ICVGR Proceedings Color

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International Conference

for Vision Guided Robotics

September 30 October 2, 2008Sheraton Detroit NoviNovi, Michigan USA

Robotic Industries Association

Automated Ima in Association

Proceedings


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Welcome to the International Conference for Vision Guided Robotics!

In todays economy, the need for vision guided robotics technologies is greater than ever.

The Robotic Industries Association (RIA) and the Automated Imaging Association (AIA)

bring you this joint conference to help you apply these technologies in order to boost

productivity, reduce costs and increase quality.

We hope you will find great ideas from the presenters as well as your fellow attendees.

And, we encourage you to meet with the vendors in the tabletop exhibit area who can

offer you products that meet your specific needs.

In addition to this conference, RIA and AIA offer a host of valuable resources that can

help you when you return to your company. We recommend visiting our websites

(www.robotics.org and www.machinevisiononline.org) to find free technical papers, case

studies, and information on upcoming events such as The Vision Show (end of March

2009 in Phoenix, Arizona) and the International Robots, Vision & Motion Control Show

(June 2009 in Chicago, Illinois).

Your feedback is very important to us, so please take the time to complete your

evaluation form and submit it to us onsite (or send it in to our office after the conference).

If you prefer, you can always talk to our staff in person, either here this week or by

calling 734/994-6088 to share your ideas.

Thanks so much for coming, and enjoy the conference!

Sincerely,

Jeffrey A. Burnstein Dana Whalls

Executive Vice President Managing Director

Robotic Industries Association Automated Imaging Association


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2008 ALL RIGHTS RESERVED

The contents of this book may not be copied or further disseminatedwithout the written approval of the Robotic Industries Association, theAutomated Imaging Association or the individual authors.

DISCLAIMERThe papers presented in this Proceedings book are the personalexpressions and positions of the respective author and presenter. Theseviews are not those of the Association, nor are they necessarily endorsedby the Association or its members. This conference was presented by theAssociation to allow robot and vision topics to be openly discussed anddiverse views disseminated. Comments about the contents will beforwarded to the authors by the Association.

900 Victors Way, Suite 140, Ann Arbor, Michigan 48108Telephone: 1-734-994-6088 Fax: 1-734-994-3338


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Table of Contents

2008 - 2009 Events ......................................................................................................... 3

About Robotic Industries Association (RIA)..................................................................... 4

About Automated Imaging Association (AIA) .................................................................. 4

Exhibitor Index ................................................................................................................ 5

Exhibitor Listings............................................................................................................. 6

Conference Speakers.................................................................................................... 10

ICVGR Conference Agenda.......................................................................................... 13

Corporate Sponsors: ..................................................................................................... 16

Media Sponsors: ........................................................................................................... 17


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2008 - 2009 EventsMark Your Calendar!

National Robot Safety Conference October 6-9, 2008Indianapolis Marriott East Indianapolis, Indiana USA

AIA Networking Reception November 5, 2008

VISION 2008 Stuttgart, Germany

16th Annual Robotics Industry Forum November 5-7, 2008Portofino Bay Hotel Orlando, Florida USA

17th Annual AIA Business Conference February 4-6, 2008

Marriott Coronado Island Resort Coronado, California USA

AIA International Pavilion March 24 26, 2008Shanghai Exhibition Center Shanghai, China

The Vision Show March 31-April 2, 2008

Phoenix Convention Center Phoenix, Arizona USA

International Robots, Vision & Motion Control Show June 9 11, 2009Donald E. Stephens Convention Center Rosemont (Chicago), Illin

USA

For full details on these or other events, visit

www.Robotics.org ~ or ~ www.MachineVisionOnline.orgor call 1-734-994-6088

Automation Technologies Council


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About Robotic Industries Association (RIA)

Robotic Industries Association (RIA) is the only trade association in North Americaorganized specifically to serve the field of robotics. Founded in 1974, RIA is dedicatedto the exchange of technical and trade related information between robotmanufacturers, distributors, corporate users, accessory equipment and systemssuppliers, consultants, research groups and international organizations. RIA is thecommon ground where these groups can come together to discuss challenges andsolutions dealing with the implementation of robotic technology. Some 285 companiesare members of RIA. Members receive many benefits, including discounts on RIAworkshops, conferences and resources.

About Automated Imaging Association (AIA)

Founded in 1984, AIA was organized specifically to promote the global use of imagecapture and analysis technology and now represents more than 300 machine visionsuppliers, system integrators, users, researchers, and consulting firms from 27 nations.The AIA Sponsors many educational conferences and workshops including theInternational Robots, Vision, & Motion Control Show, The Vision Show and the annualAIA Business Conference. AIA also produces an annual Machine Vision Market Study.Be sure to visit Machine Vision Online (www.machinevisiononline.org), the worlds

leading resource for machine vision information on the internet.


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Exhibitor Index

AIA/RIR Standards Activities...........................................................................................5

Basler Vision Technologies.............................................................................................5

CCS America, Inc............................................................................................................6

Cognex Corporation ........................................................................................................ 6

Components Express, Inc. ..............................................................................................6

DENSO Robotics............................................................................................................. 6

Dunkley International, Inc................................................................................................6

EPSON Robots ............................................................................................................... 6

FANUC Robotics America, Inc. ....................................................................................... 6

Hitachi Kokusai Electric America Ltd............................................................................... 6

HTE, Inc. .........................................................................................................................6

ISRA VISION SYSTEMS, Inc.......................................................................................... 6

Item North America ......................................................................................................... 6

KUKA Robotics ............................................................................................................... 7

LEONI Engineering Products & Services, Inc. ................................................................ 7

LMI Technologies Inc. .....................................................................................................7

Matrox Imaging ............................................................................................................... 7

Motoman, Inc. ................................................................................................................. 7Multi-Contact USA...........................................................................................................7

MVTec, LLC .................................................................................................................... 7

Nachi Robotic Systems Inc. ............................................................................................7

Northwire, Inc. .................................................................................................................7

Pilz Automation Safety L.P. .............................................................................................7

Radix Controls Inc. .......................................................................................................... 8

Schneider Optics, Inc. .....................................................................................................8

SICK, Inc. ........................................................................................................................8

Stubli Robotics .............................................................................................................. 8

StockerYale, Inc. ............................................................................................................. 8

Tectivity, Inc. ...................................................................................................................8

United Sales & Services Inc. ...........................................................................................8

Valentine Robotics, Inc.................................................................................................... 8

VMT-Pepperl + Fuchs, Inc...............................................................................................8

WireCrafters LLC.............................................................................................................9


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Exhibitor ListingsAutomated Imaging AssociationRobotic Industries Association

900 Victors WaySuite 140Ann Arbor, Michigan 48108Phone: 734-994-6088Fax: 734-994-3338Email: [email protected]

Web: www.Robotics.orgwww.MachineVisionOnline.com

Contact: Jeff Fryman

The Robotic Industries Association is anAccredited Standards Developer responsible forIndustrial Robot Standards in the United States.Working with ISO and ANSI, the RIA sponsorsthe R15 series of standards, most notably theR15.06 Robot Safety standard and the NationalAdoption of ISO 10218-1. RIA hosts annualrobot safety events throughout North America.The Automated Imaging Association is theworld leader in sponsoring interoperability

standards for digital machine visionapplications. The Camera Link and GigEVision standards are renowned for their abilityto allow integration of total vision systems usingthe best solution of components available frommultiple suppliers.

Basler Vision Technologies

855 Springdale DriveSuite 610Exton, Pennsylvania 19341Phone: 610-280-0171Fax: 610-280-7608Email: [email protected]

Web: www.baslerweb.comContact: Tim Coggins

Basler Vision Technologies specializes in stateof the art digital camera solutions for a widevariety of demanding vision applications. Over20 years of industry expertise and productdevelopment is evident in Basler's extensiveapplication knowledge and broad productoffering. Area scan and line scan camerasutilize both CCD & CMOS sensors, andFireWire, Gigabit Ethernet, and Camera Linkinterface technologies.

CCS America, Inc.5 Burlington WoodsBurlington, Massachusetts 01803Phone: 781-272-6900Fax: 781-272-6902Email: [email protected]: www.ccsamerica.comContact: Barbara Gagnon

CCS is a global manufacturer of LED lighting forMachine Vision. Due to its quality andadvanced lighting technologies, CCS Inc. is the#1 supplier for vision systems in the world andhas the largest market share in Japan. CCS

has more than 300 different types of standard

products in stock and has designed over2,000 custom lighting solutions to date. Thelatest products include our new high powerring and dome lights.

