iRVision Flying Shot: How FANUC Robots Inspect Without Stopping
In modern manufacturing, speed and precision are everything. Traditional robot vision systems often require the robot to pause for image capture, creating bottlenecks. FANUC’s iRVision changes the game with a feature called flying shot, allowing robots like the SR-6iA to inspect parts on the fly without stopping. This article dives deep into how this technology works, its advantages, and where it’s used.
What is iRVision Flying Shot?
iRVision is FANUC’s integrated vision system that runs directly on the robot controller. The flying shot function synchronizes the camera trigger with the robot’s motion, capturing images while the robot is moving. This eliminates the need for the robot to stop at each inspection point, drastically reducing cycle time.
The SR-6iA, a compact 6-axis robot with a 6 kg payload and reach of up to 911 mm, is often equipped with iRVision for high-speed pick-and-place and inspection tasks. Its lightweight design and high acceleration make it ideal for flying shot applications.
How Does Flying Shot Work?
The key to flying shot is precise synchronization. The robot controller continuously tracks the robot’s position and velocity. When the robot reaches a predefined trigger point, the controller sends a signal to the camera to capture an image. The exposure time is extremely short—often in the microsecond range—to freeze motion without blur.
The system uses a position-based triggering method. The robot’s encoder feedback ensures that the image is taken at exactly the right moment, even at high speeds. After capture, the image is processed by the iRVision software to locate parts, check for defects, or guide the robot’s next move.
Key Benefits of Flying Shot Vision
- Reduced Cycle Time: Eliminates robot dwell time for inspection, boosting throughput by up to 30% in some applications.
- Higher Accuracy: Motion blur is minimized with short exposure and synchronized triggering, maintaining inspection precision.
- Simplified Integration: iRVision is fully integrated into the FANUC controller, avoiding external PCs and complex wiring.
- Flexible Deployment: Works with various FANUC robots, including the SR-6iA, LR Mate, and M-10 series.
Real-World Applications
Flying shot is widely used in industries where speed and quality control are critical:
| Industry | Application | Benefit |
|---|---|---|
| Automotive | Part presence/absence check on moving conveyor | Prevents line stoppages |
| Electronics | PCB component inspection during pick-and-place | Increases placement accuracy |
| Food & Beverage | Label verification on high-speed packaging lines | Ensures compliance without slowing production |
| Pharmaceuticals | Vial inspection and sorting | Maintains sterile environment with minimal handling |
Technical Considerations for Implementation
To successfully deploy flying shot, several factors must be considered:
- Lighting: Strobe lighting synchronized with the camera is often necessary to freeze motion and ensure consistent image quality.
- Camera and Lens: High-speed cameras with global shutters are preferred to avoid rolling shutter distortion. FANUC offers compatible cameras like the SC130EF2.
- Robot Speed: The maximum speed for reliable flying shot depends on the robot model and application. For SR-6iA, speeds up to 2000 mm/s are achievable with proper setup.
- Calibration: Accurate hand-eye calibration is essential to relate the camera coordinate system to the robot’s tool frame.
Frequently Asked Questions
Can any FANUC robot use flying shot?
Most FANUC robots that support iRVision can use flying shot, but it requires the software option and appropriate hardware. The SR-6iA, LR Mate 200iD, and M-10iD are common choices.
What is the typical image processing time?
Processing time varies by application, but iRVision can often complete a 2D inspection in less than 100 ms. For complex 3D tasks, it may take longer.
Is flying shot suitable for high-vibration environments?
Excessive vibration can affect image quality. Proper mounting and vibration damping may be required. In some cases, the robot’s acceleration profiles can be tuned to minimize vibration.
Conclusion
iRVision’s flying shot capability is a powerful tool for manufacturers looking to maximize throughput without sacrificing quality. By enabling robots like the FANUC SR-6iA to inspect parts while in motion, it opens up new possibilities for high-speed automation. Whether you’re in automotive, electronics, or packaging, this technology can help you stay competitive.
For those seeking to see it in action, many system integrators and FANUC’s official channels provide demonstration videos showcasing flying shot on various robot models. Exploring these resources can give you a clearer picture of its potential.
