Vision sensor simplifies assembly line inspection

Edited by the Engineeringtalk editorial team Jul 3, 2007

The 48MS MultiSight from Rockwell Automation is a fully self-contained, multi-function vision sensor, which can handle up to ten different inspections simultaneously.

Machine vision systems, used to inspect parts in packaging and assembly lines for part completeness, size and orientation, typically require a variety of different hardware combined with dedicated computers running frame-grabber and image analysis software.

Complex programming, expensive hardware and lack of flexibility often make these systems expensive and difficult to implement.

But now, Rockwell Automation has launched a new industrial easy vision sensor that greatly simplifies the use of visual checking systems in automated processes.

The 48MS MultiSight from Rockwell Automation is a fully self-contained, multi-function vision sensor, which can handle up to ten different inspections simultaneously and pass a simple OK/Not OK signal to an external PLC or process controller.

Incorporating camera, optics, lighting, communications and fail/pass controller in one package saves a great deal of installation time and hardware cost, significantly reducing the total cost of ownership.

The new vision sensor features a high-resolution 640 x 480 pixel CCD element with optics, and employs three different inspection tools - pattern matching, contrast and brightness.

Advanced models with contour detection and XY position control will also be available very soon.

In combination, these capabilities allow the 48MS to perform up to ten different inspections simultaneously, including logic operations, with ten different regions of interests.

This capability makes it ideal for multiple inspection operations, which can result in great cost savings in both hardware and software.

Multiple inspections are often required in packaging and assembly processes, including labelling, coding, print quality, completeness and orientation checks - evaluating these into a single OK/Not OK signal, which can then be passed to the process controller.

Images from OK or Not OK objects can be stored inside the vision sensor and transferred to an operator system via Ethernet interface.

Combining all these capabilities into one unit makes the 48MS extraordinarily versatile in a wide variety of automated inspection operations for assembly and packaging applications in industries such as automotive, food and beverage and life sciences.

Along with ease of installation, the "Teach and Inspect" setup ensures a quick start-up time and easy modification of inspection parameters in case of product changeovers.

Using a PC and MultiSight's configuration software, the operator simply teaches the reference image, selects the region of interest and the inspection tools to use, together with the inspection parameters.

Once teaching is completed, the PC can be disconnected and 48MS is then ready for stand-alone operation.

No specialist programming or additional outboard image processing hardware is required.

Significantly reduced engineering and programming time greatly reduces the total cost of ownership while at the same time improving flexibility and versatility.

The 48MS MultiSight is packaged in an IP67-rated industrial housing, which makes it suitable for use in a wide variety of industrial environments.

The built-in LED lighting can be switched on or off, or can be combined with external lighting if required to achieve even better image recognition.

The range of accessories, including outboard lighting and mounting hardware, allows straightforward installation or retrofitting of the 48MS MultiSight into most processes or applications.