Vision and Inspection Platforms

Standard and Unique Solutions for Inspection, Guidance, and Testing

Calvary is dedicated and committed to advancing technology in our industry. Accordingly, we do this not only through our normal course of business, but also through investing a substantial amount of our profits into R&D and Product Development. For this reason Calvary maintains a full service Vision Lab which is well stocked with the latest in vision hardware and software along with leading edge products under evaluation.

Vision Lab

Our investment in our labs offers two main benefits to our customers:

  • We can mitigate risk upfront by investigating, evaluating and testing new products. In addition, we can perform feasibility and risk studies associated with new products, processes or cycle times. Therefore, in day to day execution, we do this via a documented POP process.
  • Once evaluated, we then can begin to develop systems, products and/or solutions around these enabling or potentially disruptive technologies in order to incorporate them into our systems or commercialize into the marketplace.

Machine Vision

At Calvary Robotics we are regularly challenged with vision applications that push the capabilities of the technology available to us. Under these circumstances, we address the challenges with a holistic and creative approach through sound vision engineering principles. Accordingly, these principles include expert application evaluation, accurate sensor selection, and leading edge lighting solutions.

We think of machine vision as any technology that captures, resolves, and processes the world around us into images or data. As a result, the images or data allow us to inspect, locate, read, measure, and then ultimately make deterministic decisions about the objects and surroundings we capture.

Calvary Robotics utilizes traditional 2D and 3D camera technology in a wide array of applications that fall into two categories:

Enabling Technology

As an integral component of a complex multi-technology solution including but not limited to:

  • Robot arm mounted for guidance and positional correction for object acquisition, material deposition, precision product placement and complex large-scale inspections.
  • Fixed mounted in flex feeding systems to return positional coordinates of workspace objects in three and six degrees of freedom

Deterministic Technology

Single and Multiple Sensor Deployments:

  • Object inspection of multiple features, multiple-methods (up to sub-micron resolutions).
  • Sorting, Counting, Volumetric Verification of Objects
  • Object feature absence, presence, identification.
  • Industry standard product ID reading (Barcode and 2D codes).
  • Industry standard product ID scoring.
  • OCR inspection.
  • Post laser mark and post print inspections/verification.

Key application advantages are as follows

  • Object/feature depth and/or height feedback.
  • Positional feedback of objects in 6 degrees of freedom (X,Y,Z,Rx,Ry,Rz).
  • Angular displacement or volume relative to any surface.
  • Surface defect depth/height.
  • Simplifies challenging applications by creating contrast from height changes, independent of color
  • Volumetric verification.

3D Vision/Displacement Sensing

At Calvary Robotics we are continually expanding our knowledge and experience base of solutions. We utilize many imaging technologies outside of traditional 2D object imaging.

3D vision displacement sensors combine a 2D sensor with a laser scanner and return a 3D representation of a given object. The result is a topographical representation, making possible the analysis of the 3D data and desired object characteristics listed here. 3D imagers, like their 2D counterparts can be used in both technology enabling and/or deterministic applications.

Among the many deterministic applications and advantages are:

  • Part presence/absence (single parts or in multi-part arrays)
  • Model types
  • Part counts
  • Proper orientation of an entire group of objects
  • Pass/fail feedback via Ethernet IP
  • High resistance to ambient lighting changes.
  • Cost effective solution for simpler applications
  • sorting applications for rectangular objects

3D Vision/Imaging (Time of Flight)

Calvary Robotics is constantly in search of technologies that challenge traditional sensing methods. Hence, we do this in an effort to lower total cost of ownership. This static 3D imaging technology uses time of flight algorithms to form a 3D area map of its field of view. 3D images are obtained via an integrated photoelectric sensor with internal illumination. The distance between the sensor and the nearest surface is measured point by point at distances up to 3 meters. Though not intended to detect surface defects, it is useful in area imaging – such as evaluating entire array of objects in a tray or on a pallet.

Line Scan Vision

Line Scan Vision is another example of our vast solutions knowledge base. Also, Line Scan Vision couples 2D vision technology with synchronized encoder feedback. In effect this method returns hi-resolution images of moving objects in individual vertical lines as small as a single pixel wide.

When the resulting 2D line images are rendered, a round or a moving object such as a tire or web of material will appear as a single flat image. The rendered image can then be evaluated using typical 2D vision tools that can be applied to measure, read, inspect for defects and then return pass/fail results. It can also return other data, such as 2D codes, barcodes, and alphanumeric characters.