Advanced
Machine Vision
Technical Guide Vol.3
Characteristics and Applications Capturing high-contrast images that are optimal for
of LED Illumination Unit individual inspection is crucial to obtaining reliable image
processing. In order to take the most reliable images, the
illumination should be selected according to the material,
profile, and luster of the target. In recent years, LED
lighting has generated growing attention as the light
source used for image processing.
This issue describes the basics of lighting for LED
illumination units used for image processing, as well as
the application examples and key reasons for why LED
has been selected.
Differences in images caused by irradiation methods
The surface of a target varies depending on the color differences and presence or absence of luster. In
particular, the presence or absence of luster is very important in determining the angle for setting the illumination
unit. For example, when light of the same intensity is applied from the same angle to two different areas of a
target, components of regular reflection are strong on the surface area with luster. On the contrary, components
of diffuse reflection are strong on a surface area without luster. These characteristics can be used to make the
lustrous surface area bright or dark by devising the angle of the illumination unit.
1. Regular reflection Setting for emphasizing a glossy area 2. Diffuse reflection Setting less subject to luster
Diffuse
reflection The area with The area with
Diffuse
luster appears reflection luster appears
Surface Regular bright. dark.
illumination reflection Surface Regular
illumination reflection
When imaging a target, different images can be captured by using an illumination unit on which an LED is
mounted at an angle, by using a polarizing filter, or by adjusting the volume of light emission. The following
shows examples of the variations.
When the intensity is
increased by controlling When using a
When using low-angle illumination the light polarizing filter
Illuminating angle of 30° Illuminating angle of 0°
The patterned, Only the foreign object Apply illumination of high Only the characters can be
indented characters and sticker edge are intensity to fog the isolated by filtering out
and sticker edge are enhanced by an LED set characters by halation. The regular reflection with a
enhanced. at an angle of 0°. pattern on the surface of the polarizing filter.
sticker can be cancelled.
Specific examples of illumination settings
To make a flaw distinctive
Use “Coaxial vertical light”.
Setting example
Camera Reliable flaw
detection can
Coaxial vertical Regular reflection be ensured.
light Half mirror Defective area
Close-up view Under normal surface conditions, regular
reflections from a flat surface enter the
Target
camera. If a flaw exists on the surface,
the light from the diffuse reflection does
not enter the camera. As a result, the
Uniform light from an LED is
defective area is characterized as a
applied coaxially with the
shadow or darkened area, providing
camera by using a half mirror.
Defective images with a sharp contrast.
area
To emphasize only the tapered area of a metal component
Use “Bar light”. The tapered area appears in white.
When tapered
Setting example Binary screen
Camera
Bar light
When not tapered Binary screen
Target
Illuminate the target from the
side using a bar light.
The compact design enables
flexible mounting, including the
adjustment of the illuminating The presence and absence of the tapered area can be detected by
angle. measuring the area of white pixels.
To obtain a uniform image of a round target
Use “Dome light”.
Setting example When using dome light
Color binary screen
Camera
Dome light
Target
When using conventional light
Direct light from the top is affected by
The indirect light in the dome the curved surface. As a result, the
enables the uniform light to be luster on the target surface is
distributed to a target with a emphasized by components of regular
curved surface. reflection.
Detection may become unstable due to
the influence of luster.
Machine Vision Technique Guide Vol.3
Key reasons to select LED illumination
460 525 660 850
“LED” is an abbreviation for Light Emitting Diode, a device that 100 White
Blue
Relative emission intensity (%)
emits lights when electrical current is applied in the forward Green
Red
direction. The LED has a variety of luminescent colors; red, blue, Infrared
green, and white LEDs are available.
In recent years, a growing number of LED illuminations have 50
been utilized for imaging tests in on-site production lines. The
key reasons are given below.
400 500 600 700 800 900
Wavelength (nm)
Distribution of emission wavelength
1. Long operating life
30,000
The operating life of an LED is estimated to be approximately 30,000
30000
hours and approximately 15 to 30 times longer than those of
fluorescent lamps and halogen lamps. (See the chart on the right.) 25000
Lifetime (H)
The operating life of an LED element is determined by the emission 20000
time. Therefore, its life can be extended further by controlling the 15000
emission time through external control. LED helps to dramatically 10000
reduce the post-installation costs and the time required for replacing 5000
2,000 1,000
light sources.
0
LED Fluorescent lamp Halogen lamp
2. Excellent switching behavior
The illumination can be turned on only at the moment required for capturing images (intermittent lighting). Unlike
fluorescent lamps and halogen lamps, an LED will not deteriorate by turning the light on and off repeatedly. Since
the light is turned on only when required, self-heating of an LED can be reduced, preventing deterioration of the
device.
Example of
intermittent lighting
Without target: With target:
Turned off Turned on
Machine vision systems can automatically strobe the LED light source by using the FLASH output signal.
(Supported model: CV-2100 Series)
3. Flexible illuminating configuration
Fluorescent lamps are only available in a limited number of shapes and sizes. Unlike conventional illumination units,
an LED can achieve optimal illuminating configurations and an optimal illuminating area for individual targets.
Thanks to the small size of the device, an LED can be mounted in various ways to provide direct, diffuse reflection,
regular reflection, low-angle, and thrubeam type illuminations.
4. Excellent impact-resistance
Fluorescent and halogen bulbs are filled with gas and structurally susceptible to vibrations and physical impact.
Additionally, the filament can be easily damaged. On the contrary, an LED does not require an emission mechanism
or lighting circuit because the device itself is the light-emitting element. As a result, mechanical malfunctions and
defects are extremely rare, ensuring higher reliability in on-site production lines when compared to those of
fluorescent or halogen lamps.
<Precautions for use> <Countermeasures>
• Heat degrades the luminance level and causes • Operate the product in the intermittent lighting mode.
deterioration. • Install a fan or send fresh air to enhance the heat
• The operating life is shortened when used in a high- radiation effect.
temperature environment. • Lower the light-control volume of the power supply
• The illuminating unit generates heat when used in the when using the product.
continuous lighting mode.
Machine Vision Technique Guide Vol.3
Products for Your Application
[NEW] CV-2100 Series CV-700 Series CA-D Series CA-L Series
Ultra High Speed High Performance, LED Illumination Units Macro Lenses
Digital Vision Sensors Built-in-monitor Color
Vision Systems
■ Ultra high-speed image ■ Advanced color shade-scale ■ Adjustable lighting for various ■ Telecentric lenses reduce
processing processing types of targets measurement deviation
■ On-screen statistical ■ Controller with built-in- ■ Long lifetime reduces ■ Variable focus lenses enable
processing monitor and two-camera maintenance costs magnification adjustment
■ A variety of image processing connection ■ High “Light on” speed ■ Mounting bracket for LED
tools ■ High-speed 360° rotation ■ Easy on/off control and illumination unit
■ Ethernet and PLC link adjustment adjustment of light intensity
■ Easy operation ■ High-capacity memory card ■ A wide range of applications
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