Cognex Corporation

One Vision DriveNatick, Massachusetts 01760

Phone: 508-650-3000Fax: 508-650-3344Email: [email protected]: www.cognex.comContact: John Keating

Cognex Corporation is the worlds leadingprovider of vision systems, vision software,and vision sensors used in manufacturingautomation. Cognex is also a leader inindustrial ID readers.

Components Express, Inc.

10330 Argonne Woods Drive

Suite 100Woodridge, Illinois 60517Phone: 630-257-0605Fax: 630-257-0603Email: [email protected]: www.componentsexpress.comContact: Ray Berst

Machine Vision Cables, Camera LinkCables, Cables for GigE Vision, FireWireCables, Analog Cables, SCSI Cables,Internal Ribbon Cables, Camera Enclosures,Transformers.

DENSO Robotics

3900 Via Oro AvenueLong Beach, California 90810Phone: 888-476-2689Fax: 310-952-7502Email: [email protected]: www.densorobotics.comContact: Greg Johnson

DENSO offers a wide range of compact, four-axis SCARA and five- and six-axis articulatedrobots, for payloads up to 20 kg and reachesfrom 350 to 1,300 mm. Repeatability is towithin 0.015 mm. Standard, dust- andmistproof and cleanroom models are available.

ANSI and CE compliance enables globaldeployment. UL-listed models are available forboth the US and Canada. Easy-to-useprogramming and 3-D offline simulationsoftware, controllers and teaching pendantsare also offered.

Dunkley International, Inc.

1910 Lake StreetKalamazoo, Michigan 49001Phone: 269-343-5583Fax: 269-343-5614Email: [email protected]: www.dunkleymachinevision.comContact: Pat Callan

Dunkley International is a supplier ofturnkey vision systems. Currently we havesystems ranging from high-speed fruits andvegetables to final inspection of heavy-dutytruck transmissions. While much of ourbusiness is geared towards very highvolume systems, we also manufacturemany custom one of a kind systems.Whether you need a complete vision androbotic cell or a vision system added toyour existing line we can help.

EPSON Robots

18300 Central AvenueCarson, California 90746Phone: 562-290-5958Fax: 562-290-5999Email: [email protected]: www.robots.epson.comContact: Rick Brookshire

EPSON Robots is the global leader in PCcontrolled precision factory automation with aproduct line of hundreds of easy to useSCARA, Cartesian and 6 axis robots.

FANUC Robotics America, Inc.

3900 W. Hamlin RoadRochester Hills, Michigan 48309Phone: 800-IQ-ROBOTFax: 248-276-4227Email: [email protected]: www.fanucrobotics.comContact: Ed Roney

FANUC Robotics America, Inc. is the leadingsupplier of industrial robots and roboticsystems. Over 200,000 robots are installedworldwide, and more than 200 robotvariations are available to work in a widerange of applications. The combination of theworlds most reliable robots, process

expertise, support services, regional locationsand a network of system integrators providemanufacturers in virtually every industry thetools they need to reduce costs, improvequality, maximize productivity, and increasetheir competitive position in the global market.


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Hitachi Kokusai Electric America Ltd.

150 Crossways Park DriveWoodbury, New York 11797Phone: 817-490-5124Fax: 817-490-6116Email: [email protected]: www.hitachikokusai.usContact: Phyllis Vela

Hitachi Kokusai Electric America Ltdmanufactures and sells miniaturized high-speed,high resolution analog and digital cameras.

Cameras are available as monochrome or color.Outputs include Camera Link, Firewire 1394A& 1394B, & GigE Vision interfaces. Come seeour new GigE camera line offerings.

HTE, Inc.

1100 OpdykeAuburn Hills, Michigan 48326Phone: 248-371-1918Fax: 248-371-2185Email: [email protected]: www.hte.netContact: Daniel Reed

HTE is an application engineering distributorproviding hardware and software productsspecializing in track and trace, error proofing,direct part marking, machine vision and plantfloor data collection. Now offering 2D and 3Dvision guided robotic solutions based on ShafiReliabot and Siemens vision.

ISRA VISION SYSTEMS, Inc.

3350 Pine Tree RoadLansing, Michigan 48911Phone: 517-887-8878Fax: 517-887-8444Email: [email protected]

Web: www.isravision.comContact: Diane Rizer

ISRA VISION SYSTEMS develops flexible turnkeymachine vision solutions for industrial applications.ISRA specializes in 2D and 3D robot guidance,web inspection, bead inspection, and assemblyinspection. Years of experience in machine vision,robotic technology and industrial automationprovides cost-effective, integrated solutions, fullyinstalled and performance guaranteed.

item North America

925 Glaser Parkway

Akron, Ohio 44306Phone:Fax:Email:Web:Contact: Rick Fascione

All manufacturing, assembly or automationprocesses require a robust sub-structure, base orplatform as the starting point for design,development and implementation. item NorthAmerica provides this sub-structure utilizingstructural aluminum and modular components toreplace welded steel with a more efficient, flexibleand visually appealing alternative. Machine

bases, sub-structures, frames, safety, laser and

robotic enclosures are easily designed with thesupport of items in-house engineering group.

KUKA Robotics

22500 Key DriveClinton Township, Michigan 48036Phone: 866-USE-KUKAFax: 866-FAX-KUKAEmail: [email protected]: www.kukarobotics.comContact: Rebecca Markel

KUKA Robotics offers a broad range of highlymodular robots, covering all common payloadcategories, from 3 kg to 1000 kg. Over twothirds of the 75,000 KUKA robots installed inthe field use our open architecture PC-basedcontroller, making KUKA the number one PC-controlled robot manufacturer in the world.KUKA controllers are also available forintegration with other components of yourautomation systems. Other products includeSoftPLC, Remote Service, KUKA SIMsimulation software, Networking Services anda variety of dress packages. In addition, ourSystems Partners - experts in their respective

industries - offer key technologies thattransform the KUKA robot into an application-specific solution. Our advanced KUKA Collegeenables fast learning through flexible trainingsystems that simulate a variety of real-worldapplications. KUKA Robotics offers a 24-hourservice hotline as well as engineering services.

LEONI Engin eeringProducts & Services, Inc.

2505 Industrial Row DriveTroy, Michigan 48084Phone: 248-655-1900Fax: 248-655-1905

Email: [email protected]: www.leoni-robotic-solutions.comContact: Chris Miller

Tailor Made Robotic Cable and CableManagement Solutions. Providing GlobalField Service and Project Management.

LMI Technol ogies Inc.

1673 Clivedon AvenueDelta, British Columbia V3M 6V5CanadaPhone: 604-636-1011Fax: 604-516-8368

Email: [email protected]: www.lmitechnologies.comContact: Dan Howe

LMI Technologies Inc. is a research andmanufacturing organization specializing inmachine vision applied technologies. TheLMI brands include FireSync, Sensors ThatSee, HexSight , and maest ro.

Matrox Imaging

1055 St. Regis BoulevardDorval Quebec H9P 2T4CanadaPhone: 514-822-6000, x2438Fax: 514-822-6298Email: [email protected]: www.matroximaging.comContact: Bruno Parent

Matrox Imaging is a leading provider ofcomponent-level solutions to OEMs and

integrators involved in variousmanufacturing sectors. Products includecameras, interface boards and processingplatforms, all designed to provide optimumprice-performance within a commonsoftware environment. Matrox Imagingoffers a comprehensive collection ofsoftware tools for calibrating (2D and 3D),enhancing and transforming images,locating objects, extracting and measuringfeatures, reading character strings, anddecoding and verifying identification marks.

Motoman, Inc.

805 Liberty LaneWest Carrollton, Ohio 45449Phone: 937-847-6200Fax: 937-847-6277Email: [email protected]: www.motoman.comContact: Greg Garmann

High-speed, high-performance Motomanrobots feature payloads from 3-500 kg andare available with integrated vision capabilityto facilitate multi-processing in a wide rangeof applications, including: arc welding;assembly; coating; dispensing; material

cutting; material handling; material removal;and spot welding. Integrated vision is usedfor part finding, robot guidance, identification,and inspection.

Multi-Contact USA

5560 Skylane BoulevardSanta Rosa, California 95403Phone: 440-243-4929Fax: 440-243-6628Email: [email protected]: www.multi-contact.usa.comContact: Dave Rababy

Multi-Contact is the world class provider of

industrial robotic cable connectors up to 250amp capacity. Our multilam technology hasvirtually unlimited applications due to ourdesign flexibility. Our connectors offer bothstandard and custom designed solutions for awide and diverse spectrum of applications.Multi-Contact can provide reliable and costeffective solutions for your interconnectionrequirements. The robotic line of connectorsare small in size and high in performance.


