In our ongoing news series "ATE - Ask the Expert," we once again took the opportunity to consult two of our internal experts on the subject of cameras. The experts Armin Scholz and Simon Müller have shared valuable insights into the design, use, and challenges of camera systems.

Which cameras are best suited to be used in a special-purpose machine?

High-quality cameras are indispensable in special-purpose machines with specific requirements. Some renowned manufacturers in this field are distinguished by first-class camera solutions, including models with precise image processing and high speed, ideal for demanding applications. In addition to 2D and 3D cameras with profile scanners, these providers also offer 3D cameras with stripe projection. These cameras are known for their versatility and the ability to capture accurate 3D images in real time. When choosing the best camera for a special-purpose machine, the specific requirements and the type of data to be captured should be carefully considered.

How can the cameras be set up to deliver data in real time and how can this data be best utilized?

Setting up cameras to deliver real-time data begins with capturing an image, often in the form of a bitmap. This image is created by the camera and, depending on the camera type, can be monochrome, representing grayscale values from 0 (black) to 255 (white). This image is then transferred to the software, where programming for evaluation takes place. This can involve various types of checks, such as verifying security values using OCR text recognition. The software then compares the captured data with the predefined target values. If the inspection shows that the data matches the specifications, the component is marked as "in order" (IO). However, if deviations are found, a review is necessary to determine if the part can be repaired. If not, it may be sorted out or sent back to a workstation where an employee can make the necessary adjustments. In some cases, a robot can also take over this task, which offers the advantage of automation but can also lead to time losses.

How is the connection between the camera and the PLC (Programmable Logic Controller) established in your application, and how does data exchange occur?

The connection between our camera and the PLC is a crucial part of our process. Typically, this is done via the PLC because it knows exactly when to set a trigger for image capture. This trigger signals the camera to take a picture. Furthermore, the data exchange between the camera and the PLC also involves additional information. The PLC knows exactly when and what data is needed to allow the process to run smoothly. This includes not just the start of image capture but also all other relevant information required for successful operation.
Is there also the possibility of a direct connection between the camera and a robot to perform specific tasks? Yes, in theory, there is the possibility of a direct connection between the camera and a robot. However, this also usually happens via the PLC. This has the advantage that the PLC can coordinate the entire process. It determines when a photo needs to be taken and when the robot is triggered to perform a certain action. The remaining data required for robot operation are also provided by the PLC. This ensures a coordinated and efficient flow of our processes.

What must be considered when designing camera systems?

The design of camera systems requires thorough planning and consideration of several important factors:

• Ambient light: The ambient light can significantly influence the performance of the camera. It is important to ensure that the lighting in the environment is sufficient and does not cast disturbing shadows.
• Geometry of the test object: The size and shape of the object to be tested are crucial. The camera must be positioned so that it can capture the entire test object.
• Edge disturbances: Edges or reflections can affect image quality. The camera should be placed to minimize such disturbances.
• Area (field of view): The field of view of the camera determines which area it can capture. This should be adapted to the requirements of the application.
• Minimum and maximum distances: The distances between the camera and the test object as well as between different elements in the system must be considered.
• Space for robot or handling: If robots or other automation equipment work near the camera, there must be enough space for their movements.

Many settings are made in the preparation, including the configuration of the camera with IP address, exposure time, and other parameters. The lens must also be focused to ensure clear images. The exact requirements depend on the needs of the customer and the application.

How do you ensure that the camera works correctly after installation?

After installation, we check the camera in real-time and conduct tests to ensure that it meets the requirements. This often includes live broadcasts and the adjustment of settings to achieve optimal results.
What safety measures do you take with laser scanners? With laser systems, we pay particular attention to safety regulations to minimize potential hazards. This may include the use of protective devices and special training for the operating personnel.

What could customers already consider in component design to make camera inspections easier to implement?

Customers can already consider some important factors in component design to facilitate the integration of camera inspections. First, the features or quality criteria to be tested should be designed so that they are visible to the camera. This can include adding clear markings, contrasts, or geometric features. Also, the placement of components or elements should be done so that they are easily accessible to the camera without obstacles in the way. Early communication with our team during the design process can help clarify the requirements for a successful camera inspection.

What do we do in our camera lab?

In our camera lab, we conduct a variety of validation and customer trials to ensure that our camera inspections meet the requirements. Some examples of activities in our camera lab are:

• Image capture and analysis: We take pictures of test objects and analyze them to ensure that the cameras can capture the required quality features.
• Lighting optimization: We experiment with different lighting options to determine the best conditions for image capture and to minimize disturbing influences.
• Software adaptation: We adjust the software to ensure that the camera performs the desired tests and delivers accurate results.
• Customer-specific tests: We also conduct customer-specific tests to ensure that our solutions meet the specific requirements of our customers. This can include testing components or products in a real production environment.
• Documentation and reporting: We create detailed reports on the results of our tests to ensure that the camera inspections meet quality standards.

Our camera lab is an essential part of our development and validation process and enables us to ensure that our camera systems function optimally.

Thank you, Armin Scholz and Simon Müller, for sharing your extensive knowledge and experience in the field of camera systems with us. Your insights were extremely valuable and have greatly expanded our understanding.