Professional Documents
Culture Documents
November 2013
UM_ElementInspection-AOI-Vision_01.doc
Chapter List
Station
Chapter Title
Date of Issue
2009-11-01
2009-09-16
1 and 5
2009-05-20
1 and 5
2006-03-07
2 and 3
2010-06-24
2 and 3
Gap Measurement
2011-09-29
Nop Inspection
2006-06-22
Saddle Surface
2010-07-14
November 2013
UM_ElementInspection-AOI-Vision_01.doc
User's Guide
VisionControl (Vision Self-test)
Customer:
Order Number:
Version:
30013005
As from V05-0-1
All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any
means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Rohwedder AG.
November 2009
EN_Description_VisionControl_V04_1a.doc
User's Guide
VisionControl (Vision Self-test)
Page 1 of 20
Contents
1
ElementeAdmin Operation..........................................................................................3
1.1
1.2
1.3
Control and Reference Data ................................................................................6
Element2Cam Operation .............................................................................................9
2.1
2.2
New Vision Operators ........................................................................................10
2.2.1
Analyse Focus...............................................................................................10
2.2.2
Control Classify Line......................................................................................12
2.2.3
Control Classify PatMax ................................................................................13
2.2.4
Control Classify Caliper .................................................................................13
2.2.5
Control Classify FrontBack ............................................................................13
2.2.6
Control Classify SaddleEdge.........................................................................14
2.2.7
Control Classify Torsion ................................................................................14
2.2.8
Control Classify SaddleSurface .....................................................................14
2.3
Measured Values Listing....................................................................................15
2.3.1
Overview .......................................................................................................15
2.3.2
Measuring Range Representation (Schematic).............................................16
2.4
Setting Up VisionControl and Configuration ...................................................17
2.4.1
Element2Cam................................................................................................17
2.4.2
ElementeAdmin .............................................................................................19
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VisionControl (Vision Self-test)
Page 2 of 20
VisionControl
Definition: The equipment is checked to see whether changes can be determined
between two measurements made at different times. This serves as hardware verification
for the Vision System. After a failed control run, the equipment must be checked by suitable
specialist technicians and readjusted, if required.
ElementeAdmin Operation
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VisionControl (Vision Self-test)
Page 3 of 20
Change user
User level: Service
Click "Setup" to open the Setup dialog
3.)
Configuration
2 states must be differentiated when VisionControl is used:
1. Control run
2. Reference run
Either a control run or a setup run can be selected in the Setup dialog. If the
program is restarted, the control run is set as default.
A reference run serves to determine the nominal values.
A control run serves to determine the actual values.
The generated reference data and control data are filed in the following folder
system (see also Section 1.3):
.. \ ElementeAdmin \ Control \ Reference_[inspection program]
.. \ ElementeAdmin \ Control \ Actual_[inspection program]
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VisionControl (Vision Self-test)
Page 4 of 20
Equipm.: Feed the control element to the input rail (equipment is NOT run to
empty)
PLC:
Activate the control run (click the "Control" button)
Vision: Display via the Admin status bar (see below)
PLC:
Start the equipment
Equipm.: The equipment stops automatically
Equipm.: Take the control element out of the fail bin
PLC:
View messages (NOK messages are shown by means of an own
dialog)
PLC:
Acknowledge messages (if NOK messages are shown, suitable
special technicians must be consulted)
Vision:
The last control run result is additionally shown on the Admin
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VisionControl (Vision Self-test)
Page 5 of 20
Measurements
The measurements are stored in the "Measurements" folder for each station and
camera (name for example S1_C1 = Station1_Camera1)
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VisionControl (Vision Self-test)
Page 6 of 20
A = measured value ID
B = measured value name
C = measured value
D = min. tolerance (absolute)
E = max. tolerance (absolute)
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Page 7 of 20
Example
Nominal.txt
Tolerances.txt
[Section_1] (Station_1/Cam_1)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT 60.511
GREYVAL_ROI_UPPER 83.747
FOCUS_WIDTH_[PIX]
Nominal
0.314
-0.426
0.047
4.126
59.395
5.000
[Section_2] (Station_2/Cam_1)
POSITION_X_[PIX]
0.000
POSITION_Y_[PIX]
0.000
ANGLE_[DEGREE]
0.000
RESOLUTION_[MM]
0.000
GREYVAL_ROI_BACKLIGHT_EDGE 0.000
GREYVAL_ROI_BACKLIGHT
0.000
GREYVAL_ROI_ELEMENT
0.000
Position_X_[pixels]
10.563
Position_Y_[pixels]
10.313
[Section_1] (Station_1/Cam_1)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_UPPER
FOCUS_WIDTH_[PIX]
Tol(-)
-50.000
-50.000
-50.000
-0.060
-20.000
-20.000
-20.000
-2.000
Tol(+)
50.000
50.000
50.000
0.060
20.000
20.000
20.000
2.000
[Section_2] (Station_2/Cam_1)5
POSITION_X_[PIX]
-50.000 50.000
POSITION_Y_[PIX]
-50.000 50.000
ANGLE_[DEGREE]
-5.000 5.000
RESOLUTION_[MM]
-0.060 0.060
GREYVAL_ROI_BACKLIGHT_EDGE -20.000 20.000
GREYVAL_ROI_BACKLIGHT
-20.000 20.000
GREYVAL_ROI_ELEMENT
-20.000 20.000
The following data are stored in the files for measured value
"Position_X_[pixels]"
Nominal.txt
Nominal
= 0.314
Tolerances.txt
= -50.000
= 50.000
This results in the following limit values for the ACTUAL values (calibration
run)
Lower limit value
Upper limit value
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User's Guide
VisionControl (Vision Self-test)
Page 8 of 20
2 Element2Cam Operation
2.1 Remote Data Access
1.)
