F160 VISION SENSOR The First Vision Sensor to Offer High-speed, Mid-range Machine Vision Performance The F160 is the industry's first high-speed vision sensor to deliver mid-range machine vision performance to meet more demanding vision applications. The F160 enlists high speed, two-camera image capture and vision algorithm processing to meet the needs of today's high-speed production lines. The on-screen set up and configuration system offers beginners or experts fast and easy set up. A wizardlike prompted menu option helps new users with auto setup routines, while the "expert" menu option lets those with more experience directly set configuration parameters. Several new and improved algorithms, like Omron's Quest OCR and "variable box" technology let users perform more precise and sophisticated applications. By using Flash-RAM memory cards, the memory capacity of the F160 can be expanded to handle multiple product lines. Choose from a selection of compact camera options to satisfy many inspection and measurement needs. The F160 also allows the customization of menus, "results" screen information and symbol and text colors to ensure optimum on-site operability. Omron's machine vision technology and know-how has come together to bring a new level of machine vision measurement and inspection capability. Creating New Possibilities with High-speed Vision The F160's specialized double-speed cameras can capture images up to 4 times faster than with previous cameras. In addition, cameras feature 8 user-selectable shutter speeds and an Intelligent Lighting Interface. The F160's high speed processing, inspection and measurement results are generated 2 to 10 times faster than before. In the Gray Search example image below, inspections can be completed at a rate of 5,000 inspections per-minute. Because each inspection is performed at high speed, the total inspection time for complex applications is dramatically reduced, leaving time for additional inspections that may not have been possible with previous products. This can lead to significant improvements in production line throughput and product quality. Simple Gray Search Processing of one area - 12ms 2 Image capture time Inspection processing time Existing products Up to 4 times as fast 2 to 10 times as fast F160 Gray Search Processing of multiple inspection areas - 11ms Gray Search Processing of multiple inspection areas with position compensation enabled - 35ms High-speed and Measurement Inspection Applications Product Sorting Optical Character Recognition Sort boxed product by size or labels and inspect seams. Pill presence/absence and Lot/Date code confirmation on blister packs. F160 Controller Camera Camera 0 Trigger sensor E ACM X BO E ACM X BO E ACM X BO E ACM X BO Trigger sensor F160 Controller RS-232C/422 label data Camera 1 High Speed Bottle Inspection PCB Inspection Inspect dimensions, conformance and date code. Electronic component inspection/board position measurement. F160 Controller Camera Camera 0 Trigger sensor Trigger sensor Camera 1 F160 Controller RS-232C/422 component and position data Position Reference High Speed Robotic Tool Guidance Identify random, odd-shaped product positioning on a conveyor. Communicate tool and part alignment and tool wear to robotics. I/O and RS-232C/422 position data S.C.A.R.A. Robot F160 Controller Camera Camera 0 Trigger sensor I/O and RS-232C/422 position data Tooling F160 Controller Camera 1 3 Advanced Algorithms and Functions New and improved visual inspection algorithms are available in the F160. All of the algorithms take advantage of the high-speed processing and two-camera capability to maximize your visual inspection capability and functionality. QUEST Optical Character Recognition Quest is an Omron original OCR algorithm. No character teaching required. Quest has a high level of discrimination between similar characters and adapts to changes in shape and size. OCR of one character per region. Classification 1 2 3 The box measurement region can be setup to change automatically when performing Area or Defect inspections on objects of varying sizes. This ensures that the optimum measurement region is always used for inspection. Advanced Model Search The classification tool is ideally suited for sorting of multiple objects on the same production line. A search is preformed on an image from multiple reference models and the model number with the highest correlation is output. L M S Model 1 Model 2 Model 3 Omron's Edge Width measurement function works like a caliper tool. Two edges of an object are detected to sub-pixel accuracy and from this the width of the object is calculated. Labeling Objects with unusual shapes (blobs) can be detected and counted inside a measurement region. Detected objects are then sorted according to area or