Simple. Intelligent. The SIMATIC VS 100 Series. simatic MACHINE VISION.

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1 Simple. Intelligent. The SIMATIC VS 100 Series. simatic MACHINE VISION

2 simatic Intelligence that pays off In answer to the problem of steadily increasing clock-pulse rates for production sequences, companies are depending more and more on industrial image processing. The reasons for this are considerable savings on time and money, fewer machine downtimes and, above all, a drastic increase in productivity and quality. The intelligent vision sensors of the SIMATIC VS 100 series are specially designed for application-specific image processing. Their strong points are optical control during the process of transporting small objects and workpieces for automatic assembly machines and in many other handling-related applications. The product family is distinguished by a uniform operator control concept. No special knowledge of image processing is necessary, since the sensors are trained rather than programmed. 2

3 Complete package gives you everything you need The SIMATIC VS 100 Series intelligent vision sensors come in an all-in-one package. This package contains everything you need to implement your vision Start-up in no time at all Installation, commissioning and operation of the SIMATIC VS 100 family are so easy that training courses are unnecessary. Setup software that can execute on any standard PC is available for making fine adjustments. With the aid of this software, live images are transferred from the sensor to the PC, making it possible to check for correct installation of the sensor head and lighting unit and correct sensing of the test piece. Once this has been done, the PC is no longer necessary. All further actions are carried out right on the processing unit. Training instead of programming You don t have to be an expert in image processing to create a vision solution using the SIMATIC VS 100 Series. The system is trained rather than programmed to complete the relevant task. The sensors learn the job they are to do by being trained to a specific object or pattern. This makes operation extremely easy and special know-how completely unnecessary. solution: Sensor head (camera) with pre-set lens system or CS mount Processing unit LED lighting unit (IR or red, incident light or transmitted light, depending on the sensor) All required cables Easy-to-read documentation on CD-ROM, including setup software Each processing unit can store up to 15 different results in power failureprotected memory during the training phase. This makes it possible to modify the transportation system for other batches and types in only seconds. Flexible operation Because the sensor technology is of such compact design, the SIMATIC VS 100 family can be used in conjunction with a variety of different transport systems. Examples: vibrating conveyor systems (spiral conveyors and systems, linear systems), conveyor belt and continuous workpiece carrier systems, or gripper systems (pick-and-place, robots). A stand-alone solution without additional controllers can be implemented for simple conveyor units, but the VS 100 family can also demonstrate its flexibility in complex automation environments thanks to standardized interfaces such as RS 232, PROFIBUS and Industrial Ethernet. 3

4 Form inspection with SIMATIC VS 110 Inspection tasks With SIMATIC VS 110, three different form inspection tasks can be performed in a single test step: Good part Bad part Correctly positioned part The criteria relevant to differentiation or inspection must be clearly recognizable in silhouette, that is to say, in the contours of the test piece, since the contours of the test piece are compared with the trained object during form inspection. Method of operation Sensor head and lighting unit are installed across from each other on the conveyor. The VS 110 vision sensor inspects the test piece as radiographic image with transmitted light, much like a light-beam curtain. Any inconsistencies on the surface of the test piece thus have no effect on the test result. In addition, the infrared lighting makes the VS 110 vision sensor impervious to changes in ambient light. VS 110 can also be operated by remote control via a controller even when training new test pieces! The inspection can be started in one of two ways: either externally, by means of a light barrier, for example, or automatically, that is to say, when the VS 110 detects an object within its field of vision. The test result is output in the form of digital signals, with which the SIMATIC VS 110 can directly control pneumatic valves or miniature relays for ejection or rotation of the test piece. Product-specific criteria SIMATIC VS 110 is an extremely powerful vision sensor with high-speed analysis for high inspection rates. Depending on the size of the object, it can complete up to around 25 analyses per second at transport speeds of up to 250 mm/sec. The SIMATIC VS 110 can be equipped with three sensor head versions for various object sizes. With its compact dimensions and trailing cables, sensor head and lighting unit can also be installed in mobile systems. The processing unit, with its integrated display and operator pushbuttons, can be installed in any easily accessible space for ergonomic operation. The SIMATIC 4

