SOLVING APPLICATIONS

WITH VISION SENSORS

THE GLOBAL LEADER
IN MACHINE VISION AND INDUSTRIAL BARCODE READING

$748 OVER 36
Cognex,® the world’s most trusted machine
vision and industrial barcode reading company.
With over 1.5 million systems installed in facilities YEARS IN THE BUSINESS
around the world and over thirty six years of

MILLION 500+
experience, Cognex is solely focused on industrial
machine vision and image-based barcode reading
technology. Deployed by the world’s top logistics
companies, manufacturers and machine builders,
Cognex solutions cut costs, improve efficiencies and
2017 REVENUE CHANNEL PARTNERS
maximize throughput.
Smarter automation using Cognex vision and GLOBAL OFFICES IN
barcode reading systems means fewer errors,
which equates to lower costs and higher customer
satisfaction. With the widest range of solutions and
20+ COUNTRIES
1,500,000+
largest network of vision experts to meet the most
challenging applications, Cognex is the best choice
to help Build Your Vision.

SYSTEMS SHIPPED

2 Visit www.cognex.com/machine-vision
 SOLVING APPLICATIONS
WITH VISION SENSORS
Compared to the other types of sensors on the market, vision sensors greatly expand the types of simple
inspections a manufacturer can perform and provide information beyond whether a part is simply present or
absent. Vision sensors can inspect multiple elements per target, differentiate between colors, and respond
well to misalignment and planned variability. By reducing defects and increasing yield, machine vision sensors
can help manufacturers streamline their operations and increase profitability. With an array of vision tools
and the possibility to perform multiple inspections per target, vision sensors can cut down on cycle time and
improve product quality downstream.

FIXTURING AND INSPECTION

Vision sensors perform inspections first by locating a part or object in an image, then by looking for features
of interest. The first step in any sensor application is to fixture the object within the camera’s FOV. Pattern-
matching and edge tools do this, detecting even challenging part features such as clear objects, printed text,
and rough dimensions which photoelectric sensors cannot. Once the field of view (FOV) is set, an operator can
run vision tools within the entire range of the target to inspect multiple features for their presence, completeness,
or orientation—all in a single image. The data is compared to the inspection’s specifications, tolerances, or
thresholds to make a decision, which is communicated as a binary data output.
Even though data output is binary, data in aggregate can be used downstream to improve processes and
perform diagnostics on a particular work cell. Unlike any other sensor, a vision sensor can handle misalignment
and predictable variability in a work cell, so operators can use them in pre-configured cells without needing
to make a number of costly and time-consuming changes. Whereas point source sensors must be perfectly
aligned in order to function, vision sensors are designed to handle a high degree of variability. An object can
therefore be inspected in any position on the belt.

OR
PASS FAIL

Vision sensor inspects part Pass/Fail result Data is collected

Vision sensors combine the power of a machine vision system with the simplicity and affordability of an industrial sensor, easily
solving simple inspections and communicating results.

Solving Applications with Vision Sensors 3

 VISION TOOLS
Vision technology plays a very important role for even the most basic presence/absence inspections. Typical vision
tools include pattern, pixel count, brightness, contrast, and edge tools. Notably, a vision sensor can inspect multiple
targets within a single image, as well as perform multiple inspection types relying on different tools.

Pattern Tool: Used to reference an inspection tool, as well as to perform inspection and counting.
Performs best on patterns with sharp contrast and on targets small enough to allow variability and
asymmetry in the FOV.

Pattern tool confirms that the gasket is present and installed in the correct area.

Brightness Tool: Returns the average pixel brightness for a region of interest. Illumination must be
stable and predictable.

Brightness tool confirms the presence of all 10 capsules by showing the greatest delta between pass/fail areas.

Contrast Tool: Compares contrast across an entire region of interest. A useful tool if there are
unpredictable changes in failed parts.

High contrast in the target area indicates the presence of a diode.

4 Solving Applications with Vision Sensors

 Edge tool: Inspects for a high contrast “edge” along a specific path. Can set thresholds
to eliminate noise.

Multiple edge tools measure pixels to detect a clean edge on a drill burr.

Pixel count tool: Returns the total number of pixels between a set range. This works well for large
FOV applications.

Pixel count tool confirms the presence of 13 separate hole punches within one target by determining pixel value.

Color Pixel Count: Returns a number of pixels within a specified region of interest that meet trained
colors. This works best if illumination is applied evenly, since hotspots can cause problems.

