Vision-Based Metrology

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Vision-Based Metrology
IET 405 Vision Based Metrology Project
Bill Redman, Matt Herms, Matt Waldner, Brad
Neufarth, Jason Marlar
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Vision-Based Metrology History

• Vision-Based Metrology refers to the technology
  using optical sensors and digital image
  processing hardware and software to
• Identify
• Guide
• Inspect
• Measure objects

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Vision-Based Metrology History

• Vision-Based Metrology inspection systems evolved
  from the combination of microscopes, cameras and
  optical comparators

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Vision-Based Metrology History

• Vision-Based Metrology is extensively used in
  general industrial applications such as the
  manufacturing of
• Electronics
• Automotive
• Aerospace
• Pharmaceutical
• Consumer products
• Vision-Based Metrology is being utilized in the
  automatic identification and data collection
  market as a complementary or alternative
  technology to traditional laser scanning devices
  for reading bar codes

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Vision-Based Metrology History

• Early systems were integrated into packaging
  lines for optical character recognition and
  proved to be a reliable way to check the accuracy
  of product codes and label information.
• Today, high-resolution cameras, advances in
  software and imaging processors, and the
  availability of powerful, inexpensive compact
  computers have made vision systems faster and
  more reliable than ever.

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When does a company need a vision system?

• Some products require 100-percent product
  inspection with documented inspection results.
• In other cases a vision system may be needed for
  high production product inspection
• Vision systems provide a means of increasing
  yield-that is, the ratio of good parts to bad
  parts.
• When a serial defect is spotted, the system not
  only recognizes it but can stop the conveyor and
  inform the operator of the defect and its
  magnitude.
• The yield factor is particularly important in
  manufacturing industries that produce large
  volumes, as in the compact disc and
  pharmaceutical industries.

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Vision-Based Metrology inAutomobile Wrecks

• Vision Based Metrology is now being used to focus
  on the movement of objects along with their
  deformation
• This is being used in many car wreck
  investigations

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Vision-Based Metrology in Automobile Wrecks

• Two consecutive images were grabbed from a high
  speed video sequence
• A displacement field of a car at a certain moment
  is presented

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Vision-Based Metrology in Automobile Wrecks

• The deformation pattern was obtained from the
  principle vector analysis.
• This analysis allows the representation of the
  deformation pattern.

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Vision-Based Metrology in Weather Patterns

• Vision-Based Metrology has also been used to
  study weather patterns
• Flow information from a tornado is able to be
  extracted for scientists to attempt to learn more
  about them

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Vision-Based Metrology in Companies

• There are many companies that use vision
  inspected systems today
• Some of the bigger ones are ICS/INEX and PPT
  Vision

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ICS/INEX

• INEX can be traced all the way back to the early
  1900s when they developed a system called
  OPTI-Tron which inspected bottle beverages
• The OPTI-Tron system would eventually become the
  OPTISCAN bottle inspector a worldwide standard
  in container inspection with thousands of units
  installed.
• The introduction of the company's SuperInspector
  1055 became the first commercial machine
  inspection system to integrate camera and
  computer technologies

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PPT Vision

• Founded in 1982, PPT specializes in industrial
  applications where accuracy, repeatability, high
  speed and flexibility are important requirements.
  
• They are the world leader in the design and
  manufacture of completely digital 2D machine
  vision systems.
• PPT's 2D machine vision product line is sold on a
  global basis to end-users, system integrators,
  and OEM's
• PPT is involved primarily in
• Electronics
• Semiconductor components
• Automotive
• Medical devices
• Pharmaceutical and packaged goods

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Quality Inspection at Work
Polymer Membrane Note texture defects
Machined Aluminum Bar Note tool-chatter marks
Stamped Metal Package Note scratch on grinded
surface
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Vision System Pictures
Missing Fuse
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Golf Ball Specifications

• Weight Less than or equal to 1.620 Ounces
• Size Greater than or equal to 1.680 Inches
• Shape Must be symmetrical

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USGA Golf Ball Testing

• A ball passes USGA size inspection if it falls,
  under its own weight, through a 1.680 inch
  diameter ring gauge fewer than 25/100 times in
  randomly selected positions.
• Temperature is constant at 23 C (73.4 F).
• Humidity is held constant.

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Test Outline

• Random sample testing for different brands of
  golf balls
• Determine diameter
• Analyze the results

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Procedure

• Place the ball on the test stand
• Take a picture from a standard height for each
  golf ball being tested
• Analyze the image using National Instruments
  vision analysis software
• Compare the image to the standard size for the
  USGA ball specification
• Compile and analyze the data from the testing
• Present information in graphical form

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Test Device

• Designed using Solidworks CAD program
• Made of extruded aluminum
• Center positioned ball holder that provides
  consistent images for each ball tested
• Camera is secured using the tripod mount

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Final Drawing
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Test Device
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• Images from National Instruments IMAQ Vision
  Builder

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Images from the Vision Software
Horizontal and Vertical Clamp
Horizontal Clamp
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Measurement Data

• Able to see variance between different golf balls
• Tolerance we detected was about 1.680 .010
  inches
• The device performed as expected to allow us to
  complete the vision analysis

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Conclusion

• Vision systems are a reliable way to accurately
  measure items
• A vision system can measure minute details to a
  precise and accurate level
• We were able to observe this with golf balls
  varying just a few pixels
• We now have a better understanding of vision
  systems and how they work

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http//www.cranfield.ac.uk/sme/amac/research/metro
logy/tornado.htmhttp//www.cranfield.ac.uk/sme/am
ac/research/metrology/carcrush.htmhttp//www.qual
itydigest.com/mar98/html/vision.html
http//www.rvsi.com/Pages/about.htmhttp//www.in
exvision.comhttp//www.pptvision.comhttp//www.v
isionxinc.com
References
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Acknowledgements

• Alufab located in Mt. Carmel, Ohio
• Donated materials for the prototype
• Donated their shop and tools for the
  construction
• Special thanks to Dr. Allameh for allowing us to
  use his software and office for this project

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Questions?