• Robotics Vision

Vision/Lighting 101

Because computers are always improving—think of your smart cellphone. If it’s not replaced every 2-3 years many of the applications and functions become obsolete rending the cellphone almost useless—new technologies and solutions are making robotics smarter and more capable.

One major upgrade in robotic technology is one that allows robotic vision in three dimensions (3-D) instead of two (2-D). Robotics using 2-D technology has been around for years, but for intricate work, 2-D visioning wasn’t the best way to get the job done. Thanks to improved technology and newer cameras, robotic systems can now be upgraded to see the world the same way we see it—in 3-D.

At Concept Systems, Inc., we put these visioning upgrades to work when we worked with a cake maker and decorator. The decorator used a robotics system that took a photo of the diameter of the cake as it progressed down the conveyer. Further down the line, an automated system created borders and designs on top of the cake. The camera was able to exactly diagram the surface area of the top of the cake, but every cake is a little bit different. Some were a tiny bit taller or shorter than the programmed height. The height variance meant that some of the cake designs were distorted on the finished product.

Enhancing a system doesn’t have to be costly. The cake maker earned back its investment in the updated robotic vision system in only 8 months. In some instances, upgrading from 2-D to 3-D can automate systems that were once done manually, and those cost savings add up! The cake maker’s overhead photo visioning system also made creating borders at the bottom of the cake almost impossible, so staff members were creating bottom borders by hand, costing time and labor.

While the cake maker project sounds costly and time-consuming, it didn’t require a lot of down time or new equipment expense. Existing robots were retrofitted to with a new 3-D visioning system, though laser scanners were also installed. The scanners’ lasers used triangulation to create an exact 3-D image of each cake before passing it down to the robot decorators.

The combination of the latest 3-D vision technology coupled with SCARA robots can now be used to bring automation to industries beyond the food industries. Updating and modernizing complex machinery and robots just makes sense. It can lower costs, increase productivity, simplify processes and even increase machine safety.

Let Concept Systems, Inc. put this upgraded technology to work for your business.


Why 3D Scanning Can Benefit Your Business

Concept Systems provides robotic technology solutions to companies so they can cut operation costs, increase productivity, and reduce errors. 3D laser scanning systems are often a part of our automation solutions. These unique, ultra-precise systems perfectly capture 3D shapes in order to inspect and analyze real-world objects or environments, allowing for the measurement and collection of data on the exact shapes and orientations. This collected data is ideal for constructing digital 3D model solutions.

Various industries can utilize 3D scanning systems, from manufacturing and engineering, to design, development, and surveying, to movies, art, and medicine. 3D scanning results in two key things: higher quality products and less costly manufacturing processes. It’s been estimated that 3D scanning can reduce manufacturing costs by 75 percent. At Concept Systems, we provide clients with 3D laser scanner solutions so they can consistently create high-quality products that function properly.

We’ve covered a few of the businesses that can benefit from our 3D scanning solutions, but let us get a little more specific:

The Conceptualization Phase

Individuals who work in design-based businesses always go through this phase of conceptualization and idea generation. Typically done with clay lead or foam lead, 3D scanning takes conceptualizing to a new level. The scanners can be applied during the idea generation phase by digitizing objects and then using them to interpret and enhance concept diagrams.

Design Phase and Process

As mentioned, 3D scanning can be applied at the beginning of the design phase by using a physical object to design a CAD (computer aided design) model. Designers usually need to design around or fit a design to existing objects. You can scan these parts and incorporate them into the design. This results in parts that consistently fit.
3D model scanning systems can benefit the actual design process in the following ways:

  • It increases the effectiveness of working with complex parts and shapes.
  • It assists with the design of products to accommodate other parts.
  • If CAD models are outdated, a 3D scan will provide an updated version.
  • 3D scanners quickly capture all physical measurements of any object.
  • A 3D scanner ensures that the parts fit together on the first try.
  • You can capture engineering optimizations inherent in manufactured parts with 3D scanning.
  • Scanners utilize modern manufacturing on parts that were manufactured before CAD existed.
  • Allows for a comparison between “as-designed” models and “as-built” parts.

