I am gradually establishing myself as the go-to expert for Vision Systems at my facility. The cameras I've been working with seem to have a delay in processing the images, and I suspect it might be due to the logic used. I am curious if anyone has experience with vision systems and if they have any sample code to share. The cameras are marketed as high speed, capturing 4 different images per part. Once the first image is analyzed, the system moves to the next position without a conveyor system. Rather, it is fixed on a fixture holding a metal part, with additional parts being loaded. The camera ensures that all parts are correctly positioned throughout the process. Any insights on this matter would be highly appreciated.
I have implemented a vision system in my plant using Cognex brand cameras, which are compatible with Ethernet/IP and connected to ControlLogix and CompactLogix PLCs. It is crucial to ensure that cameras are fully network compatible with PLCs. I am planning to incorporate a new brand, SICK, into my system, and a representative from SICK recently visited to provide PLC program examples and a camera for testing. Visit the Cognex website (www.cognex.com) for more information and PLC program examples.
As I continue to establish myself as the go-to expert for Vision Systems at my facility, I have noticed that the cameras I am installing are taking longer than expected to process images. I suspect that the issue may lie in the logic implementation. I am seeking advice from others who have experience working with vision systems and potentially have code samples to share. The cameras I am using are advertised as high-speed, and I am capturing 4 different images per part. After the first image passes inspection, the tooling advances to the next position on a fixture holding a metal part. Additional parts are then loaded, and the camera verifies their correct positioning throughout the process. Any insights or guidance on this matter would be highly valued. I suggest considering taking training courses specific to the systems you are using. Vision technology can be intricate, and there are techniques available to streamline image processing. If possible, attend a training session in your vicinity and bring along details of your application for personalized assistance. You may discover methods to reduce processing time and improve efficiency. It is worth noting that pattern searches can be time-consuming. If you are simply validating the presence of specific features within a defined area, you may achieve faster processing cycles.
When it comes to "slow" vision processing, two main culprits are often identified: having a larger-than-necessary field-of-interest and an excessive number of tools. To improve inspection time, it's recommended to narrow down the inspection window to where the specific feature is expected to be found within the camera's field of view. The number of tools used can also impact processing speed, with more tools typically leading to longer inspection times. However, it is possible to efficiently process inspections even with a sizable number of tools, as I have successfully done in the past. Ultimately, the speed of vision processing is influenced by various factors such as the camera being used, job configurations, and potential constraints imposed by ladder logic. Without access to your programming details, information about your PLC, and the specific camera model, pinpointing the exact cause of slow processing can be a challenge.
I have experience in integrating and programming vision systems, primarily with Cognex but also with some Keyence and IFM systems. If you can provide more details about your setup, I can offer more specific assistance.
Interested in learning more details about your construction project.
Firstly, congratulations on becoming a go-to expert in Vision Systems at your facility! From your description, it seems like a timing or synchronization issue might be causing the delay rather than the image processing logic itself. I had a similar situation and discovered it was an issue of how the triggering was set up - there was a lag between capturing images and starting an analysis. You might want to check the trigger settings of your camera and ensure that it starts processing right after an image is captured. As for code, it would depend on what software tool you’re using for image processing, so more specific details might be helpful. Remember, sometimes the problem isn't within the code itself but in the design of the system's workflow.
It sounds like you're dealing with a fairly complex system. From my experience with vision systems, CPU usage could be a bottleneck if the analyzing algorithm is too heavy, potentially causing the delay you mentioned. You might want to investigate the efficiency of your image analysis process. As for sample code, without knowing your specific setup it's tough to provide directly applicable advice. Broadly speaking, you might consider using parallel processing for the image analysis if you're not already. This could involve capturing and storing all images first, and then analyzing them concurrently. Another route could be to check the buffer settings on your camera. If images are getting queued up in the buffer because the PC can't pull them fast enough, this could also lead to delays. Depending on the Vision Systems software you're using, there should be documentation available that could guide you in adjusting these settings.
I've encountered a similar issue with my vision system project before. The problem might not necessarily reside in the logic but the efficiency of your image processing algorithm. High-speed cameras tend to generate a large amount of data that requires substantial computing resources to process. You may want to consider implementing a more efficient algorithm or using hardware acceleration, like an FPGA or GPU, for faster execution. Sometimes, adjusting the camera settings to the optimal configuration can solve the issue. As for the sample code, OpenCV and Python are both great for image processing tasks. There are tons of resources out there, like "LearnOpenCV" website, that can provide you with some good examples and starting points.
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
We have received your information. We will share Schedule Demo details on your Mail Id.
Answer: Answer: Optimizing PLC ladder logic for high-speed vision systems involves efficient programming techniques, minimizing unnecessary delays, utilizing interrupts, and ensuring streamlined image processing algorithms.
Answer: Answer: Best practices for reducing image processing delays in vision systems include optimizing image capture settings, implementing parallel processing where possible, and using hardware-accelerated image processing algorithms.
Answer: Answer: While specific ladder logic code may vary based on the PLC platform and system requirements, sample code for high-speed vision systems typically involves image capture triggers, processing logic, decision-making algorithms, and output control sequences.
Answer: Answer: Ensuring accurate part positioning without a conveyor system involves precise camera calibration, real-time image analysis for part detection and alignment, and feedback mechanisms to adjust part positions as needed.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.