NEW

Machine Vision System/LED Illumination Unit

CV-700/CA-D

Selection Guide & Lighting Techniques

LED Illumination for Machine Vision

Clearly see targets that were not visible using conventional lighting
Selecting Lighting Technique by Application Type
Field-proven Technique 1

Detecting defective plating of terminals Detecting imprints on press-molded parts Detecting chips on rubber packaging Differentiating between flat and uneven surfaces Detecting the level of transparent liquid Detecting transparent sheet width Detecting print on aluminum packaging material Detecting holes and mill scales on a curved surface

Glossy/Plated surface

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Field-proven Technique 2

Low-contrast surface

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Field-proven Technique 3

Transparent surface

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Field-proven Technique 4

Uneven/Curved surface

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Specification, dimensions & options Controller/Power Supply

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7
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Image inspection techniques using a color vision system and LED illuminator
Proper lighting and the selection of an optimal image sensor are the key to successful image inspection.

With conventional ring lamps

With optimal illumination

With color image processing

Field-proven Technique

1 glossy surface
Indirect lighting eliminates glare and applies illumination evenly

Detection of plating and imprinting on

Glossy/Plated surface

Bar type

Coaxial vertical-type

Enhances the edge of the imprinting against the reflective surface

Low-contrast surface

Detecting defective plating of terminals

Detects imperfect plating on the tips of terminals. Color image processing enables differentiation between the bare silver metal and the gold plating.

Detecting imprints on press-molded parts

Product number and specification imprints can be recognized by their patterns. Incorrect stamping and mixing of different products can also be detected.

Transparent surface

With direct reflection:

With bar-type illumination:

With direct reflection:

With coaxial vertical illumination:

Uneven/Curved surface

Color differences are small due to variations in illumination.

Illumination variations caused by the glossy surface are eliminated.

Imprint is unclear.

The edge of the imprint is enhanced.

Lighting techniques using bar-type

Select a bar-type that enables uniform illumination on long targets. Install the illuminator so that the illumination is applied from an angle. Capture the CCD camera image and perform Diffuse differentiation using reflection diffuse reflection. If the surface is very Bar illuminator glossy, use a polarizing Regular reflection filter.
Target

Lighting techniques using coaxial vertical-type

Select a coaxial vertical-type illuminator, which applies illumination on the same axis as the lens. The contrast between dark and bright parts is CCD camera captured and differentiated Coaxial vertical Regular reflection by allowing the reflected illuminator light from the glossy surface Half mirror into the camera, while blocking the diffuse light at the edge of the imprint.
Target

Color binary processing

Reliably detects only the color range of the target point. Enables reliable inspection of multi-color products and can easily do difficult color distinctions such as white and yellow, and gold and silver.
Reliably extracts only the gold-plated area.

360 rotation adjustment function

Instantaneously adjusts movement in target position angle within the inspection window. Ensures continuous reliable inspection of the same point even when targets appear in random positions.

Useful Tips

Normal position

The inspection window adheres to the target.

Field-proven Technique

2 low-contrast surface
Sharpens the contrast of edges and uneven surfaces

Detection of flaws and chips on a

Useful Tips

Glossy/Plated surface Low-contrast surface Transparent surface Uneven/Curved surface

4

Differentiates between flat and uneven surfaces

Coaxial vertical-type

Low-angle type

Detecting chips on rubber packaging

Detects minute defects such as chips on the perimeter edge, or surface flaws or deviations in thickness.

Detecting defects on the bottom of emboss tape cases

Detects defects such as crushed or ripped bottoms of the cases.

With direct reflection:

With low-angle illumination:

With direct reflection:

With coaxial vertical illumination:

The chip on the perimeter cannot be detected.

The chip on the edge is clearly differentiated in white.

Detection is unstable due to inconsistent reflection.

Only the defective areas are shaded.

Lighting technique using low-angle-type

Select a low-angle illuminator. This technique allows differentiation by illuminating at an angle onto the edge and projections on the CCD camera surface.
Low-angle illuminator

Lighting techniques using coaxial vertical-type

Select a coaxial vertical-type illuminator, which applies illumination on the same axis as the lens. The contrast between dark and bright parts is captured and differentiated by only allowing the regular CCD camera reflection from the flat Coaxial vertical Regular reflection surface into the camera. illuminator
Half mirror

Target Target

STAIN Mode
STAIN mode allows detection of changes in contrast of adjacent pixels within the inspection area. This mode is suitable for detecting minute flaws and defects while being unaffected by the surface conditions and inconsistent illumination.