2.)
Camera
selection
Result
display
Result
request
Camera selection
This operating element allows access to the second camera in a 2 camera
system.
Result display
Consists of two display windows. The left window shows the reference image.
The right window shows the current control image.
Result request
Clicking the "Result Request" button retrieves and displays the image data
administered centrally on the Admin screen.
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VisionControl (Vision Self-test)
Page 9 of 20
Focus value = 3
Focus value = 19
Search ray
Edge
ROI
The result can be improved when several search rays are used within the ROI. The results
of the search rays are averaged.
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VisionControl (Vision Self-test)
Page 10 of 20
Parameter:
Graphic:
Select the graphic
All = The result of each search ray is shown
Settings Median Filter:
Median filter
FHS X: Adjusting the filter size in x-direction
FHS Y: Adjusting the filter size in y-direction
Settings Search Ray:
Adjusting search ray
Rotation: Determine the direction of the search ray (0 - 180)
Number FHS: Adjusting the number of the search rays.
FHS
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EN_Description_VisionControl_V04_1a.doc
FHS
User's Guide
VisionControl (Vision Self-test)
Page 11 of 20
Maxima 1
Stop
Stop
Maxima 2
Threshold
Maxima 3
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VisionControl (Vision Self-test)
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Parameter:
ID for Station (1 or 5): Selection of the station
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VisionControl (Vision Self-test)
Page 13 of 20
Parameter:
ID for Station (2 or 3): Selection of the station
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VisionControl (Vision Self-test)
Page 14 of 20
ID
1
Back
10
11
12
13
14
15
16
17
20
21
22
23
24
25
26
27
30
31
32
33
34
35
36
38
40
41
42
43
44
45
46
2
SaddleEdge
Left
(2 cameras)
3
SaddleEdge
Right
(2 cameras)
4
Torsion
5
Front
6
SaddleSurface
(2 cameras)
50
51
52
53
54
55
56
57
60
61
62
63
64
65
66
67
Measured value
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_UPPER
FOCUS_WIDTH_[PIX]
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_BACKLIGHT_EDGE
GREYVAL_ROI_BACKLIGHT
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_BACKLIGHT_EDGE
GREYVAL_ROI_BACKLIGHT
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
LASER_WIDTH1_[MM]
LASER_WIDTH2_[MM]
LASER_BRIGHTNESS1_[GREYVAL]
LASER_BRIGHTNESS2_[GREYVAL]
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_BACKGROUND
FOCUS_WIDTH_[PIX]
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_BACKGROUND
FOCUS_WIDTH_[PIX]
November 2009
EN_Description_VisionControl_V04_1a.doc
Tolerance
Min
-50
-70
-5
-0.060
-20
-20
-20
-2
-50
-70
-5
-0.060
-20
-20
-20
-2
-50
-70
-5
-0.06
-20
-20
-20
-2
-70
-5
-0.06
-0.1
-0.1
-20
-20
-50
-70
-5
-0.060
-20
-20
-20
-2
-50
-70
-5
-0.060
User's Guide
VisionControl (Vision Self-test)
-20
-20
-20
-2
Tolerance
MAX
+50
+70
+5
+0.060
+20
+20
+20
+2
+50
+70
+5
+0.060
+20
+20
+20
+2
+50
+70
+5
+0.06
+20
+20
+20
+2
+70
+5
+0.06
+0.1
+0.1
+20
+20
+50
+70
+5
+0.060
+20
+20
+20
+2
+50
+70
+5
+0.060
+20
+20
+20
+2
Unit
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Pixels
Degree
mm
mm
mm
0-255
0-255
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Pixels
Pixels
Degree
mm
0-255
0-255
0-255
Pixels
Page 15 of 20
16
17
14
24
20
21
22
10
11
13 12
23
15
27
26
Station 1
[Station 5 ]
25
Station 2 / Camera 1
[Station 2 / Camera 2]
[Station 3 / Camera 1]
[Station 3 / Camera 2]
43
40 41 45
44
46
42
66
60
61
62
Station 4
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64
63
65
67
Station 6 (Camera 1)
[Station 6 / Camera 2]
User's Guide
VisionControl (Vision Self-test)
Page 16 of 20
2.4.1 Element2Cam
1.)
2.)
3.)
4.)
5.)
Delete Workpiece_Calib
6.)
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VisionControl (Vision Self-test)
Page 17 of 20
7.)
[RemoteFromAdmin]
StationID=0
=0
=1
=2
=3
=4
=5
// Adaptation of settings
[VisionControl]
Eject_Active=FALSE
Sim_Active=FALSE
// Addition of operators
[Operators_BV]
CImgOpAnalyseFocus
CImgOpControlClassifyTorsion
CImgOpControlClassifyLine
CImgOpControlClassifySaddleSurface
CImgOpControlClassifySaddleEdge
CImgOpControlClassifyFrontBack
CImgOpControlClassifyCaliper
CImgOpControlClassifyPatMax
CImgOpRotate
8.)
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VisionControl (Vision Self-test)
Page 18 of 20
2.4.2 ElementeAdmin
1.)
2.)
3.)
4.)
5.)
6.)
[MMI-Communication]
Languages=EN,NL,DE
[VisionControl]
ReferenceDirectory=Reference
ActualDirectory=Actual
ImagesDirectory=Images
MeasurementsDirectory=Measurements
FileSetting=Settings
FileMeasurement=Measurements
FileImages=Image
NumOfMeasurementVals=100
7.)
