IPC2 Machine-Vision-System - Schulz Systemtechnik GmbH

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Oct 17, 2013 (3 years and 7 months ago)

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Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 1 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.


IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET







Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 2 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


PREFACE

The IPC2 Machine-Vision-System (as well as ist predecessor, the IPC1) is the top-
level-procuct in our product range of industrial machine vision systems. It is a
industrial-PC based, ruggedized system running under either the Microsoft
Windows™ XP Professional or the Microsoft Windows™ 7 Professional operating
system. All our machine vision systems are customized in hardware (i.e. cameras,
optics, illumination, illumination controllers, cable lenghts and the else) and software
(i.e. type and number of algorithms to be used, process sequence, user interface,
host-data-interface, dialogue languange and the else) to exactly fit the individual
applications – which are mostly to be found in the environment of industrial laser
processing systems. Currently there are far more than 200 shipped systems out in
the field at customers worldwide, running reliable and with highest uptime (often in 24
hours a day / 7 days a week production environments under rough operating
conditions) even in the most demanding and complex applications. As all of our
systems are customized to the particular application (which allows a vast variety of
individual configurations), this technical description has a more or less generic
character, describing the possibilities and cornerstones of the product as well as
some mutual technical specifications, which are common to all IPC2 machine vision
systems. This technical description is not intended to be used as a obliging technical
specification for a dedicated application, which always must be discussed and
individually specified according to the individual customers needs and eventually
should end up with a written comprehensive technical product specification for the
particular project.


INDUSTRIES / APPLICATIONS

Our customer- and application-specific industrial machine vision systems are suc-
cessful applied in the following end-user industries worldwide:

 Semiconductor.
 Electronics manufacturing.
 Automotive.
 Security printing (passports, ID-cards, banknote printers).
 Medical.
 Solar business (photovoltaic cells and modules, amorph and cristalline).
 Wristwatch industry.
 Paper industry.
 Laser cusing industry.


Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 3 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


The end user customers for the systems, which are equipped with our machine vision
systems or other industrial automation equipment, are located in the following coun-
tries:

 Germany.
 Austria.
 Switzerland.
 France.
 Netherlands.
 Belgium.
 Spain.
 Italy.
 Finland.
 United Kingdom.
 Czech Republic.
 Hungary.
 Malaysia.
 Singapore.
 Taiwan.
 Japan.
 China.
 Australia.
 USA.

Some successful realized customer application examples of our industrial machine
vision systems are:

 Security reading of mechanically printed, non-machine-readable characters in
passports.
 OCR-reading on crankshafts (automotive).
 Position recognition of wires (automotive) for subsequent laser welding.
 Position recognition of cristalline solar cells (photovoltaic).
 Position recognition of amorpheous solar modules (photovoltaic).
 Position recognition of lasered reference marks on amorpheous solar modu-
les (photovoltaic).
 Position recognition of xenon-burners, 3D-application (automotive).
 Periodic automatic high-precision calibration of a high-precision security prin-
ting system.
 Position recognition of battery electrodes (automotive).
 Position recognition of elektrodes to be laser welded subsequently (automo-
tive).
Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 4 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


 Highest speed simultaneous two-row position recognition of IC-pins on SMD-
leadframes (semiconductor).
 Position recognition of SMD-IC’s within trays (semiconductor).
 Position recognition of reference marks on thin film ceramic modules (semi-
conductor).
 Position recognition of grooves on high-power-ceramic modules (semiconduc-
tor).
 Offset drift compensation for laser galvo heads (photovoltaic and others).
 Offset and gain drift for laser galvo heads (miscellaneous).
 Optical air flow measurement of holes in real time with workpiece moving at
very high velocities (paper industry).
 Position recognition of choke-leads (electronics industry).
 Position recognition of CRT-frames (electronics industry).
 Position recognition and measurement of SAW-filters (electronics industry).
 Position recognition of high-current weld points on hybrid generators / motors
(automotive).
 Position recognition of dashboard components – day-and-night design (auto-
motive).
 Position recognition of grooves on silicone wafers (semiconductor).
 And much more…….

