Unit 6

1.Contour sensor
The contour sensor, also known as the object recognition sensor, is used for objects
with defined geometry. It is used to evaluate presence and completeness, for
position detection and sorting. It has the ability to analyze shapes and capture the
outline of an object. It is ideal in applications where the object’s shape is
repeatable and defined.

This product includes an image sensor, evaluation electronics and integrated

lighting in a robust die-cast metal housing that withstands harsh industrial
environments. Objects are reliably detected and precisely evaluated with the
sensor’s fast image capture and powerful algorithms.
 Source-ifm
Working principle
The sensor finds contours based on a defined level of contrast. This can be adjusted
in the configuration software to obtain the best contrast of the contour of interest.
For the reference image shown, note the level of detail in the contours that can be
achieved when adjusting the contrast. This is easily configured during set up. If the
level is too high, you probably see too many details. If the level is too low, you
probably do not see enough details.
2. 2D Code Readers

What is a 2D barcode?
A 2D (two-dimensional) barcode is a graphical image that stores information
horizontally as one-dimensional barcodes do, as well as vertically. As a result, the
storage capacity for 2D barcodes is much higher than 1D codes. A single 2D
barcode can store up to 7,089 characters instead of the 20-character capacity of a
1D barcode. Quick response (QR) codes, which enable fast data access, are a type
of 2D barcode.

Android and iOS smartphones use 2D barcodes in their built-in barcode scanners.
The user photographs a 2D barcode with their smartphone camera, and the built-in
reader interprets the encoded URL, leading the user directly to the relevant
website.

1D vs. 2D barcode scanning

From appearances alone, 1D and 2D barcodes look very different. One-
dimensional barcodes consist of black and white lines reminiscent of a zebra print.
Two-dimensional barcodes have black and white dots and shapes that create
specific patterns.
However, the main difference between these two types of barcodes is the kind of
barcode scanner needed to read them.

Traditional 1D barcodes, also known as linear barcodes, often use laser or charge-
coupled device (CCD) scanners. Newer 2D barcodes often use imaging scanners
for data capture.

In addition, 1D and 2D codes have different uses. One-dimensional barcodes are

typically used when the encoded data may change more than once, such as prices
or product content. Meanwhile, 2D barcodes are used in various situations, such as:

• when a network connection isn't available

• when a large amount of data is needed

• when a built-in error correction is necessary

Most industries use a combination of the two. For instance, shipping companies
typically use at least five different types of barcodes on a single box. In the tech
manufacturing industry, even something as small as a circuit board has an
identifying barcode.

Types of 2D barcodes
Intermec Corporation created the first 2D barcode, called Code 49, in 1988. Today,
there are many different types of 2D barcodes and barcode systems. The
International Organization for Standardization (ISO) governs all of them to ensure
standardized quality and efficiency.

Here are some of the most common 2D barcode types.

QR code
QR codes are matrix barcodes that can contain various data types, such
as alphanumeric and binary data. This type of barcode technology is one of the
most widely used today, especially by mobile devices.

QR codes have enough capacity for 1,817 Chinese characters, 4,296 Latin letters or
7,089 numbers. They also have four error correction levels, which means that even
if a QR code is damaged, it can often still be read correctly.

Quick response (QR) barcode is a type of 2D barcode.

Aztec code
Aztec barcodes look like QR codes with a finder icon in the middle. This icon is
uniquely generated for each code, and it helps the barcode scanner decode the
surrounding squares. Compared to QR codes, Aztec codes are more space-efficient
and resilient.

These codes are still readable even with poor resolution and clarity, making this
type of barcode technology ideal in scenarios where there is limited space, such as
in small items and corners, and when there is a problem with the scanner.
Government documents and tickets such as boarding passes often use Aztec codes.

Data matrix
A data matrix is a type of 2D barcode that features uniquely generated patterns of
square modules. This barcode type can store about 2,000 characters, including
alphanumeric characters, GS1 data and even binary data. Data matrix codes are
still readable even if they are 60% damaged, which is why the electronic,
automotive, health and even document storage industries use them.

PDF417
PDF417 is a 2D barcode that can store various binary data, including alphanumeric
and special characters. It can also store images, signatures and fingerprints. As a
result, identity verification, inventory management and transportation services
often use them. The PDF part of its name comes from the term "portable document
file." The "417" part refers to its four bars and spaces arranged inside each pattern,
consisting of 17 characters.