5 Blast nozzle Position B Blast nozzle NOK Lighting unit Good part in correct position A Position B NOK Good part in wrong position will be re-entered Bad part will be ejected Sensor head Conveyor belt with blast nozzles The test object passes the sensor head and is then sorted out in dependence on the result of the inspection. In keeping with the trained views, the inspection result can be NOK (not OK), Position A or Position B. Good parts that are in the wrong position (Position B) are re-entered into the system in Position A. 5

6 Object inspection with SIMATIC VS 120 Inspection task The VS 120 is used for the reliable inspection of workpieces and patterns, such as e.g. logos, image motifs, etc.... The sensor inspects: the correctness the intactness and the position of an object and/or pattern The position determined by the inspection is output as x-/y-coordinate and angle of rotation. An inspection of the surface structure is not possible. Method of operation The SIMATIC VS 120 uses the incident light method of inspection. Lighting and sensor together form the sensor head. They can also be mechanically separated. The sensor head can also be installed in mobile systems thanks to its compact design and trailing cables. The processing unit evaluator, with integrated display and operator buttons, can be installed in any easily accessible space and ergonomically operated. The SIMATIC VS 120 can also be operated by remote control via a controller, even while training new test pieces! The inspection can be activated via an interface such as digital I/O or PROFIBUS. The result of the inspection is output in the form of digital signals and over the PROFIBUS. Based on the inspection results, the output signals can be used to control robots, pneumatic valves or miniature relays for subsequent processing of the test object. Product-specific criteria The SIMATIC VS 120 is an extremely powerful vision sensor whose flexibility allows it to be set to inspect a wide variety of objects or patterns. The VS 120 vision sensor s most outstanding feature is its ability to inspect form only, pattern only, or form and pattern simultaneously. When set for form inspection only, the sensor is not influenced by different patterns on the object surface. The kind of inspection required is determined simply by training the sensor. Depending on the object size, the VS 120 is capable of up to 20 analyses per second (object-dependent). With four possible versions of the sensor head, the SIMATIC VS 120 can process various objects and patterns. 6

7 Sensor head (camera) Robot Lighting (incident light) Ejector Inspection position Good part Bad part Trigger Conveyor with test pieces Processing unit (Digital I/O) Result (PROFIBUS DP) Control (PROFIBUS DP or Digital I/O) Remote control via any controller The object is inspected when the test object is within the sensor head s area of activity. The result is then used at two different positions. Bad parts are thrown out by the ejector. Good parts are taken over by the downstream robot on the basis of the position information. 7

8 Reading the data matrix code with the SIMATIC VS 130 Inspection task The SIMATIC VS 130 processes (detects and decodes) data matrix codes to ECC200, and is rugged and reliable. It automatically finds the code even under difficult conditions such as distortions, rotation or surface inconsistencies. The vision sensor reads codes applied with different coding methods, such as codes applied with a laser, printed codes, punched codes, or drilled codes. Method of operation The SIMATIC VS 130 works with incident light. Lighting and sensor together form the sensor head. They can also be mechanically separated. The sensor head can also be installed in mobile systems thanks to its compact design and trailing cables. The processing unit, with its integrated display and operator buttons, can be installed in any accessible space and ergonomically operated. The SIMATIC VS 130 can also be operated by remote control via a programmable controller, even when training a new code! The inspection can be activated via an interface such as digital I/O or PROFIBUS. The inspection result is output over the serial interface or PROFIBUS. The output signals generated as inspection result can be used by the VS 130 to control robots, pneumatic valves or miniature relays for subsequent processing of the test object. Product-specific criteria The SIMATIC VS 130 is an extremely powerful vision sensor which can adapt itself flexibly to a wide variety of different object surfaces and coding methods. Four sensor head versions are available for different data matrix code sizes. As many as 5 objects can be inspected per second, depending on the data matrix code size, even in the case of extremely fast-moving objects (250 mm/sec.). The VS 130 vision sensor enables the reliable identification of parts used in production (e.g. type identification, serial number, batch number). 8