A detailed reference list for our realized machine vision applications with the IPC1 /
IPC2 machine vision system is available upon request and will be issued in complian-
ce with the individual permission of our customers. Please note: due to existing non-
disclosure-agreements for a variety of projects, we may not be able to name every
customer with every application as a reference.


CAPABILITIES OVERVIEW

The IPC2 industrial machine vision system is intended to be used in the following
machine vision disciplines, which could be freely combined together in conjunction
with a application specific machine vision sequence or procedure (which is done by
us in the hardware and software configuration or development phase of a particular
customer project and results in a customer-/application specific software package):

 Position recognition of workpieces in X and Y as well as their rotational devia-
tion.
 Workpiece discrimination (i.e. to distinguish different workpieces).
 Quality control (i.e. surface inspection).
 Character reading (i.e. OCR, barcodes or 2D-codes (Datamatrix, ECC200)).
 Measurement of workpiece dimensions.
Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 5 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


More in detail, this means:

 Greyscale or pure binary operation.
 Colour or black-and-white operation.
 Multi-camera-operation (up to eight cameras).
 Position and rotational deviation recognition (X, Y, Theta) of a object / feature.
 Workpiece, object or feature discrimination.
 Quality control / Inspection.
 Contrast determination.
 Pass / Fail tests.
 Automatic measurement of workpieces, objects or features.
 Character reading (OCR or non-machine readable prints or writing).
 Barcode reading 1D (i.e. Code 39, EAN/UPC, 2 of 5 interleaved, etc.) or 2D-
codes (i.e. Datamatrix, ECC200, PDF417, etc.).

To achieve the above mentioned machine vision capabilities, the following image
processing techniques are applied within our machine vision software package:

 Edge detection (X, Y, Theta) of an object / feature.
 Blob (center of gravity) detection of an object / feature.
 Filtering of images (lowpass, highpass, sobel, erosion, dilation, median and
the else).
 Transformation of images (scaling, rotation).
 Contour-based position recognition of workpieces, objects, features (normali-
zed correlation).
 Feature-based position recognition of workpieces, objects, features (which is
tolerant to a certain degree to appearance variations, based on numerical
classification).
 Measurement functions like histogram, gradient, min/max statistics and the
else).
 And so much more……

All of the above mentioned applications and algorithms are based on our unique
“PROBAMUS-II“ machine vision software platform, in which we (up to now) invested
more than ten man-years development and engineering time and which is undergo-
ing a constant improvement / maintenance / update process.






Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 6 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


SOME EXEMPLARY PERFORMANCE DATA

As mentioned above, all of our machine vision systems are tailored to the specific
application / customer. The spectrum of possible applications and configurations is
immense, making it really difficult to give meaningful universally valid performance
specification numbers. However, the following list gives an impression of performan-
ce data, that have been reliably achieved with our IPC1 / IPC2 machine vision sys-
tems in successful real-world-projects in the past:

 Finest resolution: appr. 1.6[µm] per camera pixel in X and Y.
 Best absolute position recognition accuracy: appr. ±3[µm] in X and Y.
 Best repeatability of machine vision results: appr. ±0.5[µm] in X and Y.
 Largest field of view (FOV) for the camera: appr. 400[mm](X) * 300[mm](Y).
 Fastest recognition process (from end of reception of start command to the
begin of the result transmission): appr. 30[ms] – typical times for “standard“
IPC2 machine vision systems on a budget are to be found in the range of
appr. 100…200[ms].
 Largest distance between top of workpiece surface and bottom edge of dedi-
cated camera optics: appr. 300[mm].
 Fastest workpiece velocity, where we obtained standstill-snapshot images
during workpiece movement: appr. 700[m/min] = appr. 11.7[m/s].
 Largest focal distance for a galvo laser optic used for coaxial position recogni-
tion through this laser optic: 420[mm].
 Smallest focal distance for a galvo laser optic used for coaxial position reco-
gnition through this laser optic: 80[mm].
 Largest number of cameras used within one machine vision system: Four.
 Largest number of individual illumination units used within one machine vision
system: Eight.
 Largest number on individual software controllable illumination channels within
one machine vision system: 20.
 Highest environmental operation temperature of the camera: appr. +50[°C]
(+122[°F]).
 Best cleanroom-class our machine vision system operated in: 1000.