MaxiCode
MaxiCode is the unique barcode that United Parcel Service (UPS) developed and
uses. The barcode consists of hexagons with concentric circles in the middle.

The sole purpose of a MaxiCode is to help couriers track packages and manage
shipments. It can contain invoice numbers, customer references, tracking numbers,
purchase order numbers and carrier identification.

GS1 Composite code

A GS1 Composite code consists of two components -- one at the top and another at
the bottom. The bottom component contains the primary data, such as the item
identification number, while the top contains secondary data, such as batch codes
or expiration dates. Grocery stores use GS1 Composite codes on fresh produce, for
example.

2D Barcode uses
2D barcodes have a variety of uses in different industries, from government
processes to postal delivery to factory work.

Here are a few examples of 2D barcode uses:

• Nike included 2D barcodes on their posters positioned along the route of

a sports competition. When spectators scanned the codes with their
mobile phones, it gave them access to Nike's sponsored content.

• Newspapers add 2D barcodes to developing stories so that mobile users

can stay updated on their smartphones.

• Stores print 2D barcodes on their product packaging to link to product

reviews.

• Bloggers and content creators use 2D barcodes to promote their blogs

or social media
Benefits of 2D barcodes
Some of the main benefits of 2D barcodes are:

• Access to complete information. A single 2D barcode can deliver a

wealth of knowledge in a small package. For example, 2D barcodes
make it easier for healthcare workers to provide the proper care because
they can access detailed patient records conveniently.

• Inventory management. Two-dimensional barcodes can hold plenty of

information, which means companies can use them to keep track of
identification markers, product categories, date and time, for example.
This use allows companies to streamline their supply chains,
making logistics more efficient.

• Marketing strategies. Organizations can attach 2D barcodes to products

to provide additional information when scanned. Two-dimensional
barcodes can useful for mobile marketing because people can access the
data, regardless of internet access. Companies can also use these
barcodes in business cards and social media campaigns to promote
businesses and gain more customers.
3. Profile Sensors

A profile sensor measures the distance to the surface of an object along a laser
line it emits. This line is the sensor’s field of view (FOV) and it can measure the
height of various points within that FOV, thus creating an outline of the surface
of the object.

Technology

Profile sensors use triangulation to determine distances to an object. The sensor

emits a laser line that hits an object and reflects back to the sensor. It then
passes through a lens and subsequently hits a 2D array of pixels. By determining
where the laser hits the array, the sensor can determine the distance to an
object at multiple points thus mapping its profile.

Software

Certain algorithms within the software can then pick up different characteristics
of the profile along that line. These can include edges on an object, maximum
height, minimum height, etc. Different profile sensors have different algorithms
built in. Some are made to detect circular objects. Others are made to detect
edges. Others measure the largest change in distances (max-min).

Example1: Height Measurement.

Application: Checking closure of toothpaste tubes

Any application that requires a height measurement should be done with profile
sensors. Strictly height-based measurements cannot be performed by a vision
system as there is no way to tell how far away the camera is from the object. If
an object varies in its distance to the sensor, a vision system won’t be able to
account for this movement. It will “see” the object as bigger or smaller as the
distance changes and therefore its software tools will be affected. A profile
sensor has this measuring capability built in and therefore should always be
considered for applications with height measurements.

Example 2: Width Measurement

Application: Checking the width of tape on a web

Some applications can be solved with either a camera or a profile sensor. The
following rules are a good guide to recognizing these instances.

The object is consistently presented at a fixed distance from sensor/camera.

The object is oriented (not rotated) and consistently passes through the profile
sensor’s FOV. A profile sensor cannot locate parts. It can only “see” what directly
passes through its laser beam.

If these conditions are met, then either product should work. As we’ll see in the
conclusion, in these cases a profile sensor makes more sense.
4. Smart Camera (Vision Sensor)
A smart camera is a vision system with a built-in processor. Sometimes called a vision
sensor, it is very much a vision system based around a camera with processing powers.
In this way, it is a self-contained unit. It was designed to reduce the complexity of a
traditional PC based vision system where cameras take images and send them to a
computer to be processed. In the typical smart camera, lighting, lensing, and processing
all take place within the camera unit. This makes the system much less complicated and
cost effective.

Technology

The technology behind a smart camera is based on the same technology as any
digital camera. A lens focuses the image and lets light into the camera where it
hits a 2D pixel sensor. Pixels receive a value from 0 (pure black) to 255 (pure
white), depending on the amount of light that they receive. Together, all these
pixels create an image.

