Vision Sensor

Vision Sensor
OMRON Corporation
Industrial Automation Company
Advanced Sensors Group
Sensing Devices and Components Division H.Q.
Shiokoji Horikawa, Shimogyo-ku,
Kyoto, 600-8530 Japan
Tel: (81)75-344-7069/Fax: (81)75-344-7107
Regional Headquarters
OMRON EUROPE B.V.
Sensor Business Unit
Carl-Benz Str. 4, D-71154 Nufringen
Germany
Tel: (49)7032-811-0/Fax: (49)7032-811-199
OMRON ELECTRONICS LLC
Vision Sensor
1 East Commerce Drive, Schaumburg, IL 60173
U.S.A.
Tel: (1)847-843-7900/Fax: (1)847-843-8568
OMRON ASIA PACIFIC PTE. LTD.
83 Clemenceau Avenue,
#11-01, UE Square,
239920 Singapore
Tel: (65)835-3011/Fax: (65)835-2711
OMRON CHINA CO., LTD.
BEIJING OFFICE
Room 1028, Office Building,
Beijing Capital Times Square,
No. 88 West Chang'an Road,
Beijing, 100031 China
Tel: (86)10-8391-3005/Fax: (86)10-8391-3688
Authorized Distributor:
Cat. No. Q125-E1-1
Note:Specifications subject to change without notice.
Printed in Japan
0301-??M (????) (?)
Great Performance from
a Sensor with No Blind Spots
High
speed
New
inspection
functions
F160
Simple
operation
Adaptability
Creating New Possibilities with
Incredible Speed
The F160 can be applied to ultra high-speed lines. It allows a greater range of
inspections within the required tact time, contributing greatly to the improvement of inspection quality.
The newly-developed Double-speed Camera allows images to be captured up to 4 times faster than with previous cameras, and
image processing can now be achieved 2 to 10 times faster than before. For example, gray search for the image shown in Picture 1 below can be performed for 5,000 items-a-minute inspection lines. Also, because each individual inspection is made at
high speed, the total inspection time for complicated applications has been dramatically reduced. This creates extra time for
inspections that were not possible before, leading to significant improvements in inspection quality.
Image capture time
Inspection processing time
Existing
products
Up to 4 times as fast
2 to 10 times as fast
F160
• Example: Gray Search Processing (Picture 1)
• Example: More than one inspection item
The development of the F160 represents the arrival of a remarkable vision sensor
that answers the needs of today's inspection line. It has the processing speed
required for ultra high-speed lines and, using memory cards, has the capacity
required for multi-product lines. Choose from a comprehensive selection of cameras
for just the right type of inspection, and customize screens and operations to ensure
optimum on-site operability. Initial setup can be performed even by inexperienced
operators thanks to user-friendly conversational menus, and inspection performance
has been comprehensively improved using new algorithms.
All of OMRON's technology and know-how has come together to bring you the
optimum vision sensor - the F160, a sensor you can use with confidence.
High
speed
New
inspection
functions
F160
Adaptability
Simple
operation
2
3
High
speed
New
inspection
functions
F160
Simple
operation
Adaptability
Use in a Wide Variety of Applications with
a Greatly Reduced Installation Time
■ Data-handling Capacity Increased with Memory Cards
High
speed
New
inspection
functions
F160
Adaptability
Simple
operation
Operations
The F160 enables reductions in setup costs and allows a greater number of scenes to be used.
The F160 is equipped with a memory
card slot that allows the number of available scenes to be increased simply by
inserting a card. With a 128-MByte
card, for example, up to 1,000 scenes
can be saved (see note). The construction of computer-based systems for
exchanging scene data is no longer
required.
■ Menu Masking
■ Shortcut Keys
Incorrect operation can be prevented by masking
menu items for settings that must not be changed.
This function also simplifies the operations required
Frequently used operations can be allocated to
specific console keys. Menus can be switched at
the touch of a button.
to change menu settings and helps save time.
Measurement image
Note: The actual number of scenes that
can be saved depends on the scene
settings.
■ Password Setting
■ Increased Functionality for Storing Images
■ I/O Monitor
Up to 35 screens of measurement images and improper images (i.e. images
of improper products) can be stored. Also, because the most recent improper
image can be viewed while performing measurement, problems in the inspection line can be analyzed without stopping production.
The status of input and output terminals
can be displayed on the screen. This function can be used for checking wiring when
making adjustments to the system.