Development Phase

When a project moves on to the development phase, user requirements and documentation are followed and the project is measured by predefined criteria. It is in this phase that it is accepted by the client.

Implementation Phase

After development is completed the project can now move on to the implementation phase. This phase is the implementation of the system. It is the development of the actual tested solution. The system is configured and launched for testing. At this point feedback can be used to enhance performance and problems can be worked through. It is not unusual for the product to frequently move back and forth from development to testing. User training takes place in this phase.


Top 5 Reasons to Update Your Controls

Concept Systems, Inc. manages robotic vision technologies from start to finish. We first meet with a company that has production problems. These may be related to inefficient machinery, hazardous equipment usage, or simply not having a system that allows them to keep up with client demand for their products. Concept systems, Inc. will talk with a company about their current problem and brainstorm solutions where updated technology would be beneficial.

From here, we design from scratch or redesign current robotic controllers to become more capable of performing their designated tasks. Robotic vision has helped a variety of industries meet their unique production needs in a way that provides both consumer satisfaction and profitable returns for the company. Here are 5 reasons why businesses should consider updating their production controls and machinery.

Increase Productivity

Utilizing enhanced machine vision can increase a company’s production significantly. When the controlling technology is able to make better scans of the product, then the production process is able to speed up and put out a higher volume of work. If the technology is not currently being used at all, it can be programmed to take on a larger workload.

Efficiency and Accuracy

With increased speed comes higher efficiency and accuracy. Not only is the production line moving at a steadier pace, but the number of errors occurring during production is also cut down. This is a big bonus of having robotic vision. Human error is inevitable, but robotic technologies have little to no error when programmed and function correctly.

Less Waste

The good consequence of practically nonexistent error margins is less waste of materials and time during production and processing. This is a win for the company and the environment. Fewer resources are needed to get the job done and the resources that are used get used more fully. With less waste, the company invests less money into materials costs.

Larger Profits

Less money wasted on material costs is just part of the profits made by the company. With all the increases in efficiency and production, the company is able to get more products made or items processed through their lines and shipped out to where they need to go. Investment in robotic vision will definitely see an eventual retrieval of monies spent.

Better Safety

With robot guidance, the machines can replace or change some of the dangerous jobs once left to company workers. Special scanners and controls can be programmed to do the work in areas that are not safe for people to be around. Share a new company vision with Concept Systems, Inc.!


Why Automation is Good for the Economy

When science fiction writers started to predict that robots would someday take over many of the jobs that human workers do, they probably didn’t realize that the time would come so quickly. In the last 10 years, engineers and computer scientists have made rapid advances in the design and production of robots. Computers and robots are everywhere, but especially in the manufacturing industry. Automation will certainly change the way people do work, but that doesn’t mean that the overall number of jobs will decrease or that the economy will suffer. We can tell you about some of the ways that automation will increase jobs and the overall growth of the economy.

The Saved and Re-Invested Company Money

If a manufacturer invests in automation, it can save the business money and create jobs for people who assemble, design, and maintain the automated machines. There’s always the risk that the jobs that have become automated will be lost, but when companies have more money, they can hire in other areas, increase their existing employees’ wages, or start new off-shoot companies. This creates more money flowing through the economy and provides opportunities.

The Nature of Technological Advancement

In terms of the people creating and maintaining the machines, their skills will be highly valued. More people will study engineering and robotics, and skilled jobs will steadily grow in demand. Even what could be considered unskilled jobs, or assembly of machines or routine maintenance, will need to be completed by humans. Over the course of history, humans and machines have always worked in tandem. When the first stone chisel was invented, it took fewer people and less work to cut things, but it created a whole new field of possibilities for what humans could do with the saved time and energy. If you think about the evolution of technology as this type of progress, saved and redistributed effort, then robots are just the next phase and the economy will continue to adapt and flourish as a result. Economies adapt to these types of shifts in each age, and preventing innovation isn’t really an option anyway.

Staying Competitive

The fact is, automation has been proven to save companies resources, so eventually any company that wants to be competitive is going to invest in it. If a country wants to stay at the top of their respective field, they’ll invest in this convenient and cutting-edge technology. Automation will not only create new types of jobs and increase liquid revenue in the economy, it will also pave the way for even more advances in the future that will be the foundation of economies then.


