01-09-2023 10:58 AM
Since now i only have experience with systems from Keyence, where all components and the software are from them. Mainly we check for position of contact pins (in 2d and 3d) and all sorts of faults for injection moulding parts.
At first this seems pretty easy with keyence but its pretty expensive as well as limiting if you need anything else. With a strong software background its pretty frustrating how limited they are. Also there is not really a possibility for deep learning fault detection.
So i was looking for alternatives. I was thinking about Halcon, Cognex Vision Pro or even opencv (but i am not sure if it is suitable/less time consuming for industrial applications).
But how do I even get started? The softwares itself for programming the vision programm seem more flexible and better suited but i have no idea where to start in terms of the following, hardware related, points:
which PC to take (or how to set it up according to your requirements like how many cameras and how fast the computation should be)
how to esure real time behaviour (or at least fast enough computation of the vision programm)
how to connect the PC to my PLC (ETHERCAT/PROFINET)
which drivers i need for the communication from PC to camera
frame graber etc for 3d profile sensors?
How to deal with these kind of problems for Halcon, cognex and opencv? Which is best suitable for industrial applications? Is there another library which is better suited? Are there any books or blogs for practical applications with these libraries?
01-10-2023 12:17 AM
It is a big question. My advice is to pay the consultant fee to ask experts.
01-10-2023 10:27 AM
I am one of the instructors in the Certified Vision Professional Program from A3 Vision (https://www.automate.org/a3-content/certified-vision-professional). My first suggestion would be to look into taking some classes in that program. Machine Vision environments like Keyence, and LabVIEW Vision Builder AI, are cute, fast and so simplistic that they can be quite frustrating. Halcon, Vision Pro, Cognex are all good vision environments, but my experience is limited with those environments. The Matrox MIL library is well respected in the C programming community, however they have been acquired by Zebra Technologies Corporation, and it's hard to say what their future is.
LabVIEW vision has been my primary tool for years, and plays well with PLC, and across a variety of industrial bus topologies. Frequently I will write the vision portion, and subcontract out the interface to a factory network. This reduces my liability and puts that portion in the hands of more skilled individuals (pay the experts).
I cannot recommend NI Vision tools, as it looks like NI is letting that portion of their programming environment slide, and the new subscription service is downright scary. since you could loos access to your source code if you choose not to pay the subscription fee. That said, if you have a permanent LabVIEW professional license with the vision development module, it may do the job. It is not a feature rich as Halcon, but the runtime license is considerably less if you are deploying multiple inspection stations.
Open CV / MV shows potential but it largely geared toward deep learning models, but the price is right. Keyence is about as expensive as it gets.
The options are endless and somewhat overwhelming.
If you can be in Shanghai in March, look into http://www.visionchinashow.net/txw_sh/ Just walking the show floor and talking to vendors will be very informative.
Until this Covid thing settles down, the China vision show is not in my future. The next show in the US is October in Boston, MA (Self serving plug, I will be teaching one of the classes at that event).
I will occasionally embed with a customer who wants to develop machine vision applications in their manufacturing environment. We work side by side from the concept to a finished inspection. Over the course of that effort the customer is involved in all aspects of the project, from concept to completion. In they end the customer has first hand knowledge and experience in the process. Look for a supplier that would be willing to work with you along those lines. Kind of a mini apprentice program.
In any event, good luck. It sounds like you are embarking on an adventure.
Cheers
Robert
01-16-2023 06:09 AM
Choosing a PC: When selecting a PC for industrial vision applications, it's important to consider the processing power required for your specific application. The number of cameras and the speed at which the images need to be processed will play a large role in determining the necessary processing power. A high-end industrial PC with a powerful CPU and a dedicated graphics card is often recommended for industrial vision applications.
Real-time behavior: To ensure real-time behavior, you may need to use specialized frame grabbers or image processing hardware, such as FPGA-based or GPU-based systems. Additionally, you should ensure that your PC has enough processing power and memory to handle the image processing tasks in real-time.
Connecting to PLC: To connect your PC to a PLC, you will typically need to use a communication protocol such as EtherCAT or PROFINET. This will require the use of appropriate drivers and software on the PC side, as well as appropriate hardware on the PLC side.
Camera Drivers: To communicate with the cameras, you will need to use the appropriate camera drivers. These drivers are typically provided by the camera manufacturer and will allow you to control the camera settings and acquire images from the camera.
Frame grabber: Frame grabbers are specialized hardware devices that can be used to acquire images from cameras in real-time. They are often used in industrial vision applications where high-speed image acquisition is required.
Halcon, Cognex and OpenCV: Halcon and Cognex Vision Pro are commercial libraries that are specifically designed for industrial vision applications. They provide a wide range of image processing and analysis tools, and are often used in conjunction with specialized hardware such as frame grabbers. OpenCV is an open-source library that can also be used for industrial vision applications, but it may require more programming and development effort.
Suitable library: The best library for industrial applications will depend on your specific needs and requirements. Halcon and Cognex Vision Pro are well-suited for industrial applications and have a wide range of tools for image processing and analysis. OpenCV can also be used for industrial applications, but it may require more programming and development effort.
Books and Blogs: There are many books and blogs available that cover practical applications of Halcon, Cognex and OpenCV. You can check the official website of the libraries and check the documentation section and also check for forums, video tutorials and webinars.