The German machine vision industry already rose to a top turnover value of 1.26 billion euros in 2010 and everything points to surpassing the 1.5 billion mark in 2011. Technological advances have a big share in the economic success.

Industrial machine vision is fulfilling increasingly complex tasks, but it becoming increasingly easy to use at the same time. The experts all agree that three-dimensional technologies are providing a further boost. Various systems are already available. Visitors to the trade fair AUTOMATICA, which will take place on the grounds of the New Munich Trade Fair Centre from 22 until 25 May 2012, will find ample proof of this.

  Following many years of success in the two-dimensional area, industrial machine vision has expanded its world by one more dimension.
3D machine vision is increasingly required at the important automation drivers of the automobile industry, semiconductor production and robotics. A robot that sees three-dimensionally can interact with its environment more flexibly than it would be possible with a two-dimensional one, and the volume of ball-grid arrays on circuit boards or biscuits as well as other foodstuffs can only be determined with 3D data. Detecting persons also functions best three-dimensionally. Many additional, new application possibilities are connected with the use of 3D systems, and consequently suppliers of industrial machine vision expect further increases in growth.

Patrick Schwarzkopf, head of the VDMA specialist department Machine Vision, has been observing the development in his industry and especially events in the 3D sector very closely. He reported: "In the component sector, for example with cameras, we are seeing increasingly smaller designs with higher resolutions and less energy consumption." He also sees a change in the area of lighting: "It is still strongly in the range of visible light, but many new applications already use the ultraviolet or infrared spectrum. As a result, machine vision systems can work reliably unobstructed by ambient light."

  These developments can be seen at AUTOMATICA 2012.
Leading technology companies are going to present their innovations there from 22 to 25 May; almost 30 companies from the machine vision sector have already signed up for AUTOMATICA 2012. In addition, current trends will be presented in talks and their feasibility in actual practice will be discussed in the AUTOMATICA Forum.

  Sensors for in-line measurement engineering
The automobile industry is an essential driver of innovation in machine vision. It often requires precise 3D measurements – integrated in the process in many cases – because it is a matter of interlinking new and complex process chains optimally with each other in the production of high quality vehicles. Today, modern, highly precise 3D in-line measurement engineering enables fast, process-optimized performance of very different measurement tasks directly in the process on vehicle body shells. The advantage: The recorded measurement data can be used directly in production for optimizing quality.

Such in-line implementation in such a complex environment represents more or less the elite class of machine vision. A machine vision partner is required for this, who has a lot of experience and can provide an intelligent tool kit composed of in-line measurement engineering and in-process analysis software.

Innovative 3D measurement systems suitable for automating production must be compact, so that they can even be used at difficult-to-access spots and be integrated in very cramped spaces. In addition, substantial measurement accuracy and a very short measurement cycle are often required, so that the sensors can also be used for high-speed applications.

  Easy to install and operate
Regardless of whether highly complex in-line measurement tasks or simpler external surface detection, ease of operation and fast integration into the process environment are important success factors that can smooth the way into everyday automation. This also applies to 3D scanners. They should not only act as simple image recorders or profile generators today, but instead provide more. Consequently, suppliers are starting to integrate specially developed methods into 3D cameras, which provide an optimum of scan rate and image quality.

For example, pre-processing modules implemented in hardware can reduce data volumes, taking the load off the evaluation PC. Special software helps setting up and parameterizing the processes in cameras and supports users in integrating them into the respective process. Application programming interfaces (API) simplify integration into the user world, and integration in various machine vision libraries simplifies operation.

  Structured-light 3D scanners for mobile applications
Structured-light 3D scanning is already a common optical method to obtain depth information about an object. To this end, various patterns composed of illuminated and unilluminated stripes are projected one after another on an object and recorded by a camera. Using triangulation, it is possible to calculate depth information and reconstruct the object spatially.

The trend here is to small, portable devices that are extremely precise, but still inexpensive and easy to operate. Ideally, the projection lens can be changed fast and easily and adapted to the required measurement field according to needs in a few minutes. Such systems pave the way for new applications, especially in mobile 3D digitalization of filigree components of smaller to medium sizes.

Especially robust structured-light 3D scanners exist for larger components in the meantime, which can even be adapted to customary robot systems. Among other things, the systems offered differ in their respective projection technologies, which are also responsible for the measuring speed. The faster, the better: then you not only save time in recording data, but there is less influence from vibrations with increasing measuring speed.

  Reduced costs, increased flexibility – the future is within grasp
Until recently, it was necessary to supply the components required for production unsorted in assembly technology. Production plants could only ensure reliable and unique supply in production processes when they did extra mechanical or manual work, which is very expensive. New 3D sensor technology equipped with two standard cameras and special laser lighting makes precise determination of the position of unsorted components possible in all depth levels of containers.

Thanks to the capability of three-dimensional seeing and precise position determination of unsorted objects in all levels, highly flexible removal of unsorted components is possible. Production plants save considerable costs and production time with this solution. At the same time, production flexibility increases significantly.

  Meaningful supplement to radar and ultrasound
A comparably new 3D measurement procedure is the optical time-of-flight (ToF) technology, which is competing with previous sensor technologies such as radar and ultrasound or serving as a supplement to them. Above all, three methods are already being used in sensors and customer applications: the Continuous Wave (CW) method and the direct and indirect pulse methods.

While the CW method is based on determining the phase shift of sent and received waves, the direct pulse method uses the time measured between the sent and received pulse. In indirect time-of-flight measurements, a single light pulse is shot at the object to be detected, and the returning pulse is measured via two differently long integration windows. In another measurement, the background is detected and eliminated "on chip", which protects use in unfavourable light conditions. The ToF methods are inexpensive, easy to integrate and can be used in many applications.

  About AUTOMATICA International Trade Fair for Automation and Mechatronics
AUTOMATICA is the first and only international trade fair, which covers all areas of robotics + automation every two years. It has taken place on the grounds of the New Munich Trade Fair Centre every two years since 2004. The aim of the fair is to present the entire value-added chain in robotics and automation. Messe München GmbH and VDMA Robotik + Automation, trade fair industry advisor, are behind the industry-driven concept of AUTOMATICA. You can find additional information about AUTOMATICA 2012 at: