Keyence CV-3000 Visual System Selection

2. Advanced Color Extraction Engine (A.C.E.)

Traditional color visual processing often leads to false positives due to changes in lighting and variations in color depth. The A.C.E. of the CV-3000 series adopts the HSB (hue, saturation, brightness) extraction system, achieving two major breakthroughs:

Color grading processing (under patent examination): For low contrast targets, the tilt of hue, saturation, and brightness can be adjusted separately to significantly enhance the difference between the target and the background. For example, enhancing light colored scratches that were previously difficult to distinguish with the naked eye into clearly dark areas.

Color binarization processing: It can stably extract low brightness colors (such as dark green and dark blue), solving the problem of difficulty in extracting dark objects in traditional color systems.

Practical optimization techniques:

When setting up color extraction, prioritize using the "point&click" method, and then fine tune the brightness upper and lower limits through the color bar chart to reduce the impact of lighting fluctuations.

For objects with similar colors (such as orange and yellow plastic parts from different batches), it is recommended to use color detection tools (to quantify hue, saturation, brightness values) instead of color binarization.

3. Add a powerful toolset

The CV-3000 series comes with 16 built-in detection tools, with the following four having the highest engineering value:

Tool Name Function Typical Applications

Pattern Sort pre registers up to 256 templates, automatically matching the best shape to distinguish different models of components, and identifying positioning marks that can still be recognized after deformation detection

Stain detection compares the average contrast difference on the surface, and detects stains, scratches, foreign objects, surface defects on plastic parts, ink deficiency in printed materials, and scratches on metal plates

Differential detection and pixel by pixel comparison of registered images, output differential area detection for missing parts, assembly errors, and residues in the mold

Color detection outputs HSB values, which are used to distinguish color differences, confirm LED light colors, and determine liquid color changes based on the range of values

4. Preprocessing filters and conditional branches

Provide 14 preprocessing filters, including dilation, dilation, Sobel edge detection, and color binarization/color grading as preprocessing methods. In multi window detection, multiple filters can be used in series.

Conditional branching function: It can determine whether to execute subsequent windows based on the detection results of a certain window (such as position offset). For example, first roughly locate the approximate position of the product, and then create a high-precision measurement window only near that position, greatly saving processing time.

Software functionality and debugging optimization

1. Visual process menu and custom menu

The unique "Vision Flow" menu of Keyence guides users from top to bottom through the entire process of camera settings, detection window configuration, logic settings, and output display. For mass-produced equipment, the custom menu function can be used to separately extract the parameters (such as color thresholds and tolerance values) that are involved in daily operations, hiding advanced parameters. This feature, in conjunction with administrator mode/user mode (with password), can prevent operators from accidentally changing core settings.

2. Synchronous shift function

When the product positioning changes (such as changing fixtures), the traditional approach requires adjusting the position of each detection window one by one. The synchronous shift function allows users to select all relevant windows and move them as a whole at once. By adjusting the edge position in real-time, an "automatic following" detection area can be achieved.

3. Continuous capture mode and statistical processing

Continuous capture: After a single trigger, multiple images are captured continuously, and the average value is taken or the "data exclusion function" (in patent examination) is used to remove outliers. This function greatly improves stability for unstable detection caused by vibration or light source flicker.

Built in statistics: Store up to 20000 measurement data points directly on the controller without connecting to a PC, and display trend charts, histograms, maximum values, minimum values, standard deviations, NG counts, and yield. The corresponding historical images can be directly retrieved and replayed on the chart, making it convenient to analyze the causes of defects.

4. Batch retesting function

After debugging the parameters, thousands of previously saved images can be batch retested to quickly verify the effectiveness of parameter modifications, avoiding the expensive cost of re running the line.

Communication and Integration

1. PLC link (Ethernet/RS-232C)

The CV-3000 series supports direct data connection with Keyence KV series and other brands of PLCs. Through the PLC linking function, there is no need to write any ladder diagram receiving program in the PLC, and CV-3000 can directly read and write data storage of the PLC. This feature supports 100BASE-TX Ethernet and enables high-speed and high-capacity data exchange.