VISION SYSTEM

BEGINNER'S GUIDE
Do you think that vision systems are difficult to use or install?
It is true that vision systems have a wide variety of models and elements such as
illumination and controls; however, this guide presents important steps and points for
each phase of the implementation, installation, and operation of a vision system.

STEP 1 Camera
SELECTION 1 Selection based on resolution (high-resolution or standard type)
SELECTION 2 Selection by CCD (color or monochrome)
SELECTION 3 Selection based on the image transfer time (high-speed or standard type)
SELECTION 4 Selection based on physical sizes (compact or standard type)

STEP 2 Illumination
SELECTION 1 Determine the type of illumination needed (specular reflection/diffuse reflection/transmitted light)
SELECTION 2 Determine the appropriate model
SELECTION 3 Determine the correct color (wavelength)

STEP 3 Lens
SELECTION 1 Focal distance and field of view
SELECTION 2 Focus an image with a large depth of field (focal range)
SELECTION 3 Contrast differences due to lens performance

STEP 4 Inspection assessment

INSPECTION 1 Prepare for the inspection
INSPECTION 2 Setting tolerances
INSPECTION 3 Tact time and image processing time
INSPECTION 4 Resolution and processing time

SUPPLEMENTAL MATERIAL Installation Tips

INSTALLATION Tips 1 Camera/lens
INSTALLATION Tips 2 Illumination
 STEP 1 Camera Selection
Cameras are divided into the following types.
Camera selection should be determined by the needs of the application.

1 High-resolution type
2 High-speed type Monochrome and color
3 Standard type cameras are available.

4 Compact type

SELECTION 1 Selection based on resolution (high-resolution or standard type)

A camera's imaging sensor (CCD) is a collection of small pixels aligned in a grid. Standard resolution models have an array
of 310,000 pixels. High resolution models include a 2 million pixel and a 5 million pixel camera type. Generally, a camera is
selected based on "field of view" and "resolution". The "field of view" (FOV) is the area that the camera can cover in the X and
Y directions and the "resolution" is determined by how many mm are equal to 1 pixel. Their relationship is represented by the
following formula.

Resolution = Y direction of the FOV (mm) / the number of pixels the CCD has in the Y direction

With an FOV of 30 mm (1.18") in the Y direction the resolution can be obtained by the following formulas: (A standard
310,000 pixel camera (Y = 480 pixels) and a high resolution 2 million-pixel camera (Y = 1,200 pixels)

[Resolution when using a 310,000-pixel camera] = 30 mm (1.18") / 480 pixels = 0.063 mm (0.0025") per pixel
[Resolution when using a 2 million-pixel camera] = 30 mm (1.18") / 1200 pixels = 0.025 mm (0.001") per pixel

The "minimum detectable object size" when performing defect detections and dimensional measurements.

"Minimum detectable object size" = a 4-pixel square

"Dimensional tolerance" = ±5 pixels
Using the resolution calculated above, the "minimum detectable object size" of the "surface defect detection" can be
obtained in the following formulas:

[Minimum detectable object size when using a 310,000-pixel camera] = 0.063 mm (0.0025") per pixel x a 4-pixel square = a 0.25-mm (0.01")square
[Minimum detectable object size when using a 2 million-pixel camera" = 0.025 mm (0.001") per pixel x a 4-pixel square = a 0.1-mm (0.004") square

The formulas above show that a camera with 2 million pixels or more is required to detect a "Ø0.1 (0.004")-mm foreign
particle" within a 30 (1.18")-mm FOV".

[Reference]
Magnifies a ø0.5-mm (0.02") foreign particle in a 30-mm (1.18") FOV TIP 1
310,000 pixels 2 million pixels
The most suitable
camera can be selected
based on resolution!
The images show that the
2 million-pixel camera
can obtain a better image
with clearer contrast.
2
SELECTION 2 Selection by CCD type (color or monochrome)
Selecting a color or monochrome camera should be based on what type of flaws need to be detected. Flaws that are not
easily distinguishable from the background may require the use of a color camera. The following example illustrates this
type of scenario.

(1) Image captured with a color camera (2) Image after fine color processing (3) Stabilized stain detection image

Image captured with a monochrome camera

The monochrome camera cannot capture the contrast between the stain and the
shading gradations on the background, which results in an unstable inspection.
Image (2) shows that the color camera internally captures the contrast between
the yellow flaw and the white background. And Image (3) is in the contrast view
of the Stain tool. This example shows that color processing provides stability in
difficult flaw detection applications.

As shown in the example below, a monochrome camera can be used when there is significant brightness change instead
of a hue change.