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MVTec, LLC

One Broadway, Fl 14Cambridge, Massachusetts 02142Phone: 617-401-2112Fax: 617-401-3617Email: [email protected]: www.mvtec.comContact: Heiko Eisele

MVTec provides standard software for machinevision applications including algorithms for 2Dand 3D vision-based robotics guidance.

Nachi Robotic Systems Inc.

22285 Roethel DriveNovi, Michigan 48375Phone: 248-305-6542Fax: 248-605-6542Email: [email protected]: www.nachirobotics.comContact: Karen Lewis

Nachi Robotic Systems Inc. provides successfulrobotic solutions for several applications including:spot welding, arc welding, sealing, dispensing,material handling, machine loading and unloading,buffing, palletizing, assembly, roller hemming, die-

casting, deburring, and press-to-press handling.Nachi robots can handle load capacities from 5 to700 kg. Nachi is a full-service supplier andcertified to ISO 9001:2000.

Northwire, Inc.

110 Prospect WayOsceola, Wisconsin 54020Phone: 715-294-2121Fax: 715-294-3727Email: [email protected]: www.northwire.comContact: Ken Anderson

Northwire Endurance

Vision assemblies themost rugged assemblies for vision systemapplications. Northwire has been producing highquality industrial grade cable for over 36 years.That standard of quality has gone into our visioncable assemblies. The high-quality connectorsand Northwires advanced, industrial-grade cablesprovide ultra-reliable interconnectivity in motionand vision system applications which includeCCXC Analog Video, MVC-800 FireWire, GEV-1000 GigE Vision and Camera Link cableassemblies.

Pilz Automation Safety L.P.

7150 Commerce BoulevardCanton, Michigan 48187Phone: 734-354-0275Fax: 734-354-3355Email: [email protected]: www.pilz.comContact: Customer Service

Pilz Automation Safety L.P. manufactures andoffers a complete line of safe automationsolutions and control products. The lineincludes safety relays for automationapplications, safety and general-purpose PLCs,lockout/tagout systems utilizing safety controls,

motion control systems, monitoring relays,

touch screen HMIs, e-stop pushbuttons,safety sensors, two-hand enabling devicesand light curtains. Certified engineers andqualified consultants are available to designsystems, manage projects, perform riskassessments, perform machine/plantreviews, install equipment and trainpersonnel.

Radix Controls Inc.

2105 Fasan Drive

Oldcastle, Ontario N0R 1L0CanadaPhone: 519-737-1012Fax: 519-737-1810Email: [email protected]: www.radixcontrols.comContact: Ross Rawlings

Radix Controls Inc. has been providing NorthAmerican manufacturers with high-tech toolsthey need to keep their production linescompetitive for over 15 years. Our visionexperts specialize in vision inspection designand integration in automotive, food &beverage, pharmaceutical & packaging

markets. We also recently won the ProductInnovation Award from Windsor Chamber ofCommerce for one of our proprietary visionproducts Tool Tracker.

Schneider Optics, Inc.

285 Oser AvenueHauppauge, New York 11788Phone: 631-761-5000, x204Fax: 631-761-5090Email: [email protected]: www.schneideroptics.comContact: Stuart Singer

Schneider Optics designs, develops, andmanufactures high performance lenses formachine vision, robotics, documentscanning, industrial inspection andmetrology, gauging, military, surveillance, &other image processing applications.Standard products include Compact C-mount lenses, Bilateral Telecentric lenses, amodular Macro system, large format lenses(area & line scan), 3-CCD lenses andindustrial filters. Custom lens solutions arealso available. Key markets include MachineVision, Robotics, Document Scanning,Industrial Inspection, 2D/3D Metrology,

Surveillance, & Hyperspectral Imaging.

SICK, Inc.

6900 W 110 StreetMinneapolis, Minnesota 55438Phone: 952-941-6780Fax: 952-941-9287Email: [email protected]: www.sickusa.comContact: Brian McMorris

Whether safeguarding robot assembly areas orinspecting finished product, companies cancount on SICK for innovative products and top-

notch expertise to deliver a wide range of

product application solutions. Products fromSICK initiate, inspect, confirm, monitor, andsafeguard the movement of product inindustries that use robotics for automation.With the customer as our focus andinnovation as our guide, SICK is equipped todeliver unique and superior products to therobotics industry.

Stubli Robotics

201 Parkway WestDuncan, South Carolina 29334

Phone: 864-486-1980Fax: 864-486-5497Email: [email protected]: www.staubli.comContact: David Arceneaux

Stubli is a mechatronics solution providerwith three dedicated divisions: textilemachinery, connectors and robotics.Founded in 1892, Stubli is knownworldwide for the quality of its methods andprocesses. Featuring high productivity andprecision, Stubli robots offer solutions forall industries. The comprehensive product

range includes small 4-axis SCARA as wellas 6-axis medium to heavy-duty robots withpayloads ranging from 1kg - 250 kgfeaturing superior quality and performance.

StockerYale, Inc.

275 KesmarkMontreal, Quebec H3M 1R2CanadaPhone: 514-685-1005Fax: 514-685-3307Email: [email protected]: www.stockeryale.com

Contact: Customer ServiceStockerYale, Inc. is an independentdesigner and manufacturer of structuredlight lasers, LED modules and fluorescentillumination products, as well as phasemasks and specialty optical fibers for use ina wide range of markets and industriesincluding machine vision, industrialinspection, telecommunications, military,utilities, and medical.

Tectivity, Inc.

3099 Tall Timbers

Milford, Michigan 48380Phone: 248-676-9797Fax: 248-676-9796Email: [email protected]: www.tectivity.comContact: Jon Heywood

Manufacturer of the VideoModule, LED-Module, and Laser-Module family ofprotective enclosures for robot applications.Also, we are a distributor of lighting,lensing, CCD cameras, filters, cables, etc.


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United Sales & Services Inc.

32549 Schoolcraft RoadLivonia, Michigan 48150Phone: 734-522-8100Fax: 734-522-0818Email: [email protected]: www.ussvision.comContact: Ron Weber

USS United Sales & Services Inc., wasestablished in 1990. USS has become thelargest, most diverse total turn-key integrator in

North America. USS is the largest integrator ofDVT/ Cognex products. Our success hasenabled us to obtain a global blanket withGeneral Motors providing total turn key visionerror proofing solutions. USS has developedwith Cognex the USS Exact Scan that iscapable of reading an entire vehicle for errors atend of assembly. USS has developed the USStracker in conjunction with Shafi technologiesthat mounts on the end of any robot and readsthe entire bead real time. These are a few of thevarious intangibles we provide to all of ourclients in the most efficient and cost-effectivemanner.

Valentine Robotics, Inc.

36625 Metro CourtSterling Heights, Michigan 48312Phone: 586-979-9900Fax: 586-979-9901Email: [email protected]: www.valentinerobotics.comContact: Andrew Valentine

Valentine Robotics is the North Americandistributor of Scorpion Vision robot guidanceand machine vision software. We deliverturnkey robot and vision systems for all

application types. We offer machine visionsoftware, components, kits, studies andintegration. Contact www.valentinerobotics.comFree trial software and Integrator opportunitiesavailable!

VMT-Pepperl + Fuchs, Inc.

3600 Green CourtSuite 490Ann Arbor, Michigan 48105Phone: 269-823-4650Fax: 330-486-0288Email: [email protected]

Web: www.vmt-gmbh.comContact: Todd Belt

The Pepperl+Fuchs VMT group has over 20 yearsof success in applying complete turnkey systemsfor industrial image processing applications.System solutions are based on self developedsoftware products adaptable to clients specificneeds. With an easy-to-use test and calibrationprocess along with multiple redundancies, we cancustomize a solution to increase safety, improvequality, speed up production, and reduce costs.

WireCrafters LLC

6208 Strawberry LaneLouisville, Kentucky 40214Phone: 800-626-1816Fax: 502-361-3857Email: [email protected]: www.wirecrafters.comContact: Butch Semones

Supplier of physical barriers for robotic workcells along with value adds such as weldc u r t a i n s a n d i n t e r l o c k s .


