Omron FZ5 Vision System Selection and Configuration Guide

Omron FZ5 Vision System Selection and Configuration Guide: A Complete Technical Analysis from Controller to Lens

In the field of industrial automation inspection, the stability and accuracy of the visual system directly affect the efficiency and product quality of the production line. The Omron FZ5 series sensor controller is widely used in scenarios such as positioning, identification, measurement, and defect detection due to its high-precision detection capability, flexible system configuration, and powerful communication interface. This article will deeply analyze the technical points of the FZ5 series from five aspects: controller selection, camera and cable matching, lens configuration, communication protocol support, and installation specifications, to help engineers quickly and accurately complete system construction in practical projects.

Controller selection: performance grading and scene adaptation

The FZ5 series controllers are mainly divided into three categories: high-speed controllers, standard controllers, and Lite controllers, each of which is further divided into LCD integrated and Box type types.

High speed controller (such as FZ5-1100/1105): suitable for multi camera and high-speed detection scenarios, supporting up to 4 cameras, with fast processing speed, suitable for production lines that require real-time response.

Standard controllers (such as FZ5-1100-10/1105-10): strike a balance between performance and cost, suitable for routine detection tasks.

Lite controller (such as FZ5-600/605): designed for economical applications, suitable for scenarios with few cameras and simple detection tasks.

Key selection suggestions:

If a 5-megapixel camera is connected, a maximum of 2 cameras can be connected and FH-S series cameras are not supported.

The processing resolution of the controller automatically adapts according to the camera type: the intelligent compact camera has a resolution of 752 × 480300k pixels, the camera has a resolution of 640 × 4802 million pixels, the camera has a resolution of 1600 × 12005 million pixels, and the camera has a resolution of 2448 × 2044 million pixels.

The number of scenes is unified at 128, suitable for multi variety and small batch production scenarios.

Camera selection: Balancing pixels, frame rates, and image sensors

The FZ5 series supports multiple camera types, and engineers need to choose based on detection accuracy, speed, and ambient light conditions.

1. Digital CCD camera

300k pixels (FZ-S/SC): frame rate of 80fps, image acquisition time of 12.5ms, suitable for high-speed moving objects.

2 million pixels (FZ-S2M/SC2M): frame rate 30fps, acquisition time 33.3ms, suitable for medium precision detection.

5 million pixels (FZ-S5M2/SC5M2): frame rate of 16fps, acquisition time of 62.5ms, suitable for high-precision static detection.

2. High speed CCD camera

FZ-SH/SHC: 300k pixels, frame rate up to 204fps, acquisition time only 4.9ms, suitable for capturing extremely high-speed moving objects.

3. Small digital CCD camera

Flat type (FZ-SFC) and pen type (FZ-SPC): suitable for installation environments with limited space, frame rate of 80fps, supporting electronic shutter.

4. Intelligent compact CMOS camera

FZ-SQ series: Integrated lens and high-power light source, adjustable field of view from 7.5mm to 300mm, installation distance from 38mm to 970mm, suitable for close range and high contrast detection. Its LED rating is Risk Group 2, which complies with the IEC62471-2 standard.

Selection Tips:

When connecting a smart compact camera, the controller current consumption significantly increases (up to 7.5A), and a power margin needs to be reserved.

When different camera types are mixed, the image recording capacity may change. It is recommended to refer to the logarithmic table in the original text for estimation.

Camera Cable and Extension: Compatibility and Distance Limitations

Cable selection is the most overlooked but crucial aspect in the FZ5 system. Incorrect use may result in signal attenuation, image noise, and even system failure to recognize the camera.

1. Standard cable (FZ-VS3)

Length: 2m, 3m, 5m

Bending resistant type (FZ-VS3B): suitable for dynamic drag chain environments

Right angle type (FZ-VSL3): suitable for installation with limited space

2. Long distance cable (FZ-VS4)

Length: 15m

Combined with cable extension unit FZ-VSJ, it can be extended up to a maximum of 45m (15m cable x 3 sections+2 extension units)

3. Compatibility limitations (key)

Not all cameras support long-distance cables. According to the official "Cameras/Cables Connection Table":

The 5-megapixel camera does not support FZ-VS3 cables of 10m and above, nor does it support FZ-VS4 cables of 15m.

The 2-megapixel camera supports FZ-VS3 up to 10m in length, but does not support FZ-VS4 up to 15m in length.

The intelligent compact CMOS camera (FZ-SQ) supports all cable types, including 15m long cables.

Engineering suggestion:

When planning the system layout, prioritize confirming the compatibility between camera models and cable lengths.

When using an extension unit, it is necessary to provide a 12VDC independent power supply (maximum current of 1.5A) for FZ-VSJ, especially when connecting to smart compact cameras or lighting controllers.

Lens selection and optical calculation

The FZ5 system supports C-mount lenses and is suitable for sensors with 1/3 inch, 2/3 inch, and larger pixel sizes. Choosing the right lens can ensure clear imaging, minimal distortion, and a depth of field that meets detection requirements.