Tol(-)
-50.000
-70.000
-50.000
-0.060
-20.000
-20.000
-20.000
-2.000
Tol(+)
50.000
70.000
50.000
0.060
20.000
20.000
20.000
2.000
[Section_2] (Station_2/Cam_1)5
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_BACKLIGHT_EDGE
GREYVAL_ROI_BACKLIGHT
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
[Section_3] (Station_2/Cam_2)
POSITION_X_[PIX]
-50.000
50.000
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VisionControl (Vision Self-test)
Page 19 of 20
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_BACKLIGHT_EDGE
GREYVAL_ROI_BACKLIGHT
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
[Section_4] (Station_3/Cam_1)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_BACKLIGHT_EDGE
GREYVAL_ROI_BACKLIGHT
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
[Section_5] (Station_3/Cam_2)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_BACKLIGHT_EDGE
GREYVAL_ROI_BACKLIGHT
GREYVAL_ROI_ELEMENT
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
[Section_6] (Station_4/Cam_1)
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
LASER_WIDTH1_[MM]
LASER_WIDTH2_[MM]
LASER_BRIGHTNESS1_[GREYVAL]
LASER_BRIGHTNESS2_[GREYVAL]
-50.000
-50.000
-5.000
-0.100
-0.100
-20.000
-20.000
50.000
50.000
5.000
0.100
0.100
20.000
20.000
[Section_7] (Station_5/Cam_1)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_UPPER
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
[Section_8] (Station_6/Cam_1)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_BACKGROUND
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
[Section_9] (Station_6/Cam_2)
POSITION_X_[PIX]
POSITION_Y_[PIX]
ANGLE_[DEGREE]
RESOLUTION_[MM]
GREYVAL_ROI_LEFT
GREYVAL_ROI_RIGHT
GREYVAL_ROI_BACKGROUND
FOCUS_WIDTH_[PIX]
-50.000
-70.000
-5.000
-0.060
-20.000
-20.000
-20.000
-2.000
50.000
70.000
5.000
0.060
20.000
20.000
20.000
2.000
November 2009
EN_Description_VisionControl_V04_1a.doc
User's Guide
VisionControl (Vision Self-test)
Page 20 of 20
16.09.2009
Operating Instructions
Stone Detection in Station1
Customer:
Order Number:
Version:
304312
As from V04-3-9
All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by
any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Rohwedder AG.
16.09.2009
Page 1 / 5
16.09.2009
Contents
1
16.09.2009
Page 2 / 5
16.09.2009
16.09.2009
Page 3 / 5
16.09.2009
16.09.2009
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16.09.2009
The "Threshold Area" box serves to show the area in which a stone is recognized.
16.09.2009
Page 5 / 5
14.10.2010
User's Manual
Chipped and Broken Creation of Masks and
Contours for ROI Evaluation
Customer
Order No.
Version:
304312
ab V04-3-9
All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by
any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Rohwedder AG.
20.05.2009
Translated October 2010
Page 1/12
14.10.2010
Contents
1
20.05.2009
Translated October 2010
Page 2/12
14.10.2010
1.2 Setup
1.2.1 Creation of Mask and Contour
Mask and contour are created by the inspection program in Teach-in Mode. Frontside and
backside are considered differently. For creating the mask and the contour, two pictures
of different elements are required. These elements must not show any defects.
20.05.2009
Translated October 2010
Page 3/12
14.10.2010
Closed contour
If there are small "hairs" on the contour, these must also be removed in order to obtain a
smooth contour.
The picture of the closed and corrected contour is loaded to the ImageFromFile operator in
the creat_front_2 parameter set, the path for saving is indicated in operator
"ContourChainCode". Then the program is executed.
20.05.2009
Translated October 2010
Page 4/12
14.10.2010
The contour code is saved automatically, the mask picture ("mask") is saved using the
"SavePicture" button.
Backside:
Mask and contour for Backside are created in two steps. First the parameter set creat_back_1
is loaded. The pictures of the OK elements are loaded to operators 1 & 4. Then the program
is executed. The CutContour and CutSkelet pictures are saved using the Save button, if
branches are present these must be processed in the same way as with the frontside
pictures.
Then the Contour picture is loaded to the creat_back_2 parameter set using ImageFromFile.
The path is entered in the ContourChainCode operator, then the program is executed. The
contour code is saved automatically, the mask picture ("mask") is saved using the
"SaveButton".
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Page 5/12
14.10.2010
create_back_2
create_front_1
create_front_2
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14.10.2010
Frontside
20.05.2009
Translated October 2010
Y Coordinate
0 to 1024
ChainCode
0 to 7
Page 7/12
X standard
-1 to 1
Y standard
-1 to 1
14.10.2010
20.05.2009
Translated October 2010
Page 8/12
14.10.2010
General Parameter
The output list can be deleted by means of the Delete Object List field. This is required only
for the first inspection step.
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Page 9/12
14.10.2010
Graphic
Selection of the ROIFiltered ROI picture is done by means of the selection list on the
display.
The "GOO selection field allows viewing of search areas and edge points in the ROI picture.
The selection field Filter ROI Image allows viewing of intermediate pictures of the ROI.
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Translated October 2010
Page 10/12
14.10.2010
Classification Parameters
The Object Type selection field allows to specify if Chipped or Broken objects shall be
searched.
Features:
These features are features which allow for segmentation of an object. There are three object
features.
1.
Hole
2.
Distance
3.
