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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
Fax: 517-887-8444Email: [email protected]
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
Fax: 248-391-8532Email: [email protected]
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
10:15 am to 10:30 am Break
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
10:15 am to 10:30 am Break
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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International Conference for Vision Guided Robotics
September 30 October 2, 2008
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
The Basics of Machine Vision
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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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System Architectures
Machine Vision Systems, continuedCamera
LensImager
Electronics
Power/Control
Signal Frame Grabber
or other signalconversion
Computer
DigitalImage
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System Architectures
Machine Vision Systems, continuedCamera
LensImager
Electronics
Power/Control
Signal Frame Grabber
or other signalconversion
Computer
DigitalImage
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System Architectures
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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System Architectures
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
The Basics of Machine Vision
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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
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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
The Basics of Machine Vision
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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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Machine Vision Getting Data out of
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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Machine Vision Getting Data out of
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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Machine Vision Getting Data out of
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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Machine Vision Getting Data out of
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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Machine Vision Getting Data out of
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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Machine Vision Getting Data out of
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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Machine Vision Getting Data out of
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
The Basics of Machine Vision
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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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Application Analysis and Specif
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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Application Analysis and Specif
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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Application Analysis and Specif
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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Application Analysis and Specif
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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Application Analysis and Specif
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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Application Analysis and Specif
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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Application Analysis and Specif
Exceptions and limitations
The project specification must identify all exceptions and limitation to the performansystem
Include all possible unknowns
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Application Analysis and Specif
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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Application Analysis and Specif
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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International Conference for Vision Guided Robotics
September 30 October 2, 2008
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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International Conference for Vision Guided Robotics
September 30 October 2, 2008
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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International Conference for Vision Guided Robotics
September 30 October 2, 2008
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