Inspection menus
The CV-700 comes pre-programmed with applications that can be selected via the pull-down menu for simple setup.

Reliably detects defects in random positions.

Presence/ absence

Outer edge

Inner edge

Gap Pitch

Center Pitch

2 5

6 1 2 3 4

Flaw detection Point sensor

Count

No. of edges

Position/angle

Field-proven Technique

3 transparent object
Utilizing the silhouette enables high-accuracy transparent target detection

Differentiation of size and shape of a

Glossy/Plated surface

Recognizes the edge of a thin transparent film

Bar type

Backlight type

Low-contrast surface

Detecting the level of transparent liquid

Detects the level of a clear liquid substance in a transparent or semitransparent container.

Detecting transparent sheet width

Detects the width of a thin transparent glass or plastic sheet.

Transparent surface

With direct reflection:

With backlight illumination:

With direct reflection:

With bar illumination:

Uneven/Curved surface

The light reflecting off the surface of the container creates interference.

The liquid level is captured as a shaded edge.

The edges are unstable.

The edges are illuminated clearly.

Lighting techniques using backlight-type

Select a backlight-type illuminator, which silhouettes the shape of the target using the light passing through the target.
Target CCD camera Backlight illuminator

Lighting techniques using bar-type

Select a bar-type illuminator. Captures and detects only the diffuse reflection of the edge generated by applying angled lighting.
CCD camera

Bar illuminator

Bar illuminator

Target

Easy-to-operate inspection menus

The CV-700 automatically recognizes edges simply by drawing an inspection window.

Analog output features

The CV-700 outputs measured values as an analog voltage (range of 0 to 4 V). This feature allows you to keep records of measurement and detection results in spreadsheet applications by connecting the CV-700 with a PC.
CAM1 PROGRAM WIND1 INSPECT

Useful Tips

Loose cap

Liquid level Liquid level

H=000000 H=000000 L =000000

A/D conversion*

Draw inspection windows.

Edges are automatically recognized.

CV-700 Series
* A/D conversion software required.

Field-proven Technique

4 uneven or curved surface

Indirect lighting allows clear images without hot spots

Detection of print or stains on an

Useful Tips

Glossy/Plated surface Low-contrast surface Transparent surface Uneven/Curved surface

6

Dome type

Dome type

Uniform light allows for even illumination over a curved surface

Detecting printing on aluminum packaging material

Detection is normally difficult or impossible due to the hot spots generated by surface irregularities or glare caused by the film sheet.

Detecting holes and mill scales on a curved surface

Detects the holes and traces of mill scales after processing die-cast parts.

With direct reflection:

With dome illumination:

With direct reflection:

With dome illumination:

The light reflects irregularly, making recognition of the printing impossible.

The background glare is eliminated and only the printing is visible.

Undesired variations in illumination are generated.

Surface condition becomes uniform, enabling the detection of defects.

Lighting techniques using dome-type

Select a dome-type illuminator, which casts indirect light from various directions. Since soft diffuse light can be applied uniformly over a target with an irregular shape, the surface condition can be kept uniform, making contrast of inspection CCD camera points clear. Dome-type
Illuminator

Lighting techniques using dome-types

Select a dome-type illuminator applies uniform irradiation to every point on the curved surface ensuring reliable detection. This eliminates surface glare CCD camera that would be normally caused Dome-type by direct lighting. Illuminator

Target

Target

Inspection setting storage for 900 or more items

The CV-700 Series is the first in its class to feature a CompactFlash memory slot. Inspection settings for large number of items can be stored on a memory card, enabling quick, convenient product changeover. Maximum number of setting registrations
Main memory: 16 inspection settings 32 MB CompactFlash memory: Approx. 100 inspection settings 256 MB CompactFlash memory: Approx. 900 inspection settings

Screen-saving function to keep a record of defects

The CV-700 Series performs high-speed reading and saving of high-volume detection screens. Since the detection screens can be saved in bitmap format, the data can be used for preparing reports and documents. Saving NG screens
OK NG OK OK NG

