UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Programming of Vision System for Computer
Integrated Manufacturing
Thesis submitted in accordance with the partial requirements of the
Universiti Teknikal Malaysia Melaka for the
Bachelor of Manufacturing Engineering (Manufacturing Process)
By
Najwa Bt Khalid
UTeM Library (Pind.1/2005)
SULIT
TERHAD
√ TIDAK TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)
(TANDATANGAN PENULIS)
Alamat Tet ap:
NO9, LORONG BERTAM INDAH 9, TAMAN BERTAM INDAH,
13200 KEPALA BATAS, PENANG
Tarikh: _______________________
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________ * Tesis dimaksudkan sebagai t esis bagi Ij azah Dokt or Falsaf ah dan Sarj ana secara penyelidikan, at au disert asi bagi pengaj ian secara kerj a kursus dan penyelidikan, at au Laporan Proj ek Sarj ana Muda (PSM). ** Jika t esis ini SULIT at au TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi berkenaan dengan menyat akan sekali sebab dan t empoh t esis ini perlu dikelaskan sebagai SULIT at au TERHAD.
BORANG PENGESAHAN STATUS TESIS*
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
JUDUL: Programming of Vision Syst em f or Comput er Int egrat ed Manuf act uring.
SESI PENGAJIAN : 2006/ 2007
Saya NAJWA BT. KHALID .
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di
Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Tesis adalah hak milik Universit i Teknikal Malaysia Melaka.
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan unt uk t uj uan pengaj ian sahaj a.
3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.
4. **Sila t andakan (√)
FAKULTI KEJURUTERAAN PEMBUATAN
Rujukan Kami (Our Ref) : 16 Mei 2007 2005
Rujukan Tuan (Your Ref):
Pust akawan
Perpust akawan Universit i Teknikal Malaysia Melaka UTeM, Ayer Keroh
MELAKA.
Saudara,
PENGKELASAN TESIS SEBAGAI SULIT/ TERHAD
- TESIS SARJANA MUDA KEJURUTERAAN PEMBUATAN (PROSES PEMBUATAN): NAJWA BT. KHALID
TAJUK: PROGRAMMING OF VISION SYSTEM FOR COMPUTER INTEGRATED MANUFACTURING
Sukacit a dimaklumkan bahawa t esis yang t ersebut di at as bert aj uk
“ Programming of Vision Syst em f or Comput er Int egrat ed Manuf act uring”
mohon dikelaskan sebagai t erhad unt uk t empoh lima (5) t ahun dari t arikh surat ini memandangkan ia mempunyai nilai dan pot ensi unt uk dikomersialkan di masa hadapan.
Sekian dimaklumkan. Terima kasih.
“ BERKHIDMAT UNTUK NEGARA KERANA ALLAH”
Yang benar,
EN. AZRUL AZWAN B. ABDUL RAHMAN
Pensyar ah,
Fakul t i Kej ur ut er aan Pembuat an
06-2332042
UNIVERSITI TEKNIKAL MALAYSIA MELAKA Karung Berkunci 1200, Ayer Keroh, 75450 Melaka
PROGRAMMING OF VISION SYSTEM FOR
COMPUTER INTEGRATED MANUFACTURING
NAJWA BT KHALID
APPROVAL
This thesis submitted to the senate of UTeM and has been accepted as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process). The members of the supervisory committee are as follow:
……… Main Supervisor
DECLARATION
I hereby, declared this thesis entitled “Programming of Vision System for Computer Integrated Manufacturing” is the results of my own research except as cited in
references.
Signature :
Author’s Name : Najwa Bt. Khalid
ABSTRACT
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ABSTRAK
DEDICATION
Specially to my dearest mum and dad,
I will always love and always by your side.
Not forgetting,
My supervisor, and all UTeM lecturers,
Thanks for all your support.
Last but not least,
Thanks to all my friends whoever assist me in completing this project
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ACKNOWLEDGEMENTS
I would like to take this opportunity to express my deepest appreciations and thanks to those who help in accomplishing my final year project. Without their help, the completion of this project will not be possible. I would like to express my sincere thanks to Mr. Azrul Azwan Bin Abdul Rahman, my final year project supervisor, for his sound advices, supports and guidance while the whole project was carried out. His ideas were very inspirational and helpful not only in my project but also in my way of thinking and analyzing problem.