N-Edges
The features can be set as desired and are OR-linked. The following setting would make
sense:
Chipped:
Broken:
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14.10.2010
20.05.2009
Translated October 2010
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Tanslated:
Nov. 2013
Big Impressions
Operating Instructions
Big Impressions Real Width Measurement
Customer:
Order number:
Created:
Updated:
Valid for version:
RW/007229
07/03/2006
07/03/2006
V03-1-2
Page 1 / 9
Tanslated:
Nov. 2013
Big Impressions
Contents
1
Page 2 / 9
Tanslated:
Nov. 2013
Big Impressions
1.1
The previous classification was performed using area and length. The area
is shown using the contour profile (marked red), the length refers to the
rectangle with smallest possible dimension (marked green). The "real"
width shall be implemented as a further classification criterion.
1.2
The width of an error cannot be determined exactly using the rectangle (shown green).
This effect is very distinct especially for crescent-shaped errors.
Crescent-shaped error example:
B1 = width determined using the rectangle
B2 = real width of the error
B1
B2
1.3
Solution Approach
The principle axis is calculated for the impression to be measured. The edges of the
impressions are then searched perpendicularly to the principle axis. The "real" width can
now be calculated as approximation calculation.
A much more complex algorithm would have to be used to calculate the exact width of an
impression but this is not feasible due to the available machine time.
Approach: - Calculate a skeleton of the impression instead of the principal axis
- Scan the edges starting with the skeleton depending on the curvature
angle of the contour or skeleton
Page 3 / 9
Tanslated:
Nov. 2013
Big Impressions
IP functions: Segmentation
Task:
Realization:
Segmentation of the background and impressions
Page 4 / 9
Tanslated:
Nov. 2013
Big Impressions
Segmentation:
Provides different selection options for the graphic
Connectivity:
Provides additional IP preprocessing work steps.
NEW: Min Area:
50 pixels
Morphology Operations:
Provides additional IP preprocessing work steps.
NEW: Close Square
IP functions: Measurement
Task:
This operator tries to measure the width of each blob. The maximum and
minimum widths of the impression are calculated.
Realization:
Step 1
The principal axis is calculated for each blob segmented beforehand and then rotated so
that the principal axis runs parallel to the x-axis of the image (see images).
Y-axis
X-axis
Tanslated:
Nov. 2013
Big Impressions
Y-axis
X-axis
Blob rotated accordingly so that the principal axis is parallel to the x-axis of the image
Step 2
The blob is scanned from above and below for each column along the x-axis. The
maximum and minimum widths of the blob are calculated from the scan values. To
visualize the results, the calculated widths as well as the first maximum width found are
indicated (see image).
Step 3
Reverse transformation to visualize as blob image and camera image.
Page 6 / 9
Tanslated:
Nov. 2013
Big Impressions
Graphics:
Provides two different selection options (Standard: FALSE)
TRUE:
FALSE:
Visualization shown
Visualization not shown, only the
maximum width is indicated
Results:
Representation of results
Max Width:
Mean Width:
IP functions: Classification
Task:
Page 7 / 9
Tanslated:
Nov. 2013
Big Impressions
(no error)
(error)
Classification rule:
1. The maximum width is used (default = active)
Result = [ Length AND Width (Min) ] OR Width (Max)
(Min) = lower threshold (reduction of FalseReject through scratches)
(Max) = upper threshold (erroneous part when impression very wide)
Page 8 / 9
Tanslated:
Nov. 2013
Big Impressions
File layout:
Workpiece-ID, Station-ID, SPSCycle-ID, length, max. width, mean width...
Example:
28 ,0 ,12 ,4.3 ,0.48 ,0.33 ,3.2 ,0.27 ,0.15 , timestamp
Designation
Workpiece-ID
Station-ID
SPSCycle-ID
Object 1: Length
Object 1: Maximum width
Object 1: Mean width
Object 2: Length
Object 2: Maximum width
Object 2: Mean width
Timestamp
Value
28
0
12
4.3
0.48
0.33
3.2
0.27
0.15
Page 9 / 9
Value range
Serial number
1-6
0 - 15
05.07.2010
Bedienungsanleitung
User manual
SaddleEdge Improvement
( One Image )
Kunde:
Auftragsnummer:
Erstellung am:
Aktualisiert am:
Gilt fr Version:
14333
23/06/2010
05/07/2010
V06-0-1
Rohwedder AG
Vision Technology
Kesselbachstr. 1
88697 Bermatingen
Tel.: (0 75 44) 502-100
Fax: (0 75 44) 502-271
www.rohwedder.com
05.07.2010
Seite 1/7
05.07.2010
Bedienungsanleitung
Inhaltsverzeichnis
05.07.2010
Seite 2/7
05.07.2010
Bedienungsanleitung
1 Check sequence
1.
Cognex FindLineSegment
Elementedge search and determine
(Coarse search)
Input/Output
Image
Edgeline (LineSegment)
2.
3.
4.
ClassifySaddleEdge
Edgeobject classification
(Classification)
Input/Output
Image
List of the edgeobjects
Global Properties
Result
05.07.2010
Seite 3/7
05.07.2010
Bedienungsanleitung
2 Description Operators
In the following description only the changes are explained, which are caused of reducing
from two cameras to one camera. For further information look to description
Bedienungsanleitung_SaddleEdge-Verbesserung.
Two camera
05.07.2010
One camera
Seite 4/7
05.07.2010
Bedienungsanleitung
Startpoint
Endpoint
Attention: When you reduce the search line in this operator you also reduce the search
region in the following operators, look to the next sections.