center of gravity and measurement data for specific labels is output. Counting gears Position Compensation Flexible search allows the use of several reference models for a gray scale search. This method allows objects with modestly changing features and varying shapes to be inspected with one tool. The F160 can compensate for an object's position by using only the outline or feature of an object or by two reference points from an object. Setting priorities for the compensation direction are also possible. Compensation in the X direction followed by compensation in the Y direction Rotation Search Rotation Search can be performed on an object to detect rotation up to 360. The F160 performs this measurement 10 times faster than before and, using angle interpolation, detection angles can be detected with a degree of precision. Searching in a rotation range of 360 with a skipping angle of 5 4 M S Object Width Measurement "Variable Box" Measurements L Result Expressions Expressions using up to 32 inspection variables or constants each can be used to produce judgement or data output. Expressions allow for complex calculations based on inspection data to determine output results. User-friendly Operation The F160 offers many features to increase its ease-of-use and make its operation as convenient as possible. These features assist in the setup, operation and use of data and images produced by the F160. I/O Monitor Shortcut Keys The status of the input and output terminals can be displayed on-screen. The I/O monitor can be used for checking wiring when setting up or making adjustments to the F160. Frequently used F160 operations, like result display changes, can be assigned to specific console keys. Menus can also be switched at the touch of a single console button. On-screen Figures and Display Colors Password Option Figures such as lines, boxes, circles and crosses can be drawn and positioned on the screen at measurement positions or user set coordinates. Text message and figure colors can be set for best viewing. To prevent unauthorized use or changes to the F160, passwords can be set to restrict access to operation levels. This function will help to improve security and reduce incorrect operation. Screen Capture Setting screen Documentation on computers Setup Manual POWER Capture Procedure 1. SYNC Manageable Screen Text 2. Memory card Screen text messages can be changed to best suit the operating environment. Message position, character size and color and background can also be changed. 3. Images of menu settings, measurement screens, and camera images can be captured and stored in the memory card. This feature is very useful for creating setup and operation documentation. Menu Masking To save time and simplify setup, menus can be masked off from view to help minimize setup operations. Masking menus can also help prevent unauthorized use of menu operation. Increased Image Storage Up to 35 measurement images can be stored in memory. These stored images can consist of all images captured or only the failed images. The stored images can then be used to help diagnose production problems. Good product image RS-232C Output Formatting The output format of RS-232C data can be set to suit control system requirements. Settings include output format, number of data digits, field and record separators and zero suppression. Improper product images 5 The Right Lights & Camera For Your Action Omron's compact shutter camera is perfect for high-speed inspection applications and can be fitted with several different light sources, including those that support the Intelligent Light Source specification, depending on the application. Unique, Intelligent Light Sources (ILS) Omron's ILSs and ILS integrated cameras are designed to enhance and simplify your vision applications. The ILSs use a hood shape that reduces external interference, making conditions ideal for highly accurate inspections. The combination of red and green LEDs also enables the F160 to inspect a wide range of objects. One ILS version offers the ability of adjustable coaxial vertical lighting in addition to the adjustable ring light. The adjustable ring light lets the user adjust brightness and light direction based on the application requirements. Maximize Lighting Control With an Intelligent Light Source camera, the F160's controller menus take all of the guesswork out of proper lighting. Operators can control the illuminated area and light intensity from the controller menus. The settings are easily changed without direct adjustment to the light source. Lighting positioning is stored with other scene data so operators can change the lighting conditions to match different operating environments. Because the settings are numeric data, it is possible to recreate the lighting conditions from machine to machine. Sensing Distance & Field of Vision F160-SLC50 F160-SLC20 Object Camera distance: 15 to 25 mm Camera distance: 16.5 to 26.5 mm Object Field of vision (20 x 20 mm) Field of vision (50 x 50 mm) Field of vision: 20 mm Light intensity can be set separately to one of 8 levels for 5 illuminated areas. 