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Machine vision systems are essential for automating inspection and quality control processes in manufacturing. These systems rely on precise optical designs to capture and analyze images of products, ensuring accuracy and efficiency.
ImSym–Imaging System Simulator, is a unified platform to design, simulate, and optimize machine vision systems virtually. By modeling the entire imaging process, ImSym enables engineers to identify potential challenges, test configurations, and refine designs before physical prototypes are built.
This article explores the fundamentals of machine vision, the process of modeling such systems, and how ImSym can be used to simulate and improve optical designs for assembly line applications.
About Machine Vision
Machine vision systems are integral to modern manufacturing, enabling automated inspection, measurement, and sorting of products. These systems typically consist of a camera, an lens system, and a lighting setup, all working together to capture high-quality images of objects on an assembly line.
The captured images are processed using algorithms to detect defects, measure dimensions, or identify specific features. For example, in an assembly line for screws, a machine vision system can replace human inspectors by using a camera to capture images and image signal process algorythms to verify the screws’ quality.
Applications for machine vision extend beyond manufacturing. They are used in recycling centers to sort materials, in pharmaceutical production for quality control, and even in agricultural supply chains to inspect produce. The versatility of these systems makes them indispensable across industries.
Designing an effective machine vision system presents several challenges:
- Blurry images due to high-speed object movement: Decrease acquisition time to mitigate this issue.
- Specular reflections caused by improper lighting: Modify the position of the light source to address this challenge.
- Noisy images reducing detection accuracy: Adjust the sensor settings to improve image quality.
- Random positioning of objects complicating detection: Enhance the image signal processing (ISP) to effectively locate the object.
How Do You Model a Machine Vision System?
Modeling a machine vision system involves simulating the entire imaging process, from the scene object to the final image. This includes:
- Scene Definition: The object or environment being imaged, such as a PCB or a conveyor belt of products.
- Lighting Setup: The type, position, and intensity of light sources, which affect image quality and visibility of features.
- Optical System: The lens and sensor configuration, which determine how light is captured and converted into an image.
- Image Signal Processing (ISP): Algorithms that process raw sensor data into a usable image, such as RGB or grayscale, and perform automatic grading of the item in the resultant image.
By creating a virtual prototype of the system, engineers can test different configurations, identify potential issues, and optimize performance before building a physical prototype. This approach saves time and reduces costs, making it an essential step in the design process.
Example of end-to-end model
Modeling the Optical System with ImSym
Description of the Optical System
ImSym provides a unified simulation environment for designing and testing optical systems. For example, in a machine vision system designed to inspect PCBs, the optical system includes:
- A scene object, such as a PCB illuminated under ambient light or additional light sources.
- A lens system, which focuses light from the scene onto the sensor.
- A sensor, which converts light into electronic signals for further processing.
ImSym integrates seamlessly with CODE V and LightTools, enabling accurate radiometric simulations and optical modeling. Engineers can import lens designs, define sensor properties, and simulate the entire optical system within a single platform.
Description of an optical system that is analyzing a PCB
Image Simulation
ImSym simulates the light rays traveling through the optical system, from the scene to the sensor. This includes:
- Radiometric Image Generation: Calculating the spectral irradiance distribution at the sensor.
- Electronic Conversion: Simulating the conversion of incident photons into digital numbers at the output of the sensor.
- Image Processing: Applying default or custom ISPs to produce a final image, such as an RGB or grayscale output, as well as perfrom ISP functions like detection or grading.
For example, in a PCB inspection system, ImSym can simulate how ambient lighting and a light bar affect the visibility of holes in the PCB. By adjusting parameters such as lighting angle or sensor settings, engineers can optimize the system for better detection accuracy.
Constraints with Specular Reflection
One common challenge in machine vision systems is specular reflection, where light reflects off shiny surfaces and saturates the sensor. This can obscure critical features, such as holes in a PCB.
ImSym allows engineers to simulate these effects and test different solutions, such as:
- Adjusting the position or type of light source to minimize reflections.
- Modifying the sensor’s exposure settings to handle high-intensity light.
- Improving detection algorithms to account for missing or obscured features.
Image results in ImSym from different angles of additive illumination lights
For example, a simulation might reveal that certain lighting angles cause specular reflections that obscure some holes in a PCB. By testing alternative lighting setups in ImSym, engineers can identify the optimal configuration without the need for costly physical prototypes.
Conclusion
ImSym is a powerful tool for designing and optimizing machine vision systems. By enabling virtual prototyping, it helps engineers identify potential issues, test different configurations, and refine their designs before building physical prototypes. This not only reduces development costs but also accelerates time-to-market.
Whether you’re working on assembly line automation, medical imaging, or other optical applications, ImSym provides the tools you need to succeed. Its integration with CODE V and LightTools ensures accurate simulations, while its flexibility supports collaboration across engineering teams.
To see ImSym in action, watch the full webinar for a detailed walkthrough and live demonstration. Ready to take the next step? Contact us today at optics@synopsys.com to request a trial and experience the capabilities of ImSym for yourself.
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