Line-brightness display
Switch the display
with one touch
Passwords can be set to
restrict the personnel
allowed to operate the
F160. This function helps
to improve security and
reduce incorrect operation.
Screens
NG34
NG1
Good product image
Customize Operations, Screens, and
Output to Suit Your Requirements
■ Screen Messages
Screen messages can be changed to suit the
on-site environment and can be displayed in any
desired position on the screen.
■ It is possible to select the character-size and
the display can be black-white inverted.
NG0
Improper product image
■ Screen Capture
Images of menu setting screens,
Setting screen
measurement screens, and
improper images can be captured and stored in the memory
POWER
card. This feature is very useful
for creating documentation.
■ Color Display
Documentation on computers
■ Drawing Figures
Setup Manual
Capture
Figures such as lines,
boxes, circles, and cross
cursors can be drawn. It
is also possible to these
Procedure
1.
SYNC
2.
Memory card
Messages and figures can be made easier to
view by using different colors.
3.
figures at measurement
positions.
A Wide Variety of Cameras
OMRON's Double-speed Cameras, F150 Cameras, or F200/F300 Cameras can be connected. Use the
Camera that meets your speed, cost, and lighting requirements.
4
● Double-speed Camera
● F150 Camera
F160-S1/SLC20/SLC50
F150-S1A/SLC20/SLC50/SL20A/SL50A
The shutter speed can be set to one of 8 settings from the Controller. Cameras with intelligent lighting are also included in the lineup.
Compact and cost-effective.
Models with intelligent lighting or
compact LED lighting are available.
● F200/F300 Camera
Output
■ RS-232C Format
■ Conversational Menus
The output format can
be changed to suit system specifications.
The F160 also has menus designed in a conversational style so that
even personnel with little experience can perform settings with ease.
Existing cameras can be used by
just moving them from the
F200/F300 to the F160.
5
High
speed
New
inspection
functions
F160
Simple
operation
Adaptability
Inspection revolutionized with
new algorithms.
■ QUEST Character Recognition
A Variety of Functions Accessible with Easy-to-Use Menus
The F160 uses OMRON's character recognition system - QUEST.
Features
• The user does not have to register characters.
• High-level of discrimination of similar characters.
• Adapts to fluctuations in shape and size.
■ Rotation Search
Using this method, search is
performed while the image
Use for any type of character
is rotated. Processing is performed 10 times faster than
with existing models. Using
angle interpolation, it is possible to detect angles with a
high degree of precision.
Example: Searching in a rotation range of 360° with a skipping angle of 5°.
■ Classification
A search is performed for
more than one model, and
the model number with the
1
2
highest correlation is output.
The flexible search function
can be used for applications
■ "Variable Box" Measurement for Defect Inspection
The measurement region can be set to change automatically when performing inspections for objects
with varying sizes, such as electronic chip components. This feature ensures that the optimum measurement regions are always used for inspection.
Setting screen
3
The inspection region automatically
adapts to the object. region size.
S
M
S
Model 2
Model 3
■ Labeling
The positions of
both edges of an
object are detected
with high accuracy,
and from this the
width of the object is
The number of labels (i.e., objects) inside the measurement region is counted. After they have been sorted according to area or center of gravity, the measurement data for specified labels is output.
calculated. It is not
necessary to set
expressions for calculating the width.
Counting gears
Using this method, matching is performed using more than one reference image and so the F160 can
perform inspection for objects with varying shapes. This feature helps to reduce incorrect judgements.
6
L
Model 1
■ Edge Width
■ Flexible Search
Matching can be performed for products with varying
shapes by using more than one reference image.
M
involving objects with different shapes.
Measurement screen
Set frames for adjusting the region size.
L
■ Position Displacement Compensation
■ Expressions
With the F160, compensation using only
the outline of the
object, 2-stage position compensation,
and setting priorities
for the compensation direction are all Compensation in the X direction followed by compensapossible.
tion in the Y direction.
Judgement and data
output based on a
maximum
of
32
expressions is possible. Up to 32 variables (representing
other expressions)
can be used, ena-
Inspecting the position
and number of buttons
bling more complex
calculations.
