Machine vision systems are a fundamental cornerstone of industrial automation. They enable image processing by devices and are highly versatile solutions that can adapt to any industry and ensure total return on investment.
What do they consist of and what are the benefits?
There are five main components:

• Lighting is the starting point for the entire image collection and processing process. The light source must be placed in the correct position relative to the object and the camera. There is no one-size-fits-all rule for proper lighting, and depending on different needs, one will choose from backlighting, coaxial lighting, circular lighting, integrated lighting, and many others.
• The lenses determine the resolution of the image collected. They can be fixed or interchangeable, mechanically adjustable or autofocus. Again, it all depends on the specific applications of the vision system.
• The image sensor is the heart of the entire system. It can be line-scanning or area-scanning, depending on the type of images to be captured. Once the image has been captured by the device, it passes the information to the vision processing software.
• Through processing, it moves from information extraction to the actual decision. The system’s algorithms, in fact, “guide” it from analysis of the information received to judgment, acceptance or rejection. The system, then, recognizes or rejects as valid the qualities of the object based on the received image and communicates the result of its decision.
• At the end of the process, the communication system based on a serial connection collects the decision and transmits it to the production line.

Concrete possibilities and opportunities

Vision systems ensure accuracy, speed, repeatability and reliability.
There are basically four applications of vision systems:

• Localization is the first step. The system must understand exactly where the component to be analyzed is located within the image. Vision systems are designed to recognize objects based on geometric patterns, but we still have to keep in mind a margin of variability. The system, therefore, must be smart (and fast) enough to compare actual products moving down the production line with the given geometric patterns. Without tracking, one cannot move on to the next steps.
• Identification is used to track every single object on the production line. The vision system can read barcodes, data matrix codes, alphanumeric characters, and character strings. This allows for error control, inventory management, and maximum traceability.
• Measurement is another of the capabilities of vision systems. It calculates the distance between two points or the geometric position of an object to determine whether these measurements actually meet the required specifications. If positive, it continues with its analysis, and if negative, it stops the production line to correct the anomaly.
• Inspection is even more accurate. It is used to detect defects, contamination, irregularities and other manufacturing imperfections. It also checks products for completeness, correspondence between product and packaging, and safety seals. In this way, the company can be sure to put only perfect products on the market.

Vision systems, more generally, can be used as the starting point of robotic processes applied to production lines. These are the benefits of industrial automation: if the system has detected, for example, an incorrect alignment of a component, it communicates this to the robot controller, which will arrange it in the right way.
Robotic processes guided by machine vision are faster and more accurate than manual positioning and can be used for all those alignment, packaging, transfer and arrangement operations.

The main applications of vision systems

We have seen what a machine vision system looks like and how it works. But for which industries is it most useful? The whole branch of electronics can gain invaluable benefit from the use of vision systems: speed, reliability, maximum accuracy.
Ditto the logistics industry. With character and pattern recognition and automated reading of packing slips, the vision system simplifies all management.
The ability to package products in a fully automated way is a breakthrough for any production chain. Labeling, product orientation, content verification, print control: vision systems make it possible to zero waste, optimize processes and increase productivity.
Separate discussion for the medical and pharmaceutical sectors. Let’s stop for a moment and think about how important it is that every needle, every tablet, every contact lens, every safety seal is actually perfect. And the best way to do that is to rely on robotic processes guided by machine vision systems.

What are the advantages?

Machine vision systems guarantee unparalleled quality standards. Compared to human work, in fact, there is no room for error, delay or irregularity.
Accuracy and precision are absolutely guaranteed, as are speed and repeatability of results. Once the machine has received the requirements for the required specifications, all nonconforming products will simply be stopped.
In addition, all data is archived. We will then have total traceability and transparency to avoid any product recalls. This results in waste reduction, resource optimization, production implementation, and steadily increasing profitability.