[Dimensional measurement of a TIP 2

metal workpiece using a backlight]
Determine which camera to use, color or
monochrome, based on whether the flaw being
detected results in a change in hue or a change in
brightness.

SELECTION 3 Selection based on the image transfer time (high-speed or standard type)
The standard speed 310,000 pixel camera transfers images at a rate of 16.0 ms. The same resolution, high-speed
version has an image transfer speed of 4.7 ms. High-speed camera types are effective in inspections that require faster
processing times due to high-speed production lines.

[Application with the high-speed camera]

Surface defect detection
(7x high-speed 310,000-pixel monochrome camera)
Surface defect detection of a cap
(7x high-speed 310,000-pixel color camera)
TIP 3
Trigger interval Trigger interval

3 ms 12 ms High-speed cameras
Inspections Inspections
improve yield rates and
19980 4999
workpiece/min. workpiece/min.
stabilize inspections!
Flaw detection and Dimensional measurement, Print defect inspection, Position correction (XY),
Position correction (YX) Angle correction (360°)

3
 SELECTION 4 Selection based on physical size (compact or standard type)
KEYENCE's line of compact cameras offer the same resolution with a significantly reduced footprint.
The compact cameras are available in both color and monochrome versions. Compact cameras have an advantage when
there is limited space to install the camera on existing equipment.

[Required installation space]

A required space to install a camera is a total of A: WD (working distance = between the lens tip and a workpiece),
B: Lens size, C: Camera size and D: Cable space (including the bent part).

Example: A lens with a 6-mm (0.24") focal distance

is attached to the standard camera with a 30-mm
(1.18") FOV When it is impossible to secure a space of 215 mm (8.48"),
D a compact camera and the side view attachment is a
A: 40 mm (1.58")
perfect fit.
B: 40 mm (1.58")
C: 50 mm (1.97")
C D: 85 mm (3.35")
A + B + C + D = 215 mm (8.48")
B
This installation requires 215 mm (8.48") in the B
vertical direction.
A A

A: 30 mm (1.18"), B: 15 mm (0.59")
It requires only A + B = 45 mm (1.77").
TIP 4
Measure the space required to mount the camera on
a machine prior to specifying which camera is needed
for inspection.

SUMMARY OF THE CAMERA SELECTION

Camera selection is the most basic and important aspect for stable inspections using machine vision.
Here is a quick reference table to help select the most applicable camera.

[Step 1] "Selection based on resolution" ...

Which types of cameras have the required resolution?
[Step 2] "Selection based on the image transfer time"...
Select a high-speed camera when higher-speed or more stable processing is required.
[Step 3] "Selection by CCD type (color/monochrome)"...
Select a color camera when capturing hue changes.
[Step 4] "Selection based on physical size"...
Select a compact camera when the installation space is limited.

310,000 pixels 2 million pixels 5 million pixels

1
640 x 480 1600 x 1200 2432 x 2050
2 4.7 ms 16.0 ms 29.2 ms 58.5 ms 61.2 ms
3 Standard Standard Compact Standard Standard Compact Standard
CV-H035C CV-035C CV-S035C CV-H200C CV-200C CV-S200C CV-H500C
4
CV-H035M CV-035M CV-S035M CV-H200M CV-200M CV-S200M CV-H500M

4
STEP 2 Illumination Selection
LED illumination is necessary in most vision system Types of illumination
applications. There are three steps to select the most suitable
illumination type for an application.

1 Determine the type of illumination needed Coaxial vertical Low-angle Direct ring
CA-DX CA-DL CA-DR
2 Determine the appropriate model
3 Determine the correct color (wavelength)
Backlight Dome Bar
CA-DS CA-DD CA-DB

SELECTION 1 Determine the type of illumination needed

(specular reflection/diffuse reflection/transmitted light)
Diffuse reflection
Specular
reflection

Lighting basics

Incoming light The incoming light (the brown arrow) reflects on the target
surface in the three ways.

1 Specular reflection (light reflects at the same angle)

Target
Absorbed 2 Diffuse reflection (light is dispersed on the surface)
3 Transmitted light (light shines through or around the target)

Diffuse transmitted light Transmitted

light

Illumination used in vision system applications can be divided into the following three types:
(1) Specular reflection
Light is reflected off of the target directly back to the camera. This illumination is effective for inspecting highly reflective
targets such as glass substrates.
(2) Diffuse reflection
Light is dispersed in many directions as it reflects off of the surface of the target. This illumination method is effective for
inspecting targets through reflective packaging.
(3) Transmitted light
Light is applied from behind the target and the camera receives the transmitted silhouette. This is commonly used in
dimensional measurements.

