ACME | F300 | User manual | F160 VISION SENSOR

F160 VISION SENSOR

The First Vision Sensor to Offer

High-speed, Mid-range Machine

Vision Performance

The F160 is the industry’s first high-speed vision sensor to deliver mid-range machine vision performance to meet more demanding vision applications. The F160 enlists high speed, two-camera image capture and vision algorithm processing to meet the needs of today’s high-speed production lines. The on-screen set up and configuration system offers beginners or experts fast and easy set up. A wizardlike prompted menu option helps new users with auto setup routines, while the "expert" menu option lets those with more experience directly set configuration parameters. Several new and improved algorithms, like

Omron’s Quest OCR and "variable box" technology let users perform more precise and sophisticated applications. By using Flash-RAM memory cards, the memory capacity of the F160 can be expanded to handle multiple product lines. Choose from a selection of compact camera options to satisfy many inspection and measurement needs. The F160 also allows the customization of menus, "results" screen information and symbol and text colors to ensure optimum on-site operability. Omron's machine vision technology and know-how has come together to bring a new level of machine vision measurement and inspection capability.

Creating New Possibilities with High-speed Vision

The F160’s specialized double-speed cameras can capture images up to 4 times faster than with previous cameras. In addition, cameras feature 8 user-selectable shutter speeds and an Intelligent

Lighting Interface. The F160’s high speed processing, inspection and measurement results are generated 2 to 10 times faster than before. In the Gray Search example image below, inspections can be completed at a rate of 5,000 inspections per-minute. Because each inspection is performed at high speed, the total inspection time for complex applications is dramatically reduced, leaving time for additional inspections that may not have been possible with previous products. This can lead to significant improvements in production line throughput and product quality.

Existing products

F160

Image capture time

Up to 4 times as fast

Inspection processing time

2 to 10 times as fast

2

Simple Gray Search Processing of one area – 12ms

Gray Search Processing of multiple inspection areas – 11ms

Gray Search Processing of multiple inspection areas with position compensation enabled – 35ms

High-speed and Measurement

Inspection Applications

Product Sorting

Sort boxed product by size or labels and inspect seams.

Camera 0

AC

ME

BO

X

AC

ME

BO

X

AC

ME

BO

X

Camera 1

AC

ME

BO

X

Trigger sensor

F160 Controller

Optical Character Recognition

Pill presence/absence and Lot/Date code confirmation on blister packs.

Camera F160 Controller

Trigger sensor

RS-232C/422 label data

High Speed Bottle Inspection

Inspect dimensions, conformance and date code.

Camera 0

Trigger sensor

Camera 1

F160 Controller

PCB Inspection

Electronic component inspection/board position measurement.

Camera F160 Controller

Trigger sensor

RS-232C/422 component and position data

Position Reference

Identify random, odd-shaped product positioning on a conveyor.

High Speed Robotic Tool Guidance

Communicate tool and part alignment and tool wear to robotics.

S.C.A.R.A. Robot I/O and RS-232C/422 position data

Camera

Trigger sensor

F160 Controller

Camera 0

I/O and

RS-232C/422 position data

Tooling

Camera 1

F160 Controller

3

Advanced Algorithms and Functions

New and improved visual inspection algorithms are available in the F160. All of the algorithms take advantage of the high-speed processing and two-camera capability to maximize your visual inspection capability and functionality.

Classification QUEST Optical

Character Recognition

Quest is an Omron original OCR algorithm. No character teaching required. Quest has a high level of discrimination between similar characters and adapts to changes in shape and size. OCR of one character per region.

The classification tool is ideally suited for sorting of multiple objects on the same production line. A search is preformed on an image from multiple reference models and the model number with the highest correlation is output.

1

2

3

L

M

S

L M S

Model 1 Model 2 Model 3

"Variable Box"

Measurements

The box measurement region can be setup to change automatically when performing Area or Defect inspections on objects of varying sizes. This ensures that the optimum measurement region is always used for inspection.