2.1.2 In/Outputs
05.07.2010
Seite 5/7
05.07.2010
Bedienungsanleitung
05.07.2010
Seite 6/7
05.07.2010
Bedienungsanleitung
2.2.2 Parameter
05.07.2010
Seite 7/7
Gap Measurement
Operating Manual
Gap Measurement
Client:
Version Admin:
Version BV-Server:
from V06-0-0
from V07-0-2
All rights, including translation rights, reserved. No part of this publication may be reproduced in any form (print, copy, microfilm
or any other process) without the written permission of Rohwedder Macro Assembly GmbH or using electronic systems, be
processed, copied or distributed.
September 2011
Page 1/15
Gap Measurement
Contents
1
2
Description................................................................................................................. 3
Operators and Testing .............................................................................................. 4
2.1
Rough determination of element head edges (Cognex FindLineSegment
) ... 4
2.1.1
Operation ...................................................................................................... 4
2.1.2
Description of the parameters ....................................................................... 5
2.1.3
Overview of In- and Output ........................................................................... 7
) ..................................... 8
2.2
Rotation of the image (RotateByLineSegmentAngle
2.2.1
Operation ...................................................................................................... 8
2.2.2
Description of the parameters ....................................................................... 8
2.2.3
Overview of In- and Output ........................................................................... 9
2.3
Measuring the gap (SaddleEdge MeasureRift
) .............................................. 9
2.3.1
Operation ...................................................................................................... 9
2.3.2
Description of the parameters ....................................................................... 9
2.3.3
Overview of In- and Output ......................................................................... 13
2.4
Classification (Classify SaddleEdge
) ........................................................... 14
2.4.1
Operation .................................................................................................... 14
2.4.2
Description of the parameters ..................................................................... 14
2.4.3
Overview of In- and Output ......................................................................... 15
September 2011
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Gap Measurement
1 Description
In this documentation, the new test "gap measurement" for stations 2 & 3 of the element
system, is described.
This test is to separate those elements whose distance from the SaddleEdge to the head
of the element is too big.
To this end, three operators were inserted into the test sequence and the classifier was
amended.
September 2011
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Gap Measurement
2.1.1 Operation
Image processing scope: Detection
Task:
Realization:
Probing with the Find-Line tool
September 2011
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Gap Measurement
The operator scans the upper edge of the element head with the aid of edge locators
(calipers). A straight line (line segment) is generated, using the located points or edge
transitions.
September 2011
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Gap Measurement
Important Parameters:
Number of Calipers:
Number of edge locators (calipers) used to find the element head edge
Default value: 15
Search Length:
Projection Length:
Number to Ignore:
Number of located points which are not used for the straight line calculation
Default value: 3
September 2011
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Gap Measurement
Important Parameters:
Edge Mode:
Mode: Finding one or more edge transitions
Default value: Single Edge
Edge 0 Polarity:
Edge transition from black to white or vice versa
Default value: Light to Dark
Contrast Threshold:
Threshold for the minimum contrast which an edge must have
Default value: 20
Filter Half Size Pixels:
Indicates the size of the filter
Default value: 10
September 2011
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Gap Measurement
2.2
2.2.1 Operation
Image processing scope: Geometric transformation
Task:
Realization:
It is the operators task, to rotate the object, so that the SaddleEdge of the input image is
horizontal (see pictures below). The angle of rotation, stems from the Line-Segment of the
SaddleEdge (determined by the operator Idx. 001). The original image is not changed
during this operation, as a new image is created.
Optionally, the angle (in radians) by which the image is rotated, is output as a variable.
Camera image
September 2011
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Gap Measurement
2.3
2.3.1 Operation
Image processing scope: Measuring
Task:
Realization:
The operator measures the distance between various points between the SaddleEdge
and the head of the element. The minimum distance is filtered from the results of the
measured points and are output for further analysis.
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Gap Measurement
Graphic:
Default value: Basic
Measured Values: The located edges of the gaps are shown, as well as the result
in pixel of each measured section (see image below).
September 2011
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Gap Measurement
Note: All the previously mentioned objects will only be shown in the image, if you are
located in the operator, i.e. not during inspection.
Caliper Settings:
Number:
Width:
Height:
The height of the calipers is determined by the two Line-Segments.
However, as they are directly over the transition edge, they must be enlarged. The
parameter specifies a percentage factor by which the amount the height of the
caliper is increased.
Default value: 30
September 2011
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Gap Measurement
Important Parameters:
Edge Mode:
Mode: Finding one or more edge transitions
Default value: Edge Pair
Edge 0 Polarity:
Edge transition from black to white or vice versa
Default value: Dark to Light
Edge 1 Polarity:
Edge transition from black to white or vice versa
Default value: Light to Dark
Edge Pair Width:
The distance which must be present between the two edges ( in pixel ).
Default value: 400
September 2011
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Gap Measurement
Contrast Threshold:
Threshold for the minimum contrast which an edge must have
Default value: 50
Filter Half Size Pixels:
Indicates the size of the filter
Default value: 25
Maximum Results:
Maximum permissible valid results.
Default value: 1
September 2011
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Gap Measurement
2.4
2.4.1 Operation
Image processing scope: Classification
Task:
The minimum size of the gap between the SaddleEdge and the
element
Rift Settings
September 2011
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Gap Measurement
September 2011
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Translated:
Nov. 2013
User's Manual
Nop Inspection Station 5
Customer:
Order number:
Version:
30007776
As from V03-2-3
Rohwedder Micro Assembly GmbH
Haupteingang Opelstrae 1
Lieferanschrift Lanzstrae 2
68789 St. Leon-Rot - Germany
Fon: +49 (0) 6227 / 3412- 0
Fax: +49 (0) 6227 / 3412- 990
Mail: vision@rohwedder.com
Translated:
Nov. 2013
Contents
1
Translated:
Nov. 2013
Solution Approach
Roundness:
Circular edge searchers, so-called calipers, are laid in the nop area. These scan the edge
of the nop from the inside to the outside and find the edge points for the inner nop circle in
this manner (found circle). These interpolation points serve to approximate a best circle.
