Abstract: A system and method for generating golden template images in a vision system to inspect an acquired runtime image of an object with a multi-layer printed pattern is provided. The system and method performs a registration process on runtime images using registration models each trained on respective canonical layer mask images, and outputting poses. Based upon the poses, warped layer masks are generated. Combination masks are computed based upon differing combinations of the warped layer masks. Intensity values for pixels of the foreground regions for the combination masks are estimated. The estimated intensity values are then blended associated with the combination masks to generate a golden template image. This golden template image can be used to compare with a runtime image. An exemplary application of this system and method is in print inspection on flat and non-flat surfaces.

Abstract: This invention provides a system and method for synchronization of vision system inspection results produced by each of a plurality of processors that includes a first bank (that can be a “master” bank) containing a master vision system processor and at least one slave vision system processor. At least a second bank (that can be one of a plurality of “slave” banks) contains a master vision system processor and at least one slave vision system processor. Each vision system processor in each bank generates results from an image acquired and processed in a given inspection cycle. The inspection cycle can be based on an external trigger or other trigger signal, and it can enable some or all of the processors/banks to acquire and process images at a given time/cycle. In a given cycle. each of the multiple banks can be positioned to acquire an image of a respective region of a plurality of succeeding regions on a moving line.

Abstract: Described are machine vision systems, methods, and apparatus, including computer program products for associating codes with objects. In an embodiment, a machine vision system includes an area-scan camera having a field of view (FOV), the area-scan camera disposed relative to a first workspace such that the FOV covers at least a portion of the first workspace and a dimensioner disposed relative to a second workspace. The machine vision system includes a machine vision processor configured to: determine an image location of a code in an image; determine a ray in a shared coordinate space that is a back-projection of the image location of the code; determine one or more surfaces of one or more objects based on dimensioning data; determine a first surface of the one or more surfaces that intersects the 3D ray; and associate the code with an object associated with the first surface.

Abstract: This invention provides a system and method for enabling control of an illuminator having predetermined operating parameters by a vision system processor/core based upon stored information regarding parameters that are integrated with the illuminator. The parameters are retrieved by the processor, and are used to control the operation of the illuminator and/or the camera during image acquisition. In an embodiment, the stored parameters are a discrete numerical or other value that corresponds to the illuminator type. The discrete value maps to a corresponding value in look-up table/database associated with the camera that contains parameter sets associated with each of a plurality of values in the database. The data associated with the discrete value in the camera contains the necessary parameters or settings for that illuminator type. In other embodiments, some or all of the actual parameter information can be stored with the illuminator and retrieved by the camera processor.

Abstract: This invention provides a vision system housing having a front plate assembly that accommodates a plurality of lens mount types. The front plate includes a central aperture that is located at a predetermined axial (camera axis) distance from a plane of an image sensor. The aperture is stepped from a wider diameter adjacent to the front to a narrower diameter more adjacent to the sensor. This arrangement enables threaded mounting of a plurality of lens mount types, for example M12 and C-Mount. The exterior (front) surface of the front plate includes threaded holes and a removable spring clip arrangement constructed to accommodate a liquid lens positioned over the aperture with an associated lens assembly mounted within the aperture and in optical communication with the liquid lens. The lens is operated using an electrical connection provided by a cable that interconnects with a multi-pin socket positioned on the front plate.

Abstract: Disclosed are methods and systems for optoelectronic detection and location of moving objects. The disclosed methods and systems capture one-dimensional images of a field of view through which objects may be moving, make measurements in those images, select from among those measurements those that are likely to correspond to objects in the field of view, make decisions responsive to various characteristics of the objects, and produce signals that indicate those decisions. The disclosed methods and systems provide excellent object discrimination, electronic setting of a reference point, no latency, high repeatability, and other advantages that will be apparent to one of ordinary skill in the art.