Advanced Model Search

Object Width

Measurement

Omron’s Edge Width measurement function works like a caliper tool. Two edges of an object are detected to sub-pixel accuracy and from this the width of the object is calculated.

Labeling

Objects with unusual shapes (blobs) can be detected and counted inside a measurement region. Detected objects are then sorted according to area or center of gravity and measurement data for specific labels is output.

Counting gears

4

Flexible search allows the use of several reference models for a gray scale search. This method allows objects with modestly changing features and varying shapes to be inspected with one tool.

Rotation Search

Rotation Search can be performed on an object to detect rotation up to 360 º.

The F160 performs this measurement 10 times faster than before and, using angle interpolation, detection angles can be detected with a degree of precision.

Searching in a rotation range of 360˚ with a skipping angle of 5˚

Position Compensation

The F160 can compensate for an object’s position by using only the outline or feature of an object or by two reference points from an object. Setting priorities for the compensation direction are also possible.

Compensation in the

X direction followed by compensation in the

Y direction

Result Expressions

Expressions using up to 32 inspection variables or constants each can be used to produce judgement or data output.

Expressions allow for complex calculations based on inspection data to determine output results.

User-friendly Operation

The F160 offers many features to increase its ease-of-use and make its operation as convenient as possible. These features assist in the setup, operation and use of data and images produced by the F160.

I/O Monitor

The status of the input and output terminals can be displayed on-screen. The I/O monitor can be used for checking wiring when setting up or making adjustments to the F160.

Shortcut Keys

Frequently used F160 operations, like result display changes, can be assigned to specific console keys.

Menus can also be switched at the touch of a single console button.

On-screen Figures and Display Colors

Figures such as lines, boxes, circles and crosses can be drawn and positioned on the screen at measurement positions or user set coordinates. Text message and figure colors can be set for best viewing.

Manageable

Screen Text

Screen text messages can be changed to best suit the operating environment.

Message position, character size and color and background can also be changed.

Increased Image

Storage

Up to 35 measurement images can be stored in memory. These stored images can consist of all images captured or only the failed images. The stored images can then be used to help diagnose production problems.

Good product image

Improper product images

Password Option

To prevent unauthorized use or changes to the F160, passwords can be set to restrict access to operation levels. This function will help to improve security and reduce incorrect operation.

Screen Capture

Setting screen

POWER

SYNC

Capture

Memory card

Documentation on computers

Setup Manual

Procedure

1.

2.

3.

Images of menu settings, measurement screens, and camera images can be captured and stored in the memory card. This feature is very useful for creating setup and operation documentation.

Menu

Masking

To save time and simplify setup, menus can be masked off from view to help minimize setup operations. Masking menus can also help prevent unauthorized use of menu operation.

RS-232C Output

Formatting

The output format of RS-232C data can be set to suit control system requirements.

Settings include output format, number of data digits, field and record separators and zero suppression.

5

The Right Lights & Camera

For Your Action

Omron’s compact shutter camera is perfect for high-speed inspection applications and can be fitted with several different light sources, including those that support the Intelligent Light Source specification, depending on the application.

Unique, Intelligent Light Sources (ILS)

Omron’s ILSs and ILS integrated cameras are designed to enhance and simplify your vision applications. The ILSs use a hood shape that reduces external interference, making conditions ideal for highly accurate inspections. The combination of red and green LEDs also enables the F160 to inspect a wide range of objects. One ILS version offers the ability of adjustable coaxial vertical lighting in addition to the adjustable ring light. The adjustable ring light lets the user adjust brightness and light direction based on the application requirements.

Maximize Lighting Control

With an Intelligent Light Source camera, the F160’s controller menus take all of the guesswork out of proper lighting. Operators can control the illuminated area and light intensity from the controller menus. The settings are easily changed without direct adjustment to the light source. Lighting positioning is stored with other scene data so operators can change the lighting conditions to match different operating environments. Because the settings are numeric data, it is possible to recreate the lighting conditions from machine to machine.