2 3 1 Coaxial vertical lighting 4 6 5 Field of vision: 50 mm Light intensity can be set separately to one of 8 levels for 8 illuminated areas. 5 1 6 2 4 8 3 7 System Configuration Synchronous Sensor Controller F160-C10E (NPN input/output) F160-C15E (PNP input/output) Console F160-KP Programmable Controller Parallel Cable F160-VP Double-Speed Camera Camera with Intelligent Lighting F160-SLC20 (2 m, loose-wire cable for parallel I/O connectors) Memory Card F160-N64S (64 Mbytes) Camera Cable F150-VS (3 m, double-speed camera) F160-VSR3 (3 m, F200/F300) F160-VSR4 (3 m, F300-S) RCA/BNC Video Cable monitor cable (2 m) Camera with Intelligent Lighting F160-SLC50 Power Supply Recommended model: OMRON S82K-05024 Monitor Camera F160-S1 Color LCD Monitor F150-M05L 7 Dimensions Unit: mm (inches) Controller Console F160-C10E/C15E F160-KP 12 (0.47) Four M3 mounting holes with depth of 4.8 mm 60 (2.36) Four M3 mounting holes with depth of 4.8 mm 56 (2.20) 60 (2.36) 29.7 (1.17) 20 (0.79) 12 (0.47) 48 (1.89) 66.5 (2.62) 153 (6.02) 66.5 (2.62) SHIFT ENT TRIG ESC F3 135.5 (5.33) 66.5 (2.62) 7 (0.28) 66.5 (2.62) F1 F2 F4 F6 F5 F7 F9 F8 38 (1.50) 110 (4.33) 12 dia. 40 (1.57) 9 92 (3.62) 2000 (78.74) Four M4 mounting holes with depth of 6 mm Liquid Crystal Monitor Double-speed Camera F150-M05L F160-SLC20 Mounting plate thickness: 1.6 (0.63) to 4.8 (0.19) SYNC 2.5 12 12 31 40 (1.57) 25 (0.98) 100 (3.94) 185 (7.28) 4 dia. 42.5 70 (2.76) 10 (0.39) 30.5 (1.20) 96.25 (3.79) 8 (0.32) 145 (5.71) 155 (6.10) 85 (3.35)* 50min 46.5 (1.83) 132 (5.20) 73 (2.87) (46 max) Mounting bracket 143 (5.63) POWER 42.2 (1.66) 2.5 70 (2.76) 12 12 5.5 (0.22) F150-VM Monitor Cable 174 (6.85) Tolerance: 1 mm 23.251.3 (0.92) The dimensions in parentheses are reference values. 1/4-20UNC with depth of 10 mm Panel cutout dimensions Two M4 mounting holes with depth of 10 mm 86.25 (3.40) 133.5 +0.5mm 0 (5.26) 13.251.1 (0.52) 201.3 (0.79) 175.5 +0.5mm 0 (6.91) 46.5 (1.83) 85 (3.35)* 90 (3.54) 10 (0.39) F160-S1 31 60 (2.36) 15.5 (0.61) 4 dia. 54.5 (2.15) 46.5 (1.83) 8 14.5 (0.57) 52.5 (2.07) 2.5 16 25 (0.98) 16 103.25 (4.06) 8 (0.32) 30.5 (1.20) 23.251.3 1/4-20UNC with depth of 10 mm 1"-32UN-2A (C mount) 8 30.5 (1.20) 31.252 (1.24) 21.252 Two M4 mounting holes with depth of 10 mm 93.25 (3.67) 8 13.251.1 (0.52) 201.3 (0.79) 6 (0.24) 6.2 (0.24) 6.2 (0.24) Light connector (8.8 dia.) (30.7) 80 (3.15) 21.7 (0.85) 16 11 29 (1.14) 90 (3.54) 16 2.5 F160-SLC50 31 (1.22) Camera cable connector (11.8 dia.) Two M4 mounting holes with depth of 8 mm 1/4-20UNC with depth of 8 mm 201.3 (0.79) Specifications Rating/Function Controller: F160-C10E/C15E Item Conversational Menu Mode Connectable cameras F150-S1A/SL20A/SL50A/SLC20/SLC50, F160-S1/SLC20/SLC50, F300-S/S2R/S3DR/S4R etc. Number of cameras Connectable 1 Number of pixels 512 x 484 (H x V) Number of scenes 32 (Expansion possible using Memory Card.) Image storage function Maximum of 35 images stored Expert Menu Mode 2 Smoothing (strong, weak), edge enhancement, edge extraction (horizontal, vertical, both horizontal and vertical), dilation, erosion, median, background suppression Filtering Position displacement compensation Set either automatically or manually Compensation directions: X, Y, and (360) directions Number of measurement regions 32 regions per scene Applications 7 types available (presence, orientation, dimensions, defects, conformity, position, chips and burs) Measurement data Automatically selected according to the application. Compensation directions: X, Y, and (360) directions Detection methods: Binary center of gravity, axis angle, labeling, rotation search, gray search, edge position Gravity and area, gravity and axis, gray search, precise search, rotation search, flexible search, relative search, defect, area (variable box), defect (variable box), edge position, edge pitch, edge width, density average, labeling, OCR for 1 character, classification Number: 32 expressions can be set for judgements, data, and variables used in other expressions Operations: Arithmetic operations, square root, absolute value, remainder, distance, angle, maximum, minimum, SIN, COS, ATAN, AND, OR, NOT Data operation functions (expressions) Overall judgements, judgements for each measurement region Results output Overall judgements, judgements for each measurement region, expression results, measurement/expression data Functions for customizing operations Menu masking, password setting, shortcut keys Functions for customizing screens Display items: Character strings (measurement values, judgement results, times, user-specified characters, measurement region names) Figures (lines, boxes, circles, cross cursors) Specified parameters: Display color, position, size Number of slots for memory cards 1 Monitor interface 1 channel (color, monochrome) Serial communications RS-232C/422A, 1 channel Parallel I/O 13 inputs and 22 outputs including control I/O points Input/ output type NPN PNP Power supply voltage F160-C10E F160-C15E 20.4 to 26.4 VDC Current consumption Approx. 