TABLE OF CONTENTS
List of Sign and Symbols………...……..………...….……xii
List of Appendices………….…...……….……….………....xiii
1.INTRODUCTION……….1
1.1Objective of the project………..………...…………3
1.2 Purposes of study……….…..….……….………….………...….3
1.3 Problem statement………….……….……….………….……….3
1.4 Project structure………..…….………...………….……….4
2.LITERATURES REVIEW………..……….……….…………...5
2.1Vision system.………...…..………..…5
2.2 Computer vision system.………...………..………..5
2.2.1Computer vision functions..………..7
2.2.2 Computer vision application……….………...…8
2.2.3 Computer vision industry………...……….8
2.3 Machine vision system….………...……….……….9
2,4 Component of a machine vision system.………...………..……….16
2.5 Machine vision operation………...……….……….17
2.6 Image acquisition………. ………….……..…….17
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2,6,2 Ligthing……….………..…..…………..………....19
2.7 Camera……….……….………..…....23
2.7.1 Camera………..………..……….……….…………...24
2.7.2 Sensor…….………..…………..……….………24
2.7.3 Frame buffers and frame grabbers……….………..25
2.8 Image processing and decision making………..25
2.9 Image enhancement and preprocessing………...…..……….28
2.10 Processing Method………..…………..….………..29
2.10.1 Pixels……….29
2.10.2 Thresholding……….………….31
2.10.3 Segmentation……….………31
2.10.4 Image analysis or interpretation………..……...32
2.11 Application of machine vision………..………33
2.12 Machine vision industry……….….……….33
2.13 Programing of machine vision system………34
2.14 Interfacing of machine vision system………...……...…...….…………34
2.15 Computer interfacing………..….….………35
4.15.1 RS232………..………...………...36
4.15.2 RS485………..……..…….………...37
4.15.3 USB………..……...………..37
2.16 Inspection………..…..……….38
2.16.1 Types of inspection………..…..………...………38
2.16.2 Inspection procedure………..…..……….38
2.16.3 Example……….39
2.17 Automated Inspection………...39
2.18 Inspection Area……….40
2.19 Computer Integrated Manufacturing………40
2.19.1 CAD……….………..41
2.19.2 CAPP……….………...…….42
2.19.4 CAM……….……….………43
4.10 Summary of experimental results………67
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5.6.8.1 Filtering (position or measurement)……….82
5.6.9 BGS level……….83
5.6.10 Number of input lines………84
5.7 Classification………...………..………..85
5.7.1 Measurement image……….86
5.7.2 Model registration……….……..86
5.8 Search region………..……….………90
5.9 Judgment condition……….………91
5.10 Branch………..………...…..92
5.11 Fine matching……….………...93
6. CONCLUSION AND RECOMANDATION………...………96
6.1 Conclusion……….………….96
6.2 Recommendation………..……….………….97
LIST OF FIGURES
2.0 Pixels 12
2.1 Digital signal to binary signal 13 2.2 Image screen to binary image screen 14
2.3 Example grayscale processing 14
2.4 Machine vision operation 17
2.4 Front lighting 21
2.6 Back lighting 22
2.7 Structured lighting 23
2.8 Flow of image processing and analysis 27
2.9 Pixel counting 30
2.10 Template matching 32
2.11 RS 232 35
4.4 Component of vision controller 56
4.5 Console 58
4.6 Experimental setup 59
4.7 Flow chart 60
4.8 Machine vision flow chart 61
4.9 Hardware architecture 62
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4.11 NG result 64
4.12 OK Result for Uncovered Pinhole 64
4.13 NG Result for Covered Pinhole 65
4.14 NG Result for Half Covered Pinhole 65
5.0 Optical Chart 68
5.1 Field of Vision and Structure of CCTV Lenses 69
5.2 Lens 70
5.22 Model registration 86
5.23 Model registration 87
5.26 Select either Box, Ellipse, Circle, Circumference or Polygon 88
5.27 Select OR or NOT 89
5.28 Finish of model registration 90
5.29 Search region 90
5.30 Search region drawing 90
5.31 Judgment conditions 90
5.32 Branch 92
5.33 Branch setting 92
5.34 Fine matching 93
5.35 Measurement Condition 93
5.36 Measurement condition setting 94
5.37 OK final result 94
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LIST OF TABLES
2.0 Inspection for variables and inspection for attributes 39
4.0 Component name and functions 57
4.1 Console keys and functions 58
4.2 Summary of experimental result 67
5.0 Lens and diameters 70
5.1 Extension tube 71
5.2 Lighting details 72
5.3 Filtering types 82
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
CIM - Computer Integrated Manufacturing AID - Analog to digital converter
I/O - Input/output
USB - Universal Serial Bus WWW - World Wide Web CAD - Computer-aided design
CAPP - Computer-aided process planning CAQ - Computer-aided quality assurance CAM - Computer-aided manufacturing ERP - Enterprise resource planning OK - Good
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CHAPTER 1
INTRODUCTION
Machine vision, or the application of computer-based image analysis and interpretation, is a technology that has demonstrated it can contribute significantly to improving the productivity and quality of manufacturing operations in virtually every industry. In some industries, many products can not be produced without machine vision as integral technology on production lines.
