Industry’s Fastest Compact Vision System
Industry’s FastestCompact Vision SystemVision System FH Series»» Easy to integrate in machines»» Increase machine speed»» Perform high-precision machine operations
Industry’s Fastest* Compact Vision SystemA New Concept in Image Processing That ConsidersIt’s time to move beyond simply increasing the speed of image processing and start seriously shortening Machine cycle time. This is the conceptthat gave birth to OMRON’s FH-series Vision System and its best-in-the-industry speed.Manufacturing Machines are operated through the interaction of sensors, PLCs, servomotors, and other devices. Vision Systems measure positionsand perform inspections, and the results are used to control the operation of Machines. The demand for faster, more precise Vision System operation is the primary requirement. The FH-series Vision System provides higher speed and precision for Machine cycle time and is loaded with all ofthe performance required to move Machines quickly and at high precision into a compact Controller for embedding into Machine. And even thoughthe Camera/communications interfaces, image processing algorithms, and other features of this complete image processing system are built intoone housing, the flexibility of a PC-based image processing system is also provided to help increase efficiency in the frequent reuse of Machinedesigns and in design changes.*Based on OMRON investigation in May 2013.InputShorter Machine Cycle TimesLogiccontrolSysmac is a trademark or registered trademark of OMRON corporation in Japan and other countries for OMRON factory automation products.Think&See is a trademark or registered trademark of OMRON Corporation in Japan and other countries.EtherCAT is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.Windows, Microsoft Visual Studio are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries.The Microsoft .NET software is used to connect users, information, systems, and devices.QR Code is registered trademarks of DENSO WAVE INCORPORATED in Japan and in other countries.Other company names and product names in this document are the trademarks or registered trademarks of their respective companies.The product photographs and figures that are used in this catalog may vary somewhat from the actual products.2Microsoft product screen shot(s) reprinted with permission from Microsoft Corporation.
Machine Cycle TimeIncrease Machine SpeedSee pages 4-74 Core CPU, High Speed CMOS Camerasand Efficient Software Algorithms Resultsin High Speed InspectionsA high-speed image bus and 4-core CPU processing increase the speed at every step,from image input to data output.Calculations for Multiple Cameras Do NotIntroduce Inspection DelaysCalculations are easy to set for the resultsfrom four parallel tasks.Quickly Outputting MeasurementResults to a PLCYou can output results to an NJ-seriesMachine Automation Controller on anEtherCAT communications cycle of 500 µs.Perform High-precision Machine OperationSee pages 8-9Measurements for Out-of-focus or RotatedImagesThe new Shape Search III processing itemprovides superior stability.No Worker-dependance in CalibrationAccuracyVision master calibration is provided.Easy to Integrate in MachinesPositioningSee pages 10-21Shared Machine InterfaceMicrosoft .NET is supported.Display Only Required Menu Commandson the Operation InterfaceUser interface customization is supported.Fast Support for Additional MeasurementNeedsComplete processing item libraries areprovided.3
Process Higher-resolution Images without Increasing the Machine Cycle TimeHigh-speed Image InputRealtime Image TransferFastest: 3.3 msCamera resolution, driven by higher expectations for quality, continues toincrease. OMRON has greatly reduced the input time and image transfertime to provide high-speed processing to match the speed of Machineapplications for high-resolution images. Even with more Cameras andhigher resolution, high-speed image input will contribute to increasingthroughput.High-resolution Cameras capture large amounts of data, which can make abottleneck out of the transfer speed time in addition to the image input timebottleneck. An FH-series Controller provides a faster, multi-line image bus toenable realtime transfer of large amounts of image data for high-resolutionCameras or multiple Cameras. If high-precision measurements were sacrificeddue to speed, the FH Series returns your precision without increasing cycle time.60ms7 TimesFasterPrevious Camera40ms30msFH High-speedCamera20ms10ms5msHigh speed300,000pixels1 millionpixels2 million 3 million 4 million 5 millionpixelspixelspixelspixelsUltra-high-speed Searching Image Transfer Time(ms)Image transfer time50ms250With the FH Series, even ifthe number of connectedCameras increases, realtimetransfer of Camera imagesdoes not increase.200150100500123456Number of Cameras78Previous Controllerwith 5-million-pixelNormal CamerasFH Controller with5-million-pixel NormalCamerasFH Controller with4-million-pixelHigh-speed camera(High-speed modeusing one cable)Note:The image conversion processing time is not included.12 millionpixelsShape Search ⅢNew technology makes search algorithms nine times faster than before.Even for unstable image conditions, including light interference,overlapping shapes, gloss, and incomplete images, stable searching ispossible without reducing speed, resulting in a increased stability.Super-fast Search ProcessingFH-seriesLarge amounts of image data can be transferred in real time.FPGACPUFPGA30Up to9 TimesFasterTime (ms)2520FPGAFPGA15Multi-line10High speedImage transfer bus5Standard Vision Sensors0300,000 pixels2,000,000 pixels5,000,000 pixelsCPUInput Image SizePrevious search processing itemsShape Search IIIin Normal ModeShape Search IIIin Fast Alignment ModeNote:The image conversion processing time is not included.4FPGATransfer time increases as the data volume increases.