The shape characteristic roundness is calculated using the difference between these two
circles.
Radius:
The "best circle" approximated in the previous Section is used to check the radius of the
nop.
Translated:
Nov. 2013
Realization:
Measuring the nop
This operator scans the inner rounding of the nop with edge searchers (calipers). A best
circle is calculated from the caliper results. The individual differences between the
calculated "best circle" and the actual "found circle" are squared and added together and
then the root taken. The result is regarded as roundness (shape factor).
Roundness =
Translated:
Nov. 2013
Important parameters:
Number of Calipers:
Number of round-shaped edge searchers arranged in the nop
Default value: 25
Search Length:
Length of the edge searcher in search direction
Default value: 60
Projection Length:
Width of the edge searcher
Default value: 10
Translated:
Nov. 2013
Important parameters:
Edge Mode:
Mode: Search one or more edge transitions
Default value: Single Edge
Edge 0 Polarity:
Edge transition from black to white or vice versa
Default value: Dark to Light
Contrast Threshold:
Threshold for the minimum contrast the edge must show
Default value: 30
Filter Half Size Pixels:
Specifies the filter size
Default value: 10
Translated:
Nov. 2013
2.2
Set the parameters for thresholds for all classification characteristics using
the operator.
Classification layout:
This operator uses the classification thresholds to check whether the part is an OK or
NOK part:
1. OK
(no error)
2. NOK (error)
The classification characteristics used are:
-
Translated:
Nov. 2013
Translated:
Nov. 2013
Translated:
Nov. 2013
Translated:
Nov. 2013
14.07.2010
SaddleSurface Station 6
Users Guide
SaddleSurface
Customer:
Order Number:
Version:
Revision:
30008431
ab V04-0-0
2008.11.06
Rohwedder AG I Vision Technologies
Schiestattweg 1 I 88677 Markdorf I Germany
T +49 75 44 95 93-0 I F +49 75 44 95 93-88
vision@rohwedder.com I www.rohwedder.com
All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by
any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Rohwedder AG.
14.07.2010
Page 1/45
14.07.2010
SaddleSurface Station 6
Contents
Fault Specification.....................................................................................................4
1.1
General Conditions...............................................................................................4
1.2
Fault Types ..........................................................................................................4
2 SaddleSurface Improvements ................................................................................12
2.1
Task ...................................................................................................................12
2.2
HW Layout .........................................................................................................12
2.3
Inspection Program Sequence ...........................................................................13
3 Description of Operators and Inspection ..............................................................16
3.1
Find SaddleSurface............................................................................................16
3.1.1
Functional Method.......................................................................................16
3.1.2
Description of Parameters...........................................................................16
3.1.3
Inputs and Outputs Overview ......................................................................17
3.2
Surface Filtering .................................................................................................18
3.2.1
Functional Method.......................................................................................18
3.2.2
Description of Parameters...........................................................................21
3.2.3
Inputs and Outputs Overview ......................................................................25
3.3
Saddle Surface Equalize ....................................................................................26
3.3.1
Functional Method.......................................................................................26
3.3.2
Description of Parameters...........................................................................28
3.3.3
Inputs and Outputs Overview ......................................................................29
3.4
Cognex Blob.......................................................................................................30
3.4.1
Functional Method.......................................................................................30
3.4.2
Description of Parameters...........................................................................30
3.4.3
Inputs and Outputs Overview ......................................................................31
3.5
Convex Outline...................................................................................................32
3.5.1
Functional Method.......................................................................................32
3.5.2
Description of Parameters...........................................................................32
3.5.3
Inputs and Outputs Overview ......................................................................32
3.6
Convex Mask IPP...............................................................................................33
3.6.1
Functional Method.......................................................................................33
3.6.2
Description of Parameters...........................................................................33
3.6.3
Inputs and Outputs Overview ......................................................................33
3.7
Analyse Contour.................................................................................................34
3.7.1
Functional Method.......................................................................................34
3.7.2
Description of Parameters...........................................................................35
3.7.3
Inputs and Outputs Overview ......................................................................36
3.8
Analysis Surface.................................................................................................37
3.8.1
Functional Method.......................................................................................37
3.8.2
Description of Parameters...........................................................................38
3.8.3
Inputs and Outputs Overview ......................................................................38
3.9
Connect Surface/Contour...................................................................................39
3.9.1
Functional Method.......................................................................................39
3.9.2
Description of Parameters...........................................................................39
1
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3.9.3
Inputs and Outputs Overview ......................................................................39
3.10 Find Asperity ......................................................................................................40
3.10.1 Functional Method.......................................................................................40
3.10.2 Description of Parameters...........................................................................41
3.10.3 Inputs and Outputs Overview ......................................................................42
3.11 Classify SaddleSurface ......................................................................................44
3.11.1 Functional Method.......................................................................................44
3.11.2 Description of Parameters...........................................................................44
3.11.3 Inputs and Outputs Overview ......................................................................45
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SaddleSurface Station 6
1 Fault Specification
1.1 General Conditions
1. The saddle surface must be constantly free of dirt otherwise the fault detection
may not work properly.
2. It must be possible to differentiate faults over sufficient contrast from the
background.
3. The fault size must be clearly specified:
a) The fault area must always exceed 0!
b) The fault dimension must always ( at least in one dimension ) exceed the
disturbing textures (rolled texture)!