CAMERAS, OPTICS, ILLUMINATION

A generic rule of thumb in the field of machine vision says: Obtaining an image of the
object of interest with reproducable and good contrast as well as a good and repro-
ducable focus to the image memory of a machine vision system is at least 50% of the


Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 7 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


success of a stable and reliable machine vision application. It is always much better
to obtain a good quality image from scratch then to “optimize“ an image by means of
advanced mathematical methods in software afterwards. This is the reason, why we
pay highest and in-depth attention to the fields “camera“, “optics“ and “illumination“ of
our machine vision systems. Most of our machine vision systems are applied in
industrial laser processing environments. The peculiarities of laser systems are requi-
ring very special and unique solutions in these fields, so most of those components
required for laser applications are not readily available on the market. This is the
reason, why we:

 modify industry-standard CCD- and CMOS-cameras.
 partly specify our own camera optics manufactured for us by well reputab-
le optics manufacturers.
 develop and manufacture our own illumination units and components in
conjunction with our own illumination control electronics devices.

With all that above mentioned work (which we performed in close and trustful
cooperation with our laser partners), we gained a lot of knowlegde and experience
over the years – know how, which, we are confident, is one of our unique selling pro-
positions within the field of industrial machine vision.


CAMERAS – SOME DETAILS

Our IPC2 machine vision system mostly would be supplied with three different
models of black-and-white CCD-cameras, which all would be modified by us (i.e.
spectral response, AGC behaviour) to match the requirements that are specific for
laser material processing systems. All of these cameras are equipped with a ½[“]
CCD-chip. These camera models are:

 XC-ST50CE(SST/mod). This is a CCD-camera with analog (RS170) video
interface and conforms to the CCIR625 video standard. It has a pixel
resolution of 752[pixel](H) * 582[pixel](V) and a maximum sensivity of 0.3[lx].
 M10-SX(SST/mod). This is a fast progressive scan CCD-camera with analog
(RS170) video interface and conforms to the CCIR625 video standard. It has a
pixel resolution of 767[pixel](H) * 580[pixel](V) and a maximum sensivity of
0.05[lx].
 MARLIN-F046B(SST/mod). This is a fast progressive scan CCD-camera with
digital IEEE1394 interface (FireWire). It has a pixel resolution of 780[pixel](H) *
582[pixel](V) and a maximum sensivity of appr. 0.3[lx] (dependent on opera-
ting mode and framerate).

Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 8 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET



A selection of our machine vision cameras. From top to bottom:

 M10-SX(SST/mod) High Speed Progressive Scan CCD-Ca-
mera with a special, highest quality telecentric objective.
 XC-ST50CE(SST/mod) Standard CCD-Camera with a stan-
dard, lockable camera objective.
 MARLIN-F046B(SST/mod) High Speed IEEE1394 Firewire
CCD-Camera.

Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 9 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


The cabling to all cameras is running in a single, multicore cable, which carries all ne-
cessary signals (supply, video, sync, trigger, control). The camera cables optionally
could be of the flexible type, allowing it to be used in conjunction with cable drag
chains. The maximum cable length for the cameras is 15[m] (for the firewire camera,
it is 5[m] – longer cable lengths need to be discussed and may require a signal re-
peater or similar device).

Of course, it is always possible to use other models and types of cameras (i.e.
CMOS-cameras, other chip sizes, other spectral responses, higher resolution, other
camera interfaces) if the particular application calls for such a option.