9 Sensor head (camera) Lighting (incident light) Ejector Data-matrix-code A A B Trigger Conveyor with test pieces Processing unit (Digital I/O) Result (RS232 or PROFIBUS DP) Control (PROFIBUS DP or Digital I/O) Remote control via any controller The data matrix code is read within the active operating range of the sensor head. The result of the read operation determines what happens to the object. Objects with illegible or incorrect code are thrown out by an ejector. When the code on an object is read successfully, the decoded information is output to the PLC. Based on this information, the PLC then decides what happens next (whether the object will be ejected or processed further). 9

10 Technical specifications VS 110 VS 120 VS 130 Sensor head (camera) CCD chip, 640 x 480 square pixels Digital image data transfer CCD chip 640 x 480 square pixels Digital image data transmission CD chip 640 x 480 square pixels Digital image data transmission Scan rate 58 images/sec. Scan rate max. 58 images/sec. Scan rate 30 images/sec. IP 65 protection IP 65 protection IP 65 protection Aluminum housing with variable fixing centers on all sides Aluminum housing with variable fixing centers on all sides Aluminum housing with variable mounting centers on all sides Trailing image data transmission cable, 2.5 m Trailinge image data transmission cable, 2.5 m Trailing image data transmission cable, 2.5 m Three sensor versions available 2 fixed focus (fixed display field size) 1 C/CS mount with variable display field size Three sensor versions available 2 fixed focus (fixed display field size) 1 C/CS mount with variable display field size Four sensor versions available 3 fixed focus (fixed display field size) 1 C/CS mount with variable display field size Dimensions: 42 x 42 x 100 mm Dimensions: 42 x 42 x 100 mm Dimensions: 42 x 42 x 100 mm Lighting Strobe as transmitted lighting Flash lamp as incident-light illumination Flash lamp as incident light Light medium: infrared LEDs Light medium: red LEDs Light medium: red LEDs Trailing power supply cable, 2.5 m Trailing power supply cable, 2.5 m Trailing power supply cable, 2.5 m Dimensions: 156 x 130 x approx. 39 mm Dimensions: 102 x 102 x 27 mm Dimensions: 102 x 102 x 27 mm Degree of protection: IP 40 Degree of protection: IP 65 Degree of protection: IP 65 Wide variety of mounting options Wide variety of mounting options Wide variety of mounting options Operation temp. 0 to 50 C without fan Object sizes Test objects up to 59 mm x 45 mm (width x height), window: 70 mm x 50 mm Test objects up to 35 mm x 25 mm (width x height), window: 40 mm x 30 mm Variable with C/CS mount Test objects up to 60 mm x 40 mm (width x height), window: 70 mm x 50 mm Test objects up to 34 mm x 24 mm (width x height), window: 40 mm x 30 mm Variable with C/CS mount DMC dot size: 0.60 mm to 3.50 mm; window: 70 mm x 50 mm, code dimensions: up to max. 48 dots DMC dot size: 0.35 mm to 2.00 mm; window: 40 mm x 30 mm, code dimensions: up to max. 48 dots DMC dot size: 0.16 to 1.00 mm; window: 20 mm x 15 mm, code dimensions: up to max. 48 dots Variable with C/CS mount: DMC dot size: image width/120 to image width/22, code dimensions: up to max. 72 dots 10

