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Lighting in Machine Vision

I. Jahr, Vision & Control GmbH

3.1 Introduction 3.1.1 Prologue

One simple part and a hand full of lighting techniques (examples: Fig. 3.1 and Fig. 3.2). And everyone looks different. However, there still remain many questions, some of which are What do you prefer to see? What shall the vision system see? What do you need to see? What does the vision system need to see? How do you emphasize this? How does the vision system emphasize this? Where are the limits? Does it work stable in practice? What are the components used? What light sources are in use? What are their advantages and disadvantages? Questions over questions. But on the rst view everything seemed to be very simple: it is all only made by light, basically caused by the presence of light. But many people do not know how to do that. For them light is a closed book.

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Fig. 3.1 Different lighting techniques applied on a glass plate with a chamfer: (a) diffuse incident bright eld lighting, (b) telecentric incident bright eld lighting, (c) directed incident dark eld lighting, (d) diffuse transmitted bright eld lighting, (e) telecentric transmitted bright eld, lighting, (f) directed transmitted dark eld lighting.

Fig. 3.2 Glass plate with a chamfer in the familiar view of the human eye.

The readers mission is to learn, how to illuminate, that some features appear dark and others bright. But everything as desired (see Fig. 3.3)!

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Fig. 3.3 Different parts under different lighting conditions. (a) Metal bolt with diffuse backlight, (b) metal bolt with telecentric backlight, (c) blue potentiometer under blue light, (d) blue potentiometer under yellow light, (e) cap with diffuse lighting, (f) cap with directed lighting.

The aim of this chapter is to teach the reader to recognize, for example, why the background is dark, why the lettering is dark or how can I avoid from hot spots. They shall understand how light works.
3.1.2 The Involvement of Lighting in the Complex Machine Vision Solution

In the beginning there was light. Not only in the historical view, but also in the view of Machine Vision people this is one of the most important proverbs. Let us consider this: photog-

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raphy means writing with light. And one can consider Machine Vision as an (extended) contemporary further development of photography. So the light is the base of Machine Vision. It does not only mean writing with light, but also working with light as their information carrier. You may ask: why the light? A vision system consists of much more parts than a lamp! True, but all information that is processed comes from the light. The light information is the origin. The lighting is as important as the optics, because it carries the primary information. To mathematically do image processing, the brightness values of the object and the background have to differ. Contrast, brightness and darkness, shadows, textures, reexes, streaks are necessary. And all this is done by light. That is why the experts know that two-third of a robust Machine Vision solution is lighting. Let me express in this way: garbage in garbage out. Where none takes care of the lighting design, none should be surprised about worse results delivered by the vision system. No brightness and contrast no algorithm will nd the edges. What are a few hours to plan the lighting solution and a few hundreds of Dollars for a professional lighting against a few man-weeks of software engineering to save the consequences of bad lighting. And after that there still remains a lot of unsteadiness. To systematically search for a matching lighting saves real money, time and nerves! Knowing the main parts of a vision system one fact is obvious: Machine Vision is a complex teamwork of totally different technical disciplines that are involved (see Fig. 3.4). And depending on the discipline you are qualied the sight can be a totally different one. If you are right in the middle the view for the entirety can be lost. The same applies to Machine Vision. It is a synthesis technology, consisting of lighting

Fig. 3.4 Basic structure of a Machine Vision solution and main parts of a vision system.

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optics hardware (electronics/photonics) software engineering These are the core disciplines. But Machine Vision is always embedded in automation mechanical engineering connected with the information technology electrical engineering In this delicate mixture the lighting is the key. However, on the other hand, to nd one lighting solution we cannot divide the lighting from the rest of the vision system. All parts are in interaction (see Fig. 3.5). If you change something in the lighting design, other parameters of the vision system also change. There are many feedbacks. The lighting determines other parts of the vision system (optics, sensor, hardware, software).

Fig. 3.5 Some interactions of the components of a Machine Vision system (selection, not complete).