Furthermore, if space considerations are a premium requirement, all cameras could
bei delivered also in a version with tilted / angular head.


OPTICS – SOME DETAILS

The optics used for a machine vision are vital for the success of a total machine
vision project. Therefore, we are only using camera optics of the highes qality, with
their optical specifications meeting the requirements of the particular machine vision
application. Specific machine vision applications are calling for a vast choice of dif-
ferent optical setups, so it is beyond the scope of this document, to specify all pos-
sible optical setups and components in detail. However, some common properties of
our camera optics are:

 Standard C-mount optics thread.
 Focal range from 6[mm] to appr. 300[mm].
 Most of our optics are equipped with a adjustable aperture.
 Most of our optics are equipped with a adjustable focus.
 The settings of all adjustable optics are screw-lockable.
 Special shockproof optics are available.
 Where space is a concern: Optics with diameters, that do not exceed the outer
dimension of the camera, are available.
 Where highest demands in a geometrical undistorded image are a premium:
Telecentric optics are available.
 A wide selection of spectral response filters / IR-filters is available on request.






Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 10 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


Alternatively, the camera(s) of our machine vision system is looking coaxially
(confocal) through a laser optic – may it be a fixed optic or a galvo optic. With this
type of application, we have more than 20 years of in depth experience – a consider-
able amount of our machine vision systems is shipped with a camera looking coaxi-
ally through laser optics. The key specifications of such laser optics are:

 Main wavelength for Nd:YAG Lasers (1064[nm]).
 Main wavelength for Disc Lasers (1030[nm]).
 Main wavelength for frequency doubled Nd:YAG Lasers (532[nm]).
 Main wavelength for THG UV-lasers (appr. 355[nm]).
 Main wavelenght for CO
2
-lasers (10.6[µm], ZnSe-optics only (no Ge-optics)).
 Fixed optics or galvo optics.
 Flat-field or telecentric galvo optics.
 Focal distance in the range of appr. 80[mm] to appr. 420[mm].

Laser optics will be always specified in detail in close cooperation with our laser part-
ners, as a number of important factors (illumination, beam bending devices, filters,
field-of-view (FOV) and the else) need to be adressed in the selection process of the
approbriate laser optic for a particular laser and machine vision application.


A selection of camera optics and laser optics used with our machine vision systems


Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 11 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


A interesting example which illustrates the optical capabilities of our machine vision
systems is pictured with the following image:



This image has been taken with the CCD-camera viewing coaxial / confocal through
a ZnSe galvo optic for CO
2
lasers
with a focal length of 100[mm]. Looking through
ZnSe laser optics and achieving a focussed image with good contrast is the utmost
challenge for machine vision cameras. The data of this image are:

 “Workpiece“: High quality print of a standard television test image.
 Illuminated by our below described linelights (LEDLINIE 040) with 850[nm] IR
wavelength.
 Field of view (FOV): appr. 10.98[mm](H) * appr. 8.24[mm](V).
 Resolution: appr. 14.3[µm] per Pixel in X and Y.

The very good contrast in conjunction with the absence of any geometrical distortion
(allowing precision machine vision software algorithms to be applied to such an ima-
ge) should be especially noted with that image.

Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 12 of 22
© Schulz Systemtechnik GmbH, Obersoechering / Germany 2010 – all rights reserved.

No part of this document may be altered, modified, duplicated or copied without our prior written consent. No liabilities
whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


ILLUMINATION – SOME DETAILS

A correct illumination of a workpiece is cruical for the success of the total machine
vision application mainly for the following reasons:

 Homogenity of illumination.
 Stability of illumination over time.
 Possibility of bright-field or dark-field illumination.
 Freeness of unwanted reflections from the illumination.
 Possibility to illuminate a given field-of-view (FOV) without exposing distur-
bance contours (important for laser galvo applications).
 Ability to control the illumination by the machine vision software.
 Minimized generation of heat by the illumination.
 Selection of different illumination colours or wavelengths (blue, green, yellow,
red, white or infrared (IR)).
 Low weight and size of illumination.

