Smarter & more accessible

There have been massive developments in embedded processors in recent years. These developments, combined with the latest CMOS image sensors have resulted in a new generation of smart cameras, offering much more sophisticated image processing capabilities at the top end down to low cost intelligent vision sensors for simpler inspection tasks.

Developments in embedded processor capability have been driven by the demand for smartphones and increasing use in the automotive industry to control the core functions in vehicles. Smartphones sales to end users between 2007 and 2014 rose from around 122 million to 1, 244 million. This has resulted in the availability of increased processing capabilities, speed and memory on smaller boards. In addition, the latest generation of CMOS sensors offer image quality normally only associated with CCD sensors including low noise and enhanced dynamic range. This new range of sensors also offers high spatial resolution and high frame rates at lower cost, leading to smart cameras with scalability to meet increasing factory environment demands such as faster throughput, lower production costs, improved productivity and full runtime automation.

Versatile smart cameras

The scalability of smart camera capabilities can be illustrated through the Boa range from Teledyne DALSA. Boa and Boa2 cameras provide a choice of resolution, performance levels and embedded software. They incorporate multiple processing technologies – DSP, CPU and FPGA for algorithm, communication and control optimisation respectively. Onboard software is accessed through a standard web browser for both set-up and runtime monitoring. Boa Pro features the advanced Sherlock application software, previously only available on PC-controlled vision systems. This is ideally suited for vision integrators and provides the flexibility and tools to tackle a diverse range of applications across all industrial sectors.

Standard Boa systems utilise iNspect Express embedded software offering a versatile set of tools and capabilities. A subset of these tools limited to identification, tracking and verification applications can be found in the Boa IDR. For applications such as precision part measuring and the detection of small defects, Boa2 cameras with 2, 3 and 5 Mpixel resolution are available. This level of scalability is extremely important, since smart cameras provide single point inspection. Using a system that is over specified for the particular application has significant cost implications.

Smart vision sensors

While the top-end of the smart camera range has significantly benefited from developments in processing and sensor technology, there has also been a major impact at the lower end of the market with the introduction of smart vision sensors for automating basic inspection tasks on production lines, such as detecting the presence or absence of features and performing simple measurements. This new approach provides vision system performance at vision sensor pricing. The low cost of ownership allows processing to be distributed along the production line at more points of inspection. This gives better failure analysis and allows corrective action to be taken more quickly and easily, leading to improved quality, reduced scrap, and increased throughput.

In the Boa range, Boa Spot vision sensors are available with 640 x 480 or 1280 x 960 image resolution and integrated LED lighting with multiple available colours. Embedded vision tools are provided for part locating, feature finding, counting and measuring applications. These tools can be combined and used numerous times to solve simple or complex inspection tasks. The new vision sensors can inspect multiple part features at the same time, and at higher speeds and with greater accuracy than traditional photoelectric sensors.