Software

Once an image is formed, the smart camera can process the image using a
variety of tools. For example, it can look for pre-trained patterns, test the
average brightness of a certain area within the image, or measure the distance
from one area to another. Much in the same way that profile sensors have built
in software, the smart camera software is built into the camera.
Example 1: Fixturing and Mounting Limitations

Application: Machined parts not presented consistently

If parts are not being presented consistently, a profile sensor won’t be able to
measure the correct widths or distances. A camera can take an image, locate the
part within the image, and then apply measuring tools in the correct locations.

Another advantage for the camera is a greater freedom in mounting. Although

the camera itself is typically larger than the sensor, it can be mounted closer or
further to the object thanks to a variety of lenses. Profile sensors have blind
spots directly in front of them for some distance as well as a limit to their range.
If mounting distances are an issue, vision systems have more options. Winner =
Smart Cameras

Example 2: Complex Inspection

Application: Depth of plunger inside tube

Consider this example. The depth of a plunger inside a glass tube is being
measured. A profile sensor would only be able to measure the profile of the glass
tube whereas a smart camera can see through the tube to the plunger within.
This is one example of many where an application becomes too complicated for
profile sensors and a smart camera becomes more appropriate.

Multiple inspections on a single part is another example of complexity. A smart

camera allows many tools to be processed on one image whereas several profile
sensors may be required to complete the same inspections. Of course, any
application with code or text reading along with many other tools that a vision
system can perform would be impossible for a profile sensor and should be
looked at through the lens of a smart camera. Winner = Smart Cameras.
5. Safety Sensors
Safety sensor switches are used in machines and other industrial applications to
prevent accidental contact with live electrical connections.

Construction

Safety sensor switches work together with hinged, sliding, or lift-off guards and
barriers. The power supply to the machine is disconnected as soon as the guard
is opened. Safety sensor switches include safety interlock switches, limit switches,
and cable-pull limit switches. These safety sensor switches are available with a
wide range of actuators, switch types, voltage and ampere ratings, contact
materials, and termination types.

Application
A safety sensor switch can be used on machinery gates or doors guards where key
removal brings the machine to a safe condition either immediately or at a pre-
determined interval.

Types
The most common types of safety sensor switches are break-a-beam switches,
interlocks, and tag out devices, perimeter guards, photoelectric safety sensors,
safety blocks, safety interlock switches, and wireless safety. Safety sensor
switches provide readily accessible emergency stop over a long linear distance
such as exposed conveyor lines.
Function
Safety sensor switches function in a variety of ways. A majority of sensors respond
to different physical phenomena, such as an ultrasonic sensor, infrared sensor,
and microwave sensor. A safety sensor switch is used at different positions to
manage for sensor safeguarding. To minimize failure and faults during disruption
or tampering, the outputs of these sensors are individually linked to a central
processing unit and alarm generator circuits by a plurality of redundant signal
links. Safety sensor switches include proximity sensors with varying ranges of
sensitivity and beam switches of varying size and means of activation. Industrial
safety is managed by the presence of sensing devices, control machine operations
protects personnel by detecting the presence of objects that could interfere with
or be harmed by machinery. Safety sensors are designed and manufactured to
meet most industry specifications.

Safety sensor switches are high-quality, dependable and cost-effective solutions

for a variety of industrial safety applications and are modeled to meet all
appropriate OSHA and ANSI standards. Safety sensor switches are used in
machines and other industrial applications to safeguard equipment and prevent
personal injury.

Benefits

• Safety sensors and switches for a wide variety of applications

• Rugged housing versions with LED indicator
• Reduced installation expense and space requirements
• Also suitable for heavy protective equipment
• Tamper resistant
• Insensitive to vibration and imprecise door alignment
6. Image Sensor
What is an Image Sensor?

An image sensor is used to detect & transmit information for making an

image. These sensors are used in both analog & digital type electronic
imaging devices like digital cameras, imaging tools used in medical, camera
modules, night vision tools like radar, thermal imaging devices, sonar, etc.
The analog sensors which are used in the past are video camera tubes. At
present, semiconductor CCDs (charge-coupled devices) is used otherwise
active pixel sensors within CMOS (complementary metal-oxide-
semiconductor) technologies. Analog sensors are vacuum tubes
whereas digital sensors are flat-panel detectors.