7
System Configuration
Standard Models
Sync sensor
Console
F160-KP
Name
F150-KP
Controller
Programmable Controller
Double-speed
Camera
Double-speed Camera
Controller
F160-C10E
F160-C15E
Camera with Intelligent Lighting
F160-SLC20
F160-SLC50
Compatible
F150 Cameras
Model number
Comments
F160-C10E
NPN Input/Output
F160-C15E
PNP Input/Output
Camera with
Intelligent Lighting
F160-SLC20
Camera only
F160-S1
Camera with
Intelligent Lighting
F150-SLC20
F160-SLC50
F150-SLC50
F150-SL20A
Camera with Light
F150-SL50A
Parallel Cable
F160-VP
Camera only
Camera
F150-S1A
F200-S
F300-S
Compatible
F200/F300 Cameras Shutter Camera
F300-S2R
F300-S3DR
Frame-shutter Camera
With separable head.
F300-S4R
F160-KP
Camera
F160-S1
Console
Memory Card
F160-N64S (64 Mbytes)
QM300-N128S (128 Mbytes)
Camera
Cable
F150-VS
F150-KP
Color LCD Monitor
F150-M05L
Monochrome CRT Video Monitor
F150-M09
Memory Card
F160-N64S
Memory capacity: 64 Mbytes
F150-VS
For Double-speed Camera and compatible F150 Cameras.
Cable length: 3 m
F160-VSR3
For compatible F200/F300 Cameras.
Cable length: 3 m
F160-VSR4
For F300-S only.
Cable length: 3 m
Monitor Cable
F150-VM
Cable length: 2 m
Parallel Cable
F160-VP
Loose-wire cable for parallel I/O connectors
Cable length: 2 m
Monitor Cable
F150-VM
Compatible F150 Cameras
Camera Cable
Power
supply
Camera with Intelligent Lighting
F150-SLC20
F150-SLC50
Recommended model:
OMRON S82K-05024
Monitor
Camera with Light
F150-SL20A
F150-SL50A
Camera Cable
F160-VSR4
(For F300-S only)
Color LCD Monitor
F150-M05L
Monochrome CRT
Video Monitor
F150-M09
F300-S3DR
F300-S4R
Camera Cable
F160-VSR3
Compatible F200/F300 Cameras
F300-S
F200-S
F300-S2R
Camera
F150-S1A
Note 1: Operation is not possible with combinations of different Cameras. When using the F200-S in Internal Synchronous Mode, only one Camera can be connected.
Note 2: Connect the F300-S with the F160-VSR4 Camera Cable.
Note 3: F150-M09, F200-S, F300-S3DR, and F300-S4R do not conform to the EC Directive.
8
9
Specifications
Component Names and Functions
■ Ratings/Functions
● F160-C10E/C15E
● Controller: F160-C10E/C15E
Item
Conversational Menu Mode
Specifications
Expert Menu Mode
F150-S1A/SL20A/SL50A/SLC20/SLC50, F160-S1/SLC20/SLC50, F300-S/S2R/S3DR/S4R etc.
Connectable Cameras
1
Number of Cameras connectable
2
Number of pixels
512 x 484 (H x V)
Number of scenes
32 (Expansion possible using Memory Card.)
Maximum of 35 images stored
Image storage function
Smoothing (strong, weak), edge enhancement, edge extraction (horizontal, vertical, both
horizontal and vertical), dilation, erosion, median, background suppression
Filtering
Position displacement compensation
4
8
9
32 regions per scene
7 types available (presence, orientation, dimensions,
defects, conformity, position, chips and burs)
Applications
Measurement data
Number : 32 expressions can be set for judgements, data, and variables used in other expressions
Operations : Arithmetic operations, square root, absolute value, remainder, distance, angle, maximum, minimum, SIN, COS, ATAN, AND, OR, NOT
Overall judgements, judgements for each measurement region
Results output
10
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
Automatically selected according to the application.
Data operation functions
(expressions)
5
11
12
Overall judgements, judgements for each measurement region, expression results, measurement/expression data
Menu masking, password setting, shortcut keys
Functions for customizing operations
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
Functions for
customizing screens
13
6
1
Number of slots for Memory Cards
14
1 channel (color, monochrome)
Monitor interface
RS-232C/422A, 1 channel
Serial communications
13 inputs and 22 outputs including control I/O points
Parallel I/O
Input/
Output type
F160-C10E
NPN
F160-C15E
PNP
20.4 to 26.4 VDC
Power supply voltage
Current consumption
Approx. 1.6 A (with two F160-SLC50 Cameras are connected)
Ambient temperature
Operating: 0 to 50°C Storage: -25 to 65°C (with no icing or condensation)
56 x 160 x 110 (W x H x D) mm (not including connectors and other protruding parts)
External dimensions
Approx. 570 g (Controller only)
Weight
● Double-speed Camera: F160-S1
Picture element
1/3” Interline CCD
Effective pixels
1/60-s non-interlace (frame) mode, 1/120-s 2:1 interlace (field) mode
Shutter
Electronic shutter; select from 8 shutter-speed settings (1/120 to 1/20,000 s) using menu.
