Machine Vision Stream Mode for Continuous Image Acquisition
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Solution Overview
Problem
Existing machine vision inspection systems face challenges in programming continuous-motion type operations, which are complex and difficult for unskilled users to program efficiently, especially when combined with interspersed-type operations, leading to inefficiencies and errors due to non-intuitive programming representations.
Innovation Solution
A precision machine vision inspection system with a learn mode that records user inputs to create part programs, allowing for stream mode execution where image acquisition operations are performed in a sequential order without interrupting continuous motion, and image analysis is performed after image acquisition, with an editable representation that maintains the original order of instructions for intuitive editing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous-motion type operations are programmed in traditional ways, then image acquisition speed is improved, but programming complexity increases significantly
Solution Approach 1:
The part program is divided into distinct segments: stream mode segments that contain only image acquisition instructions for continuous motion operations, and non-stream mode segments that contain interspersed-type operations with both acquisition and analysis instructions. This segmentation allows the programming system to handle continuous-motion operations separately, simplifying the overall programming structure while maintaining high acquisition speeds.
Solution Approach 2:
The patent introduces stream mode instruction elements as intermediary markers that designate specific portions of a part program for stream mode execution. These instruction elements act as mediators between the user's high-level programming intent and the low-level continuous motion control requirements, abstracting away the complexity of continuous-motion programming while enabling high-speed acquisition.
2Reliability
If image analysis operations are performed during continuous image acquisition, then inspection completeness is improved, but image acquisition throughput decreases
Solution Approach 1:
Image acquisition instructions in stream mode segments are executed first in a continuous sequence to capture all necessary images at high speed. The image analysis operations are then performed subsequently on the acquired images. This preliminary action of acquiring all images before analysis ensures no inspection is missed while maintaining maximum acquisition throughput during the critical capture phase.
Solution Approach 2:
The stream mode enables continuous image acquisition without interruption for analysis operations. By separating acquisition and analysis into different execution phases, the system maintains continuous useful action during image capture, ensuring maximum throughput while still performing complete inspection through subsequent analysis of all acquired images.
3Productivity
If part programs are edited with rearranged instructions for stream mode execution, then execution efficiency is improved, but ease of editing deteriorates
Solution Approach 1:
The patent creates and maintains a copy of the part program instructions in their original sequential order for display and editing purposes, while a separate internal representation handles the stream mode execution optimization. This copying approach allows users to edit intuitive, sequentially-ordered program representations without sacrificing the execution efficiency gains from proper stream mode arrangement, as the system automatically manages the transformation between the two representations.
Data Source
AI summary
In a machine vision system editing environment for a part program, a continuous stream of image acquisition operations are performed during a run mode. Previously, a continuous stream of image acquisition operations was achieved by utilizing different programming representations and syntax for programming and grouping image acquisition operations together in the part program. A new common syntax and representations are utilized wherein such continuous image acquisition operations are recorded in the same way as regular operations, with the running of the part program being performed in two stages. First, the portion of the part program that is to have the continuous stream of image acquisition is scanned for image acquisition operations, and the most efficient order for acquiring the images is determined. Second, while the image acquisition process is being performed, the portion of the part program is scanned again, with the image analysis operations then being performed.