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The intention of this chapter is to give you an approach to solve lighting problems. It was made with the view to the practical everyday life in the factory oor of Machine Vision.

3.2 Demands on Machine Vision lighting

A Machine Vision Lighting for industrial applications is not only a lamp but also more than only a cluster of LEDs. Against the expectations of an uninitiated user there are a few important aspects to pay attention (see Fig. 3.6). State-of-the-art Machine Vision illumination components for industrial use are complex technical systems consisting of light sources mechanical adjustment elements light guiding optical elements stabilizing, controlling and interface electronics if necessary software (rmware) stable and mountable housing robust cabling. All these features are necessary to form a device that resists the adverse environmental conditions of the industrial oor. The demands of industrial lighting components are manifold. Partly they are opposing and challenge the developers. Not all criteria are always necessary: Demands of optical features: wavelength (light color): dened and constant distribution, especially for color image processing no (low) aging no (low) drift caused by temperature no differences from device to device brightness:

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Fig. 3.6 Examples for the variance of Machine Vision lighting. (a) Illumination of the calibration process for medical thermometers. Demands: robustness, brightness, homogeneity, protection against vibrations and splashes of water. (b) Illumination of mechanical parts, running on a dirty and dark conveyor belt. Demands: robustness, tough mounting points, brightness, protection against dust, protection against voltage peaks. (c) Precise illumination for measurement of milled parts. Demands: obvious mounting areas for adjustment, brightness, homogeneity. (d) Lighting stack of a free adaptable

combination of red and IR light in an automat for circuit board inspection. Demands: brightness control of different parts of the illuminations using standard interfaces, brightness, shock and vibration protection. (e) Lighting plates for inspection in the food industry. Demands: homogeneity, wide range voltage input, dened temperature management. (f) Telecentric lighting and optics components for highly precise measurements of optically unfavorable (shiny) parts. Demands: stable assembly with option to adjust, homogeneity, stabilization, possibility to ash (source: www.visioncontrol.com).

dened and constant no (low) aging no (low) drift caused by temperature no differences from device to device homogenous or dened, known and repeatable brightness prole

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only one component for static, pulsed and ash light possibility of ashing independent of the illumination wavelength bright and powerful, but not dangerous (lasers and in some cases LEDs can also cause damages at the human eye retina) Demands of electrical features: operation with no dangerous low voltage wide range voltage input with stabilization for typical industrial voltages between 10 and 30 V dc protection against wrong connection different controlling/operation modes (static, pulsed, ash, programmable) process interfacing: standard interfaces such as PLC inputs/outputs, data interfaces with USB or Ethernet (if necessary). simple storage and adjustment of operating parameters (see Fig. 3.7) all controlling circuitry included in the housing temperature management to avoid overheating exible and tough cables for operation in robotics with a high resistance against bending stress

Fig. 3.7 Elements to adjust lighting characteristics (brightness and ash duration) on a telecentric backlight directly on the lighting component. All electronics are included (source: visioncontrol.com).

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Demands of mechanical features: mechanically robust, packed in black anodized aluminum housing or industrial polyamide diverse and solid mounting points for a rm xing and adjustment (see Fig. 3.8) protection of all elements against vibrations and strong acceleration (lighting in robotics can be stressed up to 10 g or > 100 m s2 )!) dust and splash water protection

Fig. 3.8 Robust mounting threads for a tough xing and adjustment (source: vision-control.com).

Above all stands the demand for an easy and fast installation without additional components, such as mechanical adaptors or holders, electrical convertors or boxes. Further, the compliance with national and international standards such as CE, IP, radiation protection decree and so forth is needed. Industrial users usually accept a 10,000 h (longer than a year) minimum life and operation time of the light sources. Only this is the base for short downtimes and low maintenance. This fact often limits the choice of a matching lighting components. It is expected from the users that standard components are in use. This is not only meant for the light source but also for the complete lighting. These components should be if sometimes necessary replaced very fast. A supplier with an ISO9001:2000 certicate and a wide distributor network can guarantee a fast spare part delivery even after many years.