Different Types

There are two types of image sensors available which include the following.
• Charge-coupled Device (CCD)
• Complementary Metal Oxide Semiconductor (CMOS)

1.Charge-coupled Device (CCD)

A CCD image sensor includes a collection of capacitors, which carries

electric charge related to the pixel’s light intensity. A control circuit in the
senor will cause every capacitor to transmit its contents toward its neighbor
& the last capacitor within the array of capacitors will unload its electric
charge into an amplifier. The method like bucket-brigade of data transfer can
be a feature of CCD sensors.
 2. Complementary Metal Oxide Semiconductor (CMOS)
In a CMOS image sensor, it includes a CMOS transistor switch & a
photodiode for every pixel, permitting the pixel signals to be improved
separately. By operating these switches, the signals can be allowed
straight and in sequence with high-speed compare with a CCD sensor.
Including an amplifier for every pixel can also provide another benefit: it
decreases the noise that arises as understanding the electrical signals
which are changed from captured light.
Working Principle of Image Sensor
The image sensor in a camera system gets photon that is focused on using
a lens otherwise optics. Based on the type of sensor like CCD / CMOS, the
information will be transmitted to further stage like a voltage otherwise a
digital signal.
The main function of the CMOS sensor is to change photons into electrons,
after that to a voltage or digital value with the help of ADC (analog to digital
converter).is generated.
The general components used in the camera will change based on the
manufacturer. The main intention of this design is to change beam into a
digital signal to examine to activate some upcoming action. Consumer
cameras have extra components to store the image and for viewing whereas
the machine vision cameras doesn’t have.
Some advanced applications of Robot
1.Professional Robots in the field of Drug Delivery.

2. Medical Field

The robots have found to be successfully applied in following medical fields:

1. Neurological:
Brain surgery involves accessing a buried target surrounded by delicate tissue, a task that benefits
from the ability for robots to make precise and accurate motions based on medical images

The first published account investigating the use of a robot in human surgery was in 1985 for brain
biopsy using a computed tomography (CT) image and a stereotactic frame

2. Orthopedics
The expected benefit of robot assistance in orthopedics is accurate and precise bone resection.
Through good bone resection, robotic systems can improve alignment of implant with bone and
increase the contact area between implant and bone, both of which may improve functional
outcomes and implant longevity.
Orthopedic robots have so far targeted the hip and knee for replacements or resurfacing

3. Laparoscopy
Laparoscopy, also called Minimally Invasive Surgery (MIS) or keyhole surgery is a revolutionary
procedure that has improved the quality of life of patients.
The procedure is done with a laparoscope which consists of a video camera and specific thin
instruments. In the operating room, the laparoscope is maneuvered by a camera assistant according
to instructions from the surgeon.
Its demand has grown over the years due to major advantages such as faster wound healing, less
morbidity, less discomfort, quicker recovery time, and better outcomes. Many advancements both in
procedure and in the instruments used have occurred in recent decades.
Robots can help enhance laparoscopic surgery and are classified into the master-slave type and
hand-held forceps.
The master-slave type has a 6-degrees-of-freedom (DOF) of motion.
The robot has a 4-DOF arm outside the abdominal cavity and a 2-DOF wrist joint at the forceps tip.
The forceps tip can approach the target in the abdomen from an arbitrary position and posture.
The surgeon operates the remote slave arms with the wrist joint via the master console. The robot
enables an intuitive operation since the slave arms in the abdomen reproduce the surgeon’s 6-DOF
hand motion at the console.

3. Tele Robots
Tele robotics is the area of robotics concerned with the control of semi-autonomous robots from a
distance, chiefly using Wireless network (like Wi-Fi, Bluetooth, the Deep Space Network, and
similar) or tethered connections. It is a combination of two major subfields, teleoperation and
telepresence

4. Laboratory Robots
Laboratory robotics is the act of using robots in biology or chemistry labs. For example,
pharmaceutical companies employ robots to move biological or chemical samples around to
synthesize novel chemical entities or to test

5. Hobbyist Robots
This category of robots are generally used for entertainment purpose and experimenting purpose.
These robots usually equipped with speech synthesis techniques
Bullet Points Summary

• Contour sensor, construction and working principle with suitable sketch

• Compare between 1D and 2D bar code scanning.
• 2D barcode, Uses, types of 2D barcodes
• Profile sensor, technology and software used in it, its applications
• Vision sensor, technology and software used in it, its applications
• Safety Sensor, construction, applications, types, functions and benefits of safety sensors
• Image sensor, types and working principle.
• Advanced applications of Robots

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