Sensing Distance & Field of Vision

F160-SLC20 F160-SLC50

6

Object

Field of vision (20 x 20 mm)

Camera distance:

15 to 25 mm

Field of vision: 20 mm

Light intensity can be set separately to one of 8 levels for 5 illuminated areas.

3

2

1

Coaxial vertical lighting

4

5

Object

Camera distance:

16.5 to 26.5 mm

Field of vision (50 x 50 mm)

Field of vision: 50 mm

Light intensity can be set separately to one of 8 levels for 8 illuminated areas.

6 2

5

1

3

7

4 8

System Configuration

Synchronous Sensor

Programmable Controller

Double-Speed Camera

Parallel Cable

F160-VP

(2 m, loose-wire cable for parallel

I/O connectors)

Controller

F160-C10E (NPN input/output)

F160-C15E (PNP input/output)

Camera with

Intelligent Lighting

F160-SLC20

Camera Cable

F150-VS (3 m, double-speed camera)

F160-VSR3 (3 m, F200/F300)

F160-VSR4 (3 m, F300-S)

Camera with

Intelligent Lighting

F160-SLC50

Camera

F160-S1

Power Supply

Recommended model:

OMRON S82K-05024

Monitor

Console

F160-KP

Memory Card

F160-N64S

(64 Mbytes)

RCA/BNC Video Cable monitor cable (2 m)

Color LCD Monitor

F150-M05L

7

8

Dimensions

Unit: mm (inches)

Controller

F160-C10E/C15E

12 (0.47) 60 (2.36)

Four M3 mounting holes with depth of

4.8 mm

56 (2.20)

Four M3 mounting holes with depth of

4.8 mm

60 (2.36) 12 (0.47)

Console

F160-KP

ESC

48 (1.89)

SHIFT

ENT

TRIG

F1

F4

F7

F2

F5

F8

F3

F6

F9

29.7 (1.17)

20

(0.79)

110 (4.33)

12 dia.

40 (1.57) 2000 (78.74)

9 92 (3.62)

F160-SLC20

12

70 (2.76)

12

12

31

40 (1.57)

12

F160-SLC50

16

90 (3.54)

16

16

31

60 (2.36)

16

Four M4 mounting holes with depth of 6 mm

Double-speed Camera

73 (2.87) 46.5 (1.83) 85 (3.35)*

10

(0.39)

25

(0.98)

96.25 (3.79)

30.5

(1.20)

8 (0.32)

23.25

±

1.3 (0.92)

1/4-20UNC with depth of 10 mm

86.25 (3.40)

Two M4 mounting holes with depth of 10 mm

13.25

±

1.1 (0.52)

20

±

1.3 (0.79)

Liquid Crystal Monitor

F150-M05L

POWER

SYNC

Mounting plate thickness: 1.6 (0.63) to 4.8 (0.19)

(46 max)

Mounting bracket

100 (3.94)

185 (7.28)

174 (6.85)

5.5 (0.22)

F150-VM Monitor Cable

¥ Tolerance:

±

1 mm

¥ The dimensions in parentheses are reference values.

Panel cutout dimensions

133.5

+0.5mm

0

(5.26)

175.5

+0.5mm

0

(6.91)

80 (3.15) 46.5 (1.83) 85 (3.35)*

10

(0.39)

25

(0.98)

103.25 (4.06)

30.5

(1.20)

8 (0.32)

23.25

±

1.3

1/4-20UNC with depth of 10 mm

93.25 (3.67)

Two M4 mounting holes with depth of 10 mm

13.25

±

1.1 (0.52)

20

±

1.3 (0.79)

F160-S1

15.5

(0.61)

8

54.5 (2.15)

46.5 (1.83) 6 (0.24)

6.2

(0.24)

6.2

(0.24)

Light connector

(8.8 dia.)