Abstract: A system and method for training multiple pattern recognition and registration models commences with a first pattern model. The model is trained from multiple images. Composite models can be used to improve robustness or model small differences in appearance of a target region. Composite models combine data from noisy training images showing instances of underlying patterns to build a single model. A pattern recognition and registration model is generated that spans the entire range of appearances of the target pattern in the set of training images. The set of pattern models can be implemented as either separate instances of pattern finding models or as a pattern multi-model. The underlying models can be standard pattern finding models or pattern finding composite models, or a combination of both.

Abstract: A method and apparatus for decoding codes applied to objects for use with a camera and a conveyor system wherein the camera includes an image sensor having a two dimensional field of view (FOV) and the conveyor system moves objects in a first direction of travel through the FOV such that objects enter the FOV along an entry edge and exit the FOV along an exit edge, the method comprising the steps of providing a processor programmed to perform the steps of obtaining images of the FOV, for each image identifying code candidates in at least portions of the image, ordering at least a subset of the code candidates for decoding in a candidate order wherein the candidate order is determined at least in part as a function of the first direction of travel through the FOV, attempting to decode code candidates in the order specified by the direction of travel and when a new image event occurs, foregoing attempts to decode at least a portion of the identified code candidates.

Abstract: This invention provides a system for measuring displacement of an object surface having a displacement sensor that projects a line on the object surface and receives light from the projected line at an imager in a manner defines a plurality of displacement values in a height direction. A vision system processor operates on rows of imager pixels to determine a laser line center in columns of imager pixels in each of a plurality of regions of interest. Each region of interest defines a plurality of rows that correspond with expected locations of the projected line on the object surface. A GUI can be used to establish the regions. In further embodiments, the system generates grayscale images with the imager. These grayscale images can be compared to a generated height image to compensate for contrast-induced false height readings. Imager pixels can be compared to a reference voltage to locate the line.

Abstract: This invention provides a system and method for expanding the field of view of a vision system camera assembly such that the field of view is generally free of loss of normal resolution across the entire expanded field. A field of view expander includes outer mirrors that receive light from different portions of a scene. The outer mirrors direct light to tilted inner mirrors of a beam splitter that directs the light aligned with a camera axis to avoid image distortion. The inner mirrors each direct the light from each outer mirror into a strip on the sensor, and the system searches features. The adjacent fields of view include overlap regions sized and arranged to ensure a centralized feature appears fully in at least one strip. Alternatively, a moving mirror changes position between acquired image frames so that a full width of the scene is imaged in successive frames.

Abstract: A handheld scanner incorporates vision software to allow the handheld scanner to be trained for OCR. The handheld scanner can include a user interface to allow a user to associate an image of a mark with electronic data for the mark. The user interface, along with a range finder, can also be used to influence variables that affect the quality of an image scan, thereby improving the quality of results for the image scan and/or decode process.

Abstract: A method and apparatus for assessing at least one of motion linearity of a motion stage, stage motion straightness of a motion stage, image capture repeatability of a motion stage and camera and accuracy of a calibration plate used to assess motion stage characteristics, the method including using a line scan camera to generate two dimensional images of a calibration plate having a plurality imageable features thereon, examining the images to identify actual coordinates of the imageable features and using the actual coordinates to assess linearity, straightness, repeatability and/or plate accuracy.

Abstract: This invention provides a system and method for aligning a first work piece with an underlying second work piece in the presence of occlusion by the first work piece of critical alignment features of the second work piece. The vision system, which guides the motion of a manipulator holding the first work piece and a motion stage holding the second work piece, learns secondary alignment features at least one of the first and second work pieces. Using these secondary features, the vision system determines alignment between the work pieces and guides the manipulator and the motion stage to achieve alignment as the first work piece engages the second work piece. The secondary features are used to define a course alignment. Deterministic movements of the manipulator and/or motion stage are used to learn the relationship between the secondary and primary features. Secondary features are used to direct alignment.