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Conference Speakers

Mr. Robert AndersonNew Technology ManagerAdvanced Manufacturing Engineering

Chrysler LLC800 Chrysler Drive, CIMS 482-04-16Auburn Hills, Michigan 48326Phone: 248-944-6076Fax: 248-841-6272Email: [email protected]

Mr. David ArceneauxBusiness Development Marketing ManagerStubli Corporation Robotics Division201 Parkway WestPO Box 189Duncan, South Carolina 29334Phone: 864-486-5416Fax: 864-486-5497Email: [email protected]

Mr. David DechowPresident

Aptra Machine Vision Solutions3130 Sovereign DriveSuite 5ALansing, Michigan 48911Phone: (517) 272-7820, x11Fax: (866) 575-1583Email: [email protected]

Mr. Ren Dencker EriksenChief Technology OfficerScape TechnologiesKochsgade 31 C, 3. salDK-5000 Odense CDenmarkPhone: 45 70 25 31 13Fax: 45 70 25 31 14Email: [email protected]

Mr. Greg GarmannSoftware & Controls Technology LeaderMotoman, Inc.1050 Dorset RoadTroy, Ohio 45373Phone: 937-440-2668Fax: 937-440-2626Email: [email protected]

Mr. Babak HabibiPresident & CTOBraintech Inc.

102 - 930 West 1st StreetNorth Vancouver, British Columbia V7P 3N4CanadaPhone: 604-988-6440Fax: 604-986-6131Email: [email protected]

Mr. Eric HershbergerSenior Engineer

Applied Manufacturing Technologies219 Kay Industrial DriveOrion, Michigan 48359

Phone: 248-409-2000Fax: 248-409-2027Email: [email protected]

Mr. John KeatingProduct Marketing ManagerCognex Corporation1 Vision DriveNatick, Massachusetts 01760Phone: 508-650-3000Fax: 508-650-3338Email: [email protected]

Mr. Jens KuehnleResearch AssociateFraunhofer Institute ManufacturingEngineering and Automation (IPA)Nobelstrasse 1270569 StuttgartGermanyPhone: 49 711 970 1861Fax: 49-711-970-1004Email: [email protected]

Mr. Jerry LaneGreat Lakes Office Director

Applied Research Associates48320 Harbor DriveChesterfield Township, Michigan 48047Phone: 586-242-7778Fax: 802-728-9871Email: [email protected]


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Mr. Eric LewisPresidentFlexomation, LLC586 Northland BoulevardCincinnati, Ohio 45240Phone: 513-825-0555

Fax: 513-825-1870Email: [email protected]

Mr. Frank MaslarTechnical SpecialistFord Motor Company6100 Mercury DriveDearborn, Michigan 48239Phone: 313-805-3904Email: [email protected]

Mr. Michael Muldoon

Business Solutions EngineerAV&R Vision & Robotics Inc.(Averna Vision & Robotics269 Rue PrinceMontreal, Quebec H3C 2N4CanadaPhone: 514-788-1420Fax: 514-866-5830Email: [email protected]

Mr. Mark NoschangManager of Applications Engineering

for North AmericaAdept Technology, Inc.11133 Kenwood RoadCincinnati, Ohio 45242Phone: 513-792-0266, x106Fax: 513-792-0274Email: [email protected]

Mr. Steven PrehnSenior Product Manager VisionFANUC Robotics, Inc.3900 W. Hamlin Road

Rochester Hills, Michigan 48309Phone: 248-276-4065Email: [email protected]

Mr. Bob RochelleNorth American Sales ManagerKawasaki Robotics (USA), Inc.28140 Lakeview DriveWixom, Michigan 48393Phone: (248) 446-4211

Fax: (248) 446-4200Email: [email protected]

Mr. Adil ShafiPresidentSHAFI Innovation, Inc.8060 Kensington CourtBrighton, MI 48116-8520Phone: (248) 446-8200Fax: (248) 446-8282Email: [email protected]

Ms. Jane ShiSenior Research ScientistGeneral Motors Corporation30500 Mound RoadMC 480-106-359Warren, MI 48090-9040Phone: 586-986-0353Fax: 586-986-0574Email: [email protected]

Mr. Kevin TaylorVice President

ISRA VISION SYSTEMS, Inc.3350 Pine Tree RoadLansing, Michigan 48911Phone: 517-887-8878


Mr. James WellsSenior Staff Research EngineerGeneral Motors Corporation30500 Mound RoadWarren, Michigan 48090

Phone: 810-602-9879Fax: 856-856-0574Email: [email protected]


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Mr. Steven WestDevelopment Manager Robotic Vision Technology

ABB, Inc.1250 Brown RoadAuburn Hills, Michigan 48326Phone: 248-393-7120


Mr. Brian WindsorBusiness Development Manager Machine VisionSICK, Inc.6900 West 110th StreetMinneapolis, Minnesota 55438Phone: 952-941-6780Fax: 952-941-9287Email: [email protected]

Mr. David WyattStaff Engineer

Applied Manufacturing Technologies 219 Kay Industrial DriveOrion, Michigan 48359Phone: 248-409-2073Fax: 248-409-2027Email: [email protected]


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ICVGR Conference AgendaTuesday, September 30, 20087:00 am to 8:00 am Registration and Continental Breakfast

8:00 am to 8:15 am Conference Overview and Introductory Remarks

8:15 am to 9:45 am The Basics of RoboticsBob Rochelle, North American Sales Manager,Kawasaki Robotics (USA), Inc.

9:45 am to 10:00 am Break

10:00 am to Noon The Basics of Machine VisionDavid Dechow, President, Aptra Machine Vision Solutions

Noon to 1:30 pm Group Luncheon

1:30 pm to 5:00 pm Successfully Integrating Vision Guided RoboticsDavid Dechow, President, Aptra Machine Vision Solutions

Evening Optional Group Dinner

Wednesday, October 1, 20087:30 am to 8:30 am Registration andContinental Breakfast

8:30 am to 8:45 am Review of Day One and Preview of Day Two

Moderator: Frank Maslar, Advanced Manufacturing TechnologyDevelopment Ford Motor Company

8:45 am to 9:30 am Technology Advances in 2D Vision Guided RoboticsJohn Keating, In-Sight Product Manager, Cognex Corporation

9:30 am to 10:15 am Top Lessons Learned in Vision Guidance ApplicationsEric Hershberger, Senior Engineer & David Wyatt, Staff EngineerApplied Manufacturing Technologies


10:30 am to 11:00 am How Advancements in Vision Guidance Making FlexibleFeeding Applications DesirableEric Lewis, President, Flexomation

11:00 am to 11:30 am Vision Guided Robot Applications for Packaging & Flexible FeedinMark Noschang, Applications Engineer, Adept Technology

11:30 am to 1:30 pm Group Lunch and Tabletop ExhibitsSee the offerings of leading vision and robotics companies fromaround the world who can assist you with your specific needs.


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ICVGR Conference AgendaWednesday, October 1, 2008

1:30 pm to 2:15 pm High Accuracy Robot Calibration, Wireless Networking, andRelated Technical IssuesEric Hershberger, Senior Engineer & David Wyatt, Staff Engineer,Applied Manufacturing Technologies

2:15 pm to 2:45 pm Vision Based Line TrackingFrank Maslar, Advanced Manufacturing Technology Development,Ford Motor Company

2:45 pm to 3:00 pm Break

3:00 pm to 3:30 pm Case Study: Robots & Vision in the Automated PharmacyDavid Arceneaux, Business Development & Marketing, Stubli Robotic

3:30 pm to 4:00 pm Unmanned Systems Intelligence, Vision and Automation Concepts

for Combat Engineer and Other Battlefield MissionsJerry Lane, Director, Great Lakes Office, Applied Research Associates

4:00 pm to 5:15 pm Tabletop Exhibit Viewing and ReceptionYour Chance to spend more time with the exhibitors while enjoyingrefreshments and networking with your peers.

6:00 p.m. to 10:00 p.m. Exclusive Dinner/Comedy EventTo maximize networking, on October 1st attendees will be transported by bus for dinner at one of metro Detroitsfinest Italian restaurants, Andiamo. This will be immediately followed by a comedy show at The Second City,whose unique brand of social and political satire mixed with improvisation has delighted audiences for over 45years. Sports comedy will be the theme be prepared for raucous laughs!

Thursday, October 2, 20087:30 a.m. to 8:30 a.m. Continental Breakfast

Moderator: Frank Maslar, Advanced Manufacturing TechnologyDevelopment Ford Motor Company

8:30 am to 9:15 am International Trends and Applications in 3D Vision Guided RoboticAdil Shafi, President SHAFI Innovation Inc.

