One of the greatest advantages that humans have compared to machines is our exceptional eyesight, our ability to spot small visual details, and react to them. Machine vision technology strives to give this strength to our manufacturing processes by replicating human vision and perception via computers and artificial intelligence.
Machine Vision: A Breakdown
Machine vision is a group of technologies that strive to replicate a living creature’s capacity for vision and perception, typically for use in various industrial processes. By using a combination of hardware and software, industrial computers can “see” their surroundings and objects, which opens up a huge range of uses that were previously impossible.
A typical machine vision system consists of three parts. First, there are the objects being seen or scanned. Cameras and sensors detect the objects and feed this image to a computer. Lastly, the computer analyzes the image for details that are or are not present. For example, a machine vision system used for quality control will have an image library of products that are correctly assembled, allowing it to identify any product that does not match the image. These defective products can then be separated from the assembly line and marked for disposal.
Types of Machine Vision
Machine vision has existed since the 1970s, with modern systems coming in four primary varieties:
- 1D Measuring: A 1D machine vision system inspects objects or surfaces along a single line or axis. It uses a linear camera to capture images, letting a computer inspect them for defects or scan their barcodes for inventory management..
- Line Scan: Line scan systems are used to scan objects or material as they move past the camera, scanning them line by line in two axes. This creates high-resolution images that are extremely useful for capturing small details such as scratches, dents, or dirt.
- Area Scan: Area scan systems capture images in a two-dimensional plane, providing a more comprehensive view of the object or area. This lets them capture multiple features or details at the same time.
- 3D Scan: As their name implies, 3D scans use multiple cameras and angles to create a three-dimensional image of an object. While more complex and expensive than other types of machine vision, the detail they offer is essential for fine motor control, such as controlling industrial robots or precision cutting and welding.
Machine Vision vs. Computer Vision
Given how similar their names are, understanding the difference between machine vision and computer vision is essential. Machine vision is the process of detecting pre-defined aspects of an image, while computer vision can draw new conclusions from what it sees. For example, a machine vision system could look at a steel bolt and identify if it is defective or not. A computer vision system could look at the same bolt and determine what size it is, what it’s made out of, and what it’s commonly used for.
Applications of Machine Vision
What is machine vision’s primary role? There are several applications for the technology, all of them leveraging the technology’s strengths to enhance industrial operations.
Automation
Machine vision can be used to help automate the operations in a manufacturing facility. For example, a machine vision system connected to an industrial computer can be used to sort products based on their size or classification, sending the right components down the right assembly line.
Quality Control
Machine vision excels for quality control jobs. A machine vision system never gets tired or distracted, meaning it will inspect every single product that passes through its gaze to the same degree and under the exact requirements. This makes it ideal for quality control systems, where it can automatically examine products before they get shipped to customers. This helps ensure fewer defective products are sold and shipped.
Logistics and Shipping
Machine vision systems also play a key role in logistics and shipping. A machine vision system for warehouse operations can scan packages, barcodes, and other labels to route them to the right section or shipping truck automatically. This leads to a smoother logistics operation with fewer misplaced packages or delayed shipments.
Agriculture
Machine vision is a key technology for supporting precision agriculture, the effort to use resources more effectively by using them in a more targeted and precise manner. For example, machine vision systems can be used to detect early warning signs of crop failure, such as wilting leaves or withered fruit. It can also detect parasites that might threaten crops, such as locusts, alerting farmers before their fields are ruined.
Benefits of Machine Vision
The precision and reliability that machine vision offers make an impact in numerous ways, with the most important being:
Improved Product Quality
With better quality control thanks to machine vision, companies can ensure that only products that have been properly manufactured and inspected go out to customers. This, in turn, leads to fewer returns or recalls, better customer satisfaction, and a better reputation as a manufacturer. Even something as innocuous as a tortilla can benefit from the quality control that a machine vision system offers.
Waste Reduction
By catching flawed products, manufacturers can identify the cause of defects, especially if there is a common issue shared between multiple defective products. This reduces waste and scrap rates, bringing down the overall cost of operations. In the previous example, sorting out defective or spoiled tortillas can prevent them from damaging other tortillas they are packaged with.
Reduced Reliance on Labor
With greater automation comes less reliance on human labor. Machine vision is particularly good at taking over tasks that are tiring, boring, and incredibly repetitive, reducing the need for humans to perform menial labor like watching over an assembly line. In turn, this lets them focus on other roles that still require human oversight.
Improved Safety
While industrial operations have undeniably become safer over the years, there will always be a degree of threat just from being around heavy machinery while it’s working. Machine vision systems help workers minimize the amount of time they spend near said machinery, and can instead watch the system’s output on their computers in a safer spot. If there is a malfunction or breakdown, they can use those same systems to remotely inspect the issue, rather than going out there themselves.
Considerations for Using Machine Vision
Like other technologies, there are challenges to overcome for using machine vision. Most of these revolve around integrating the technology into a pre-existing work environment, as well as the reliability issues that come with working in harsh industrial settings.
Technology Integration
One of the greatest challenges for using machine vision systems is trying to integrate them into a factory or assembly line that was never built with them in mind. These places may not have the space or wiring to efficiently support the cameras and computers that a machine vision system requires. One way to alleviate this issue is to use rugged mini PCs, which are small enough to fit into cramped work environments while still offering the processing power needed to support machine vision programs. Alternatively, consulting with an original equipment manufacturer (OEM) can help. These specialists can recommend products that fit your needs, and can even develop customized solutions specifically for the situation at hand.
Reliability
Industrial work environments are not known for being comfortable and pleasant places. This is especially true for computers and cameras, which can be shaken apart by vibrations or damaged by extreme temperatures. If you are planning to integrate a machine vision system on your assembly line, you will want to select devices that are tested and certified to rigorous standards, such as IEC 60068.
Training and Adoption
Like with any new tool or process, there needs to be a training period for employees to familiarize themselves with machine vision. After all, what’s the point of trying to use it if your employees just come to resent and ignore these tools? If possible, try a trial run with machine vision, using it in a limited and focused capacity before expanding it throughout your facility. This will let you identify and address pain points early on, rather than letting them overwhelm you during the full integration.
Machine Vision-Ready Computers from Cybernet Manufacturing
What is machine vision? It’s not science fiction; it’s a real-world technology adopted by industries around the world. With the accuracy and close monitoring that machine vision offers, manufacturers can enjoy greater product quality, more automated processes, and safer work environments.
If your company wants to integrate machine vision systems into its operations, contact the team at Cybernet Manufacturing. We’d be happy to explore how our industrial PCs can support machine vision, providing the processing power they need in a rugged computer package.