IEN: How are manufacturers using existing technologies in new ways?
Williams: Rather than a pass or fail inspection point, machine vision is being used to monitor process limits and provide information about a manufacturing line via the Ethernet. With DVT continually driving down the price of machine vision sensors (prices for a complete system and training starting at $2995), more manufacturers are finding applications to implement machine vision where it was previously prohibited by high costs.
IEN: What are the major concerns facing machine vision in the next few years?
Williams: Implementation in foreign markets. As more and more manufacturing is leaving the US, machine vision will be counted on to make sure quality is still present in cheap labor markets. Machine vision will have to be easy to set up, locally supported, affordable, and have the capability to have troubleshooting done from a remote location. DVT meets these concerns: 1) By offering a global network of ASPs (Automation Solution Providers) to service local accounts, 2) By offering the most affordable vision systems on the market -- prices starting at just $2995 for a complete system with free training, and 3) By offering Ethernet connectivity built right into every SmartImage Sensor. This allows for users to perform online diagnostics from any Ethernet connection in the plant or from any Internet browser around the globe.
Educating end users becomes another challenge -- as the price of traditional machine vision drops and new offerings in color and high resolution hit the street, it broadens the customer base for machine vision. The successful companies will be the ones that train their end users to maintain systems as well as discover new applications in their plants. DVT''s new free CD-ROM, the VirtualTOUR, contains over 40 hours of training on vision sensors, lighting techniques and lensing instructions.
IEN: Has the use of vision systems spread beyond traditional end-use markets, and if so, why?
Williams: Machine vision systems started out in the hands of integrators and OEMs. The systems of 20 years ago were difficult to set up and finicky to keep going. As DVT invented the "smart camera" and developed the first Windows-based user interface (FrameWork), the market has shifted to traditional end users.
IEN: What innovations are in store for users (e.g. color, intelligent sensing, high-end edge detection)?
Williams: The innovations really take place in three areas. Innovations in education will allow people from all over to learn about setting up machine vision systems and solving their applications. Web- and CD-based training (like DVT''s free VirtualTOUR CD-ROM) let end users set their own pace and still interact with a qualified trainer. A variety of hands-on classes will also be rolled out to cater to users at different skill levels. Innovation in hardware will impact the price, performance, and range of applications that can be reached by machine vision technology. Over the past 5 years, prices have dropped on complete vision systems from $10k to under $3k. In that same time, high resolution (Mega Pixel CCDs) and color systems have entered the low price market. Innovations in software will make setting up applications easier. In addition, the connectivity between machine vision systems and other plant automation devices will be enhanced.
IEN: How are software and equipment being improved?
Williams: DVT''s next generation product, being released in late 2001, will use SVGA CCD chips for high resolution imaging and color CCDs to provide the capability for color monitoring and color object finding. The software will support IP over Ethernet and TCP/IP communications. Improved thresholding techniques including some innovative uses of edge finding algorithms will make it easier to solve complex applications.
- Model 530: (Affordable Vision) World''s smallest machine vision sensor is 12% smaller than any other "smart camera" on the market today. Built-in Ethernet connectivity allows for easy integration and positions the vision sensor to serve as the "visual data source" for the company enterprise. A 200% increase in digitizing (image acquisition) time and control for up to four separate lights are added features that make the 530 the best value on the market today.
- Model 540: (High Performance Vision) The DVT Model 540 delivers 8 times the performance over the fastest "smart cameras" already on the market today. This is achieved by the addition of a powerful Hitachi SH4 processor, which delivers an ultra-fast image processing rate -- up to 8 times that of the previous model. This boosts the digitizing time to 13 milliseconds, which allows the vision sensor to be used in even the fastest manufacturing lines. No separate PC or "frame-grabber board" is required since all hardware is integrated into the compact housing which is only 1.5 in. thick and 4 in. tall. In addition to precise machine vision inspections, the Legend 540 reads virtually any linear and 2-D barcode as well as performs OCR (Optical Character Recognition) -- all at lightning fast speeds. Ethernet connectivity allows users to simply drop the sensor in on the manufacturing line without incurring the integration costs associated with traditional machine vision. This networking feature allows for remote diagnostics and data acquisition from any node on the company''s network or from any Internet connection around the globe.
- Model 542C: (Color Vision) The DVT Model 542C is the world''s first COLOR "smart camera." Color recognition is another DVT breakthrough that has added new levels of flexibility and power to many inspection applications. Until recently, color machine vision systems were expensive, bulky, and complex to implement into the factory floor. DVT''s newest SmartImage Sensor, the Legend 540C, represents the industry''s first Ethernet-ready vision sensor with color capability. The 540C is designed to perform a multitude of color inspections in a diverse group of industries. For example, it can be used in the automotive industry to automatically check proper placement of color-coded fuses in the car''s fusebox; in the packaging industry to inspect print and decorations in full color; in food processing to verify color of fruits and vegetables; and in the electronics industry to verify the sequence of colored wires and components on circuit boards. Color SmartImage Sensors can quickly and easily be added to any point on the manufacturing line where color inspection is required, for thousands of dollars less than traditional color inspection systems.
IEN: How is machine vision being used in e-manufacturing?
Williams: The complete electronic integration of the plant floor is a process that is being hastened by the need to improve quality and provide accountability for processes and suppliers. DVT Corporation pioneered the VDN (Visual Data Network), a network of Ethernet-linked SmartImage Sensors that report such statistics as units produced, orders shipped and defects found directly into the plant''s ERP systems via the Ethernet for executives to evaluate. Eventually, plants will make this factory-floor, visual data available to their suppliers over the Web to improve the inventory process. With a vision sensor''s Ethernet capability, one can easily perform maintenance, monitoring and diagnostics of large numbers of vision sensors. Users can upload data to a desktop program or download the parameters to the vision sensors on the shop floor, from hundreds or even thousands of miles away. The Visual Data Network allows manufacturers to remotely monitor and control factory equipment over the Web to find out why it is running slow and to prevent it from breaking down.