Four-core CPU* to Meet High-speed Demands for Different Machines*for high speed controllers onlyCase1 Perform Calculations for Multiple Cameras without DelayEven when the measurement results of sequential operations are dependent on the speed of the independent action, parallel processing allows highspeed performance without any dwell time. The measurement results from four cores can be easily calculated on one Controller to achieve continuousinteraction without any special programming.Process 0Measuring chip positionProcess 1Process 2Measuring grippingpositionProcess 3Determining placementpositionConfirming placement positionMeasuring the Next Workpiece without Waiting TimeCore0Process 0Core1Process 1Workpiece 1Workpiece 2Workpiece 1Workpiece 3Workpiece 2Workpiece 4Workpiece 3Workpiece 4Because there is only one Controller, the difference between thegripping position and placing position can be calculated at high speed.Core2Process 2Core3Process 3Workpiece 1Workpiece 1Frequently Waiting for Processing with aStandard Vision SensorThe lack of the ability for standard Vision Sensors to handle parallelprocessing creates waiting time everywhere. If the Machine cycletime cannot be increased, a Controller must be added for eachprocess to perform parallel processing, increasing costs.Workpiece 2Workpiece 3Workpiece 2Process 0 Workpiece 1Process 1Process 2Process 3Workpiece 3Waiting for processingWorkpiece 2Workpiece 1Workpiece 2Workpiece 1Workpiece 15
Four-core CPU* to Meet High-speed Demands for Different Machines*for high speed controllers onlyCase2 Machine Cycle Time Reduced to1/4* of Previous TimeCase3 Process Multiple Lines in Parallelwithout Any Waiting TimeFour cores process triggers, so the trigger interval can be 1/4th* ofprevious models.*In-house comparison.Four controllers are compressed into one without increasing the line cycletime. You can greatly reduce costs for processes that involve many lines.100Process 1Process 2TriggerFHProcess 3Process 1Core2Process 3Core1Process 2Core3Process 4Core0Process 1Core2Process 3Core1Process 2Core3Process 4TriggerTriggerCore0Core1Core2TriggerCore0Process 1Core2Process 3Core1Process 2Core3Process 4Core3TriggerMulti-input FunctionLine 0ImageinputEach camera has its own image buffer for storing image data that is separatefrom the main memory used for measurement processing. This allows for up tomemory is processing measurement data.Measurementprocessing2nd3rd4thOutputLine 1ImageinputMeasurementprocessingEliminate the‘Waiting Time’BottleneckOutputLine entprocessingOutputLine 3OutputStandard Vision SensorsWhen multiple triggers are input to a standard vision sensor, only imageinput is performed in parallel, and waiting time occurs when startingmeasurement processing. This time becomes a bottleneck in terms of theMachine cycle time.Line 0256 frames of continuous high-speed image capture even while the main1stMeasurementprocessingContinuous High-speed Image CaptureHigher Speed from Advanced Image Captureand Parallel MeasurementsImageinput3FH-seriesProcess 4Reduced to 1/4Core0232StandardVision ent of workpieceLine 11st2nd3rd4thImageinput*The number of images that can be captured depends on theMeasurementOutputprocessingLine 2Controller and the Camera that is connected to it.Refer to the user’s manual for details.Waiting TimeImageinputWaiting TimeMeasurementOutputprocessingLine 3Imageinput6Waiting TimeMeasurement Outputprocessing
Fast Output of Measurement Results to Reduce Machine Cycle TimeEtherCAT Machine Control NetworkEtherCAT is a high-speed open network that is ideal for Machinecontrol. You can use EtherCAT to connect to NJ-series MachineAutomation Controllers and motion control G5-series Servomotorsand Servo Drives to increase the control speed over everydaycommunications protocols from workpiece detection to startingaxis motion.Communications CycleConventionalcommunicationsstandard4 ms0.5 msEtherCATReduced to 1/8Time from Trigger Input to Producing Measurement ResultsTrigger inputFeaturesCommunications cycle as low as 500 µsConventionalcommunicationsstandardMotion control that is synchronized with thecommunications cycleEtherCATMeasurement resultsShortened byapprox. 6 ms.Note:The times given above are typical times. They depend on parameter settings.Positioning Solution That Eliminates Workpiece Dwell Time:Continuous Alignment Patent PendingNJ-series MachineAutomation ControllerFor a Machine that requires micron precision, one alignmentis not always enough to obtain an acceptable error level, butexecuting multiple alignments greatly increases the processing time. OMRON provides control methods that eliminateworkpiece dwell time, the main cause of increased processing time. Our Sysmac Automation Platform achieveshigh-speed, high-precision control that continuouslydetects workpiece positions and successively updates thetravel distance to quickly approach the target position.G5-series Servomotors andServo Drives[Previous Vision Sensors]MeasurementStage movement Measurement Stage movement Measurement Stage movement MeasurementStage moving speed0YThis graph indicates the speed changes inone specific axis (the X axis).Alignment1st2ndX3rdThe dotted box indicates the target precision range.