Successful techniques in manufacturing tend to be very specific and often capitalize on clever tricks associated with manipulating the manufacturing environment. Nevertheless, many useful applications are possible with existing technology.
Machine vision is the science that develops the theoretical and algorithmic basis by which useful information about the world can be automatically extracted and analyzed from an observed image, a set of images or an image. This achieved from computations made by special purpose or general purpose computer and involved the processes which extract, characteristics and interpret information from image of a 3-D world. This makes machine vision a multidisciplinary field, which includes psychology, neurophysiology, cognitive science, geometry, and areas of physics such as optics, artificial intelligence, and pattern recognition.
from a scene and converts the energy to an image the computer can use. The computer extracts data from the image, compares the data with previously developed standards, and outputs the results usually in form of a response.
Machine vision system is actually to create a model of the real world from images. A machine vision system recovers useful information about a scene from its two-dimensional projections. Since images are two-two-dimensional projections of the three-dimensional world, the information is not directly available and must be recovered. To recover the information, knowledge about the objects in the scene and projection geometry is required. The goal is to build computer-based vision systems which perform the same functions as the human eye.
Many fields are related to machine vision. The techniques developed from many areas are used for recovering information from images. There are three main categories of vision system. First, path planning and obstacle avoidance, second is grasping and manipulating of objects and third is object recognition. This machine vision has many applications such as industrial inspection, robotic manipulation (i.e. grasping), and automatic vehicle navigation, document processing (i.e. character recognition), image compression and enhancement, medical applications such as microscopy and radiology, remote sensing, and visual inspection of industrial products, to name only the major areas.
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few years much more work and scientific debates have been conducted on the “right” approach to machine vision.
1.1 Objectives of Project
This project has the main objective as to establish:
(a) To monitor or operate Omron’s Vision Sensor
(b) To program vision system for Computer Integrated Manufacturing(CIM)
1.2 Purpose of The Project
The purpose of this project is to program vision system for CIM. In the CIM system this vision system will be as inspection area that control the quality of the products.
1.3 Problem Statement
Sophisticated manufacturing systems require automated inspection and test methods to guarantee quality. Methods are available today, such as machine vision, that can be applied in all manufacturing processes either in incoming receiving, forming, assembly, and warehousing and shipping. However, hardware alone should not be the main consideration. The data from such machine vision systems is the foundation for CIM. It is the manufacturing data that impact quality, not quality data that impact manufacturing.
1.4 Project Structure
Followings are the project structure of this report.
Chapter 2: LITERATURE REVIEW
This chapter explains the vision system concept Chapter 3: PROJECT METHODOLOGY
This chapter shows the methods using in order to complete this project. Chapter 4: RESULTS
This chapter presents the analysis and the results of project. Chapter 5: DISCUSSIONS
This chapter provides general discussion on the results of the project. Chapter 6: CONCLUSIONS AND RECOMMENDATIONS
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CHAPTER 2
LITERATURE REVIEW
This chapter describe about of the source and the history of the research which had been done by others in vision system and the methods that had being used by them. It also summarized a several of the vision system and the application of it’s depends on the field related to. By taking some of the example and guidance from other research then it can be studied and applied in this project.
2.1 Vision System
Vision systems are used to inspect product quality. The inspection might be used to check to ensure that all components are on a printed circuit board, to measure the size of product or to read labels and ensure they are complete and accurate. Vision systems are increasing in use and importance in industry. They are much more accurate than humans for performing repetitive inspection tasks.
2.2 Computer Vision System