Because all of these requirements in conjunction with the laser application specific
requirements turned out to be a limitation in terms of readily market available illumi-
nation units, we develop and manufacture most of our illumination units on our own in
order to meet the requirements typical for a application of these illumination units in
industrial laser systems. Our current product range of illumination units consists:

 LED linelight with 20[mm] active length (LEDLINIE020).
 LED linelight with 35[mm] active length (LEDLINIE035).
 LED linelight with 40[mm] active length (LEDLINIE040).
 LED linelight with 52[mm] active length (LEDLINIE052).
 LED linelight with 120[mm] active length (LEDLINIE120).
 LED linelight with 170[mm] active length (LEDLINIE170).
 All LED linelights could be equipped with a variety colour selection of high-
power-LED’s (i.e. blue, green, yellow, red, white, IR 850[nm], IR 890[nm]).
 All LED linelights could be equipped with individually intensity controllable
LED’s (either single or as a string of LED’s).
 All LED linelights could be equipped with a diffusing filter (either 30% or 70%
light absorption).
 High power telecentric illumination with 30[mm] beam diameter (TC30LED).
This illumination produces a strictly homogeneous beam with only a minimal of
beam divergence.
 High power telecentric illumination with 55[mm] beam diameter (TC55LED).
This illumination produces a strictly homogeneous beam with only a minimal of
beam divergence.

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granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
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IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


 All telecentric illumination units could be equipped with a variety colour selec-
tion of high-power-LED’s (i.e. blue, green, yellow, red, white, IR 850[nm], IR
890[nm]).
 RodLight 01/7. The RodLight 01/7 is a side emitting illumination unit designed
for space restricted applications (i.e. for illuminating the inner wall of holes).
The light emitting rod has a diameter of 7[mm], thus allowing the illumination
even of small holes. The light emitting rod could be supplied in any length up
to appr. 400[mm].
 RodLight 01/REF. This is a front side emitter, equipped with a highest preci-
sion optical crosshair (reticle) with a line with of precisely 60[µm]. Thus, this
type of illumination images a precise reference crosshair to the focal plane of
the camera, thus allowing for high precision reference position alignments by
means of the machine vision system.
 All RodLight illumination units could be equipped with a variety colour selec-
tion of high-power-LED’s (i.e. blue, green, yellow, red, white, IR 850[nm], IR
890[nm]).


A selection of our illumination components as described above in detail



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granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


This product range constantly will be expanded, as with many new applications also
new illumination approaches are necessary. This new illumination approaches finally
will turn into new illumination components, which then will be added to our product
range.

All of our illumination units could be either used for incident light or for backlight illu-
mination setups – also a combination of both illumination techniques often is used.
Furthermore, our illumination units could be applied either in a brightfield or in a
darkfield illumination arrangement. The cable length for each of our illumination units
could be up to 15[m] and optional could be of the flexible type, allowing them to be
used in conjunction with cable drag chains.

All of our illumination units can be controlled by our own illumination controllers,
which allow control of the illumination units by the software of the machine vision
system. Two models of illumination controllers are currently available:

 LIC20. This illumination controller can control up to 20 individual illumination
channels, each with a maximum current of 200[mA]. Each illumination channel
could be set from zero to maximum illumination in 256 steps. The control inter-
face to the machine vision computer is either parallel or USB. The settling time
for a complete new illumination scenario up to the point, where the new
illumination intensity is stable is in the range of appr. 1[ms] (parallel interface).
The LIC20 illumination controller needs a 24[V]DC power supply, which must
be available on site at the customers system (maximum current: 4.5[A]).
 µLIC02/3. This is a small, economic illumination controller, which could control
two (2) illumination channels, each of which could be preset in illumination in-
tensity by means of three trimming potentiometers. Each of these illumination
channels could supply a maximum current of 200[mA]. The selection of these
preset illumination settings is done by a digital 24[V]DC bit-parallel-interface
(total 6 bits). This interface could be either connected to the customers
controls (i.e. PLC, CNC) or to our machine vision system. The settling time for
a complete new illumination scenario up to the point, where the new
illumination intensity is stable is in the range of appr. 1[ms]. µLIC02/3
illumination controller needs a 24[V]DC power supply, which must be available
on site at the customers system (maximum current: 0.5[A]). The µLIC02/3
illumination controller is a snap-on-device, intended to be mounted on so
called “DIN-Rails“. Alternatively, it could be supplied with side brackets, allow-
ing to mount it onto a mounting plate by means of screws.