1.6 A (with two F160-SLC50 Cameras connected) Ambient temperature Operating: 0 to 50C (32 to 122F) Storage: -25 to 65C (52 to 149F) with no icing or condensation Ambient humidity Operating and storage: 35% to 85% (with no condensation) External dimensions 56 x 160 x 110 (W x H x D) mm (not including connectors and other protruding parts) Weight Approx. 570 g (Controller only) Double-speed Camera: F160-S1 Item Specifications Picture element 1/3" Interline CCD Effective pixels 659 x 494 (H x V) Scanning method 1/60-s non-interlace (frame) mode, 1/120-s 2:1 interlace (field) mode Shutter Electronic shutter; select from 8 shutter-speed settings (1/120 to 1/20,000 s) using menu. Camera with intelligent lighting F160-SLC20 (field of vision: 20 mm), F160-SLC50 (field of vision: 50 mm) External dimensions 31 x 40 x 54.5 (W x H x D) mm (not including connectors and other protruding parts) Weight Approx. 85 g (Camera only) F150-M05L Color LCD Monitor Item Specifications Size 5.5 inches; 111.36 x 83.52 mm (H x V) Type Liquid crystal color TFT Resolution 320 x 240 dots Input signals NTSC composite video (1.0 V/75 ) Power supply voltage 20.4 to 26.4 VDC Current consumption Approx. 700 mA Ambient temperature Operating: 0 to 50C (32 to 122F); Storage: -25 to 65C (52 to 149F) with no icing or condensation Ambient humidity Operating or storage: 35% to 85% (with no condensation) Weight (monitor only) Approx. 1 kg Accessories Instruction manual and 4 mounting brackets 9 F160 Vision Sensor Selection Guide First: Start by selecting the controller part number with the correct input/output type, NPN or PNP, to meet the applications needs. Second: Choose from the three F160 double-speed cameras. Select one or two cameras based on the application. If a 20 or 50 mm field of vision can be used with the Intelligent Light Source, choose from the F160-SLC20 or F160-SLC50. (See page 6 for SLC20 & SLC50 setting information.) If different field of view and lighting is required, use the F160-S1 camera without lens and light source. Third: Choose camera cables, Parallel I/O cable, monitor and monitor cable as required. For additional camera cable and parallel I/O cable lengths and monitor options, please consult your Omron vision representative. Fourth: If F160-S1 camera option is used, refer to the Lens Selection Guide next to choose a lens for the application. The F160-S1 camera also offers the intelligent lighting interface to allow the use of controllable external lighting options. Please consult your Omron vision representative for additional assistance in lens selection and lighting options. + + + + Ordering Information Name Model Number Controller F160-C10E F160-C15E Comments NPN Input/Output PNP Input/Output Double-speed camera with fixed lens & intelligent lighting Camera only Console Color LCD monitor Memory card Camera cable F160-SLC20 F160-SLC50 F160-S1 F160-KP F150-M05L F160-N64S F150-VS F160-VSR3 F160-VSR4 Monitor cable RCA/BNC Video Cable Parallel I/O cable F160-VP Extension tubes F150-EXT 10 20 mm field of view 50 mm field of view Without lens or light source Keypad with shortcut buttons 5.5 inch color LCD Memory capacity: 64 Mbytes For double-speed camera & compatible F150 cameras; Cable length: 3 m For compatible F200/F300 cameras; Cable length: 3 m For F300-S only; Cable length: 3 m Cable length: 2 m Loose-wire cable for parallel I/O connectors; Cable length: 2 m A set of six extension tubes that are 40, 20, 10, 5, 1, and 0.5 mm in length respectively Lens Selection Guide First: Start by defining the field of view requirements for each camera. Refer to the diagram at bottom left. The field of view is considered to be the area or areas requiring inspection. This does not necessarily include the entire part or object in the field of view. Second: Determine the camera distance, measured from the object surface to the camera. Refer to the lens setting illustration for additional information about setting distance. This distance can impose limitations on the field of view and lens choice. To get the greatest flexibility in lens selection, keep the camera setting distance as flexible as possible. Third: Using the field of view and camera setting distance requirements, use the optical graph axis marked "Field of view L (mm)" to find the