Three key aspects of sensor technology are crucial in image processing for industrial automation: performance, adaptability, and user-friendliness. Basic Vision sensors fulfill these criteria. They are just as simple to use as optical sensors and equally as robust as camera systems. The Sensor People at Leuze present this concept as a fast and easy way to learn about vision technology.
Vision sensors serve as the ‘eyes for industrial automation.’ This is due to the fact that these tiny wonders allow machines to observe and understand their environment. They are simpler to incorporate and function than camera systems. The devices are appropriate for a variety of tasks: They serve for detecting presence or absence, identifying parts, conducting inspections, reading codes, performing measurements or counts, and verifying print quality. When choosing the best sensor technology, it is important to take into account its effectiveness in the relevant detection, identification, and inspection activities. Moreover, the setup and adjustment of sensors should be kept as straightforward as possible to conserve both time and resources. The Sensor Team at Leuze offers a product lineup that fulfills these needs through their Simple Vision concept.
Easy configuration, effective identification
Leuze’s image processing tools are advanced: They integrate image capture, processing, and communication capabilities into a single unit. A typical use of sensors is to identify whether objects are present or absent. In filling systems, it is essential to accurately detect caps, labels, or prints on bottles or containers. Sensors can likewise be utilized to verify the alignment of an object, irrespective of its shape, material, color, or size. Users need to confirm that the device functions properly. The IVS 108 Simple Vision Sensor by Leuze, for instance, exhibits a steady response time of only 50 milliseconds – regardless of varying objects, environmental factors, or application conditions. This allows system operators to easily determine if the sensor satisfies their production process needs. An efficient sensor configuration is also crucial. The IVS 108 does not demand programming or extensive setups. Simply place the ‘GOOD’ and ‘NOT GOOD’ items in front of the sensor and press the teach button to confirm.
Code reading made easy
Vision sensors can also be used to read 1D or 2D codes. Practical: Sensors such as the DCR 1048i from Leuze read single or multiple codes simultaneously. This is relevant for packages containing several secondary packaging units, for example. Multicode decoding makes this possible. If DPM codes printed on the packaging need to be detected, a sensor such as the DCR 1048i DPM is recommended. This is equipped with an optimized reading algorithm for reliable decoding.
Anyone looking for a particularly powerful sensor for print quality verification will find what they need in the DCR 1048i OCV: It can read 1D/2D codes within one application and also check print quality (e.g. best-before date, batch and others) using the OCV process. OCV stands for “Optical Character Verification”. The vision sensor can be taught in particularly easily, quickly and without any complex parameters: all you need to do is present it with a reference image of the optimum print. The DCR 1048i OCV then reliably detects defective printing – for example, clogged print heads, low ink cartridges, or adhesion problems.
All-rounder application
Depending on the application and system design, an all-rounder vision sensor can prove worthwhile. This enables system operators to respond quickly to market requirements and product changes. The all-rounder vision sensors such as the IVS 1048i from Leuze are recommended for detection, inspection and identification tasks. For example, checking whether labels or adhesive have been applied correctly on a packaging line.
Another possible use is checking whether bottles are sealed correctly in a beverage-filling system. Some manufacturers offer devices with different resolutions. The IVS 1048i is available with a lower (736 x 480 pixels) or higher resolution (1,440 x 1,080 pixels). This allows very flexible sensor use. There is also a choice of four interchangeable S-mount lenses with variable focus adjustment. This means that the reading distance, field of view and depth of field can also be adapted to each system’s requirements.