Up to 1000 screens can be saved on a memory card

Up to 8 screens can be saved on the main unit

LED illumination unit

Direct-ring type
CA-DR
Model CA-DRR4F CA-DRW4F CA-DRR10F CA-DRW10F LED color Red White Red White Weight Power (g) consumption (W) Approx. 35 1.5 Approx. 35 2.9 Approx. 120 8.3 Approx. 110 7.9

Unit: mm

Low-angle type
CA-DL

Model CA-DLR7 CA-DLR12

* When the mounting bracket is attached 20 Camera mounting slot 14.8 30

Weight LED Power (g) color consumption (W) Red Approx. 40 2 Red Approx. 90 3,3

CA-DRx4F
43 28 15 20 3 x M1.6, Depth: 3 max. l=500 2-P SM connector

CA-DRx10F
100 70 4 x M3, Depth: 5 max. 50 2-P SM connector

CA-DLR7
4 x M3, Depth: 3 max. 75 56 46 10 l=500

CA-DLR12
125 110 4 x M3, Depth: 3 max. 10 95 l=500 2-P SM connector

78

4 x M3, Depth: 5 max.

21.2 45 40 95

20 3 x M1.6, Depth: 3 max. l=500

69 70

2-P SM connector

2 x M3, 16.6 Depth: 5 max.

Bar type
CA-DB
Model CA-DBR5 CA-DBW5 CA-DBR13 CA-DBW13 LED color Red White Red White Weight Power (g) consumption (W) 1.7 Approx. 35 2.9 Approx. 40 4.2 Approx. 80 7.3 Approx. 90
l=500 A B 2-P SM connector 2 x M2, Depth: 4 max. D C

Dome type
CA-DD

Model CA-DDR15

Weight LED Power (g) color consumption (W) 11 Red Approx. 130

CA-DBxxx

CA-DDR15
55 2-P SM connector 4 x 2.1 l=500

E 2 x M3, Depth: 3 max.

55

73 50

152 114

Model CA-DBR5/CA-DBW5

A 60

B 50

Dimensions C D E 17 15 20

F 30

Model

CA-DBR13/CA-DBW13 142 132 17

Dimensions C D E 15 20

F 80

66

* CA-DBx5 features two lines of LED

Backlight type
CA-DS
Weight LED Power (g) color consumption (W) Red Approx. 40 3.6 Red Approx. 110 14

Coaxial vertical type

CA-DX
LED color Weight (g) Power consumption (W) 5 6.7

Model CA-DSR3 CA-DSR9

Model CA-DXR5A CA-DXR7

Red Approx. 230 Red Approx. 380

CA-DSR3
46 43 32 (Lightemitting surface) 62 63 (Light- 40 emitting surface) 2-P SM connector 8.2

CA-DSR9
112 106 92 (Light-emitting surface)

Model

Dimensions A B C D E F G CA-DXR5A 97 60 36 32 16 59 40 CA-DXR7 120 82 50 50 17 79 60 Dimensions H I J K L M N CA-DXR5A 32 10 15 80 40 CA-DXR7 50 11 14 50 14

CA-DXxx
K

A 2 x M4, Depth: 5 max. L

2 x 3.5 l=500 92 93 (Light- 70 emitting surface)

4 x 3.5 l=500

Model

E JI G 4 x M4, Depth: 5 max.

D 2-P SM connector

N Half mirror Glass plate

2-P SM connector 8.2

l=500

2 x 2 x M4, Depth: 5 max.

Options
Extension cable Diffuser
For LED reflection prevention
Eliminates the reflection of LED and inconsistencies generated in capturing the image of glossy targets. (Compatible with direct-ring type and bar type)
Compatible illuminator CA-DRx4F CA-DRx10F CA-DBx5 CA-DBx13 Model OP-42337 OP-42339 OP-42283 OP-42282 Model Cable length (m) CA-D2 2 CA-D5 5

Polarizer
For glare prevention
Eliminates glare of glossy targets together with the lens polarizing filter. (Compatible with direct-ring type and bar type)
Compatible illuminator CA-DRx4F CA-DRx10F CA-DBx5 CA-DBx13 Model OP-42336 OP-42338 OP-42281 OP-42280

