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Application notes

Robotics application note

Vision inspection with robotic guidance opens up new opportunities in the quality control process.

Opto Engineering® machine vision components can be bundled as special optical probes and integrated on a robotic arm, allowing to successfully perform challenging measurements and inspections of parts of different shapes, sizes, materials and colors.

OVERVIEW

PRECISION MEASUREMENT PROBES

SURFACE INSPECTION PROBES

CAVITY INSPECTION PROBES

This application note presents a wide range of components that can be integrated on a robot arm to create special optical probes for precision measurement, surface inspection or cavity inspection.

You can easily build a robot-based system.

Just select the suitable optical probe matching your application task (camera + lens + lighting + accessories),add a robot, NI Vision or third-party software along with DigiMetrix Robotics Software libraries:

Cavity inspection probe with a boroscopic lens
Cavity inspection probe with a boroscopic lens

Opto Engineering ® optical probes

Opto Engineering ® offers a wide range of machine vision lenses, illuminators, cameras and accessories that can be successfully bundled together to create special optical probes for robotic applications.

The following application examples present demanding tasks such as precision non contact measurement, cavity inspection and other applications that require adjustments to FOV, working distance, lens focus and aperture.

Opto Engineering ® offers many other components that may be used instead of the ones suggested here, and can also develop custom mounting mechanics to fit specific application requirements.

DigiMetrix robotics libraries

The DigiMetrix Robotics Libraries for National Instruments LabVIEW allow to easily control and guide a robot arm without being experts in advanced robot programming, enabling users to achieve better results in less time. Tight integration with NI Vision libraries opens opportunities for fast and productive Machine Vision based application development.

The LabVIEW Real-Time or MS Windows execution platform is connected to a brand-specific robot controller through Ethernet network. The robot controller software provides path kinematics calculation, motion precision and safety, while the LabVIEW program dictates where to go and what to do based on sensors and vision information. As a result just one powerful software development tool is used for entire robot base application programming including Motion, Vision, Sensors, Tests Management and HMI.

Robot brands

DigiMetrix Libraries support Denso, Epson, Fanuc, Kawasaki, KUKA, Mitsubishi, Yaskawa Motoman and Toshiba Machines

CORE telecentric lenses and illuminators deliver excellent optical performance in a package that is up to 70% smaller than other solutions on the market.

Thanks to the unique opto-mechanical design, these innovative optics open up possibilities for new applications with maximum flexibility.

They can be mounted not only in tight spaces but also on robotic arms, thus expanding the range of use of this precision measurement setup.

CORE robotic optical measurement probe acquiring an image of a shaft
CORE robotic optical measurement probe acquiring an image of a shaft
Image of the shaft presents very sharp edges and no reflections, allowing precise 2D measurement.
Image of the shaft presents very sharp edges and no reflections, allowing precise 2D measurement.
USB 3.0 2/3” Camera USB 3.0 1/1.8” Camera USB 3.0 1/1.2” Camera USB 3.0 1.1” Camera
RT-mvBF3-2051aG RT-mvBF3-2032aG RT-mvBF3-2024aG RT-mvBF3-2124G
2464 x 2056, 3.45 μm 2064 x 1544, 3.45 μm 1936 x 1216, 5.86 μm 4112 x 3008, 3.45 μm
+ + + +
Bi-telecentric lens Bi-telecentric lens Telecentric lens Telecentric lens
TCCR23048 TCCR12048 TCCR2M048-C TCCR4M048-C
FOV: 46.2 x 38.55 mm FOV: 53.14 x 39.75 mm FOV: 42.33 x 26.59 mm FOV: 38.45 x 28.12 mm
+
Telecentric light
LTCLCR048-G
Green collimated illuminator
+
Robot holder clamp USB Camera Cable LED Power Supply
CMHORBCR048 CBUSB3001 RT-SDR-120-24
Compatible with a ISO 9409-1-31/5 robot flange type
(4xM5 holes on 31.5 mm diameter)
Passive USB 3.0 cable, industrial level,
horizontal screw locking, 3 m
24VDC DIN rail power supply
 
Compatible with a 6-axis and SCARA robot arm with 4kg+ payload
Cameras Optics Lighting Accessories
CMHORBCR048 gripper flange close-up.
CMHORBCR048 gripper flange close-up.