9:15 am to 9:45 am Advances in 3D Vision Guided Robotics at Fraunhofer IPA

Jens Kuehnle, Research Associate, Fraunhofer IPA

9:45 am to 10:15 am Vision Guided Part Loading/Unloading from Racks for AutomotiveApplications Lessons LearnedRobert Anderson, New Technology Manager, Chrysler LLC


10:30 am to 11:00 am Random Bin Picking Technical Challenges and ApproachBabak Habibi, CTO, Braintech Inc.


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ICVGR Conference AgendaThursday, October 2, 200811:00 am to 11:30 am Random Bin Picking Applications/Solutions

Steven West, Business Development Manager, ABB Inc.

11:30 am to Noon The Need for Generic 3D Bin Picking

Ren Dencker Eriksen, CTO, Scape Technologies

Noon to 1:00 pm Group Luncheon

1:00 pm to 1:45 pm Robot Visual Servoing Opportunities and Challenges AheadJane Shi, Senior Research Scientist & James Wells, Senior StaffResearch Engineer, General Motors Corporation

1:45 pm to 2:15 pm 3D Robot Guidance for Cosmetic Sealer ApplicationsKevin Taylor, Vice President, ISRA Vision Systems, Inc.

2:15 pm to 2:45 pm Combining Machine Vision and Robotics to Mimic ComplexHuman TasksMichael Muldoon, Business Solutions Engineer, Averna Vision & Robot

2:45 pm to 3:00 pm Break

3:00 pm to 3:30 pm Using 3D Laser Scanning for Robotic GuidanceBrian Windsor, Business Development Manager, SICK, Inc.

3:30 pm to 4:00 pm Vision Options for Dual Arm Robot GuidanceGreg Garmann, Software & Controls Technology Leader, Motoman Inc

4:00 pm to 4:30 pm Distance, Pitch & Yaw from a 2D ImageSteve Prehn, Senior Product Manager Vision, FANUC Robotics Ame

4:30 pm to 5:00 pm VGR Panel DiscussionYour opportunity to ask specific questions and get insight from thisexperienced panel of VGR leaders.


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Thank you to our

Corporate Sponsors:


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Thank you to our

Media Sponsors:


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The Basics of Robotics

Presented by:

Bob RochelleKawasaki Robotics USA


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International Conference for Vision Guided Robotics

September 30 October 2, 2008

Bob RochelleNorth American Sales ManagerKawasaki Robotics USA

Bob RochelleKawasaki Robotics USA28140 Lakeview DriveWixom, Michigan 48393Phone: 248-446-4211Fax: 248-446-4200

Email: [email protected]

Bob Rochelle has a Bachelors and Masters degree in Engineering from Virginia Techand holds numerous US and International patents in the automation and food packagingfields. He has been in the Automation Industry for over 25 years and has held positionsas Design Engineer, Project Manager, R & D Engineer, Engineering Manager, SalesEngineer and Sales Manager.

He is currently the North American Sales Manager at Kawasaki Robotics withresponsibility for robot and system sales through a direct sales staff or via an IntegratorNetwork located throughout North, South and Central America.

Bob is a veteran seminar speaker and has taught General Engineering, ProjectManagement and Robotics for Baker College in Southeast Michigan. He is also theChair for the RIAs New Markets Committee.


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The Basics of Robotic

BobNorth American Sale

Kawasak


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References

References: Robotic Industries Association www.robotics.o Kawasaki Robotics (USA) Inc. www.kawasakir Denso Robotics www.densorob

Advance Products Corp www.advancep Practical Robotics Services www.prsrobots TDI Covers www.tdicovers. Adept Technology www.adepttech PAR Systems, Inc www.par.com Conveying Industries Inc www.conveyind ANSI / RIA Standard R15.0 Handbook of Industrial Robotics Edited by Shim The Top 10 Application Mistakes Article by Geor


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Outline

Flexible Automation

The Robot Industry

Yesterday, Today, Tomorrow

Terms and Types of Robots

Basic Robot Technology

Mechanical, Controls, Programmi Tooling

Robots in Systems

Robot Based Systems

Vision

Examples - Case Studies Final Thoughts


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Robotics = Flexible Autom

Flexible A

Quick

Progr

Highe

Repea

Chang

config Respo

Dedicated Automation

High Volume

Requires Set-up time

More maintenance

Air Cylinders /actuators

Rigid conveyors /fixtures

Manual

Quick productchange

Breaks

Monotonoustasks

Health Claims


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The Robot Industry

History

Today

Tomorrow

General Terms Types of Industrial Robots


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First Robots

Steam Man and Electric Man Robota

Czech word for forced labor or serf

Karel Capek - Rossums Universal Robots Written in 1920, Premiered in Prague in

1921 Translated into English and performed in

New York in 1923

Isaac Asimov Coined the word Robotics 1950s wrote the Robot Series - part of the

Foundation Series Drafted the Three Laws of Robotics.


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Todays Industrial Robo

People

George Devol

Joseph Engleberger Father of Robotics

History

1956

George Devol & Joseph Engleberger met

Began development work of first commercial ro

First Working Model late 1956

1961 - First Installation

GM - Die Cast Part Extractor

Patented in 1961

Formed Unimation


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Early Industrial Robot

Unimation Universal Automation

Unimate Robot 4000# Arm Step by Step Commands

stored on a magnetic drum Hydraulic Actuators $100,000 Plus Price

Puma

ProgrammableUniversalMachine forAssembly


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Robot Industry - Toda

Over 850,000 at work today

Over 100,000 sold per year

Revenue $5,000,000,000 - robots

$15,000,000,000 - systems

Growth rate greater than 18% yearly

Largest Users Automotive - 47%

Electronic -15%

Major Applications Material Handling - 39%

Welding - 30%

Assembly - 8%


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90% of Industries that could use robotic automation have yet to consider pur

Robots Today


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Applications

Spot Welding

Arc Welding

Coating & Dispensing Less than 10 pounds

Greater than 10 pounds

Assembly Less than 10 pounds

Greater than 10 pounds

Material Handling Packaging / Palletizing

Machine Tending

Body Shop

Other Material Handling

Material Removal

Inspection

Defined by Robotics


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New Markets and Applicat

Service Industry

RoboBar, Food Serv

Care for the Elderly

Humanoids

Medical and Pharmac

Prescription Dispens Lab Automation

Surgery System Do

Prosthetics Researc

Construction

Manufactured Housi

Machining


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Flexible Manufacturing


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Terms and Types of Rob

Common Industry Terms and Concepts

Various Types of Industrial Robots


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General Terminology

Work Envelope, Work Space or Reach The set of points representing the

maximum extent or reach of the robothand or working tool in all directions.Also referred to as the working envelopeor robot operating envelope.

All encompassing range of motion

Payload The maximum total weight that can be

applied to the end of the robot armwithout a sacrifice of any of theapplicable published specifications ofthe robot.

Weight carrying capacity

Cycle Time or Speed Execution time for one task


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The Axes Degrees of Fre

Degrees of Freedom - Axes One of a limited number of ways in which a robot joint ma

Joint 1 - Base Rotation Joint 2 - Rotation of the lower arm Joint 3 - Rotation the upper arm

Joint 4 - Swivel of the upper arm Joint 5 - Bend of the wrist Joint 6 - Rotation of tool mounting plate

Joint 7 - ??? - Traverse, Turntable, or other motions

Coordinates Base or World - Origin is in the robot base Tool Coordinates - Origin is the Tool Center Point

X


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Multiple Axis System

Axis 1 to 6 - Robot

Axis 7 - Turntable

Axis 8 and 9 Part Rotators

Axis 10 and 11 Part Spinners


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Common Industrial Rob

Cartesian / Gantry

SCARA

Telescopic

Parallel Articulated

Modular


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Cartesian / Gantry Robo

Four Plus Axes

Simple Motions

Linear X, Y, Z

Tool Rotation

Components Base / Superstructure

Arm / Runway

Telescope / Carriage

Controls

Packaging / Machining / Water Jet


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SCARA Robots

Four Degrees of Freedom / Advanced Control

One Linear Axis and multiple rotary axes

Motions

Rotational

Linear Z Axis

Highly Accurate

0.015 mm

Fast and Vibration Free

Adept Cycle: 0.30 0.35 seconds

Packaging / Ass

30

Adept Cy


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Telescopic Robots

Semi Conductor Ind

Clean Room applications 3, 4 and 5 Axis designs Specific to Application

Wafer Handling Systems

Flat Panel Screens


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Parallel Robots

Tripod with three axes

Hexapod with six axes

Very Stiff

Accurate

High Speed

High Speed Pick a


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Articulated Robots

Most Common / Most Flexible

4, 5 or 6 Degrees of Freedom Rotational Motions


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Modular Robots

System with a combination of robot types


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Beyond Industrial Robot


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Robot Technology

Controller

Ar

Robot Mechanical Components

Robot Controls

Robot Programming

Robot Communication


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Arm or Manipulator

Arms

Fork Lift Pockets

Base

Counter Balance

Joint 2 Motor

Wrist

Join


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Mounting and Environm

Mounting Floor, Ceiling or Walls Proper Fasteners - no Casters Tracks or Traverse Units