1"-32UN-2A

(C mount)

30.5 (1.20)

31.25

±

2 (1.24)

21.25

±

2

8

31 (1.22)

Camera cable connector

(11.8 dia.)

Two M4 mounting holes with depth of 8 mm

1/4-20UNC with depth of 8 mm

20

±

1.3 (0.79)

Specifications

Rating/Function

Controller: F160-C10E/C15E

Item

Connectable cameras

Conversational Menu Mode Expert Menu Mode

F150-S1A/SL20A/SL50A/SLC20/SLC50, F160-S1/SLC20/SLC50, F300-S/S2R/S3DR/S4R etc.

Number of cameras Connectable

Number of pixels

Number of scenes

Image storage function

1

512 x 484 (H x V)

32 (Expansion possible using Memory Card.)

Maximum of 35 images stored

2

Filtering

Position displacement compensation

Number of measurement regions

Applications

Set either automatically or manually

Compensation directions: X, Y, and

θ

(360

°

) directions

32 regions per scene

7 types available (presence, orientation, dimensions, defects, conformity, position, chips and burs)

Smoothing (strong, weak), edge enhancement, edge extraction (horizontal, vertical, both horizontal and vertical), dilation, erosion, median, background suppression

Compensation directions: X, Y, and

θ

(360

°

) directions

Detection methods: Binary center of gravity, axis angle, labeling, rotation search, gray search, edge position

Measurement data

Data operation functions

(expressions)

Automatically selected according to the application.

Gravity and area, gravity and axis, gray search, precise search, rotation search, flexible search, relative search, defect, area (variable box), defect (variable box), edge position, edge pitch, edge width, density average, labeling, OCR for 1 character, classification

Number:

Operations:

32 expressions can be set for judgements, data, and variables used in other expressions

Arithmetic operations, square root, absolute value, remainder, distance, angle, maximum, minimum, SIN, COS, ATAN, AND, OR, NOT

Results output

Functions for customizing operations

Functions for customizing screens

Overall judgements, judgements for each measurement region Overall judgements, judgements for each measurement region, expression results, measurement/expression data

Menu masking, password setting, shortcut keys

Display items: Character strings (measurement values, judgement results, times, user-specified characters, measurement region names) Figures (lines, boxes, circles, cross cursors)

Specified parameters: Display color, position, size

Number of slots for memory cards

Monitor interface

Serial communications

Parallel I/O

Input/ output type

NPN

PNP

Power supply voltage

Current consumption

Ambient temperature

Ambient humidity

External dimensions

Weight

1

1 channel (color, monochrome)

RS-232C/422A, 1 channel

13 inputs and 22 outputs including control I/O points

F160-C10E

F160-C15E

20.4 to 26.4 VDC

Approx. 1.6 A (with two F160-SLC50 Cameras connected)

Operating: 0 to 50

°

C (32 to 122

°

F) Storage: -25 to 65

°

C (52 to 149

°

F) with no icing or condensation

Operating and storage: 35% to 85% (with no condensation)

56 x 160 x 110 (W x H x D) mm (not including connectors and other protruding parts)

Approx. 570 g (Controller only)

Double-speed Camera: F160-S1

Item

Picture element

Effective pixels

Scanning method

Shutter

Camera with intelligent lighting

External dimensions

Weight

Specifications

1/3” Interline CCD

659 x 494 (H x V)

1/60-s non-interlace (frame) mode, 1/120-s 2:1 interlace (field) mode

Electronic shutter; select from 8 shutter-speed settings (1/120 to 1/20,000 s) using menu.

