be made even when measuring targets with height differences or where the distance from the target to the camera could vary.

2D/3D Laser Profiler
LJ-X8000 series

2D laser displacement sensors can measure both width and height, allowing for panel gaps to be accurately measured, regardless of the surface finish or color.

2D/3D Laser Profiler
LJ-X8000 series

Detect chipping or dents in laser welded beads using 3D laser profilers. The measurement is unaffected by color or gloss of the weld, making inspection results stable through glare or bead shape variation.

2D/3D Laser Profiler
LJ-X8000 series

Using thrubeam sensors, roller position can be accurately measured at high line speeds.

High-speed optical micrometer
LS-9000 series

Targets with multiple materials can be captured in a single profile, allowing measurements to be made between glass and metal surfaces. The LJ-X Series is equipped to handle reflectances ten times higher than conventional products.

2D/3D Laser Profiler
LJ-X8000 series

For targets with different diameters, conventional vision systems often have a hard time focusing on the larger and smaller diameter areas at the same time. Measuring the height of the dents with a laser profiler makes it possible to inspect the whole surface at once.

2D/3D Laser Profiler
LJ-X8000 series

Measure the position and projection of connector terminals simultaneously. Conventionally, two measurement steps were required using an image processing system and a contact sensor. The LJ-X8000 Series can perform both inspections simultaneously. This achieves cost reduction by reducing the amount of installed equipment.

2D/3D Laser Profiler
LJ-X8000 series

3D inspection allows users to accurately detect whether components are properly seated in the assembly or if elements are tilted. Using a KEYENCE 2D/3D laser profiler with a blue laser ensures stable measurement, even for targets with varying materials.

2D/3D Laser Profiler
LJ-X8000 series

Robot teaching is used to ensure tools are set in the specified position. The 2D Telecentric Measurement System enables precise position feedback for end tools and other axial targets.

Telecentric Measurement System
TM-X5000 series

The laser profiler's wide field of view makes it possible to inspect multiple targets traveling on a conveyor belt together. 3D position correction can be used to identify and inspect each cookie within the measurement range, enabling accurate sorting to improve quality and eliminate waste.

2D/3D Laser Profiler
LJ-X8000 series

Measure the flatness of the terminals of power modules. The target is detected by its surface and the flatness is measured based on the reference plane calculated with the least squares fitting method. The errors caused by the tilted positions of targets can be canceled, which ensures accurate inspection.

2D/3D Laser Profiler
LJ-X8000 series

Angled mirrors can be used for measurement where installation space is limited. This setup enables position detection of tangent circle coordinates or intersection point coordinates as well as simultaneous shape and dimension verification for wafer notches.

Telecentric Measurement System
TM-X5000 series

Inspect motor height after powder welding using the LJ-X8000 Series. The 3D laser profiler provides reliable 100% inspection with its high speed and measurement stability.

2D/3D Laser Profiler
LJ-X8000 series

Measure transparent films and coatings with a single displacement sensor. Confocal sensors give an accurate thickness measurement from one side of transparent targets.

Confocal Displacement Sensor
CL-3000 series

In-line thickness measurements can be altered by roller eccentricity, wrinkles, or tension in the sheet. Up to 6 measurement points and 4 layers of clear film can be measured with a single controller.

Confocal Displacement Sensor
CL-3000 series

2D Profilers can measure width, height, and volume of sealant beads inline, regardless of surface finish or color.

2D/3D Laser Profiler
LJ-X8000 series

Check for press fit failure with contact displacement sensors.

High-Accuracy Digital Contact Sensor
GT2 series

Detect burrs arising on terminals after electrode slitting. With ultra-high-resolution 3200 points/profile measurement, the LJ-X8000 Series produces stable detection even for minute burrs.

2D/3D Laser Profiler
LJ-X8000 series

Profile measurement can be continuously performed on captured 3D shapes. This allows pass/fail criteria to be applied to maximum and minimum values over an area or period of time, making it possible to catch small defects in continuous processes.

2D/3D Laser Profiler
LJ-X8000 series

Free-form planes allow the system to pick up on deviations from the typical contour of a surface.This makes stable defect detection possible, even for targets with complex shapes.

2D/3D Laser Profiler
LJ-X8000 series

Highly accurate measurements can be made even when measuring targets with height differences or where the distance from the target to the camera could vary.

2D/3D Laser Profiler
LJ-X8000 series

2D Thrubeam sensors allow high-speed dimensional inspections to be taken on the silhouette of a part.

Telecentric Measurement System
TM-X5000 series

Target positioning is used to ensure the next process is performed accurately. Laser profilers provide stable position feedback anywhere in the measurement range, regardless of target material, color, or size.

2D/3D Laser Profiler
LJ-X8000 series

Detect chipping or dents in laser welded beads using 3D laser profilers. The measurement is unaffected by color or gloss of the weld, making inspection results stable through glare or bead shape variation.

2D/3D Laser Profiler
LJ-X8000 series

Targets with multiple materials can be captured in a single profile, allowing measurements to be made between glass and metal surfaces. The LJ-X Series is equipped to handle reflectances ten times higher than conventional products.

2D/3D Laser Profiler
LJ-X8000 series

For targets with different diameters, conventional vision systems often have a hard time focusing on the larger and smaller diameter areas at the same time. Measuring the height of the dents with a laser profiler makes it possible to inspect the whole surface at once.

2D/3D Laser Profiler
LJ-X8000 series

3D inspection allows users to accurately detect whether components are properly seated in the assembly or if elements are tilted. Using a KEYENCE 2D/3D laser profiler with a blue laser ensures stable measurement, even for targets with varying materials.

2D/3D Laser Profiler
LJ-X8000 series

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