(1) Sample image of specular illumination (2) Sample image of diffuse reflection (3) Sample image of transmitted light
Detecting chips on the edge of a glass substrate Inspecting print on a chip through transparent film Inspecting foreign particles on nonwoven fabric

TIP 5
Select the appropriate illumination from the following three types: specular reflection, diffuse
reflection and transmitted light according to the target material, shape, and application.
5
 SELECTION 2 Determine the appropriate model
Once an illumination method has been selected according to the type (specular-reflective, diffused-reflective, or
transmissive), the model is selected according to the target to be inspected, the background of the inspection target, and
its surroundings.

Typical illumination devices by illumination type

Specular-reflective Coaxial vertical Ring Bar
Diffused-reflective Low-angle Ring Bar
Transmitted light Area illumination Bar -

1. Sample inspection of specular illumination

Select illumination according to the target’s characteristics and detection details

1 The illumination reflects on the glass surface.

2 It is necessary to enhance the difference between the glass plate and background.

3 It is best to apply illumination vertically to the target.

4 A space can be provided above the target.

The best selection is coaxial-vertical illumination.

2.Detection sample of transmitted light

Select the illumination according to the target’s characteristics and detection details

The target is a metal object with projections and depressions,

1 resulting in irregular specular reflection.

By using a transmitted light, the edge of the target can be detected

2 without the influence of the projections and depressions.

3 An illumination device can be installed behind the target.

The best selection transmitted illumination (backlight).

SELECTION 3 Determine the correct color (wavelength)

The last step is to determine the color of illumination according to the target and background. When Green

w
a color camera is used, the normal selection is white. When a monochrome camera is used, it is

Blu
llo
Ye

e
necessary to know the following information. e
Hue circle

Pu
ng

Complementary colors are those on the opposite side from each other on the hue

rp
Complementary color
ra

le
O

circle. When light from a complementary color is applied to an object, the object Red
will appear very dark.

Wavelength Lights of different wavelengths appear as different colors. The wavelength

determines the characteristics of a particular color such as being transmitted easily
(red long wavelength) or being scattered easily (blue short wavelength).

Invisible Invisible
Visible light
light light

Ultraviolet light Purple Blue Green-blue Blue-green Green Yellow-green Yellow Orange Red Ultraviolet light

380 430 480 490 500 560 580 595 650 780

(Unit : nm)

TIP 6 Do not randomly select an illumination method. Instead, follow the procedure below to efficiently select a suitable unit.

(1) Determine the type needed (specular-reflective, diffused-reflective, or transmissive).

(2) Determine the appropriate model.
(3) Determine the correct color (wavelength).
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STEP 3 Lens Selection

SELECTION 1 Focal distance and field of view

Lens
Typical lenses for factory automation Example 3.6 mm
have focal distances of 8 mm (0.32")/

CCD size
0.14"
View angle
16 mm (0.63")/ 25 mm (0.98")/ 50
mm (1.97"). From the necessary field 16 mm
0.63"
of view of the target and the focal WD Focal distance
distance of the lens, the WD (working 45 mm
The WD and viewable area are determined by the focal
distance) can be determined. 1.77"
distance and the CCD size. When NOT using a close up WD = 200 mm 7.87"
ring, the following proportional expression can be applied.

Example: When the focal distance is 16 mm (0.63”)

Working distance : View angle = Focal distance : CCD size and the CCD size is 3.6 mm (0.14”), the WD should be
200 mm (7.87”) to make the field of view 45 mm (1.77”).

SELECTION 2 Focusing an image with a large depth of field (focal range)

(1) The shorter the focal distance, the larger the depth of field
(2) The longer the distance from the lens to the object, the larger the depth of field In this situation, pictures are taken to compare the
Close up rings and macro lenses make the depth of field smaller focal depth when the aperture is open and closed.

(3) The more closed the aperture is the larger the depth of field
A narrower aperture and bright illumination make focusing easy

Camera

View

Tape
(3 mm 0.12")
15 mm
(059")

45°
When the aperture is closed When the aperture is open
(CA-LH25) (CA-LH25)

SELECTION 3 Contrast differences due to lens performance

CA-LH16 CV-L16
The images on the right are captured with KEYENCE’s high-resolution CA-LH16
lens and a standard CV-L16 lens. The difference in the image quality is caused
by the lens materials and structures. Higher-contrast images can be produced
by using a high-resolution lens.
High-resolution lens Standard lens

Lenses used CA-LH16/CV-L16

Target Copy paper

Field of view 60 mm (2.36”)/ Stain size: Approx. 0.3 mm (0.01”) Stain level 54 Stain level 38

TIP 7 Follow the steps below when selecting a lens.

