Machine Vision Continuous Motion Image Acquisition Sequences
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Solution Overview
Problem
General-purpose machine vision inspection systems face challenges in rapid programming for various workpieces and camera positions, especially when combining continuous-motion and interspersed image acquisition operations, which limits throughput and requires skilled users.
Innovation Solution
The system allows users to define both compatible and incompatible operations during a consistent learn mode, automatically re-sequence operations to include continuous motion image acquisition sequences, and transparently manage interruptions for incompatible operations, enabling rapid programming by unskilled users and increasing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous-motion image acquisition is used to increase throughput, then inspection throughput is improved, but the ability to perform incompatible operations (image analysis, coordinate system changes) is limited
Solution Approach 1:
The patent segments the program into two distinct types: continuous-motion program portions for high-speed image acquisition and interspersed program portions for incompatible operations. This segmentation allows the system to maintain high throughput during continuous motion while enabling incompatible operations at appropriate interruption points, resolving the contradiction between productivity and adaptability.
Solution Approach 2:
The patent implements dynamic programming mode switching that allows the system to transition between continuous-motion mode and interspersed mode based on the operations being performed. The programming capability dynamically adapts the execution mode, enabling the system to optimize for throughput when possible and for operational flexibility when needed.
2Ease of operation
If programming is made simpler for unskilled users, then ease of operation is improved, but the ability to handle complex continuous-motion sequences is reduced
Solution Approach 1:
The patent implements self-service programming where the system automatically manages the complexity of continuous-motion sequences and interruption handling. Users simply define their operations in a consistent learn mode, and the system automatically generates the appropriate program structure, handling the complex sequencing and mode transitions without requiring user intervention or expertise.
Solution Approach 2:
The patent introduces an intermediary programming layer that translates user-friendly operation definitions into complex continuous-motion program sequences. This intermediary processing layer handles the technical complexity of mode switching, timing, and sequence management, allowing unskilled users to achieve sophisticated functionality.
3Measurement precision
If image acquisition operations are interspersed with analysis operations, then measurement precision is maintained, but inspection throughput is reduced
Solution Approach 1:
The patent enables continuous-motion image acquisition where the camera continuously captures images during stage movement without interruption for analysis operations. This continuous acquisition maximizes throughput by eliminating idle time between image capture and analysis, while the system maintains measurement precision by ensuring images are acquired at the correct positions and orientations.
Solution Approach 2:
The patent performs image acquisition operations in advance during continuous motion, storing multiple images before analysis operations are needed. This preliminary action allows the system to batch process images, maintaining high throughput while ensuring all necessary images are captured with the required precision before analysis begins.
Data Source
AI summary
Methods and systems of part programming for machine vision inspection systems are provided, which permit a user to readily define multiple image acquisition operations interspersed with associated image analysis and/or inspection operations during learn mode operations and in the resulting part program image acquisition operations for at least some of the images are arranged into a continuous motion image acquisition sequence that acquires images and stores images in a “non-interspersed” manner in order to increase the throughput of the machine vision inspection system. Image analysis/inspection operations associated with the stored images are performed subsequently by recalling the store images. The programming systems and methods disclosed herein may operate automatically to facilitate rapid programming for a variety of workpieces by relatively unskilled users, wherein the resulting programs include continuous motion image acquisition sequences.