Cognex In-Sight 3D-L4000 Series User manual

In-Sight®3D-L4000 Series
Vision System
Reference Guide
2021 March 08
Revision: 1.0.0.90

Legal Notices
The software described in this document is furnished under license, and may be used or copied only in accordance with
the terms of such license and with the inclusion of the copyright notice shown on this page. Neither the software, this
document, nor any copies thereof may be provided to, or otherwise made available to, anyone other than the licensee.
Title to, and ownership of, this software remains with Cognex Corporation or its licensor. Cognex Corporation assumes
no responsibility for the use or reliability of its software on equipment that is not supplied by Cognex Corporation.
Cognex Corporation makes no warranties, either express or implied, regarding the described software, its
merchantability, non-infringement or its fitness for any particular purpose.
The information in this document is subject to change without notice and should not be construed as a commitment by
Cognex Corporation. Cognex Corporation is not responsible for any errors that may be present in either this document or
the associated software.
Companies, names, and data used in examples herein are fictitious unless otherwise noted. No part of this document
may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, nor
transferred to any other media or language without the written permission of Cognex Corporation.
Copyright © 2020. Cognex Corporation. All Rights Reserved.
Portions of the hardware and software provided by Cognex may be covered by one or more U.S. and foreign patents, as
well as pending U.S. and foreign patents listed on the Cognex web site at: cognex.com/patents.
The following are registered trademarks of Cognex Corporation:
Cognex, 2DMAX, Advantage, AlignPlus, Assemblyplus, CheckitwithChecker, Checker, CognexVisionforIndustry,
CognexVSOC, CVL, DataMan, DisplayInspect, DVT, EasyBuilder, Hotbars, IDMax, In-Sight, LaserKiller, MVS-8000,
OmniView, PatFind, PatFlex, PatInspect, PatMax, PatQuick, SensorView, SmartView, SmartAdvisor, SmartLearn,
UltraLight, VisionSolutions, VisionPro, VisionView
The following are trademarks of Cognex Corporation:
The Cognex logo, 1DMax, 3D-Locate, 3DMax, BGAII, CheckPoint, CognexVSoC, CVC-1000, FFD, iLearn, In-Sight
(design insignia with cross-hairs), In-Sight2000, InspectEdge, Inspection Designer, MVS, NotchMax, OCRMax,
PatMaxRedLine, ProofRead, SmartSync, ProfilePlus, SmartDisplay, SmartSystem, SMD4, VisiFlex, Xpand
Portions copyright © Microsoft Corporation. All rights reserved.
Portions copyright © MadCap Software, Inc. All rights reserved.
Other product and company trademarks identified herein are the trademarks of their respective owners.
2
Legal Notices

Table of Contents
Legal Notices 2
Table of Contents 3
Precautions 5
Symbols 6
Introduction 7
About the In-Sight 3D-L4000 7
Support 7
Accessories 7
Cables 7
Correction Targets 8
Connectors and Indicators 9
Working Distances and Fields of View 10
Theory of Operation 11
Operation of the Triangulation Sensor 11
Raw 2D Images 11
Point Cloud 13
Invisible Points 14
Compensation of Perspective 14
Installation 16
Mount the Vision System 16
Mount the Vision System: Top Housing 17
Mount the Vision System: Rear Housing 18
Mount the Vision System: Through-Body 18
Connect the Ethernet Cable 19
Connect the Breakout Cable 20
Powering the Vision System 20
Cleaning and maintenance 22
Clean the Housing 22
Window Maintenance 22
Vision System Specifications 23
Dimensions 24
Laser Specifications 25
Ethernet Cable 26
Breakout Cable 27
Encoder Specifications 27
Encoder Inputs 28
Encoder Wiring 29
Trigger and Laser Enable Inputs 30
Trigger and Laser Enable Wiring 31
Outputs 31
Output Wiring 32
Laser Models 34
3
Table of Contents

Laser Compliance 34
Laser Safety Warnings 35
Label Locations 35
Regulations and Conformity 36
China RoHS 37
For European Community Users 38
Product Service 38
4
Table of Contents

Precautions
To reduce the risk of injury or equipment damage, observe the following precautions when you install the Cognex
product:
lThe vision system requires a UL or NRTL listed power supply with a 24VDC output that meets the following rating
requirements:
lAt least 1A continuous current.
lA maximum short circuit current of less than 4A.
lA maximum power of less than 50VA and marked as a Limited Power Source (LPS) or National Electrical
Code (NEC) Class 2.
Any other voltage creates a risk of fire or shock and can damage the components. Applicable national and local
wiring standards and rules must be followed.
lThis product is intended for industrial use in automated manufacturing or similar applications.
lThe safety of any system incorporating this product is the responsibility of the assembler of the system.
lDo not install Cognex products where they are exposed to environmental hazards such as excessive heat, dust,
moisture, humidity, impact, vibration, corrosive substances, flammable substances, or static electricity.
lRoute cables and wires away from high-current wiring or high-voltage power sources to reduce the risk of
damage or malfunction from the following causes: over-voltage, line noise, electrostatic discharge (ESD), power
surges, or other irregularities in the power supply.
lThis product does not contain user-serviceable parts. Do not make electrical or mechanical modifications to
product components. Unauthorized modifications can void your warranty.
lChanges or modifications not expressly approved by the party responsible for regulatory compliance could void
the user’s authority to operate the equipment.
lInclude service loops with cable connections.
lEnsure that the cable bend radius begins at least six inches from the connector. Cable shielding can be
degraded or cables can be damaged or wear out faster if a service loop or bend radius is tighter than 10X the
cable diameter.
lThe vision system’s M/S connectors are not supported.
lThis device should be used in accordance with the instructions in this manual.
lAll specifications are for reference purposes only and can change without notice.
5
Precautions