Creating a Foolproof Automation System for Your Business

In an age with increasing costs and additional demands, finding a way to automate some business processes using technology may be the key to solving problems. At Concept Systems, our engineers are problem solvers who use the latest in technology to create foolproof automation systems for businesses.

There are 2 primary reasons businesses choose to automate some or all of their processes whether those processes are related to production or fulfillment. First, manual processes are costly, and employee skills can be better allocated if the repetitive tasks are done by machinery. Already, engineers are hard at work designing robotic controllers that can grind and brew coffee to order and machines that can be used to eliminate weeds without the use of herbicides on corporate farms.

Second, automation increases production. Automating a manufacturing operation typically means increased production rates and labor productivity. In the simplest terms, business owners get more output per labor hour.

So how do Concept Systems engineers hammer out a robotic vision and controller for a specific industry or organization?

We start with a problem. When we kick-off a project, we spend time getting to know the full scope of a project and the necessary elements for success. The proposal to solving your problem will include the cost and a schedule. Fully understanding the problem and developing ideas for an automated solution or upgrade to your existing processes requires a bit of time as we determine what your system will do and how it will work. Our engineers work with key players in your company to draft on paper an elegant system including materials, electrical schematics and software.

For example, for a coffee roasting company, we upgraded a robot that was designed to unload pallets full of raw coffee beans and place the bags on a conveyor belt to send to the roaster. The robot’s vice grips, however, were a problem and often tore bags and spilled beans.

A Concept System team met with company stakeholders to design pneumatically-operated tines that eliminated tearing as well as a control system with 3D vision and advanced software to precisely position bags on the pallet.

Once a company approves a design, Concept Systems engineers get to work creating software and hardware to alleviate or solve the problem. This phase of development involves procuring materials, assembling the project, and testing.

During the final phase of development, engineers work closely with vendors at the factory or operation site to ensure proper installation of equipment and to train personnel to support and maintain the automated system.

Automation and robotics are the wave of the future. With specially engineered tools and resources, a team of engineers can create a foolproof automation system for your business and move your company into the future today. Contact us today to get started!


Key Methods of Robotic Vision Technology

The idea of a machine being able to see, interpret, and respond to information based on visual input alone is not just science fiction. Robotic vision technologies have become an integral component to manufacturing, as well as packing and shipping, and continue to grow in other industries as well.

Appropriate lighting is the most significant factor in ensuring that these technologies are working properly, and we’ve compiled a few tips for creating the best lighting solutions for robotic vision systems that help ensure the safety and efficiency of your technology and your team.

Bright Lights

If you’re working with molds and are trying to identify missing material in the mold or product, a short shot can help you out. This is a short burst of bright light that quickly illuminates inconsistencies in a mold from above. This method requires the container of the target object to have a flat top surface; otherwise, what the robot sees would be distorted. Any coarse or rough textures on the top surface of the mold also make the images a little spotty.


On an assembly line for electronics, robotic vision is what helps machines detect if parts are oriented correctly as they pass on down the line so that they’re able to be put together properly. Different colors emit different wavelengths when reflecting light, and you can get equipment that reads the distinctions in wavelengths to quickly determine the variety of materials in your assembly line. This could be the difference between a part being put in with the correct orientation or not.

Nondiffused Light

When it comes to glass or other transparent products, especially when they’re blazing past employees on an assembly line, small cracks or fractures in the material can be difficult to detect with the naked eye. Nondiffused light provides an efficient solution, as it essentially shows up on these robotic vision screens as a bright accent in a very dark image—any brightness highlights the imperfection.

Diffuse Light

Your teacher in grade school may have challenged you to estimate how many marbles were in the prize jar, but manufacturing a jar with an exact amount of marbles inside requires far more precision and much less guesswork. Using diffuse light in robotic vision technology is essentially bathing the object in light from every direction to remove any shadow. The image created from this technique can be quickly assessed for missing volume content.

Vision technologies rely heavily on light to produce accurate images, so choosing the right lighting for your workcell is important. If you are considering integrating vision technology into your plant processes and aren’t sure where to start, send us an email at