11 VS 110 VS 120 VS 130 Processing unit Integrated flash control and voltage supply for the lighting unit Integrated flash control and supply voltage for the lighting unit Integrated flash control and power supply for the lighting unit Object rate max. 25 objects/sec. Object rate max. 20/sec. (object-dependent) Object rate max. 5/sec. (code-dependent) Max. permissible object speed 250 mm/sec. Max. permissible object speed 250 mm/sec. Max. permissible object speed 250 mm/sec. Option of external or automatic triggering External triggering External trigger Comprehensive remote control possible via digital inputs/outputs from a separate controller including enabling/disabling manual input Up to 15 different types of test objects can be stored in the processing unit, which provides protection against loss of data due to power failure, and selected manually or via digital inputs, e.g. from a controller Test objects can be fed into the system from left to right or vice versa (in the case of automatic triggering) or as required (when using an external trigger) Comprehensive remote control possible via digital inputs/outputs resp. PROFIBUS interface from a separate controller including enabling/disabling of manual input Up to 15 different kinds of test objects can be stored in the processing unit, where they are protected against loss due to power failure, and selected manually or by remote control, e.g. from a programmable controller Objects can be transported to the system from any direction (external trigger) Comprehensive remote control possible via digital inputs/outputs resp. PROFIBUS interface from a separate controller including enabling/disabling manual input Various filter functions are available for sequential comparison (MATCH) and sequential output of decoded information Up to 15 different types of test objects can be stored in the processing unit, where they are protected against loss due to power failure, and selected by hand or via remote control e.g. from a programmable controller Three inspection results are possible: OK_A (good part in position A) OK_B (good part in position B) NOK (bad or damaged object or good part, wrong view) Permissible height offset for test objects specifiable One of two inspection results is possible: OK (correct, good part) NOK (bad or damaged part) Additional output of x/y position and angle of rotation Objects can be fed into the system from any direction (external trigger) Three results are possible: READ MATCH NOK Rugged plastic housing, user-friendly on-site installation Rugged plastic housing, user-friendly on-site installation Rugged plastic housing, user-friendly on-site installation LCD display field (4 lines of 10 characters each) and 6 operator pushbuttons for menu-driven operator LCD display field (4 lines of 10 characters each) and 6 operator buttons for menu-driven operator LCD display field (4 lines of 10 characters each) and 6 operator buttons for menu-driven operator Interfaces: 8 x digital IN 24 V DC, one of which is a trigger input of type BERO II 6 x digital OUT 24 V DC (three of which are suitable for direct switching of pneumatic valves) Digital image data interface for connecting the sensor head Interface for connecting the lighting unit (power supply, flash control) RS 232 serial interface for connection of a standard PC for displaying the sensor image during setup All cables with plug-in connection system IP 40 protection, suitable for control cabinet-free installation Power supply 24 V DC; 2.5 A Dimensions: 170 x 140 x 76 mm Interfaces: 8 x digital IN 24 V DC, one of which is a trigger input of type BERO II 6 x digital OUT 24 V DC (3 of which are suitable for the direct switching of pneumatic valves) Digital image data interface for connecting the sensor head Interface for connecting the lighting unit (power supply, flash control) PROFIBUS V 1.0 Ethernet for connecting a standard PCs for displaying the sensor image during setup All cables with plug-in connection system IP 40 protection, suitable for control cabinet-free installation Supply voltage 24 V DC; 2.5 A Dimensions: 170 x 140 x 76 mm Interfaces: 8 x digital IN 24 V DC, one of which is a trigger input of type BERO II 6 x digital OUT 24 V DC (3 of which are suitable for the direct switching of pneumatic valves) Digital image data interface for connecting the sensor head Interface for connecting the lighting unit (power supply, flash control) PROFIBUS V 1.0 RS 232 serial interface for connecting a standard PC for displaying the sensor image during setup All cables with plug-in connection system IP 40 protection, suitable for control cabinet-free installation Power supply 24 V DC; 2.5 A Dimensions: 170 x 140 x 76 mm

12 Subject to change without prior notice 03/03 Order No. E20001-A60-P285-V DISPO C8091 MK.AS.MV.XXXX WS Printed in Germany Siemens AG 2003 Siemens AG Automation and Drives SIMATIC Machine Vision The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.