Fault description
Statistic description
Impression/Abriss: reject
Abriss / Impression
Abriss / Impression
3
4
5
Asperity
14.07.2010
Abriss / Impression
Auenriss
Einriss
Asperity
Page 4/45
Width
14.07.2010
SaddleSurface Station 6
1. Impression/Abriss: Reject
X Mean
Z Rect
X Open
X Rect
Limits:
X-Rect
Z-Rect
X-Open
X-Mean
Contrast
Asperity
Reject Limit
> 4.0 mm
> 0.5 mm
--AND
> tbd
> 40
?
Accept. Limit
< 0.2 mm
< 0.2 mm
--< tbd
< 40
?
OR
Classification:
Abriss is detected when ( X-Open > 0 ) AND ( X-Open top )
Impression is detected when
Range:
Abriss and Impression are detected within the red search area.
Caution: Intersection to the blue search area Abriss respectively Impression
Abriss / Vorriss
Rounding
X-Curve
Value
1,0 mm
X-Curve
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X Mean
Z Rect
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SaddleSurface Station 6
Rounding
Z Rect
X Mean
X Rect = X Open
Flat inclined faults are not detected in the rounding range. Due to the production flow, the
contour gradient in this range is subject to wide variation.
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SaddleSurface Station 6
Z Rect
Z Rect
L Open
L Open
Depth
X Rect
X Rect
Limits:
X-Rect
Z-Rect
L-Open
Depth
Contrast
Asperity
Reject Limit
> 0.4 mm
> 0.4 mm
> tbd
AND
> none
> 40
?
Accept. Limit
< 0.2 mm
< 0.2 mm
< tbd
none
< 40
?
OR
Classification:
Auenriss is detected when
( L-Open > 0 )
Range:
The Auenriss is detected within the blue search area.
Caution: Intersection to the red search area no Auenriss but Abriss respectively
Impression
Rounding
14.07.2010
Abriss / Vorriss
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SaddleSurface Station 6
5. Einriss
Z Mean
Z Rect
X Rect
Limits:
X-Rect
Z-Rect
Z-Mean
Contrast
Asperity
Ratio X/Z
Reject Limit
> 4.0 mm
> 0.4 mm
AND
> tbd
> 40
?
Accept. Limit
<
<
<
<
?
0.2 mm
0.2 mm
tbd
40
Classification:
Einriss is detected when a connection to the outer edge is inexistent.
Range:
Einriss is detected within the blue and red search area.
Rounding
14.07.2010
Abriss / Vorriss
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OR
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SaddleSurface Station 6
6. Asperity
Z Rect
X Rect
Limits:
X-Rect
Z-Rect
Flche
Contrast
Asperity
Reject Limit
> 0.005 mm
> 0.005 mm
AND
>0.020 mm
> 40
?
<
<
<
<
?
Accept. Limit
0.002mm ?
0.002mm ?
OR
0.010 mm ?
40
Range:
Asperity is detected within the blue and red search area.
Rounding
14.07.2010
Abriss / Vorriss
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SaddleSurface Station 6
Exception:
Remark: Will be detected most likely in the red search area as flat Impression/Abriss fault
Dirt
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SaddleSurface Station 6
2 SaddleSurface Improvements
2.1 Task
Detection of SaddleSurface faults at IP station 4, see as well chapter Fault Specification.
2.2 HW Layout
No modification necessary.
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SaddleSurface Station 6
5. Convex Outline
Calculate convex cover
(Preprocessing)
Inputs/outputs
ImgRot
BlobMask
ConvexPolygon
Polygon
6. Convex Mask IPP
Calculate convex mask
(Preprocessing)
Inputs/outputs
ConvexPolygon
ImgRot
ImgMaskConvex
7. Convex Mask IPP
Calculate contour mask
(Preprocessing)
Inputs/outputs
Polygon
ImgRot
ImgMaskContour
8. Analyse Contour
Calculate contour objects
(Segmentation)
Inputs/outputs
ImgRot
ImgMaskConvex
ImgMaskContour
Polygon
ConvexPolygon
PointOutside
Calibration data
GlobalParams
ContourList
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SaddleSurface Station 6
9. Analysis Surface
Define surface objects
( Segmentation )
Inputs/outputs
ImgRotEqual
ImgRotMedianEqual
ImgMaskConvex
SurfaceList
10. Connect Surface/Contour
Summarize contour and surface objects
( Segmentation )
Inputs/outputs
ImgRot
SurfaceList
ContourList
ConnectList
11. Find Asperity
Summarize contour and surface objects
( Segmentation )
Inputs/outputs
ImgRot
Calibration data
ImgRotFilterHighP1
ImgRotFilterHighP2
ImgMaskConvex
Width
AsperityList
12. Classify SaddleSurface
(Classification)
Inputs/outputs
Camera image
Calibration data
Trafo
AsperityList
ConnectList
Width
Length
Result
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SaddleSurface Station 6
This operator calculates the rotation and the start point of the saddlesurface.
In a first step the direction ( Rotation ) of the saddle surface is specified by
means of a linefit and the Element width is determined. The start point
(Point outside) is defined in the second step.
Graphic:
No alternative
General Settings:
Selection of element type and camera
The selection box SearchType serves to select the element type.
The selection box Search Direction serves to select the camera.
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Remark: The settings are saved as GlobalParams, so the information can be used by
following Operators.
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SaddleSurface Station 6
The Operator calculates the rotated ROI-image, the median image, the
high-pass image, the mask image and the element length.
Realization:
In this Operator all filter functions which are necessary for the program run
are effected.
The input image is reduced (ROI = Region of Interest) and rotated. Every
following calculation is effected on the basis of this image or from the
images derived.