The cabling (data cable, supply cable) to the illumination controllers will be supplied
to the customers request. The maximum cable length is 15[m] (except for the USB-
interface, where it is 3[m]).

Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
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File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 15 of 22
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whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET



A selection of illumination controllers. From left to right:

 Model LIC20, 20 individual channels (details see above).
 Model µLIC02/3, 2 individual channels (details see above).

Furthermore, we can supply third party illumination units as a part of our machine
vision systems also, which may be of the following type(s):

 Cold light sources with fibre and remotely controllable intensity as well as
colour temperature.
 Ring illuminations.
 Gaped ring illuminations.
 Dome illuminations.
 Flat area illuminations.
 Illuminations based on incandescent or halogen lamps.
 Illumination units based on discharge lamps.
 Flashed illuminations.

As mentioned above, illumination is a very vital part of a machine vision system and
therefore cruical for the success of an application. For this reason, each illumination
approach must be discussed in detail and eventually tested by means of application
trials in our lab before deciding, what components to use in which manner. There is
no universal applicable illumination setup for every imaginable project!


Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
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File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 16 of 22
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whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


MACHINE VISION COMPUTER


IPC2 machine vision computer, front cover closed


IPC2 machine vision computer, front cover open

The “heart“of our IPC2 machine vision system is our IPC2 (I
mage P
rocessing
C
omputer, model 2
) industrial computer. The IPC2 ist the successor of the IPC1,
which was shipped for many, many years and was a 19[“] / 4[HU] rackmount
computer. However, on request, the IPC1 is still available. The IPC2 is PC-based,
thus allowing all software designed for the Microsoft Windows™ operating systems to
be run on this platform. The IPC2 computer is a ruggedized, reliable industrial
computer, able to run even in rough environments, with the following key specifica-
tions:

Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
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whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


 19[“] / 2[HU] computer, rack mountable.
 Dimensions: 427[mm] = 16.81[“] (W, without 19[“] brackets), 482[mm] =
18.98[“] (W, including 19[“] brackets) * 450[mm] = 17.71[“] (D, without connec-
tors and front handles) * 88[mm] = 3.46[“] (H).
 Weight: appr. 13[kg] (appr. 28.7[lbs]).
 CPU: Intel™ Pentium-IV, 2.4[GHz] clock frequency.
 Optional: Dual Core CPU (for highest throughput requirements).
 RAM: 512[MByte].
 Harddisk: 40[GByte], UDMA100 interface.
 DVD / CD combi drive, able to read and write DVD’s (single and dual layer)
and CD’s (DVD: +R/-R 8X, +RW/-RW 4X, CD: 24X).
 Floppy Disk: 3-½[“], 1.44[MByte].
 LAN: 2 * Ethernet, 10[Mbit/s]/100[Mbit/s], RJ45.
 Serial: 1 * RS232C (COM1:)
 Parallel: LPT1.
 USB: 2 * back panel (USB 1.1 / 2.0), 2 * front panel (USB 1.1 / USB 2.0).
 Second keyboard connector accessible from the front panel.
 Reset button accessible from the front panel.
 Fan filters accessible from the front panel without need to dismantle the IPC2.
 Optional: IEEE1394 FireWire interface.
 Imaging electronics: approbriate for the application (number of cameras,
camera type and model, speed) by means of PCI-add-on-board(s). Standard
pixel resolution of our imaging electronics is 768[pixel](H) * 576[pixel](V),
resulting in an image aspect ratio of 4:3.
 Mains supply: 110[V]AC…240[V]AC wide range input, 47[Hz]…63[Hz], single
phase, maximum power consumption: 400[W].
 Operating temperature range: 0[°C]…+55[°C] (+32[°F]…+131[°F]).
 Storage temperature range: -20[°C]…+80[°C] (-4[°F]…+176[°F]).