Typical Environmental Specifications IP65 / 67 Standard

Ambient Temperature: 0 - 52oC Relative Humidity: 35% - 85% Non Condensing Optional: Clean Room / Wash down Hazardous Duty Units - Spray painting


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Robot Controllers

Two Components

Controller

Teach Pendant

Design

Microprocessor based Programmable

Generally One Controller per Robo

Multi Controllers available


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Teach Pendant

Design Hand Held

Programmer's Interface to Robot Controller and Program

LCD Display

Hard keys for Functions / Keyboard

Functions Communicates with Controller Dead man Switches

E - Stop

Monitor

Teaching / Programming

User Interface to robot

Operators System Interface Possibility


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Communication and Netwo

Discrete I/O

Photocoupler, relays, transistors

Relay modules add on

Remote I/O to PLCs

DeviceNet

Master, Slave, Master & Slave

Profibus Master, Slave, Master & Slave

Interbus

Ethernet

TCP / IP, I/O adaptor

RS232 / RS485

Internet

Intranet


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Programming

PC Programming

Teach Pendant Programming

Teach Pendant Programmer ho

Manually teach

Off Line Programm Program written

Higher level lang

Loaded into Rob

Touch up requir

No additional ha

Check Programs Slow speed ope

Program Storage Flash RAM

PC Hard Drive

Other media


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Basic Robot Motion Teac

Motion Instruction Defines a target position

Interpolation Instruction Defines how to get to the position Joint Move - Robot articulates any axis to accomplish the m Linear Move - Maintains the tool in the orientation specified Circular Move - Generated by defining three points and a rad

Speed Expressed in percent of full speed or a software settable ma

Termination Instruction Expressed as a number [1 - 9] most to least accurate. Defines approach to the target position

Additional Programming Activities Activities to be complete before moving to the next target po

I / O switching Data acquisition


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Repeatability

Repeatability

Ability of the robot to return to a preprogrammed

Closeness of agreement of repeated position movthe same conditions to the same location.

Assume repeatability to be +/- 0.004

0.008

Robot cananywhere0.008 dia

and still farepeatabi


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Robots In Systems

Whos Who in Robot System Industry

Tooling

Control Systems

Systems

Vision Safety


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Whos Who in the Robotics' I

Robot Manufacturers Manufactures the robot

Provides robot training, maintenance and service

System Integrator [System Builder]

Integrate the robot into a system to perform a specified task

Independent business, industry specific, some allegiance to rob

Has knowledge of End Users business

Designs and builds the robot based system

Purchases robot and all peripheral equipment

Designs and builds systems, writes and maintains programs

Trained on entire cell / provides training on system

Provides system components, installation, training, service

End Users

Uses the robotic-based system in production or processing Knows what is required to accomplish tasks

Ultimate user - needs training, service, maintenance, spare p


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Tooling / End Effectors / E.

The tool attached to the robot manipulator or arm that actually p

Examples

Vacuum Cups

Grippers

Spatulas / Fingers

Spray Nozzles

Dispensers

Buffing Wheels

Machine Tools

Water Jets

Welding Torches / Resistance Welding Guns

Saws

Laser Cutters

Ladles

Adds to the Work Envelope Adds to the Payload / Torque / Inertia


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Tooling Consideration

Parts Fixtures

Repeatable and Positive

Sensors

Part locators / verification of action / QC

Tool Changers

Quick change / machine set-up

Environmental Considerations

No Parts Fixture?

Can Locate

Do I move the part ? Do I work on a stationary part?


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System Control Philosop

Philosophy 1

Robot Controller does all

System I/O, Tooling Control, Motion Control, Operator

Philosophy 2

Robot Controller

Tooling Control, Motion Control

PLC or PC

System I/O, Operator Interface

Philosophy 3

Robot Controller

Motion Control only

PLC or PC System I/O, Tooling Control, Operator Interface


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Robot System Safety

Responsibility

Robot Manufacturer

Integrator / System Builder / Installer

User

Refer to Resources

ANSI / RIA R15.06-1999 OSHA Standards

CUL / UL [Underwriters Laboratories]

Hazardous materials requirements

Local Codes

Good manufacturing practices

Plant Standards Personnel training policies

AN

RobotAnn


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System Development Pro Identify the System Specifications

What do you want to do?

Existing Process, Reach, Payload, Speed, Operator InvoQC Issues, Interface with Production System, TechnoloCapability of User

Who is going to Integrate the system?

End user, Integrator, Robot Manufacturer, Combination

System Design and Build Preliminary Layouts and Design Proposal

Space Required, Parts Movement, Tooling, Safety ConcInterfaces and Communication, Operator Involvement

Simulations / Cycle Time Study / Verification Tests

Build and test the system prior to shipment

System Start Up and Commissioning Installation, Start-up and Customer Acceptance

Continuous Improvement


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Industrial Robot System

System Components

Robot and Controller

Arm Dressing and Risers

End of Arm Tooling

Parts Fixtures or Locators

Interfaces

Pneumatics Sensors

Electrical Components

Cables

Peripheral Equipment

Varies by application

PLC or External Control

Communication via Network or Discrete I/O

Safety Components

Fence, Gates, Interlocks, Light Curtains, Barriers, Awar


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Selecting a Systems Integ

Determine if the Integrator has experience in your indu Transferable knowledge

Evaluate the Integrators background and capabilities Full Service

Commercial Issues

Check references

The Integrators Robot Manufacturers

Prepare for disaster What happens?

After sale maintenance Integrator / Robot manufacturer

Cost Is the lowest bid the best?


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Vision Systems

Peripheral Equ

Camera

Camera Con

Light Source

Calibration C

Robot Compon

Robot and C

Interface to

Software

Applications

Part Locatio

Inspection

Bin Picking Real Time F


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Bin Picking


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Locating or Orientating P

Cameras

Camera

PartsRack


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Robot Guidance

Real Time

Welding

Seam Sealing

Dispensing


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The Green Sand Casting Pr

Green Sand Casting Process Create the mold

mixture of sand, clay and moisture simple materials materials can be reused or regenerated low cost materials

Pour molten metal into the molds Remove the parts Machining or clean up is required

Green Sand Cast Parts Require surface finish Lowest cost casting process

Labor intensive process Automated mold creating

Recently automated the pouring process Manual parts removal


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Robotic Pouring

Customers Results Four times the capacity

impeded by peripheral equipment One part every 30 seconds Reduced labor by three per shift Energy reduction

automatic furnace lid closure provides in Operator Safety is vastly improved Reduced material use

same quantity for every part Parts consistency is 100% reliable

repeatable process Increased Parts Quality

metal heat more consistent

pour efficiency


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10+ Mistakes in Robot Integ

Underestimating Payload and Inertia.

Expecting the robot to do to much.

Underestimating Cable Management Issues.

Not considering all current and future application nee

Misunderstanding accuracy and repeatability.

Focusing on the robot alone.

Not planning for disaster.

Overlooking the need for options or peripheral equipm

Not fully utilizing the capabilities of a robot.

Choosing a robot or system solution solely on price.

Thinking that robots are too complicated.

Failure to consider using robotic technology.

Expect System Re


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Applications

Welding

Spot Welding

Plasma Welding

Coating & Dispensing

Glue Dispensing

Paint

Packaging / Palletizing Bag Palletizing

Box Palletizing

Muffin Packaging

Material Handling

Press Tending

Forging

Investment Casting

Machine Tending

Die CastingDefined by Rob


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Contact Information

Bob RochelleNorth American Sales M

Kawasaki Robotics28140 Lakeview Drive

Wixom, Michigan 48393

USA

Telephone: 248-446-4211

Email: bob.rochelle@kri-u

Web: www.kawasakirob


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The Basics of Machine Vision

Presented by:

David DechowAptra Machine Vision Solutions


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David DechowPresidentAptra Machine Vision Solutions

David DechowAptra Machine Vision Solutions3130 Sovereign Drive, Suite 5A

Lansing, Michigan 48911Phone: 517-272-7820, x11Email: [email protected]

David Dechow is president and founder of Aptra Machine Vision Solutions, LLC. Mr.Dechow has worked in the field of machine vision for over 25 years as a programmer,engineer, and manager. He served 14 years on the AIA board of directors, and was atwo term president of that board. Mr. Dechow is the 2007 recipient of the AIAAutomated Imaging Achievement Award honoring industry leaders for outstandingcontributions in industrial and/or scientific imaging. Mr. Dechow is a regular speaker atconferences and seminars, and a frequent contributor to industry trade journals and

magazines and has served on the editorial boards of Vision Systems Design magazineand Quality Magazines Vision and Sensors.


