The growing importance of image processing on the manufacturing line for analyzing the quality of a component’s surface suggests there are advantages over other inspection techniques. For one, sidestepping human interaction in the inspection process, vision-based inspection systems help reduce production lead-time, increase inspection efficiency and quality.
During a demo at Automate 2024, Todd Jarvey, vision product manager, Beckhoff Automation, introduced new vision hardware that incorporates EtherCAT functionality into the camera and the lighting. This enables the functionality of advanced EtherCat XFC control for Beckhoff’s vision products.
“The camera has a 2.5 gigabyte Ethernet port for transferring the image back to the controller and all setup and triggering information is controlled over EtherCAT, down to the microsecond level,” said Jarvey.
The demonstration was set up to show how an image was triggered at different speeds over the EtherCAT bus-based network. “The accuracy is spot on, whether we’re running slow or fast for the coordinated motion to image capture,” he said.
Real-Time Image Processing for PLC Programmers
Beckhoff introduced TwinCAT Vision in 2017. TwinCAT Vision provides the required image processing capabilities in the form of PLC functionality on a universal, end-to-end software platform.
“Vision software integrates into Beckhoff’s complete control system to process images in the same real time environment as our machine control,” said Jarvey. “This allows for results to be obtained from the image and transferred to the machine control environment at 0 latency, as they’re all operating within the same environment.”
READ MORE: 10 Considerations for Designing a Machine Vision System
Engineers can tailor an ideal solution for their unique applications with these new products
More specifications according to Beckhoff’s press notes:
- Cameras: The IP65/67, EtherCAT-enabled area-scan cameras generate high-quality image data via monochrome and color Sony CMOS sensors with up to 24-megapixel resolution and GigE Vision transfer rates of 2.5 Gbit/s.
- Lenses: The robust, industrial C-mount lenses ensure ease of use and high availability, along with an innovative robust locking mechanism, VIS to NIR AR coating, up to 2 μm resolution, and models for camera formats of up to 1.2” (19.3 mm image circle).
- Lighting: The IP65/67, EtherCAT-enabled multicolor LED illumination, in panel, ring and bar configurations, produces highly controlled illumination for consistently high-quality images. Incorporated current-based controls allow precise operation even in spectrally adjustable pulse mode.
- All-in-one solutions: Complete machine vision units consisting of a camera, illumination and electronically focusable liquid lens are also available.