Optionally, the IPC2 computer could be supplied with a key-lockable front cover,
allowing it to be used in sensible and sensitive security applications (i.e. banknote
printing and the else).


SOFTWARE

The customized application specific machine vision software of our IPC2 industrial
machine vision system is based on our “PROBAMUS-II“ machine vision software
platform. This software is running on an industrial PC (see above) under either the
MS-Windows™ XP Professional or the MS-Windows™ 7 Professional operating
system. Currently, we have implemented application specific machine vision software
packages in the following user interface languages:

Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
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File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 18 of 22
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whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


 English.
 German.
 French.
 Spanish.

The customized machine vision software normally divides into two parts:

 The machine vision application itself.
 The setup / teaching / training part of the software.

To obtain the highest level of security, several password levels could be implemented
into the machine vision software, allowing different levels of access rights to this soft-
ware. Additionally, comprehensive logging of system activities, status, user actions,
erroneous images etc. is possible, including a time stamp. Therefore, tracking of
problems is easy. All logging will be done in accordance with the secrecy obligation
laws of the countries, in which the machine vision system will be operated.

As the machine vision software application usually is a fully automated program,
which is completely controlled by the host system (i.e. laser computer), there is nor-
mally no need for any user interaction during the normal production process, where
the data output of the machine vision system is used for. So, user interaction normal-
ly is limited to the following situations only:

 Setup of a new workpiece type.
 Training / teaching of a new workpiece model (for contour- or feature-based
recognition processes).
 Maintenance.
 Service.

This means, that in theory the machine vision system (after having been setup) could
be operated as a pure black box, completely eliminating the need for a monitor /
keyboard / mouse to be connected to the machine vision system all the time. How-
ever, for the operators convenience it is often requested to have at least a monitor for
displaying the video image be present on the machine vision system permanently. If
space is a limited factor here, it is absolutely possible (and often practised), to share
the monitor / keyboard / mouse assembly with the master computer (host) by means
of a electronic switch.





Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
Phone: +49/8847/1214 - Fax: +49/8847/1246 - eMail: info@schulz-systemtechnik.de





File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 19 of 22
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whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET



Exemplary software screenshot of a edge detection on a solar cell coaxial / confocal
through a 254[mm] Nd:YAG galvo laser optic (illumination toplight)


Exemplary software screenshot of a edge detection on a SMD-chip coaxial / confocal
through a 160[mm] Nd:YAG galvo laser optic (illumination toplight)
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File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 20 of 22
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whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET



Exemplary software screenshot of a shape based contour position detection of a
20[µm] wire passing a circular electrode coaxial / confocal through a 100[mm]
Nd:YAG laser galvo optic (illumination toplight)


Exemplary software screenshot of a shape based contour position detection of a
plastic key knob integrated in an automotive component (day and night design)
coaxial / confocal through a 254[mm] Nd:YAG laser galvo optic (illumination toplight)
Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
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whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


Upon request, the machine vision software could be accompanied by a simple and
easy to use backup-and-restore tool. In case of such a request, we will integrate the
“Norton Ghost“ software package onto the machine vision computer, thus allowing
easy and hassle-free backups to be made.

Furthermore, occasionally there is a request for the ability of the machine vision
software to be remotely maintained. In such a case, we will integrate the
“PCanywhere“ software package onto the machine vision computer. However, please
note, that this option will require a full and unrestricted internet access via Ethernet to
the machine vision computer. As an (more secure) alternative, the machine vision
computer may be optionally equipped with an ISDN-board in order to allow automatic
callback scenarios to be implemented for remote access. This option needs a full
equipped and unrestricted ISDN-connection to be routed to the machine vision com-
puter. Furthermore, as ISDN is somewhat limited in speed, there may be no “real-
time“ feeling possible at the controlling remote site.