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The Basics of Machine Vi

Davi

Aptra Machine Vision


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Session Outline

1 Overview/Introduction to Machine Vis

2 Imaging, Lighting and Optics

3 Machine Vision Getting Data From Im

4 Application Analysis and Specificatio


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MACHINE VISION INTRODUCTI



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Overview

Machine Vision

Machine vision is the substitution of the human visjudgment capabilities with a video camera and coperform an inspection task. It is the automatic acqanalysis of images to obtain desired data for cont

evaluating a specific part or activity. Key Points:

Automatic self-acting

Acquisition and analysis machine vision uses bot

Non-contact

Data acquisition value of the technology

Control necessary for reasonable ROI


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Overview

Machine Vision Integration

Machine vision systems integration is thewhere significant value is added to a maccomponent by the incorporation of softwa

peripheral hardware, mechanical devicesand engineering.


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Overview

Prerequisite Integration Expertise:

Application-based lighting and optics

Understanding of imaging and input devic

Electrical and mechanical engineering

Industrial automation systems and compo

Machine vision algorithms

Programming and/or system configuratio

Project management and customer suppo


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Process Overview

Hardwareexecution

Camera and(if applicable)strobe trigger

Softwareexecution ofinspectionprogram

Determinepart status

andcommunicateresults

InitiateInspection

external event

Results

Analysis

AcquireImage

-Recipechangeovers

-Multipleimages/lights-Part tracking


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System Architectures

Machine Vision SystemsCamera

LensImager

Electronics

Power/Control

Signal Frame Grabber

or other signalconversion

Computer

DigitalImage


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Machine Vision Systems, continuedCamera

LensImager

Electronics

Power/Control



Computer

DigitalImage


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Machine Vision Systems, continuedCamera

LensImager

Electronics

Power/Control



Computer

DigitalImage


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Machine vision hardware is an imagesystem!

Differentiation of products at the hardwarelimited

Physical structure and system layout Available camera resolutions

Input/output options

Other hardware integration capability


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Machine vision software drives compocapability, reliability, and usability

Available image processing and analysis

Ability to manipulate imaging and system

Methodology for inspection task configura

Main component differentiation is the implementation

Often, system software complexity inc

with system capability


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IMAGING, LIGHTING AND OPTI



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Imaging, Lighting and Optic

Key Issues

Imaging Application requirements will dictate image space and cam

Lighting The purpose of lighting for machine vision is to create the

contrast between features to be inspected relative to the bother features

Competent lighting technique contributes over 80% to theapplication

Optics Most machine vision applications use off the shelf optics

Select proper machine vision quality lenses


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Imaging Basics

Image Acquisition

Performed by a light-gathering silicon device

CCD, CID, CMOS

The imaging chip comes in a variety of physical la

Area

Line

Size of the chip varies widely as does the numberpicture elements (pixels)

Typical area chip for machine vision: from .3 to 4+

Physical sizes from " diag. up

Typical line scan array: from 1K to 12K+


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Imaging Basics

Cameras

Image sensor supported by electronic circpackaged for industrial use

Final output may be analog or digital

RS170, CCIR, NTSC, PAL, USB, FireWire (13Camera Link, GigE

Camera

Lens

ImagerElectronics

Power/Control

Signal Out


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Imaging Basics

Digital image representation

Common thread is the internal representaimage as seen by most algorithms

The image is stored as a single or multipl

planes containing arrays of integer numbe Each number represents one small sectio

image a pixel (picture element)

Lower numbers are darker, higher numbelighter

Typical range is 0-63, -127, or -255


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Imaging Basics

Internal representation gray scale im

255 255 255 105 51 41 43 49 10

255 255 255 116 62 44 42 57 12

255 255 255 112 68 41 46 58 11

105 110 111 109 60 42 48 61 11

60 68 62 57 42 41 46 41 43

44 42 41 46 46 42 48 44 42

41 46 42 48 44 42 41 41 46

59 54 60 59 41 46 42 46 46

100 120 120 115 51 41 43 49 11

255 255 255 118 62 44 42 57 11

255 255 255 121 68 41 46 58 12

255 255 255 100 60 42 48 61 10


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Imaging Basics

Color Images

Color images commonly are acquired andrepresented as three planes of digital datfor Red, Green, and Blue

Difference between 3-chip color and Baye Other representations such as HIS, LAB a

from the RGB data


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Lighting Basics

Illumination for machine visionmust be designed for imaging, nothuman viewing Selection must be made relative to

light structure, position, color, diffusion

We need to know how light works so

our light selections are not hit andmiss guesswork

Light is both absorbed and

reflected to some degree from allsurfaces

When an object is clear ortranslucent, light is also

transmitted Angle of incidence = angle of

reflection

Light Source

Tran(if obcomopaq

Diffuse

Reflect

Refraction,Absorption


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Lighting Basics

Dedicated lighting must be used for machinefew exceptions.

Where feasible, LED illumination is the best

Long life with minimal degradation of intensity

Able to be structured into a variety of shapes May be directional or diffuse

May be strobed at very high duty cycles and overdtimes nominal current specifications

Available in many visible and non-visible colors

Other sources fluorescent, fiber-optics


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Lighting Basics

Lighting Techniques

The goal of lighting for machine vision apusually is to maximize the contrast (graysdifference) between features of interest a

surrounding background Techniques are categorized generally by

of the illumination source

Most may be achieved with different sources


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Lighting Basics

Direct bright-illumination

Sources: hilights (showbar-lights (s

or Fiber-opti Uses: gene

of relatively objects; lighcamera is m

Images: CCS America; www.ccsamerica.com


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Lighting Basics

Diffuse brightillumination

Sources: hdiffuse ring ldiffuse bar-l

fluorescent Uses: gene

of relatively objects; lighcamera is m

Images: CCS America; www.ccsamerica.com


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Lighting Basics

Direct dark-fiillumination

Sources: lolights (showbar-lights; L

optic guides Uses: illum

geometric sulight reflectiomostly spec

dark field is

the field ormay be lightsurface objeImages: CCS America


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Lighting Basics

Diffuse dark-fillumination

Sources: diangle ring ligspot-lights, b

LEDs or fluo Uses: non-

illumination reducing glaunwanted su

Images: CCS America


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Lighting Basics

Diffuse backl

Sources: hLED or fluorlighting

Uses: provi

silhouette of

Images: CCS America


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Lighting Basics

Structured lig

Sources: Flinear array,patterned la

Uses: highl

shapes, creabased upon 3D informatiimages

Images: CCS America,Stocker & Yale; www.stockeryale.com


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Lighting Basics

On-axis (coaxillumination

Sources: diLED or fiber

Uses: produ

illumination surfaces, macontrast surfmay highlighgeometric sudepending o

angle

Images: CCS America


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Lighting Basics

Collimated ill

Sources: diangle ring ligspot-lights, bLEDs or fluo

Uses: non-illumination reducing glaunwanted su

Images: Edmund Optics; www.edmundoptics.com,CCS America


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Lighting Basics

Constant DiffIllumination (cloudy day il

Sources: spintegrated lig

Uses: provnon-speculareflecting colighting fromangles; goodor specular s

Images: Siemens; www.nerlite.com

Object

Light Source(on-axis)

Camera

Beam Splitter

LightSource

(off-axis)


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Lighting Basics

Other lighting considerations

Color

The effect of monochromatic light on colored f

Camera response to different colors

White light and color imaging Non-visible colors

Light degradation over time; component ldissipation

Light intensity and uniformity

Strobing

Elimination of ambient and other stray lig


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Optics Basics

Application of optical components Machine vision requires fundamental und

of the physics of lens design and perform

Task is to competently specify the correct

Create a desired field of view (FOV) Achieve a specific or acceptable working dista

Project the image on a selected sensor based primary magnification (PMAG)