Color pixel count tool confirms the integrity of packaging by identifying pixel values of colors trained in the region of interest.

Solving Applications with Vision Sensors 5

SELECTING COMPONENTS
Vision sensors share many common components with vision systems, including lighting, lenses, image sensors,
controllers, vision tools, and communications protocols. Most machine vision hardware components, such as
lighting modules, sensors, and processors are available commercially off-the-shelf (COTS). In many cases, they
can also be purchased as an integrated system with all components in a single device. Though the configuration
of these individual components may vary, all successful vision sensors applications must include the following:

Lighting: Illuminates the part being inspected, allowing its features to stand out so they can be clearly seen by
camera.
Lens: Captures the image and presents it to the sensor in the form of light. Image sensor: Converts light into a
digital image which is then sent to the processor for analysis.
Vision Processing Tools: Processes and optimizes an image for analysis; reviews the image and extracts
required information; uses algorithms to run the necessary inspection and make a related decision.
Communications: A discrete I/O signal or data sent over a serial connection to a device that is either logging
information or using it.

Vision
Processing
Part being Lighting Lens Image Tools
inspected Sensor

A sensor’s compact, modular, powerful vision tools, and dedicated

processing can be easily configured to solve a wide range of applications.

CONCLUSION
Increased throughput, higher quality, and lower costs are key drivers for automated inspection in manufacturing.
Manual inspection can be slow, prone to errors, and often impossible considering the product size, lighting
conditions, or line speed. Given these factors, companies in a wide range of industries rely on vision sensors to
perform simple pass/fail inspections that help ensure products and packaging are error-free and meet strict quality
standards. Cognex vision sensors provide easy and reliable inspections thanks to powerful vision tools, integrated
lighting, modularity, and an easy-to-use setup environment.

6 Solving Applications with Vision Sensors

 THE COGNEX DIFFERENCE
Whatever your environment, resource constraints, and specific tool needs, Cognex sensors can help. At
speeds up to 6,000 parts per minute, Cognex vision sensors set new standards for value, ease of use, and
flexibility thanks to a powerful combination of proven Cognex In-Sight® vision tools, simple set-up, and a
flexible, modular design. In-Sight 2000 series vision sensors are compact, configured for inline and right-
angle mounting installation in tight spaces. Field-changeable, integrated optics and lighting adjust to changing
application requirements and eliminate the cost of external lighting. The In-Sight Explorer EasyBuilder
interface provides a fast, step-by-step application setup which allows even novice users to achieve extremely
reliable inspection performance in nearly any production environment. In-Sight 2000 vision sensors are
configured with In-Sight Explorer software—the world’s most widely used environment for configuring and
maintaining machine vision applications.

The In-Sight 2000 series offers a modular design with field changeable lights, lenses, filters, and covers. An integrated LED ring light
produces even, diffuse illumination across the entire image, minimizing the need for costly external lighting.

Solving Applications with Vision Sensors 7

 BUILD YOUR VISION
2D VISION SYSTEMS
Cognex machine vision systems are unmatched in their ability to
inspect, identify, and guide parts. They are easy to deploy and provide
reliable, repeatable performance for the most challenging applications.

▪▪ Industrial grade with a library of advanced vision tools

▪▪ High speed image acquisition and processing
▪▪ Exceptional application and integration flexibility

www.cognex.com/machine-vision

3D LASER PROFILERS
Cognex In-Sight laser profilers and 3D vision systems provide ultimate
ease of use, power and flexibility to achieve reliable and accurate
measurement results for the most challenging 3D applications.

▪▪ Factory calibrated sensors deliver fast scan rates

▪▪ Industry-leading vision software with powerful 2D and 3D tool sets
▪▪ Compact, IP65-rated design withstands harsh factory environments

www.cognex.com/3D-laser-profilers

IMAGE-BASED BARCODE READERS

Cognex industrial barcode readers and mobile terminals with
patented algorithms provide the highest read rates for 1-D, 2-D,
and DPM codes regardless of the barcode symbology, size, quality,
printing method, or surface.

▪▪ Reduce costs
▪▪ Increase throughput
▪▪ Control traceability

www.cognex.com/BarcodeReaders

Companies around the world rely on Cognex vision and barcode reading
solutions to optimize quality, drive down costs and control traceability.

Corporate Headquarters One Vision Drive Natick, MA 01760 USA

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