Mastering Topics from the Basics of Lighting and

Lens Selection to Inspection Algorithms

Correspondence Course -
An Introduction to Vision Systems
Vol.1 What Is an Optimum Image for Vision Inspection?
Vision inspection can be divided into the four main processes shown below.
Image capture ➝ Data transfer ➝ Processing (image enhancement and measurement processing) ➝
Output (transferring data to another device)
In actuality, the most important of these processes is “image capture.” In order to obtain the optimum result, it is first necessary to
display the optimum image. This seminar will explain the CCD, lighting, and lens that are used to capture images and “image
enhancement.”

[Image processing flowchart]

Controller
Camera Image data
Light Image Measurement Judgment/ Judgment output
Target

enhancement processing Output Data output

Illumination Preserve intensity Area sensor Tolerance settings

Binary processing Pattern matching (shape), etc.
Filter processing
Color extraction processing, etc.

1. Image capture 2. Data transfer 3. Processing 4. Output

1 Image receiving element CCD X pixels

0.31 megapixel camera

640 (X) × 480 (Y) pixels

2 megapixel camera
1600 (X) × 1200 (Y) pixels
Y pixels

5 megapixel camera
2432 (X) × 2050 (Y) pixels

Image receiving 21 megapixel camera

element CCD
5104 (X) × 4092 (Y) pixels

The CCD (Charge Coupled Device) image receiving element is a semiconductor element that outputs an electrical
signal converted from the image, based on the light that strikes it. It is approximately 1 centimeter square and is
made of small pixels arranged in a square block. The number of pixels determines the inspection accuracy.

[Expressing an image with 2500 pixels] [Image of 256 brightness gradations]

The eye has been Brightness Level
magnified and converted Bright 255
90 90 90 to shading level values.
90 30 30 30 90 Every pixel has data
90 30 90 90 90 30 90 ranging from 0 (black) to
255 (white). This data is
90 30 90 90 30 90
used to perform image
(The blank parts use 255 gradations.)
processing.
Dark 0
2 Lens types and selection methods
[Lens types]

Standard lens Macro lens Telecentric lens

CA-LH4 CA-LH8 CA-LH12 CA-LH16

CA-LM0510

CA-LM2 CA-LM4 CA-LM6 CA-LM8

* The image has no distortion,
CA-LH25 CA-LH35 CA-LH50 CA-LH75
* These lenses are suited to image so these lenses are suited to
capturing with high magnification applications such as precise
* These are the lenses that are generally used for image
at a viewing angle of 3 mm 0.12" dimension measurement.
processing applications.
or less.

[Lens selection method 1: Focal distance]

“Focal distance” is one of the standard lens specifications. Typical lenses for FA have focal distances of 4 0.16",
8 0.31", 16 0.63", 25 0.98", 35 1.38", 50 1.97", and 75 mm 2.95". The position that matches the focal point—the
working distance (WD)—can be determined from the field of view and the focal distance that are required for
the target to capture.

Example 1
Lens 3.6 mm
0.14"

16 mm
Viewing angle 0.63"
CCD size

45 mm
1.77" WD = 200 mm
7.87"
WD Focal distance

[Lens selection method 2: Field of view chart]

4 8 12 16 25 35
-LH -LH A-LH A-LH A-LH A-LH
1000 CA CA C C C C H50
39.37" -L
The lens to use can be determined by which CA H75
-L
CA
curve crosses closest to the intersection of
the desired field-of-view on the vertical axis
Y field of view (mm inch)

100
and Working Distance (WD) on the horizontal 3.94"

axis. It’s useful to remember how to read these 0.5

0.5
0.5
1.0
0.5 5

1.0 1.5 1.5

1.0 10
charts! 1.5
1.5

5
5 15
20
10 5
5 10 10
30
0.39" 11
10
15
20 40
15 20

Numbers on the 20 30
60
40
100
60

curves refer to width

of the close-up ring
0.04" 1
required in mm. 10 100 1000 10000
0.39" 3.94" WD (mm inch) 39.37" 393.70"

1/3-inch, 640 × 480 (when the CV-020, CV-070, CV-035M/C, or CV-H035M/C is attached)

[Lens selection method 3: Lens performance differences] [Lens selection method 4: Depth-of-field]
(1) The more the aperture is closed, the deeper the depth range.
CA-LH16 CV-L16
(2) The shorter the focal distance of the lens, the deeper the depth
range.
(3) The larger the distance to the target, the deeper the depth range.