Goal, as always, to create the highest levbetween features of interest and the surro

background; with the greatest possible imaccuracy


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Optics Basics

Considerations for lens selection

Magnification, focal length, depth of focusnumber, resolution, diffraction limits, aber(chromatic, spherical, field curvature, dist

parallax, image size, etc. The physics of optical design is well know

be mathematically modeled and/or empir

Specification or control of most of the lens critour hands


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Optics Basics

Considerations for lens selection

Practical specifications for machine visiondictated by focal length) and WD to achieFOV

Use a simple lens calculator and/or manufactuspecifications

Simple state the required FOV, the sensor sphysical selection of camera and resolution, aworking distance calculate the lens focal len

Test your results

Always use a high-resolution machine visNOT a security lens


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Optics Basics

Why use machine vision lenses only

Light gathering capability and resolution

Images: Edmund Optics; www.edmundoptics.com


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Optics Basics

Specialty Lenses

Telecentric

Microscope stages

Macro, long WD


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MACHINE VISION GETTING D

FROM IMAGES



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Machine Vision Getting Data out of

Inspection Concepts What are the capabilities and limitations o

vision technology for the target applicatio Requirement: specify a processing direction to

respect to system architecture, and the ability

deliverables, performance, and acceptance cr

Analysis of the inspection concept can beby general type of inspection

Assembly Verification/Recognition

Flaw Detection

Gauging/Metrology

Location/Guidance

OCR/OCV


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Assembly Verification/Object Recogni

Feature presence/absence, identificationdifferentiation of similar features

Imaging Issues

Must create adequate contrast between featurbackground

Accommodate part and process variations

May require flexible lighting/imaging for varyin

For feature presence/absence, feature should1% of the field of view (med. resolution cameridentification or differentiation


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Defect/Flaw Detection

A flaw is an object that is different from thimmediate background

Imaging Issues

Must have sufficient contrast and geometric fedifferentiable from the background and other

Typically must be a minimum of 3x3 pixels in spossibly up to 50x50 pixels if contrast is low aclassification is required

Reliable object classification may not be poss

upon geometric shape of the flaws


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Gauging/Metrology

Measurement of features

There are physical differences between gfeatures in an image produced by a came

use of a gauge that contacts a part. Thesdifferences usually can not be reconciled


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Gauging/Metrology

Gauging concepts

Resolution, repeatability, accuracy

Sub-pixel measurement

Measurement tolerances Resolution must be approximately 1/10 of req

in order to achieve gauge reliability/repeatabil


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Gauging/Metrology

Imaging Issues

Lighting to get a repeatable edge

Backlighting, collimated light

Telecentric lenses Calibration

Correction for image perspective/plane

Calibration error stack-up


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Location/Guidance

Identification and location of an object in 2space

May be in a confusing field of view

Imaging Issues Measurement tolerances and accuracies as d

gauging/metrology applications

Sub-pixel resolutions may be better than discrresults

For guidance applications, the stack-up error imay be significant


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OCR/OCV

Optical Character Recognition/Verificationor verifying printed characters

Can be fooled by print variations

Verification is difficult depending upon the

Imaging Issues

Consistent presentation of the character string

May require extensive pre-processing


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APPLICATION ANALYSIS AND

SPECIFICATION



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Application Analysis and Specif

Define the target application and inspecriteria

Describe the desired inspection

Avoid discussion of machine vision technique

Clearly define good part criteria and bad

What is the reason for the inspection

What will happen to a bad part


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Define the part(s) to be inspected

Include physical detail about geometric stfeatures

Identify all possible part variations; color,

structure Describe the materials and surface finish

Will the part change over time

Get photos, samples


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Production Process Analysis

Background information about how the pamanufactured and moved

Production rates, number of shifts

What factors in the process cause the ba

Benefits of implementing inspection

What happens if a bad part gets through

Will costs, yield, quality be improved

What is the cost of a falsely reject part

Can rejects be recovered/repaired


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Part Handling and Presentation Existing automation

Physical description of the mechanism/conveybackground objects, surfaces, and colors at thinspection station

Physical envelope available for inspection com Mounting surfaces available for inspection com

Other processes taking place at the inspection

Other physical constraints or obstacles

Reject method

Interfacing method to existing controls system

Inspection triggering, reject signal, alarms Operator interface requirements


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Part Handling and Presentation

Environment

Type of environment: factory, lab, clean-roomhazardous, etc.

Air quality in the vicinity of the inspection Oil, smoke, debris

Dirt, oil, lubricant, water, other contaminants o

Things damaging to cameras: weld spatter, relight, radiation, etc.

Ambient light

Temperature and humidity

Shock or vibration


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Business Issues

Scope of supply/deliverables; who is respwhat

Engineering: design, integration, shipping, ins

Hardware components Warranties

Documentation and training

Contractual items

Performance guarantees

Terms IP ownership


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Once the constraints of the application are futhe system performance can be quantified.

The performance criteria of the system shou

Actual inspection capability (measurement tolerandetection, etc.) with respect to the target applicatio

Throughput and speed of inspection

Anticipated lighting and imaging methodology

General overview of the operation of the inspectio

Description of the automation and appropriate perelated a specific process if applicable


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Exceptions and limitations

The project specification must identify all exceptions and limitation to the performansystem

Include all possible unknowns


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Acceptance Criteria

How to prove the machine is functioning p

How to resolve differences in opinion regmachine function

Clearly state acceptance criteria AND mequantifiable terms

Acceptance will be based on stated perfocriteria


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Acceptance Criteria Analysis of system performance must be done us

sample or challenge set of parts Verifiable: All parties agree that each specific challenge p

stated criteria, either reject criteria or feature size if a gau

Static testing is done with challenge parts

A gauge R&R is appropriate for gauging applicatio

Production testing can be done with parallel visua Rejected parts will be judged against the set of challenge

The acceptance criteria will list false accept and fa


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Contact Information

David DechowPresident

Aptra Machine Vision

3130 Sovereign Drive, SuLansing, Michigan 48911USA

Telephone: 517-272-7820email: ddechow@aptura.

www.aptura.com


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Successfully Integrating

Vision Guided Robotics

Presented by:

David DechowAptra Machine Vision Solutions


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David DechowPresidentAptra Machine Vision Solutions

David DechowAptra Machine Vision Solutions3130 Sovereign Drive, Suite 5A

Lansing, Michigan 48911Phone: 517-272-7820, x11Email: [email protected]

David Dechow is president and founder of Aptra Machine Vision Solutions, LLC. Mr.Dechow has worked in the field of machine vision for over 25 years as a programmer,engineer, and manager. He served 14 years on the AIA board of directors, and was atwo term president of that board. Mr. Dechow is the 2007 recipient of the AIAAutomated Imaging Achievement Award honoring industry leaders for outstandingcontributions in industrial and/or scientific imaging. Mr. Dechow is a regular speaker atconferences and seminars, and a frequent contributor to industry trade journals and

magazines and has served on the editorial boards of Vision Systems Design magazineand Quality Magazines Vision and Sensors.


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Presentation not available at time of production.


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International Conference for

Vision Guided Robotics

A Special thanks to our Moderator:

Frank MaslarFord Motor Company


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Frank MaslarTechnical SpecialistFord Motor Company

Frank MaslarFord Motor Company36200 Plymouth RoadLivonia, Michigan 48150

Phone: 313-805-3904Email: [email protected]

Key Responsibilities:Work with universities and key suppliers to develop and implement advancedmanufacturing technology in the manufacturing of powertrain systems. Areas of focusinclude vision systems and traceability.

Previous Positions Held:Advanced Manufacturing and Quality Engineer at Ford ElectronicsResearch Scientist at Siemens Corporate Research

Degrees:B.S.M.E. Penn State


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Technology Advances in

2D Vision Guided Robotics

Presented by:

John KeatingCognex Corporation


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John KeatingPrincipal Product Marketing ManagerCognex Corporation

John KeatingCognex Corporation1 Vision DriveNatick, Massachusetts 01760Phone: 508-650-3000Fax: 508-650-3338Email: [email protected]

John Keating is a Principal Product Marketing Manager for In-Signtvision systems atCognex Corporation. He holds a B.S in Electrical Engineering from Boston Universityand an MBA from Babson College. Since joining Cognex in 1994, he has held roles inapplications engineering management, as well as a variety of positions in industry andproduct marketing.


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Technology Advances in 2DGuided Robotics

John KPrincipal Product Marketing

Cognex Corp


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Types of Robotic-Vision Applica

Vision Guided Robotics (VGR)

Alignment & placement of parts

Provides X, Y, to robot

VGR Plus Inspection Inspect parts while providing positional data

Assembly verification, product ide

Documents

ICVGR Proceedings Color