CMHORBCR048 metrology probe clamp is designed to mount TCCRxx048 lenses and LTCLCR048-x illuminators on 4kg+ payload robots. It is compatible with a ISO 9409-1-31/5 robot flange type (4xM5 holes on 31.5mm diameter). This flange type is popular on small/medium robots like Mitsubishi, Epson, KUKA, Denso, Fanuc and others.

Custom mounting clamps can be developed on request to fit larger CORE telecentric optics for up to 97mm FOV or supplied with a different gripper flange type.

Robotic CORE optical probes can be used in a wide variety of measurement and inspection applications where telecentric optics are greatly beneficial but traditionally difficult to integrate because of their size.

For example, measuring shiny metal parts with non-telecentric optics is very challenging, due to light reflections off the of metal surface that cause inaccurate readings.

Often times, fragile or complex-shaped parts cannot be inspected on a conveyor belt and must be checked by a robotic arm moving in tight areas.

CORE optical measurement probes overcome the size issue of classic telecentric benches, allowing to combine robotic motion and telecentric optics to inspect and precisely measure complex parts.

In robot guided vision inspection, it is often necessary to both locate an object over a large area and to image small details on it. Inspecting complex objects like a car engine or the car itself requires a robot arm with a probe that can be moved to any desired position. In order to optimize image quality accounting for all variables, such as changing lighting conditions, modified working distances or even different inspection tasks, focus and aperture adjustments are typically required.

ENMT series are high resolution fixed focal length lenses with motorized focus and aperture control, allowing for precise and repeatable adjustments of the lens settings. They are ideal for fully automated systems and for installations that require remote control of the optical parameters. Motorized iris and focus allow the user to optimize image capture in different working environments and to accurately perform multiple point inspection of parts of various sizes, shapes and complexity.

ENMT lens
ENMT lens
USB 3.0 2/3” Camera
RT-mvBF3-2051aG
2464 x 2056, 3.45 μm
+
12 mm motorized lens 16 mm motorized lens 25 mm motorized lens 35 mm motorized lens 50 mm motorized lens
ENMT-M1224-MPW2-MM ENMT-M1620-MPW2-MM ENMT-M2518-MPW2-MM ENMT-M3520-MPW2-MM ENMT-M5028-MPW2-MM
5 Mpix, 12 mm lens,motorized focus and aperture 5 Mpix, 12 mm lens,motorized focus and aperture 5 Mpix, 12 mm lens,motorized focus and aperture 5 Mpix, 12 mm lens,motorized focus and aperture 5 Mpix, 12 mm lens,motorized focus and aperture
+
USB Camera Cable Lens cable Lens motion controller
CBUSB3001 CBMT001 MTDV3CH‐00A1
Passive USB 3.0 cable, horizontal screw locking, 3 m 12 wires PVC grey cable, circular standard DIN 13Pos Female to DB15M connector cable - 2 m 24VDC DIN rail power supply
 
Compatible with a 6-axis and SCARA robot arm with 2kg+ payload
Cameras Optics Lighting Accessories

Inspecting holes and cavities is a difficult task, that can be further complicated by the complex shape of the part or hard to reach features of interest. Many components for the automotive industry – i.e. engine cylinder blocks - have bores of various sizes located at different positions that need to be checked thoroughly.

Boroscopic probes and hole inspection lenses allow to image the inner surface of cavities in perfect focus. They can be mounted on robotic arms to increase the system flexibility, allowing to perform deep surface scan and to check holes on multiple areas.

Inner cavity inspection with a hole inspection lens
Inner cavity inspection with a hole inspection lens
Engine block inspection with a boroscopic probe
Engine block inspection with a boroscopic probe
USB 3.0 2/3” Camera USB 3.0 1/1.8” Camera
RT-mvBF3-2051aG RT-mvBF3-2032aG
2464 x 2056, 3.45 μm 2464 x 1544, 3.45 μm
+ +
Hole Inspection Optics Boroscopic Probe
PCHI023 PCBP012
Hole inspection optics for 2/3" Boroscopic probe for 1/2"
FOV Ø = 10 mm - 120 mm FOV Ø = 25 mm - 100 mm
+
Telecentric light
LTCLCR048-G
Green collimated illuminator
+
USB Camera Cable LED Power Supply
CBUSB3001 RT-SDR-120-24
Passive USB 3.0 cable, horizontal screw locking, 3 m 24VDC DIN rail power supply
 
Compatible with a 6-axis and SCARA robot arm with 2kg+ payload
Cameras Optics Lighting Accessories
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