F160-SLC20 (field of vision: 20 mm), F160-SLC50 (field of vision: 50 mm)

31 x 40 x 54.5 (W x H x D) mm (not including connectors and other protruding parts)

Approx. 85 g (Camera only)

F150-M05L Color LCD Monitor

Item

Size

Type

Resolution

Input signals

Power supply voltage

Current consumption

Ambient temperature

Ambient humidity

Weight (monitor only)

Accessories

Specifications

5.5 inches; 111.36 x 83.52 mm (H x V)

Liquid crystal color TFT

320 x 240 dots

NTSC composite video (1.0 V/75

Ω

)

20.4 to 26.4 VDC

Approx. 700 mA

Operating: 0 to 50

°

C (32 to 122

°

F); Storage: -25 to 65

°

C (52 to 149

°

F) with no icing or condensation

Operating or storage: 35% to 85% (with no condensation)

Approx. 1 kg

Instruction manual and 4 mounting brackets 9

F160 Vision Sensor Selection Guide

First:

Third:

Start by selecting the controller part number with the correct input/output type, NPN or PNP, to meet the applications needs.

Second: Choose from the three F160 double-speed cameras. Select one or two cameras based on the application.

If a 20 or 50 mm field of vision can be used with the Intelligent Light Source, choose from the

F160-SLC20 or F160-SLC50. (See page 6 for SLC20 & SLC50 setting information.) If different field of view and lighting is required, use the F160-S1 camera without lens and light source.

Choose camera cables, Parallel I/O cable, monitor and monitor cable as required. For additional camera cable and parallel I/O cable lengths and monitor options, please consult your Omron vision representative.

Fourth: If F160-S1 camera option is used, refer to the Lens Selection Guide next to choose a lens for the application. The F160-S1 camera also offers the intelligent lighting interface to allow the use of controllable external lighting options. Please consult your Omron vision representative for additional assistance in lens selection and lighting options.

+ + + +

10

Ordering Information

Name

Controller

Model Number

F160-C10E

F160-C15E

Double-speed camera with fixed lens & intelligent lighting

Camera only

Console

Color LCD monitor

Memory card

Camera cable

F160-SLC20

F160-SLC50

F160-S1

F160-KP

F150-M05L

F160-N64S

F150-VS

Monitor cable

Parallel I/O cable

Extension tubes

F160-VSR3

F160-VSR4

RCA/BNC Video Cable

F160-VP

F150-EXT

Comments

NPN Input/Output

PNP Input/Output

20 mm field of view

50 mm field of view

Without lens or light source

Keypad with shortcut buttons

5.5 inch color LCD

Memory capacity: 64 Mbytes

For double-speed camera & compatible F150 cameras;

Cable length: 3 m

For compatible F200/F300 cameras; Cable length: 3 m

For F300-S only; Cable length: 3 m

Cable length: 2 m

Loose-wire cable for parallel I/O connectors; Cable length: 2 m

A set of six extension tubes that are 40, 20, 10, 5, 1, and

0.5 mm in length respectively

Lens Selection Guide

First: Start by defining the field of view requirements for each camera. Refer to the diagram at bottom left. The field of view is considered to be the area or areas requiring inspection. This does not necessarily include the entire part or object in the field of view.

Second: Determine the camera distance, measured from the object surface to the camera. Refer to the lens setting illustration for additional information about setting distance. This distance can impose limitations on the field of view and lens choice.

To get the greatest flexibility in lens selection, keep the camera setting distance as flexible as possible.

Third: Using the field of view and camera setting distance requirements, use the optical graph axis marked "Field of view L (mm)" to find the matching field of view size. Use the optical graph axis marked "Camera distance A (mm)" to find the approximate camera setting distance. Follow the values across the chart until they cross. Refer to the lens part reference on the right at the end of the graph line to find the correct lens size. (If a "t" value other than 0 is indicated, corresponding lens extension tubes will need to be added in between the camera and lens in order to properly focus the image. The "t" value indicates the thickness of the extension tubes required.)