[Sysmac]MeasurementStage movementStage moving speed0Y1stMeasure- Measure- MeasurementmentmentThis graph indicates the speed changes inone specific axis (the X axis).The workpiece quickly approaches thetarget position without stopping.AlignmentXThe dotted box indicates the target precision range.Note:Please ask your OMRON representative for details.7
High-precision Object Detection Required for PositioningLow-error Position Detection Even with Blurry ImagesOver the years, OMRON has perfected techniques to search for and match templates at high speed. From these techniques Shape Search III providesadvanced robustness, which is critical on FA sites. When measuring lamination of glass or other processes where the distance to the workpiece from theCamera varies, size differences and focal shifts can occur. Even in cases like this, the new Shape Search III algorithm detects positions with limited error.0.60CameraError (pixels)0.50Previous searchprocessing items0.400.30Shape Search III0.20Error0.100.00-5Glass 1-4-3-2Glass 2-101234Z-axis travel amount [mm]Close5FarStable Searching with Limited Error Even under Adverse ConditionsStable searching is possible even under the following adverse conditions, which occur far too often in actual measurement applications.Shape Search ⅢPrevious Search10.90.8Error (pixels)0.70.6Focal shiftContrastChipsHiddenOverlappingThinning andthickening0.50.40.30.20.10Focal shiftContrastChipsHiddenOverlappingThinning andthickeningVisualization of Comparisons Enables Easy Setup of High-precision SearchingPatent PendingAdvanced searching is accompanied by many parameters that must be tuned to match the application. However, it is difficult for the person making thesettings to see the internal process. Extensive time is required to make the most of tool performance. With Shape Search III, you can visualizecomparisons between the model data and a part of the measurement object to easily see when comparisons are not matched well for the inspection.Visualization of the comparison level, allows for parameters to be adjusted simply to obtain the best performance.Registered modelYou can see at a glance the differencebetween the registered model andmeasurement image.Measurement imageReduction incorrelationDeformationYou can adjust a parameter calledNo reduction the Acceptable Distortion Level toenable measurements withoutreducing the correlation even ifthere is distortion.You can easilyadjust this parameter whilemonitoring the comparison.Chip8
Converting Measurement Results to Output User UnitsSupport for the Main Stages andRobots Used for 2D PositioningUser Interface ExampleItemXYCamera axis movement: NoneCamera axis movement: X axisθ axis: Direct driveThe FH Controllers contain special setup displaysfor the stages and robots that are commonly usedon FA sites. You just fill in the settings to easilyoutput axis travel amounts for stages and robots.Camera axis movement: Y axisCamera axis movement: XY axesXYθCamera axis movement: NoneCamera axis movement: X axisθ axis: Linear driveCamera axis movement: Y axisCamera axis movement: XY axesCamera axis movement: NoneStagesApplication ExamplesRobotsCamera axis movement: X axisθ axis: Direct driveCamera axis movement: Y axisCamera axis movement: XY axesθXYStagesCamera axis movement: NoneCamera axis movement: X axisθ axis: Linear driveCamera axis movement: Y axisCamera axis movement: XY axesDirect fulcrum motionUVWRotary fulcrum motionUVWRRobots3 axes4 axesDirect fulcrum motionRotary fulcrum motionControl method: Fixed positionsControl method: Measured positionsVision Master Calibration for High-precision Positioning Even with Standard LensesTo perform high-precision positioning, the coordinate system must be accurately aligned between image processing and the stage or robot. Calibration is usedto achieve this. Normally trial and error in the actual application environment is necessary, which requires experience in moving sampling points and anexperience knowing the influence of minor tilt in the Camera installation, lens distortion and other factors. With an FH Controller, all you need to do is set aminimum number of conditions. Movement patterns for the sampling points are automatically calculated to optimize the stage/robot axis travel ranges, imagingprocessing field of view, and