Machine vision is an inherent terminology in factory automation but selecting the most efficient and cost-effective vision product for your project or application can be tricky.
We can see machine vision from many angles of view, for example market segment and application or image processing deliver different perspectives. In this article I will focus on the “sensing element” itself, which scan your application.
The sensing element is a product which observes the application, analyzes it and forwards an evaluation. PC is a part of machine vision that can be embedded with the imager or separated like the controller. We could take many different approaches, but let’s look at the project according to the complexity of the application. The basic machine vision hardware comparison is
- smart sensors
- smart cameras
- vision systems
Each of these products are used in a different way and they fit different applications, but what do they all have in common? They must have components like an imager, lens, lighting, SW, processor and output HW. All major manufacturing companies, regardless of their focus or market segment, use these products, but what purpose and under what circumstances are they used?
Smart Sensors
Smart sensors are dedicated to detecting basic machine vision applications. There are hundreds of different types on the market and they must quickly provide standard performance in machine vision. Don’t make me wrong, this is not necessarily a negative. These sensors are used for simple applications. You do not want to wait seconds to detect QR code; you need a response time in milliseconds. Smart sensors typically include basic functions like:
- data matrix, barcode and 2D code reading
- presence of the object,
- shape, color, thickness, distance
They are typically used in single purpose process and you cannot combine all the features.
Smart Cameras
Smart cameras are used in more complex projects. They provide all the function of smart sensors, but with more complex functions like:
- find and check object
- blob detection
- edge detection
- metrology
- robot navigation
- sorting
- pattern recognition
- complex optical character recognition
Due to their complexity, you can use them to find products with higher resolution , however it is not a requirement. Smart cameras can combine more programs and can do parallel several functions together. Image processing is more sophisticated, and limits may occur in processing speed, because of embedded PC.
Vision Systems
Typically, machine vision systems are used in applications where a smart camera is not enough.
Vision system consists of industrial cameras, controller, separated lighting and lens system, and it is therefore important to have knowledge of different types of lighting and lenses. Industrial cameras provide resolution from VGA up to 30Mpxl and they are easy connected to controller.
Vision systems are highly flexible systems. They provide all the functions from smart sensors and cameras. They bring complexity as well as flexibility. With a vision system, you are not limited by resolution or speed. Thanks to the controller, you have dedicated and incomparable processing power which provides multi-speed acceleration.
And the most important information at the end. How does it look with pricing?
You can be sure that smart sensor is the most inexpensive solution. Basic pricing is in the range of $500 – $1500. Smart cameras can cost $2000 – $5000, while a vision system cost would start closer to $6000. It may look like an easy calculation, but you need to take into consideration the complexity of your project to determine which is best for you.
| Pros | Cons | Cost | |
| Smart sensor |
|
|
$ |
| Smart camera |
|
|
$$ |
| Vision system |
|
|
$$$ |