Camera with Intelligent Lighting
External dimensions
Approx. 85 g (Camera only)
● Monitor
Name
Model number
F150-M05L
F150-M09
Color LCD Monitor
Monochrome CRT Video Monitor
Size
5.5 inches
9 inches
Type
Liquid crystal color TFT
CRT monochrome
800 TV lines min. (at center)
320 x 240 dots
NTSC composite video (1.0 V/75 Ω)
Input signals
Power supply voltage
20.4 to 26.4 VDC
Current consumption
Approx. 700 mA
Ambient temperature
Operating: 0 to 50°C
Storage: -25 to 65°C
(with no icing or condensation)
Ambient humidity
Operating or storage: 35% to 85%
(with no condensation)
Weight (Monitor only)
2 RUN indicator
Lit while the F160 is in Run Mode.
8 Console connector
Connects the F160 to the Console.
3 ERROR indicator
Lit when an error has occurred.
9 Memory Card slot
Inserts the Memory Card.
4 I/O terminals (control lines)
Connect the F160 to external devices such as
sync sensors or PLCs.
10 Camera 0 connector
Connects to Camera 0.
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)
Weight
Resolution
7 Memory Card indicator
Lit while the Memory Card is accessed.
659 x 494 (H x V)
Scanning method
Item
1 Power indicator
Lit while power is ON.
Operating and storage: 35% to 85% (with no condensation)
Ambient humidity
10
7
Compensation directions: X, Y, and θ (360°) directions
Detection methods: Binary center of gravity, axis angle, labeling, rotation search, gray search, edge position
Set either automatically or manually
Compensation directions: X, Y, and θ (360°) directions
Number of measurement regions
Accessories
1
2
3
5 I/O connector (data lines)
Connects the F160 to external devices such as
sync sensors or PLCs.
6 Power supply terminals
Connect the power supply.
11 Camera 1 connector
Connects to Camera 1.
12 RS-232C/422 connector
Connects the F160 to an external device such
as a computer or PLC.
13 Monitor connector
Connects to the Monitor.
14 Ground terminal
Connects to the ground wire
100 to 240 VAC (-15%, +10%)
Approx. 200 mA
Operating: -10 to 50°C
Storage: -20 to 65°C
(with no icing or condensation)
10% to 90%
(with no condensation)
Approx. 1 kg
Approx. 4.5 kg
Instruction manual and 4 mounting brackets
Instruction manual
11
Menus
Dimensions (Unit: mm)
■ Menu Trees
● Expert Menu Mode
SET
Start
Adjust
Console
● F160-C10E/C15E
● F160-KP
Shutter Speed
12
Four M3 mounting
holes with depth
of 4.8 mm
60
Light control
66.5
66.5
TRIG
F3
F1
F2
F4
135.5
66.5
66.5
Filtering (Measurement)
F6
F5
F7
F9
F8
BGS levels (Measurement)
Orient'n
Calibration
110
7
Chip/Bur
1st direction
Gravity and axis
2nd region (P2, P3)
Edge position
2nd direction
Gray search
3rd region (P4, P5)
Rotation search
3rd direction
Labeling
4th region (P6, P7)
End
4th direction
MON
12 dia.
40
9
(15.5)
(14.5)
(6)
Gravity and area
1"-32UN-2A
(C mount)
(6.2)
8
Area (var. box)
SHIFT
Camera cable
connector (11.8 dia.)
31
CONSOLE
12 dia.
Two M4 mounting holes with depth of 8 mm
2000
23
5
10
Defect (var. box)
Display
1/4-20UNC with depth of 8 mm
Edge position
20±1.3
Operation settings
Edge width
90
73
12
12
46.5
(10)
Classification
2.5
Flexible search
*Cannot be used with conversational menus.
12
31
40
16
80
4 dia.