other factors, and the required axis travel amounts are sent to the PLC. By moving the system according to the instructions, optimumsampling is achieved and the coordinate systems for image processing and the stage/robot are accurately aligned. Correction coefficients are simultaneouslycalculated for Camera tilt and lens distortion. If you use the calibration conversion parameters that are made with this function, you can easily achievehigh-precision positioning even for standard lenses with high distortion rates. Page 15: Setup Flow for Vision Master CalibrationCoordinate SystemDistortion Caused by Camera angleXDifferent X and Ymagnificationscause distortion.Three Types ofAutomatic CalibrationAffine transformationXYXYThe installation can causetrapezoidal distortion.This distortion iseven greater with anormal lens.YTrapezoidal distortioncorrectionConverted to a coordinatesystem with correctX and Y factors.Distortion due to lens performanceThe influence ofdistortion increasestowards the edgesof the field of view.If sampling is performedaway from the center ofthe field of view,distortion reducesthe calibration accuracy.Lens distortioncorrectionConversion is made to the coordinatesystem even at the edges of thefield of view.9
Easily Integrate Interfaces into the MachineEasy Integration with Machine PC to Display FH Images and/or MeasurementsSupport for .NET User Interface ControlsCustom .NET controls are supported so that you can easily display FH Controller measurement images and measurement results on a Machine PC.Integrated Machine MonitorFHRUNProduction5Lot No.StartStopTest Process1 Process 2 Process 3StartStopAdjustResetErrorTimer settingMain menuRobot operationI/O MonitorEasy CustomizationCustom controls for FH measurement images and measurementresults are laid out on Microsoft Visual Studio .RUNInstead of writing the program code from scratch to build interfaces,you can easily build the interfaces simply by pasting custom controls.Pasting customcontrolsProductionProduction5Lot No.5Lot No.StartStartStopTestStop Process1 Process 2 Process 3StartTest Process1 Process 2 Process 3StartStopAdjustResetErrorTimer settingMain menuStopAdjustResetErrorTimer settingMain menuRobot operationI/O MonitorEasy Setting and Operation Using Touch Panel MonitorThe Touch Panel Monitor FH-MT12 has been added to the FH Series.The FH-MT12 is equipped with a 12.1-inch screen that, when used inconjunction with the FH controllers, is ideal for replacement of FZ visioncontrollers with integrated touch screens. You can adjust all the settingsby touching the screen.・12.1 inch XGA・Panel mountable・VESA mountable10RUNNEWRobot operationI/O Monitor
Design the Connected Components with One Software ApplicationDevelop Machine Control Programs withOne Software Application: Sysmac StudioUse the Automation Software Sysmac Studio to set up all ofthe slaves connected via EtherCAT. Simulate and debugmotion control, logic, drives, and sensing on an integratedplatform to reduce the work required for Machine design.One SoftwareSysmac Studio version 1.07 or highersupports the FH Series.NJ-seriesMachine Automation ControllerFH-seriesVision SystemG5-seriesServomotors and Servo DrivesMinimize Commissioning and Adjustment Workwith SimulationsIntegrated simulations linked to an NJ-series Machine Automation Controller lets you verify the NJ-series program logic andcheck how the FH-series Vision System responds to each controlsignal. You can directly edit the EtherCAT I/O map to sendmeasurement commands to the FH-series Vision System.EtherCATConfigurationWindowI/O Map WindowProgrammingWindowData Trace Window11
Easy Setup with Program ScalabilityCustomize Original Operation InterfacesShow only the buttons you needChoose from our library of buttons and position themanywhere on-screen to best support your daily operation,without ‘screen clutter”.Arrange the InterfaceElements FlexiblyYou can flexibly change the imagedisplay composition to display anentire image, enlarge part of animage, or display images from different Cameras.Move windows freelyDrag and drop windows where you want.You can also change the box size anddelete.Nine screen layoutUp to 9 screens can be stored depending on the application or userclassification.Hide Unnecessary AdjustmentCommandsFreely Lay Out Dialog Box ContentsCompletedWith only menu operations on the Cont
*for high speed controllers only With the FH Series, even if the number of connected Cameras increases, realtime transfer of Camera images does not increase. FPGA CPU Large amounts of image data can be transferred in real time. FPGA FPGA FPGA Multi-line High speed Image transfer bus 60ms 50ms 40ms 30ms 20ms 10ms 5ms High speed 300,000 pixels 1 .
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