Abstract: Described is an apparatus, including computer program products, for adjusting the focus of an image capturing device. An apparatus for capturing a focused digital image of a scene includes a lens having an optical surface including a deformation that is asymmetric with respect to an optical axis of the lens, and an aperture component configured to adjust a position of the aperture stop of the lens on a plane that is substantially perpendicular to the optical axis of the lens. The apparatus includes an image sensor configured to capture a digital image of an optical image formed by the lens, the digital image being defocused based on the position of the aperture stop. The apparatus includes a digital image processor configured to generate a focused digital image based on the digital image captured by the image sensor.

Abstract: This invention provides a system and method for generating camera calibrations for a vision system camera along three discrete planes in a 3D volume space that uses at least two (e.g. parallel) object planes at different known heights. For any third (e.g. parallel) plane of a specified height, the system and method then automatically generates calibration data for the camera by interpolating/extrapolating from the first two calibrations. This alleviates the need to set the calibration object at more than two heights, speeding the calibration process and simplifying the user's calibration setup, and also allowing interpolation/extrapolation to heights that are space-constrained, and not readily accessible by a calibration object. The calibration plate can be calibrated at each height using a full 2D hand-eye calibration, or using a hand-eye calibration at the first height and then at a second height with translation to a known position along the height (e.g. Z) direction.

Abstract: Described are computer-based methods and apparatuses, including computer program products, for wafer identification fault recovery. A digital image is received that includes a data symbol comprising a message encoded in a set of data cells. The digital image is processed to form a set of classified data cells, wherein one or more classified data cells from the set of classified data cells comprises an error. User interface data is transmitted comprising the digital image and interactive graphics, the interactive graphics including at least one data cell control. Interaction data is received from the interactive graphics that modifies a data cell location, a data cell state, or both, of at least one classified data cell from the set of classified data cells to form a modified set of classified data cells. An error free decoded message string is generated based on the modified set of classified data cells.

Abstract: A modular focus system for image based code readers includes swappable lens attachments enables fixed focus, manual focus, and variable focus operation from a single reader. A manual focus lens cap includes a manually adjustable focus ring to change the focus of the reader. A variable focus lens module includes a liquid lens that is manipulated by a voltage delivered via a pair of electrodes to adjust the focus of the reader. The lens attachments can be swapped out and replaced as needed.

Abstract: This invention provides a system and method for determining and controlling focal distance in a lens assembly of a vision system camera using an integral calibration assembly that provides the camera's image sensor with optical information that is relative to focal distance while enabling runtime images of a scene to be acquired along the image axis. The lens assembly includes a variable lens located along an optical axis that provides a variable focus setting. The calibration assembly generates a projected pattern of light that variably projects upon the camera sensor based upon the focus setting of the variable lens. That is, the appearance and/or position of the pattern varies based upon the focus setting of the variable lens. This enables a focus process to determine the current focal length of the lens assembly based upon predetermined calibration information stored in association with a vision system processor running the focus process.

Abstract: This invention provides a vision system camera, and associated methods of operation, having a multi-core processor, high-speed, high-resolution imager, FOVE, auto-focus lens and imager-connected pre-processor to pre-process image data provides the acquisition and processing speed, as well as the image resolution that are highly desirable in a wide range of applications. This arrangement effectively scans objects that require a wide field of view, vary in size and move relatively quickly with respect to the system field of view. This vision system provides a physical package with a wide variety of physical interconnections to support various options and control functions. The package effectively dissipates internally generated heat by arranging components to optimize heat transfer to the ambient environment and includes dissipating structure (e.g. fins) to facilitate such transfer.

Abstract: A portable machine vision component for use in machine vision systems is provided. The component can include a base portion configured to removably connect with a machine vision device, the base portion including an electrical input and an electrical output. The component can also include a control system operatively connected with the base portion, the control system configured to control an operation of the machine vision device and to receive feedback from the machine vision device. The component can further include one or more interface elements associated with the base portion, the one or more interface elements configured to allow a user to access the control system and communicate with the machine vision device.