12
30.5
(85)
(10)
8
16
31
60
23.25±1.3
(96.25)
Relative search
46.5
25
2.5
System information
42.5
Rotation search
70
Precise search
Date/Time
16
(85)
2.5
● F160-SLC50
70
25
4 dia.
Gray search
● F160-SLC20
52.5
Density data
90
Edge pitch
Switch menu
2.5
Measurement control
Startup mode
16
30.5
8
23.25±1.3
(103.25)
1/4-20UNC with depth of 10 mm
1/4-20UNC with depth of 10 mm
Labeling
OCR for 1 chara
Camera: 0 to 31
Cameras: 0 to 15 (Camera 0) and 16 to 31 (Camera 1)
Judge (0 to 31)
MON
Data (0 to 31)
RUN
SYS
Camera settings
Liquid Crystal Monitor
Mounting plate thickness: 1.6 to 4.8
(46max)
Mounting bracket
POWER
(100)
185
● F150-M09
250
222
(5.5)
42.2
174
• Tolerance: ntlpplus/minus1 mm
• The dimensions in parentheses are
reference values.
Panel cutout dimensions
5
Startup mode
133.5 +0.5mm
0
Date/Time
TOOL
Video Monitor
F150-VM Monitor Cable
Operation settings
SAVE
20±1.3
50min
Output
Switch menu
(93.25)
● F150-M05L
Communications
Measurement control
13.25±1.1
20±1.3
SYNC
Display
Two M4 mounting holes
with depth of 10 mm
13.25±1.1
233
Display
Two M4 mounting holes with depth of 10 mm
(86.25)
(145)
(155)
Variable (0 to 31)
143
Expression
132
SAVE
143
TOOL
12
13
ENT
TRIG
(6.2)
Light connector
(8.8 dia.)
30.5
31.25±2
21.25±2
Defect
Output*
ESC
54.5
(46.5)
8
1.5
50
● F160-S1
Gravity and axis
Communications
● F150-KP
11
Measurement
Camera settings
2000
Four M4 mounting holes
with depth of 6 mm
Double-speed Camera
These items appear only when 2 Cameras are connected.
RUN
92
87
Position
Gravity and area
29
Conform
1st region (P0, P1)
38
Position
Surface
(30.7)
Dimns'n
SYS
ENT
ESC
153
Filtering order (Measurement)
Presence
20
SHIFT
Filtering (Position)
Position
29.7
12
48
BGS levels (Position)
Region
60
Filtering order (Position)
Ref image
Up to 32
regions
can be set.
Four M3 mounting
holes with depth
of 4.8 mm
56
(21.7)
SET
Controller
12.5
● Conversational Menu Mode
190
50
160
22
System information
175.5+0.5mm
0
13
Lenses (for use with the F150-S1 and F150-S1A only)
■ CCTV Lenses
Dimensions
Model
CCTV Lenses
3Z4S-LE
C815B
3Z4S-LE
C1614A
3Z4S-LE
B1214D-2
42 dia.
42 dia.
30 dia.
3Z4S-LE
B2514D
3Z4S-LE
B5014A
3Z4S-LE
B7514C
62 dia.
48 dia.
30 dia.
37.3
33
50
40
Locking
mechanism
● With reference to the optical
graph below, select the lens
and combination of Extension Tubes that give the
required field of vision and
camera distance.
79
48
None
Focus locking mechanism
■ Extension Tubes
Model
Contents
3Z4S-LE EX-C6
A set of six Extension Tubes of thicknesses 40, 20, 10, 5, 1, and 0.5 mm respectively.
■ Meaning of Optical Graph
The X axis of the graph shows the field of
vision L (mm), and the Y axis shows the
camera distance A (mm). The curves on the
graph indicate different lenses, and the "t"
values indicate the lengths of the Extension
Tubes.
Camera
Extension Tube
thickness, t (mm)
Lens
Camera distance
A (mm)
Field of vision L (mm)
■ Optical Graph
Lens model:
3Z4S-LE
Camera distance A (mm)
● The values given in the optical graph are only approximate values. It is recommended that the camera distance is adjusted by sliding
the Camera forward or backward to get the required
field of vision for actual operation.
5,000"
3,000"
2,000"
1,000"
500"
300"
200"
t: Extension Tube thickness
100"
50
4"5"""
10"" "
20"
30"
50""" 200
100
300
500
Field of vision L (mm)
14
15
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