(1) Determine the appropriate focal distance and field of view needed
(2) Determine the lens aperture according to the depth of field needed
(3) Select a high-resolution lens or standard lens according to the inspection accuracy
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 STEP 4 Inspection assessment

INSPECTION 1 Preparation for the inspection

Prepare more than one sample including Good item Defective item
both acceptable and defective targets
It is effective to conduct tests with samples of both acceptable and
defective targets in order to verify the vision system's detection accuracy.
Actual examples of flaws that occur in production should be used to
test the system in order to give the most accurate representation of
inspection results.

Determining minimum tolerances

The size of the flaw in an inspection will determine whether or not the particular vision system setup will be able to
accurately perform the inspection. Some inspections require very tight tolerances while others only need to detect very
obvious flaws.

Good item Defective item [large tolerance] Defective item [tight tolerance]

Chip Chip (small)

Burr Burr (small)

Deformation Deformation
(small)

White defect White defect

(small)

The inspection accuracy will factor into determining the type of camera that is needed and should be calculated prior to
purchasing. For example, when detecting a 20-mm (0.79") target by using a 1 million-pixel camera with a 25-mm (0.98")
FOV, one pixel represents 0.025 mm. Theoretically, the detection limit is 0.025 mm (0.001") if one pixel is regarded as the
minimum detectable size. However, it is necessary to factor in a larger margin for error due to various conditions that may
affect an inspection in actual production scenarios.

For example, if the chip flaw above is 0.5 mm (0.02"), it can be stably detected since the minimum flaw size would be
represented with 20 pixels. On the other hand, if the chip is 0.05 mm (0.002"), it is more likely to cause unstable results
since the flaw is represented by just 2 pixels.

If the flaw is 0.5 mm (0.02") Stable detection!

If the flaw is 0.05 mm (0.002") Unstable inspection

8
INSPECTION 2 Setting tolerances
A reliable way to assess the stability of the detection accuracy is to use statistical processing obtained by measuring multiple
acceptable and defective items. The graph below indicates the measurement results of 256 targets by using the statistics
function equipped on the CV-5000 Series Vision System. The targets with a measured value exceeding the upper limit are
detected as NG. The upper and lower limits are displayed on the screen for reference.

Statistical processing
The average measurement value is 6.3 pixels and the upper limit is set to 17 pixels. Any measurements that exceed this
threshold will be counted as NG parts. The red circles indicate large flaws while the blue and green circles indicate those
flaws that cannot be stably extracted. This may be corrected by using a higher resolution camera.

Upper limit: 17

Good items: 250

The two graphs

The average line of indicate the number of
There are large gaps between the
good items and the upper limit.
good items
good targets decreases
from 250 to 244 when
lowering the upper
limit from 17 to 11,
which means the yield
rate also decreases.

Stricter tolerances
If the upper limit is decreased in order to detect the flaws circled in green, the detection range overlaps the maximum
value of the good items. Therefore, if the upper limit is further decreased, the good targets are more likely to be
detected as NG.

Upper limit: 11

Good items: 244

The average line of

There is no margin between the good items
good item line and the upper limit.

9
 INSPECTION 3 Tact time and image processing time
It is inevitably necessary to consider the image processing time of the vision system. The latest vision systems allow for
high-speed processing and can inspect up to 100 targets in one second. However, since the processing time varies
according to the number of pixels in the camera's CCD, number of inspections in the program, etc, it is still important to
confirm the processing time of the vision system and the tact time of the inspection lines.

The processing flow of a vision system

Image capturing/ Image
Trigger input processing Status output Control
transfer

Vision system

Sensor, etc.

PLC PC PLC

Image capture/transfer: The time during which an image is captured and the captured image is transferred to the
controller. Image processing: A captured image is processed and various inspections are completed.
(Presence detection/dimensional measurement/position inspection/count, etc.)
Status output: Outputting OK/NG judgement.

Processing speed of the vision system Convert into the inspection tact time
Image capture/transfer time: X ms to XX ms
Image processing: X ms to XXX ms X00/min. to X000/min.

INSPECTION 4 Resolution and processing time

The minimum resolution differs based on the total pixels contained in the
2432 x 2050
camera's CCD. The more pixels the camera has, the higher its resolution.
At the same time, the processing time becomes slower. The example
below is a black flaw on a container detected with a 310,000-pixel, 2
million-pixel and 5 million-pixel camera respectively. The detection of
small flaws such as the black contaminate on the container becomes
1600 x 1200 more stable using a higher resolution camera.