CONNECTIVITY - INTERFACES TO THE OUTSIDE WORLD

Communication to the outside world is essential for a machine vision system in order
to accept commands from the host system (i.e. laser computer) and to return the
results from the machine vision process (i.e. X/Y/Theta offset coordinates, quality
numbers, reading results for OCR and barcode and the else) to the host system. The
IPC2 machine vision system always acts as a pure slave, meaning that it only takes
action if the host system commands it to do so. Furthermore, all communication is
accompanied by a simple yet effective checksum scheme, so transmission errors will
be detected and corrected by a 2nd or 3rd retry transmission. The following commu-
nication interfaces are available with the IPC2 machine vision system:

 Serial, asynchroneous interface according to RS232C / V.24 (standard).
 10[Mbit/s] / 100[Mbit/s] RJ45 Ethernet interface (hardware standard, software
to be defined).
 USB (1.1 and 2.0) interface (hardware standard, software to be defined).
 Serial, asynchroneous interface according to RS422 / RS485 (optional).
 1[GBit/s] Ethernet (optional).
 24[V]DC-Digital Bit-I/O for PLC’s, CNC’s etc. (optional).
 CANopen (optional).
 Interbus-S (optional).
 Profibus-DP (optional).
 DeviceNet (optional).
 ControlNet (optional).
 ISDN interface for remote maintenance (optional).
Schulz Systemtechnik GmbH - Herbstweg 2 - D-82395 Obersoechering - Germany
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File: IPC2 Machine-Vision-System – Product Description V1.02.doc – V1.02 – 09.12.2010 HS Page 22 of 22
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whatsoever taken for errors, inaccuracies, technical and other changes. No fitness for a particular purpose or application is
granted without our prior written consent. All trademarks and registered trademarks are the property of their respective owners.
This document is subject to change without any prior notice.

IPC2 INDUSTRIAL MACHINE-VISION-SYSTEM
GENERIC TECHNICAL PRODUCT DESCRIPTION – FACTS SHEET


Most common and standard industrial communication protocols could be implemen-
ted for communication over the above mentioned interfaces.

Besides its maturity, the vast majority of the IPC2 machine vision systems, that have
been shipped up to now, communicates over the serial RS232C interface in plain
readable ASCII. The reason lies in the fact, that the amount of data to transfer is
usually very small (making speed and timing concerns negligible) and that this inter-
face is a well known, robust, easy to maintain and easy to diagnose point-to-point
interface. Please note, that due to space and technical restrictions, not all above
mentioned interfaces may be installed in the machine vision computer at the same
time.


TRAINING

Customized machine vision systems are – as could be seen in the previous part of
this document – are individual tailored to a specific application. Therefore, in most
cases, in-depth training of the operating as well as the maintenance personell is a
must with such systems. We provide training classes for our machine vision systems
either in english or in german language and either at our facilities, at our customers
site or at the end users facilites. In order not to jeopardize the efficiency of such a
training session, the maximum number of attendees is limited to six. All attendees of
such a training should have knowledge and practice in the usage of computers
running under the Microsoft Windows™ operating system, as the knowledge transfer
for the generic use of such computers is not part of our training classes.


EPILOGUE

Besides the fact, that presenting the capabilities of customized machine vision sys-
tems in a generalized yet comprehensive manner is a difficult (if not impossible) task,
we hope, that this document gave a brief overview over the does and dont’s of our
industrial IPC2 machine vision system. We would be glad to discuss the details of
your specific application in depth with you, finally resulting in a reliable, durable and
cost effective solution for a machine vision application tailored to your needs and
delivered within the time schedule approbriate for your project.Test us – we are sure,
you won’t regret it.