What are vision systems?

Vision systems are solutions that are increasingly appearing in many industries. Their main application is in the broad field of quality control. Thanks to advanced technologies,artificial intelligenceandneural networks, such solutions streamline production, reduce waste and provide great support for operators andquality control personnel. You can read about detailed implementations of machine vision systems here, while below we will explain what machine vision basically is.

What are vision systems?

The vision system is an advanced tool that combines not only a physical camera, but most importantly intelligent software. It is a comprehensive solution, using advanced algorithms to analyze video data. A key component of vision systems is the software that defines their functions and capabilities. It is worth noting that the camera itself, without the right software, does not provide relevant information. It is the intelligent software that determines what the vision system is able to analyze. By combining hardware with advanced software, a vision system can provide information on product quality. Vision systems are becoming an indispensable tool in the field of visual analysis and industrial process automation.

Where are vision systems used?

Vision systems are widely used in various industrial areas where quality control plays a key role. In the food industry, vision systems play an important role in meat and fish quality control, among others. Inspection of packaging is crucial, enabling monitoring of the correctness of product packaging and the identification of damage or defects. In the paper and printing industry, vision systems are used for, among other things, color control. In the furniture and window and door joinery sectors, vision systems support quality control. They identify defects, inconsistencies in shape and colors of components. They also determine the correctness of the assembly when production variability is very high. In the recycling area, vision systems are invaluable for quality control in paper processing.

Construction of vision systems

At the heart of a vision system are cameras. Also indispensable components of a video system are illuminators, lenses, as well as data acquisition devices and the software that enables data processing.

The main task of illuminators is to provide adequate illumination of the object, which is crucial to the quality of the images obtained. The illumination can be spot, focusing light on a specific area, or diffuse, which evenly illuminates the object. The choice of the type of illumination depends on the nature of the video task and can significantly affect the effectiveness of the system.

Lenses are essential for proper focusing of the image on the camera matrix. They must be selected taking into account parameters such as field of view, depth of field and resolution. A good match between the lens and the application is key to obtaining high-quality images for accurate processing and analysis.

Data acquisition devices are responsible for capturing video signals from cameras and transmitting them to the computer system.

Software, too, is an essential component in vision systems, enabling analysis and processing of collected data. Advanced vision algorithms allow detection, pattern recognition, object tracking and many other functions that find applications in a wide variety of fields, from industrial quality control to medical applications and scientific research.

Types and capabilities of vision systems

Among vision systems, we distinguish:

2D systems – allow verification that an object’s contour, geometry and rotational position conform to a predetermined specification. In addition, they provide solutions for code and text identification.

3D systems – are used in various fields such as conveyor technology, packaging and intralogistics. 3D systems can detect objects and people in an area considered potentially dangerous, reducing the risk of collisions.

Multispectral systems – provide images from the visible band to the far infrared. They are used, among other things, when checking the correctness of color reproduction, in the printing industry.

Hyperspectral systems – are systems that enable detection of defects that the human eye will not see. They are used in the food industry, among others, to detect mold in its early stages.

Examples of vision applications:

• Determining position, color, shape or size,
• Counting items on a production belt, for example,
• Shape control such as correctness of casting or cutting,
• Control of thickness, soiling cavities, and lint in the production cycle,
• accurately dimension objects,
• Inspection of the surface for scratches, discoloration and color consistency,
• Control of the assembly of several elements into a whole,
• OCR (optical character recognition) text reading,
• Optical character recognition (bar codes and all kinds of inscriptions),
• Tracking of components, for example, on the production line or during the packaging process.

2D vision systems

2D systems are the most commonly used systemsbased on camerasthat take pictures, which are then processed in an industrial computer. Due to their simplicity, they have many applications and continue to solve measurement problems in industry. Among other things, 2D systems are used for sorting and classifying geometric features, edge and blob analysis, product assembly validation, automation positioning in bin picking/pick&place applications, or filling inspection of bulk packaging. Due to the scope of use, they are divided into 3 types: inspection, measurement and positioning systems.

3D vision systems

3D systems mostly rely on cameras combined with a lighting system. It is this combination that makes it possible to obtain 3D information about the observed object. Instead of images, point clouds are created, which are then processed, allowing more accurate measurements than a 2D system. By being much more accurate, they are used for surface inspection (e.g., dirt, inclusions, defects, scratches, holes), correct placement of labels and marks, verification of geometric correctness, optimization of object cutting/portioning, component inspection and in robotic applications. 3D systems are ideal for measuring complex shapes and specific object features (such as roughness).

Multispectral and hyperspectral vision systems

Multispectral and hyperspectral systems are the most technically demanding variety of vision systems. They collect photons in the same way as 2D systems, but allow forprecise wavelength discrimination of light. This makes it possible to see very subtle differences in the spectrum of reflected light, which carries additional information unavailable to other types of vision systems. They are excellent for inspecting the correctness of color reproduction of printing, and can detect mold (at an early stage) in food products. Interestingly, these types of systems can confirm the authenticity of works of art, provide support for archaeological work, and even study ocean flora and perform environmental pollution detection. In addition, they are able to detect contaminants such as pieces of gloves on production lines with ground meat, sugar deposits in breakfast cereals, or mold or bruises on vegetables. Multispectral systems are able to “see” across a broad spectrum, allowing them to spot differences that the human eye will not see.

Video system – summary

From experience and work on various projects, we know how much vision systems can make a difference in the production process.

Some of the biggest advantages of vision systems are undoubtedly:
Safety and accuracy – the measurement or inspection process is non-contact – there is no risk that an object will deform or the measurement will be disturbed by temperature.

Working time, efficiency – vision systems work continuously, and their accuracy is constant. Unlike humans, they do not get tired and do not get bored. In addition to these issues, human work is affected by various factors, making it impossible to achieve highly repeatable parameters.

Hygiene – wherever there is a need to isolate the human factor due to biological aspects, vision systems work well.

Speed – vision systems are able to analyze objects, processing information at high speed.

Proprietary vision systems from Scanway – trust the professionals!

Vision systems are complex solutions, and implementing them requires knowledge, experience and market expertise. At Scanway,a team of experienced engineersworks every day to improve the quality of companies’ work with vision systems. Our solutions have been used at the Polish Energy Group, New Era Materials, and HCP Cegielski Plant, among others. By entrusting us with the task, you are assured of responsible action, as well as comprehensive analysis and implementation of the vision system in your company. It is natural that entrepreneurs want to produce not only more, but also better – after all, it is the product that speaks for them on the national and international stage. At Scanway, we understand this very well and place great emphasis on maximizing system customization. Why? Because it’s a step to reducing waste and increasing the effects of optimization from day one of implementation! The tailored system works continuously, with constant accuracy. It controls quality, verifies safety and takes care of the correctness of the product, ultimately resulting in multi-objective profit. At Scanway, we emphasize the principle of long-term partnership, which is the foundation of our company philosophy. Scanway’s main goal is to build lasting relationships with our customers. We strive to ensure that they are not only satisfied with our services, but also eager to return to us with new projects. We believe that customer trust and loyalty are key elements of success, so we focus on building solid business ties based on mutual trust and understanding. If you choose to work with us, you can be sure that you will receive full support. We focus on providing assistance, customer service and education to our business partners. We guarantee that our cooperation will not be a one-time activity, but the beginning of a long-term and fruitful path that we will follow together.