Note: Extension tube length should not exceed 10% of the focal length of the lens. When looking at other manufacturers’ lenses not referenced by Omron, please use a 1/3-inch CCD size as a selection value reference.

Fourth: If an appropriate lens cannot be found to satisfy your application, please consult your Omron vision representative for additional assistance in lens selection options.

CCTV Lens

Model

Dimensions

Focal length

Brightness

F150-L8

29 dia. x 34.5 L*

8.0 mm

F1.3

F150-L12

30 dia. x 34.5 L*

12.5 mm

F1.4

F150-L16

30 dia. x 24.5 L*

16.0 mm

F1.4

F150-L25

30 dia. x 24.5 L*

25.0 mm

F1.4

F150-L50

32 dia. x 37 L*

50.0 mm

F1.8

F150-L75

32 dia. x 42.5 L*

75.0 mm

F2.7

* Lens diameter does not include lens ring lock screw height.

Note: Omron reserves the right to change lens suppliers and specifications without notification. Please verify all lenses with sales personnel.

Optical Graph

Unit: mm

Camera distance A (mm)

5,000

Max. outer dia.

1" -32UN

-2A

30 dia.

3,000

Total length

2,000

1,000

Lens model: F150-________

L75

L50

L25

L16

L12

L8

Camera distance

A

(mm)

Field of view

L (mm)

Camera

Extension Tube

Lens

500

300

200 t: Extension Tube thickness

100

50

4 5 10 20 30 50 100 200 300 500

Field of view L (mm)

Note: All values are approximate values. It is recommended that the camera distance be adjusted by sliding the camera forward or backward in actual operation.

11

Vision Sensors and Support Software

Solve Your Toughest Inspection Problems

F-10 Vision Sensor

The ultimate, easy-to-use, grayscale processing package for pattern and shape matching.

Setup is ultra quick with no monitor required using a one button teach function and a visible target, integrated lens and light source.

Four different camera choices are available, each with different sensing area sizes. One model even includes 8-model bank memory and RS-232C/422 communications capability.

F-30 Vision Sensor

Compact, self-contained vision sensor includes the camera, light source, lens and controller all in one unit. This easy-to-use menu driven binary vision sensor has a 256-level contrast setting and one inspection area that is perfect for most pixel counting applications.

F150-2 Vision Sensor

Uses drop down menus to setup functions including filtering, adjusting the shutter speed, background suppression, X, Y, and Theta position compensation, and image calibration.

Measurement tools include center of gravity, area, edge position, edge pitch, degree of defect, and more with 16 setup scenes and up to 16 measurements per scene. Other features include a 23-image storage memory, RS-232C and DeviceNet communications.

F150-3 Vision Sensor

Delivers 2-camera performance and lighting control based on the F150-2’s easy-to-use format. The camera splitter unit and built-in menus or PC software allows the controller to integrate images from two cameras and perform multi-angle inspections on a single object simultaneously.

Vision Composer Software

This optional Windows ® -based Vision Composer software allows you to use more sophisticated functionality in a drag-and-drop flow chart environment with the F150-3 Vision Sensor.

Vision Composer can also help collect and report the measurement results without specialized programming.

F400 Vision Sensor

The industries first color Vision Sensor using

Hue, Saturation, and Intensity to combine Color

Pickup and 5 color filters into an easy-to-use and powerful color vision solution at an affordable price. With Color Pickup, the F400 can be quickly configured to detect and measure up to

8 colors simultaneously or use the industry’s first Colorgray filter to convert a color into 256 level grayscale to analyze and measure very fine differences in the isolated color’s image, even in fluctuating lighting conditions.

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OMRON ELECTRONICS LLC

Technical Automation Solution Division

Schaumburg, IL

OMRON CANADA, INC.

Scarborough, Ontario

UNITED STATES REGIONAL SALES OFFICES

800.55.OMRON or 847.843.7900

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Toronto 416.286.6465

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SB F160-1 6/01/7.5M