LED Illumination Controller

CA-DC100

Designed for easy use in the field

High light-emitting frequency of 100 kHz Ensures consistent image capture even under high-speed shutter settings on highspeed lines. 2-channel connection for a wide range of applications Switching between two illuminators enables multiple inspections and 2-line inspections. Limit function to extend LED life Industry First Limits current flow through LEDs to prevent rapid deterioration. DIN-rail mountable design Industry First Light adjustment trimmer for fine-tuning External switching of ON/OFF status

Dimensions
CA-DC100
15 85 Unit: mm

Specifications
Model CA-DC100 Light control method Light-emitting frequency: 100 kHz, pulse width modulation method 2 channels Number of outputs Output 12 V Voltage 30 W max. (20 W per channel) Capacitance External control input (EXT), 2 contacts (non-voltage contact input) Input 24 VDC 10% Power supply voltage 1.8 A (under maximum load) Current consumption 0 to +45C Ambient temperature 35 to 85%, No condensation Relative humidity Approx. 220 g Weight * Environment for illumination unit: Ambient temperature of 0 to +40C and relative humidity of 35 to 65% (no condensation).

110 11

5 45 Mounting hole 2 x M3, Depth: 6 max.

81.2

39

16

11.2

(40)

24 VDC Power Supply Unit

CA-U2
Specifications
Model Input voltage Efficiency Input current (100/200 VAC) Power factor (100/200 VAC) Leakage current (100/200 VAC) Rush current (100/200 VAC) Overvoltage category Rated output voltage Rated output current Ripple/noise voltage Input fluctuation Load fluctuation Starting time* Output holding time Overcurrent Overvoltage Input conditions CA-U2 100 to 240 VAC (10%) 50/60 Hz 78 to 80% (typical) 1.2 A max. 0.99/0.95 (typical) with maximum load applied 0.4/0.75 mA max. 18/36 A max. (at 25C (77F) cold start) II 24 VDC, Class2 3.5 A (Total of 3 output terminals) 1% (p-p) max. 0.4% max. 0.7% max. 1500/1000 ms max. 20 ms min. (100 to 240 VAC) Provided Provided UL60950, UL508, CAN/CSA C-22.2 60950-00, EN60950, EN50178 FCC part 15B class A, EN55011 class A FCC part 15B class A, EN55011 class A Conforms to EN61000-3-2. Approx. 700 g

Dimensions
CA-U2
0.5 0.5 0.5 11.8 120 Unit: mm

Protection

Safety standards Noise terminal voltage Radiated interference field strength Limits for harmonic current emissions Weight

7.62 123 65.5

10

* Specified with the rated input voltage (100 or 200 VAC) and 100% load applied.
20.5 14.5 20 63 Mounting screw hole 4 x M3: Screw insertion depth= 6 max. 28 3 60 28 17

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Specifications are subject to change without notice. KEYENCE CORPORATION 1-3-14, Higashi-Nakajima, Higashi-Yodogawa-ku, Osaka, 533-8555, Japan Phone: 81-6-6379-2211 Fax: 81-6-6379-2131
KEYENCE CORPORATION OF AMERICA Phone: 201-930-0100 Fax: 201-930-0099 KEYENCE DEUTSCHLAND GmbH Phone: 06102-36 89-0 Fax: 06102-36 89-100 KEYENCE (UK) LIMITED Phone: 01908-696900 Fax: 01908-696777 KEYENCE FRANCE S.A. Phone: 01 47 92 76 76 Fax: 01 47 92 76 77 KEYENCE SINGAPORE PTE LTD Phone: 6392-1011 Fax: 6392-5055 KEYENCE (MALAYSIA) SDN BHD Phone: 03-2092-2211 Fax: 03-2092-2131 KEYENCE (THAILAND) CO., LTD Phone: 02-369-2777 Fax: 02-369-2775 KEYENCE TAIWAN CO., LTD Phone: 02-2627-3100 Fax: 02-2798-8925 KEYENCE (HONG KONG) CO., LTD Phone: 3104-1010 Fax: 3104-1080
KEYENCE CORPORATION, 2002 CV-LED-PG-C-1-0902 Printed in Japan

Output conditions

KEYENCE INTERNATIONAL TRADING (SHANGHAI) CO., LTD. Phone: 021-68757500 Fax: 021-68757550 KEYENCE KOREA CORPORATION Phone: 02-563-1270 Fax: 02-563-1271