Median image:
Rolled textures are filtered out by median filtering ( vertical textures )
High-pass images:
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SaddleSurface Station 6
Horizontal texture transitions are displayed via high-pass filter. The direction
of the edge transitions is considered and displayed inverse in both images.
High-pass image 1:
Edge transitions from dark to bright are displayed bright.
High-pass image 2:
Edge transitions from bright to dark are displayed bright.
Mask image:
The mask image is calculated from the median image ( Rolled textures have
no effect on the mask). The target is to generate a mask which separates
the background clearly from the saddle surface. However, dark faults shall
be masked additionally, i.e. be black in the mask image.
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SaddleSurface Station 6
Globale Binarisierungsschwelle
Global threshold
Histogram threshold
By means of the
histogramm the image is
evaluated segment by
segment and the
binarization threshold is
calculated.
Threshold image
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SaddleSurface Station 6
Settings Median:
Settings for the calculation of the median image
The filter sizes are set with the two Median X boxes. Since the indication is made in
pixel and corresponds to the half filter size (FilterHalfSize), it is possible to state the
filtered out texture width directly in pixel. For example, if a vertical texture with a width of
up to 10 Pixel ( = 0,11 mm ) shall be filtered out, then the Median X must be set to not
less than 10.
The median filtering is subdivided into 2 sections:
1. Range Outside (see yellow box)
2. Range Inside (see blue box)
Therefore different filter sizes may be used for both ranges. As a result rolled texture
which, depending on production, occurs more often in the inner range, can be filtered out
better ( see example ).
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SaddleSurface Station 6
Example:
Input image
Rolled texture
existent
Rolled texture
filtered out
The Inside Size X box specifies the factor of the range Inside expressed as a
percentage of the total length, e.g. 0,3 = 30% of the total length.
The Median Y box reduces the effect of horizontal textures. Due to the calculation time
the value should not exceed 5.
Settings Mask:
Settings for the mask calculation
Histo Width
Steps = 10
Histo
Height
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SaddleSurface Station 6
Histogram
Max.
Background
Max.
SaddleSurface
Thres. Range
of e.g. 30%
Quantity
Binarization
threshold
255
Grey-scale
value
The Fill Length box fills in the inner border area of the mask ( designation is made in
Pixel ).
Point Inside
Original mask
Fill Length
Filled in mask
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= 53
= 51
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= 53 + 35 = 88
= 51 + 35 = 86
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SaddleSurface Station 6
Realization:
The visible surface brightness of the saddle surface originates from the
combination of various surface characteristics and environmental
conditions, e.g. :
Faults
Textures (rolled texture)
Lighting gradient (shadow / reflection)
Surface roughness
Dirt
Figure
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Task:
The operator calculates the rotation and the start point of the saddle surface.
Realization:
In a first step the direction ( Rotation ) of the saddle surface is defined via a
line fit and the element width. The start point (Point outside) is defined in
the second step.
Graphic:
No alternative
General Settings:
Selection of element type and camera
The selection box SearchType serves to select the element type.
The selection box Search Direction serves to select the camera.
Remark: The settings are saved in GlobalParams, so the information can be used by
following operators.
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The operator calculates the convex outer contour of the saddle surface, i.e.
contour damages are selected.
The contour gradient is extracted over the Blob of the afore defined mask.
The convexe cover is calculated from the contour gradient by means of an
appropriate method.
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Mask
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Segmentation, classification
Task:
Realization:
Convex mask
Contour mask
The Blob Tool defines the contour faults from the differential image.
Result: Segmentated contour fault
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RVT Params:
The X-Curve box serves to set the range for the Auenriss
Segmentation:
Parameter see CognexBlober
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Realization:
The surface faults are measured by means of fine search. However, the
existing texture and dirt may cause pseudo detections.
Fine search
Therefore the results are linked with the rough search UND in order to
select the pseudo objects without changing the measuring result for the
worse.
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RVT Params:
The Erode box serves to reduce the mask, i.e. the masked range (background and
contour range) can be adjusted.
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The operator links the detected contour objects with the surface objects. As
a result a definite classification is realized.
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Functional Method
In a first step the input image is vertically high-pass filtered and an image is
genereated for each direction.
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In a third step pairs are searched, i.e. a positive (yellow) and a negative
(blue) edge transition form a pair if they match in a specified assembly.
Should this be the case a new search region (ROI), in which both edge
transitions are located, will be defined.
In a fourth step a bright Object is searched for in the ROI. Since the
parameter settings take dynamically place it is not necessary to make
manual settings. The found object is classified via characteristic vectors, see
Settings Small.
3.10.2
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Description of Parameters
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Setting Mask:
The Erode box serves to reduce the mask, i.e. thereby the masked area (background
and contour area) can be adjusted.
Settings Big Asperity:
The Area box serves to specify the area where a Big Asperity can be found. If a Big
Asperity is found, it is checked after the second step whether a significant edge transition
is present in the upper range of the saddle surface.
The Search Length Y box serves to specify the height of the search area.
Settings Small:
The Area (virtual) box serves to specify the minimum area of the Asperitys. Virtual
means that the area depends on the contrast. The higher the contrast, the higher the area
is to be weighted.
The Contrast box serves to specify the minimum contrast.
The Elongation box serves to specify the maximum proportion (Width/Height).
The Contour Outside box serves to specify the maximum luminosity of the
environment. The calculation is carried out with a 2 pixel distance to the object contour.
3.10.3
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Functional Method
IP fuctions: Classification
Task:
3.11.2
Description of Parameters
Reject Limit:
Accepted Limit:
Remark:
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3.11.3
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