Keyence Case Study: Keyence Intuitive Vision System enables ALPHR Technology to deliver reliable, customised automation testing solutions

Keyence (UK) - ALPHR Technology is a global market leader providing an industry-leading range of high-end automation solutions, specialising in Test & Measurement, advanced robotics and world class modular automation solutions.

Customers around the world have turned to ALPHR for a range of modular and bespoke solutions, whether a relatively straightforward assembly station or a fully automated assembly and test line.

ALPHR chose the CV-X Series Intuitive Vision System manufactured by KEYENCE:

Consisting of a controller, camera and lighting solution, this vision system makes use of a wide range of high-resolution cameras designed to satisfy any application need. It delivers up to 64 megapixels and features a multi-spectrum image capture system that uses eight wavelengths of coloured light.

The CV-X Series is not only a powerful and sophisticated vision tool but is also designed to be extremely easy-to-use. By making use of the ShapeTrax™3 search tool, the CV-X ensures stable detection of the target even if changes occur such as chips, contrast reduction and size changes.

Furthermore, it is compatible for communicating with Vision Guided Robots from most robotics manufacturers. This is vital because calibration is the most difficult factor when developing and operating a system that links robots and vision systems. The KEYENCE solution uses an auto-calibration function to provide highly accurate and effortless calibration. Through a single click, reliable and stable results are delivered without the subjectivity of a manual process. Because calibration can be carried out immediately, it’s possible to recover quickly from any positional shift and achieve fast and accurate reproducibility regardless of location.

A key feature of the KEYENCE CV-X Series Intuitive Vision System chosen by ALPHR is the CA-DQP12X Pattern Projection Lighting (PPL) system which offers simultaneous 2D and 3D inspection. The PPL light works by flashing multiple projections onto a part using its eight-directional projectors, and calculating the height of the part based off the distortion in the projections. Due to this, inspections can be carried out without being affected by surface conditions or contrast between the part and the background. By adding height data to conventional 2D inspection, PPL provides dramatically improved stability during inline inspection.

The CA-DQP12X projects multiple stripe patterns at the target surface at high speed and an ultra-fast CMOS sensor and processor analyse the reflected light in real-time to generate a 3D height image.

Says Iqbal Kazi, General Manager at ALPHR: “When implementing a vision system, having the correct lighting is paramount in determining if the installation will be a success or otherwise. KEYENCE was able to demonstrate why a specific light source should be used and proved that the CA-DQP12X PPL system was the right lighting for the applications we operate in.”

For more conventional imaging applications, the CV-X Series makes use of 2D inspection lighting such as the LumiTrax™ capture mode as well as the Auto-Teach Inspection function, providing stable inspection for a wide range of different products.

In most cases, dimension or geometric measurement for image processing requires multiple tools and complicated calculation processing but with the CV-X Series’ Measurement and Dimensions tools these processes can be carried out through a few simple clicks.

“Not only are KEYENCE’s sales engineers highly knowledgeable of their products but they are also very approachable and willing to help” continued Iqbal Kazi. “KEYENCE makes the whole process from specifying to integration and set-up as simple as it could be. When working with them we know we are dealing directly with a manufacturer of highly complex hardware, and we can discuss projects with acknowledged experts in their field. KEYENCE can also carry out trials on the product to be tested and create detailed reports, eliminating guesswork.”

The direct approach of specialised product experts, as well as the unparalleled capabilities of the CV-X Series Intuitive Vision System, set KEYENCE apart from the competition.

KEY FIGURES:

• 64 megapixels - Allowing accurate inspection.
• 1 - The entire target can be imaged with a single camera.
• 16 - Different ranges of lighting systems to adapt to any application.

About Keyence:

As a leading supplier of sensors, measuring systems, laser markers, microscopes, and machine vision systems worldwide, KEYENCE is at the forefront of factory automation. We strive to develop innovative and reliable products to meet the needs of our customers in every manufacturing industry.

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