matching field of view size. Use the optical graph axis marked "Camera distance A (mm)" to find the approximate camera setting distance. Follow the values across the chart until they cross. Refer to the lens part reference on the right at the end of the graph line to find the correct lens size. (If a "t" value other than 0 is indicated, corresponding lens extension tubes will need to be added in between the camera and lens in order to properly focus the image. The "t" value indicates the thickness of the extension tubes required.) Note: Extension tube length should not exceed 10% of the focal length of the lens. When looking at other manufacturers' lenses not referenced by Omron, please use a 1/3-inch CCD size as a selection value reference. Fourth: If an appropriate lens cannot be found to satisfy your application, please consult your Omron vision representative for additional assistance in lens selection options. CCTV Lens Model Dimensions Focal length Brightness F150-L8 29 dia. x 34.5 L* 8.0 mm F1.3 F150-L12 30 dia. x 34.5 L* 12.5 mm F1.4 F150-L16 30 dia. x 24.5 L* 16.0 mm F1.4 F150-L25 30 dia. x 24.5 L* 25.0 mm F1.4 F150-L50 32 dia. x 37 L* 50.0 mm F1.8 F150-L75 32 dia. x 42.5 L* 75.0 mm F2.7 * Lens diameter does not include lens ring lock screw height. Note: Omron reserves the right to change lens suppliers and specifications without notification. Please verify all lenses with sales personnel. Lens model: F150-________ Optical Graph L75 L50 Camera distance A (mm) Unit: mm 5,000 Max. outer dia. 1" -32UN 30 dia. -2A L25 3,000 L16 L12 2,000 Total length L8 1,000 Camera 500 Extension Tube 300 Lens Camera distance A (mm) 200 t: Extension Tube thickness 100 50 4 Field of view L (mm) 5 10 20 30 50 100 200 300 500 Field of view L (mm) Note: All values are approximate values. It is recommended that the camera distance be adjusted by sliding the camera forward or backward in actual operation. 11 Vision Sensors and Support Software Solve Your Toughest Inspection Problems F-10 Vision Sensor F-30 Vision Sensor F150-2 Vision Sensor The ultimate, easy-to-use, grayscale processing package for pattern and shape matching. Setup is ultra quick with no monitor required using a one button teach function and a visible target, integrated lens and light source. Four different camera choices are available, each with different sensing area sizes. One model even includes 8-model bank memory and RS-232C/422 communications capability. Compact, self-contained vision sensor includes the camera, light source, lens and controller all in one unit. This easy-to-use menu driven binary vision sensor has a 256-level contrast setting and one inspection area that is perfect for most pixel counting applications. Uses drop down menus to setup functions including filtering, adjusting the shutter speed, background suppression, X, Y, and Theta position compensation, and image calibration. Measurement tools include center of gravity, area, edge position, edge pitch, degree of defect, and more with 16 setup scenes and up to 16 measurements per scene. Other features include a 23-image storage memory, RS-232C and DeviceNet communications. F150-3 Vision Sensor Vision Composer Software F400 Vision Sensor Delivers 2-camera performance and lighting control based on the F150-2's easy-to-use format. The camera splitter unit and built-in menus or PC software allows the controller to integrate images from two cameras and perform multi-angle inspections on a single object simultaneously. This optional Windows(R)-based Vision Composer software allows you to use more sophisticated functionality in a drag-and-drop flow chart environment with the F150-3 Vision Sensor. Vision Composer can also help collect and report the measurement results without specialized programming. The industries first color Vision Sensor using Hue, Saturation, and Intensity to combine Color Pickup and 5 color filters into an easy-to-use and powerful color vision solution at an affordable price. With Color Pickup, the F400 can be quickly configured to detect and measure up to 8 colors simultaneously or use the industry's first Colorgray filter to convert a color into 256 level grayscale to analyze and measure very fine differences in the isolated color's image, even in fluctuating lighting conditions. UNITED STATES REGIONAL SALES OFFICES www.omron.com/oei OMRON ELECTRONICS LLC Technical Automation Solution Division Schaumburg, IL OMRON CANADA, INC. Scarborough, Ontario 2001 OMRON ELECTRONICS LLC SB F160-1 6/01/7.5M 800.55.OMRON or 847.843.7900 CANADA REGIONAL SALES OFFICE Toronto 416.286.6465 BRAZIL SALES OFFICE Sao Paulo 55.11.5564.6488 ARGENTINA SALES OFFICE Buenos Aires 54.114.787.1129 MEXICO/LATIN AMERICA SALES OFFICE Florida 954.227.2121 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Omron: F160-VSR3