1. Standard C-mount lens (1/3 inch)

Focal length: 3.5mm to 100mm

Aperture: F1.4 to F35

Applicable cameras: FZ-S, FZ-SC series

2. High seismic C-mount lens (2/3 inch)

Focal length: 6mm to 100mm

Features: Suitable for vibration environments such as stamping and conveyor lines

Model example: 3Z4S-LE SV-0614H to SV-10028H

3. Specialized lens for small cameras (FZ-LES series)

Focal length: 3mm, 6mm, 16mm, 30mm

Aperture: F2.0 to F16

The maximum outer diameter is only 12mm, suitable for narrow spaces

4. Microscopic lens (VS-MC series)

Optical magnification: 0.03 × to 0.65 ×

Fixed aperture options: F2, F5.6, F8

Example of Depth of Field Calculation (40 μ m Diffuse Circle):

15mm lens, 0.03 x magnification, depth of field at F2 is 183.1mm

50mm lens, 0.48 x magnification, depth of field at F8 is 4.1mm

Suitable for precision measurement, wafer inspection, and electronic component positioning.

Engineering Tip:

When using extension tubes, it is not recommended to stack multiple extension tubes of 0.5mm, 1.0mm, and 2.0mm together, otherwise the threaded connection may become loose.

When the total length of the extended pipe exceeds 30mm, seismic reinforcement measures must be added.

Communication interface and network protocol

The FZ5 series supports multiple communication methods, making it easy to integrate with devices such as PLCs, robots, and upper computers.

1. EtherNet/IP

Supports 100Mbps (100Base TX)

Recommend using CAT5e and above STP cables

Official recommended cable brands: Hitachi Metal NETSTAR-C5E, Cangmao Electric KETH-SB, SWCC FAE-5004, etc

Attention: The shielding layer of EtherNet/IP cable is only grounded at one end to avoid ground current interference.

2. Serial communication

RS-232C/422A: 1 channel

Suitable for communication with old PLCs or instruments

3. USB interface

LCD integrated type: 4-channel (USB 1.1/2.0)

Box type controller: 2 channels

Supports mouse, USB flash drive, trackball

Attention: When using two USB drives at the same time, do not insert them into adjacent ports to avoid physical interference and malfunction.

4. Parallel I/O

Input: Up to 17 points (including RESET, STEP, encoder signal, etc.)

Output: Up to 29 points (including RUN, BUSY, GATE, OR, ERROR, STGOUT, etc.)

Support multi line random triggering mode, suitable for complex synchronous control.

Processing Items for Image Processing

The FZ5 system provides a wide range of image processing tools, covering the entire process of localization, recognition, measurement, filtering, calibration, and more.

1. Positioning and Search

Flexible Search: Adapt to Workpiece Deformation

Shape Search III: Resistance to environmental changes (individual differences, posture fluctuations, noise occlusion)

EC Circle Search: High precision circle detection

2. Measurement

Edge Position/Edge Pitch: Edge Detection Based on Color Changes

Circular Scan Edge Position: detects the center and radius of a circular workpiece

Gravity and Area: Extract color regions, calculate centroid and area

3. Identification

OCR+OCR User Dictionary: Character Recognition and Custom Dictionary

2D Code/Barcode: Supports Data Matrix, QR Code, Code 39, Code 128, etc

Character Inspect: Character Comparison Based on Model Dictionary

4. Image enhancement and conversion

Color Gray Filter: Convert color to grayscale and enhance specific colors

Anti Color Shading: Eliminating Uneven Background Colors

Polar Transformation: Polar coordinate transformation, suitable for circular printing character recognition

5. Data processing and process control

Parallelize: Parallel the measurement process to shorten the total time

Statistics: Calculate the average of multiple measurements

Unit Macro/Calculation: Custom Formulas and System Variable Operations

Installation and Environmental Standards

1. Power supply and grounding

Power supply voltage: 20.4-26.4 VDC

Special warning: It is strictly prohibited to ground the 24VDC positive pole of the Lite controller, otherwise touching the SG (0V) part (such as the controller housing or camera housing) may cause electric shock.

2. Working environment

Temperature: 0-50 ° C (standard), 0-45 ° C or 0-50 ° C depending on fan speed

Humidity: 35% to 85% (no condensation)

Storage temperature: -20 to 65 ° C

3. Weight and size

LCD integrated type: approximately 3.2kg (2 camera type) or 3.4kg (4 camera type)

Box type Lite controller: approximately 1.8kg

Installation hole: M3 depth 6mm, four installation holes

Common configuration errors and troubleshooting

Problem 1: The camera cannot recognize

Check if the cable length exceeds the supported range (especially for 5-megapixel cameras)

Confirm if the extension unit FZ-VSJ is powered (12VDC)

Confirm if the camera is correctly connected to the camera interface (1-4)

Problem 2: Image flicker or severe noise

Check if the power grounding is compliant (Lite controller positive pole must not be grounded)

Check if the cable is STP and if the shielding layer is grounded at one end

Check if the recommended EtherNet/IP cable is being used

Problem 3: Unstable measurement results

Confirm if the lens aperture is fixed and locked

Check if the expansion tube is loose or stacked too much

Use the Precise Calibration processing item to correct lens distortion and keystone distortion

Problem 4: Unable to save image or data

Confirm if the USB drive format is FAT32

Do not insert two USB drives into adjacent USB ports

Check if Image Logging or Data Logging is configured correctly

System Expansion and Accessory Selection

LCD monitor (FZ-M08): 8.4-inch TFT, resolution 1024 × 768, suitable for box type controllers

USB memory: 2GB or 8GB, used for image and data recording

Industrial switch: 3 or 5 ports, supports EtherNet/IP, some models support fault detection

External lighting and controller: FLV/FL series light source, to be used in conjunction with FLV-TCC or FL-TCC series controllers