iRVision Flying Shot: How FANUC Robots Inspect Without Stopping
In high-speed manufacturing, every second counts. Traditional machine vision often requires the robot to stop for image capture, creating bottlenecks. FANUC’s iRVision with flying shot capability changes the game by allowing robots like the SR-6iA to inspect parts while in motion. This article dives into how this technology works, its advantages, and practical considerations for implementation.
What Is iRVision Flying Shot?
iRVision is FANUC’s integrated vision system that runs directly on the robot controller. The flying shot feature enables the camera to capture images while the robot arm is moving, without pausing at the inspection point. This is achieved through precise synchronization between the robot’s motion and the vision trigger. The system uses the robot’s encoder feedback to know the exact position at the moment of image acquisition, compensating for motion blur and ensuring accurate measurements.
Unlike static inspection, flying shot reduces cycle time significantly. For example, in a pick-and-place application, the robot can verify part orientation on the fly, eliminating the need to stop at a vision station. This is particularly valuable for high-speed operations like packaging, assembly, and material handling.
How It Works on the SR-6iA and Other FANUC Robots
The SR-6iA is a compact 6-axis robot with a 6 kg payload and a reach of up to 1,100 mm, often used in electronics and small part handling. When equipped with iRVision, it can perform flying shot inspections seamlessly. The setup involves:
- ▶ A GigE or Camera Link camera mounted on the robot arm or in a fixed location.
- ▶ The vision process running on the R-30iB Plus controller.
- ▶ A trigger signal sent at a specific robot position, often using a high-speed output or a position-based trigger.
The controller records the robot’s joint angles at the trigger instant. The vision tool then uses this data to relate the image to the robot’s coordinate system. Advanced algorithms correct for motion blur, allowing clear images even at high speeds. Typical flying shot speeds can reach several hundred millimeters per second, depending on the application and lighting conditions.
Key Benefits in Industrial Automation
| Benefit | Description |
|---|---|
| Reduced Cycle Time | Eliminates robot stops for inspection, boosting throughput by up to 30% in some cases. |
| Higher Accuracy | Position-synchronized triggering ensures consistent measurements regardless of speed. |
| Simplified Integration | No need for external vision controllers; everything runs on the robot controller. |
| Flexibility | Works with 2D and 3D cameras, supporting a wide range of inspection tasks. |
Real-World Application Examples
Flying shot is widely used in industries where speed and precision are critical:
- ▶ Automotive assembly: Verifying the presence and orientation of clips, bolts, or connectors on a moving conveyor.
- ▶ Electronics manufacturing: Inspecting PCB components while the robot places them, reducing placement errors.
- ▶ Food and beverage: Checking label alignment on bottles moving at high speed.
- ▶ Logistics: Reading barcodes on packages during sorting without stopping the robot.
Technical Considerations for Implementation
To achieve reliable flying shot performance, several factors must be addressed:
- ▶ Lighting: Strobe lighting synchronized with the camera trigger is essential to freeze motion. LED strobes with short pulse widths (e.g., 10-50 microseconds) are common.
- ▶ Camera selection: Global shutter cameras are preferred to avoid rolling shutter artifacts. Resolution and frame rate must match the inspection requirements.
- ▶ Trigger accuracy: The trigger signal must be precisely timed. FANUC controllers offer high-speed digital I/O with microsecond-level accuracy.
- ▶ Calibration: Proper hand-eye calibration is critical. iRVision provides automated calibration routines using a grid pattern.
Comparing iRVision Flying Shot with Traditional Vision
| Feature | Static Vision | Flying Shot |
|---|---|---|
| Robot Motion | Stops at inspection point | Continuous motion |
| Cycle Time | Longer due to stops | Shorter, higher throughput |
| Image Quality | No motion blur | Requires strobe lighting and fast shutter |
| Complexity | Simpler setup | Needs precise synchronization |
Getting Started with iRVision Flying Shot
If you’re considering implementing flying shot on an SR-6iA or similar robot, start with these steps:
- Ensure your robot controller supports the iRVision option (usually requires software package R510 or higher).
- Select a compatible camera and lens. FANUC offers pre-validated cameras, but many third-party GigE cameras work.
- Set up the vision process in the teach pendant, defining the trigger condition (e.g., when the robot passes a certain position).
- Calibrate the camera using the built-in grid calibration tool.
- Test with static images first, then gradually increase speed while monitoring image quality.
Training resources are available through FANUC’s education programs, and many system integrators offer support for vision integration.
Pro Tip: For high-speed applications, consider using a dedicated vision processor like FANUC’s iRVision 3DL for 3D flying shot, which can handle complex part localization without stopping the robot.