* The following images indicate the processing time

(the shortest trigger interval) with each type of camera.
640 x 480

310,000 pixels 2 million pixels 5 million pixels

7ms 32ms 64ms

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SUPPLEMENTAL MATERIAL Installation tips camera/lens

This page provides information on camera/lens installation.

Close-up ring
Attention needed when using more
than one close-up ring.
TIPS
Make sure that the lens is tightened
securely to the camera especially
when using multiple close-up rings.
If the required FOV is 2 mm or less, it
is recommended to use a macro lens
instead.
Camera installation
Is the camera insulated from shock and vibration?
TIPS
The camera could be damaged if installed without
insulation. This can be prevented by mounting the
camera with the resin mounting bracket supplied with
the camera when purchased. in order to secure the
insulation.
Camera mounting hole
The bracket used to mount the
camera should have an elongated
hole for adjustments.
TIPS
It is often necessary to fine-tune the
camera position in order to capture
images. In doing this, the adjustment
time can be reduced by using a jig
with an elongated hole which allows
the camera to move up and down.

Target

Lock screw
Are the focus ring and aperture iris Aperture
tightly mounted?
Working distance Do not open the aperture
(WD) more than needed.
TIPS FOV (Y)

The lock screw should be tightly TIPS

secured since the screw may gradually
Opening the aperture too far
loosen with even minor vibrations,
decreases the depth of field as
which will lead to false detections.
illustrated previously. In addition to
this, if the intensity of the illumination
Dirt on the lens decreases over the lifetime of the unit,
A protective filter is effective in preventing dirt the aperture may be opened further.
and contaminates from building up on the lens. This is not possible if the aperture is
already fully open.
TIPS
In environments where airborne particulates
may collect on the lens of the vision system it is
recommended to use a protective filter. If the filter is
damaged, it is easy to replace.

TIP
CCTV lenses are generally used in vision systems. In order to set the view angle to
approximately 2 mm (0.079") with a CCTV lens, close-up lenses are used. However,
too many close-up lenses may hinder the capture of clear images and, as a result,
inspections may become unstable. Therefore, macro lenses are more effective when
capturing an FOV from 0.5 (0.02") to 2 mm (0.079"). KEYENCE offers various telecentric
macro lenses that work effectively for dimensional measurements.
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 SUPPLEMENTAL MATERIAL Installation tips Illumination

As with cameras and lenses, there are also installation tips when it comes to illumination. Sometimes
it takes time to install the illumination device, even when the appropriate illumination is selected. This
page introduces technical tips to minimize your installation time.

Direct ring type

Installation position
Has the illumination device been installed in the
appropriate position?
TIP
Even the best illumination device is useless if it is not
installed in the appropriate position. The captured
image should be black when the illumination
device is off. (Of course, images are clear while the
illumination device is on)
Installation method
Is it possible to adjust the illumination device
towards and away from the target?
TIP
Captured images differ greatly just by moving the
illumination device towards and away from the
target. For this reason, it is recommended to allow
Bar type future adjustment of the illumination device during
installation. This will be useful when making final
adjustments.

Intensity fluctuation
The illumination intensity fluctuates immediately
after the power is turned on.
TIP
The illumination intensity becomes unstable
immediately after the power is turned on due to
temperature drift. Set the intensity after it becomes
stable (generally, it takes about 15 to 30 minutes).
Controller and monitor
Is the monitor placed near the controller?
TIP
Area type The illumination adjustment is done with the
controller. When performing this operation, it is better
to place the monitor near the illumination so that the
live image can be viewed while making adjustments
to the intensity level of the light.

Maintenance Tip 1 Maintenance Tip 2

The illumination devices are expendable items. It
Spot type
may be required to replace them in long-running
operations.
TIP
If the illumination device has been installed in a
deep, narrow place, it is likely to be a problem when
replacing the lamp. Determine the installation position
keeping in mind the possibility of having to replace
the light in the future.
Mark the brackets used to secure the illumination
unit for future replacement.
TIP
When replacing the illumination unit, keeping the
exact position of the unit is critical. To ensure this,
mark the brackets used to secure the unit so that the
new unit can installed in the exact same position.

Operational life of an illumination device Operational life by light source

(typical example)
100
The operational life of an illumination device is limited. The graph % Red LED

to the right shows that an LED has the longest operational life Fluorescent
Halogen
and a halogen has the shortest. Since LEDs have good response 50
0
times, which allows for strobe lighting, it is possible to make the
0
30 000
00

00

h
00

00
10

20

10
20

operational life of an LED even longer when they are strobed.

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Copyright (c) 2009 KEYENCE CORPORATION. All rights reserved. CVbeginner-KA-EN0714-E 0079-1 611277