High-resolution lens Standard lens

Stain level: 54 Stain level: 38

Image with the aperture narrowed Image with the aperture opened
* Using a high-resolution lens makes it possible to capture
➝ The image is in focus and clear. ➝ The image is not in focus.
clearer images.
3 Light types and selection method
[Light types]

LED light Fluorescent Light source service life

light

Coaxial light Low angle method Direct ring method

Service life
(on-axis) method CA-DL CA-DR
(H)
CA-DX
Optical fiber light
(Light source: Halogen)

Backlight method Dome method Bar method

CA-DS CA-DD CA-DB LED Fluorescent light Halogen light
(optical fiber)

The most commonly used light sources are LEDs. The largest advantage of LEDs is their long service life, as
shown in the above graph. It is also possible to create these lights in a variety of shapes and colors, as shown in
the photographs. There are also cases where it makes sense to use fluorescent lights, which have excellent light
exposure over a wide range, and optical fibers/strobe lights, which can perform exposure with extremely bright light.

[Light selection steps]

1 Determine how the light will strike the target (specularly reflected light, diffuse reflected light, or transmitted light).

 iew the characteristics of the part to detect (such as the scratches on and
V Movement of light Diffuse Specularly
shape or presence of the part). reflected light reflected light
View the surface to determine whether it is flat, curved, or uneven.
Specularly reflected light example Transmitted light example
Incident
light

Workpiece
Absorption
The stamped The edges of The foreign particle The shadow of
characters are the stamped appears indistinctly the foreign Diffuse Transmitted
indistinct. characters are transparent. particle is clearly transmitted light light
noticeable. visible.

2 Determine the method and shape of the lighting.

Determine these items according to the workpiece’s three-dimensional and installation conditions.
(For example, determine whether to use a ring, low angle, coaxial, or dome light.)
With a coaxial light (on-axis) With low angle light

Glass breakage inspection Rubber packing flaw

The entire glass surface inspection
can be exposed in Edge flaws are noticeable
a uniform manner. as white areas.

3 Determine the light color (wavelength).

Determine the color according to the materials and colors of the part and background. (For example, select blue, red, or white.)
Wavelength Complementary color circle
Green
Non-visible Non-visible
light Visible light light Yellow Blue
Ultra-violet
light
Purple Blue Verdigris Turquoise Green Pea green Yellow Orange Red Infrared light Orange Purple
Red
380 430 480 490 500 560 580 595 650 780
(Unit: nm)

Different wavelengths cause light to appear as different colors. The different wavelengths lead to Complementary colors are those that are arranged opposite
light having different characteristics such as it transmitting easily (red light with a long each other on this circle. Mixing light having complementary
wavelength) or diffusing easily (blue light with a short wavelength). colors will result in a color that is close to black.

The trick for selecting light lies in carrying out the three steps shown above in order and in a theoretical manner.
First, view the workpiece and select the exposure method (specularly reflected light, diffuse reflected light, or
transmitted light) that will make the characteristics to detect stand out. Then, select the optimum shape and color
of the light to match the application according to the color and brightness of the part and background.
 4 Optimizing images for vision inspection using image enhancement filters

The key concept of vision inspection is capturing a clean image (one that is in focus and has clear contrast).
Additionally, using image enhancement filters makes it possible to optimize images to extract the detection
details. Capturing the best possible image and, when necessary, applying image filters with tools, such as stain
detection or dimension measurement, increases the possibility of performing stable inspections.

Maximum
Expanding intensity value
One typical image enhancement process is
2 5 9 using the intensity data (0 to 255) of neighboring
pixels to calculate and replace the data of the
Input image 4 9 3 pixel being examined. Resultant images, when
using the “expand” and “shrink” filters, are shown
0 1 2
on the left. The conversion process is executed
White emphasized on all the pixels within the inspection area to
replace the image with one that is optimum for
Shrinking the main inspection. In the next addition,
advanced image enhancement methods will be
2 5 9
introduced, including image calculation using
4 0 3 multiple images, like the examples shown below.

0 1 2
Minimum
intensity value
Black emphasized

[Image conversion examples using image enhancement]

Using a shading correction filter Using a blur filter + shading correction filter
Image prior to filter processing Image after filter processing Image prior to filter processing Image after filter processing

* The glare is eliminated, which makes the characters clearly *T

 he shallow defects on the surface are clearly visible.
visible.
Using a blur filter + contrast conversion filter Using an edge extraction (X direction) filter

Image prior to filter processing Image after filter processing Image prior to filter processing Image after filter processing

* The packing material irregularities are eliminated to create *T

 he screw thread shapes are eliminated to make only
an image that can be counted accurately. the black spots clearly visible.

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