Symbols
The following symbols indicate safety precautions and supplemental information:
WARNING:This symbol indicates a hazard that could cause death, serious personal injury or electrical shock.
CAUTION:This symbol indicates a hazard that could result in property damage.
Note: This symbol indicates additional information about a subject.
Tip: This symbol indicates suggestions and shortcuts that might not otherwise be apparent.
6
Symbols

Introduction
The In-Sight Vision System is a compact, network-ready, stand-alone machine vision system used for automated
inspection, measurement, identification and robot guidance applications on the factory floor. All models can be easily
configured remotely over a network using an intuitive user interface..
About the In-Sight 3D-L4000
TheIn-Sight 3D-L4000 Vision System is a breakthrough in three-dimensional (3D) vision technology. This unique vision
system combines 3D laser displacement technology with a smart camera allowing factory engineers to quickly,
accurately, and cost effectively solve a wide variety of inspections on an automated production line. The patented
speckle-free blue laser optics, an industry first, acquires high quality 3D images and on-board high-performance
processing powers a comprehensive set of true 3D vision tools, without the need for external processing. 3D vision tools
are set up as easily as 2D vision tools thanks to the familiar and robust In-Sight spreadsheet environment.
The vision system offers the following advanced features:
- High performance 2K resolution 3D smart camera
- Broad suite of true 3D vision tools
- In-Sight spreadsheet-based setup
- Speckle-free blue laser optics
Support
Several resources are available to assist you in using the vision controller with the connected Cognex device:
lThe In-Sight® 3D User Guide, provided with In-Sight software.
lOn-demand training: cognex.com/on-demand-training.aspx
lThe In-Sight online support site: cognex.com/support/insight.
Accessories
You can purchase the following components separately. For a list of options and accessories, contact your local Cognex
sales representative.
Cables
Note: Cables are sold separately.
CAUTION:All cable connectors are keyed to fit the connectors on the vision system. Do not force the connections
or damage may occur.
Accessory Product Number Illustration
X-Coded Ethernet Cable, straight, xx (xx specifies
length: 2m, 5m, 10m, 30m)
CCB-84901-2001-xx (straight, xx specifies
length: 2m, 5m, 10m, 15m, 30m)
X-Coded Ethernet Cable, Straight, xx (xx specifies
length: 2m, 5m, 10m)
CCB-84901-2002-xx (right-angled, xx
specifies length: 2m, 5m, 10m)
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Introduction

Accessory Product Number Illustration
M12 with 17 pins to Flying lead, Straight, xx (xx
specifies length:2m, 5m, 10m, 20m)
CCB-PWIO17-S-xx (xx specifies length:2m,
5m, 10m, 20m)
M12 with 17 pins to Flying lead, Right Angle, xx (xx
specifies length:2m, 5m, 10m, 20m)
CCB-PWIO17-R-xx (xx specifies length:2m,
5m, 10m, 20m)
Correction Targets
To perform a correction on a 3D smart camera, you must use a Cognex-supplied correction target. The target consists
primarily of a frustum, a feature exhibiting six different planes with eight intersecting points.
Accessory Correction Target Illustration
40 mm correction target IS3D-CORR40-00
20 mm correction target IS3D-CORR20-00
10 mm correction target IS3D-CORR10-00
The following table lists all the correction target models.
Model Top side (mm) Height (mm) Camera Model
CT40 40 20 3D-L4300
CT20 20 10 3D-L4100
CT10 10 2 3D-L4050
Contact your Cognex sales representative for choosing the right calibration target for your application.
8
Introduction

Connectors and Indicators
Number Component Description
1 ENETConnector Connects the Ethernet cable, which provides 10/100/1000 Ethernet connectivity. For
more information, refer to Ethernet Cable on page26.
2 PWRConnector Connects the Breakout cable, which provides connections to an external power
supply, the acquisition trigger input, general-purpose inputs and high-speed
outputs. For more information, see Breakout Cable on page27.
3 M/S TRIG
Connectors
Not supported.
4Power
lHardware driven, this LED is always ON.
5Laser Status
lON: This LED is on when the vision system performs acquisition, and stays
on until the acquisition is complete and a final profile is acquired for a given
image.
lOFF: No acquisition is in progress
6Pass/Fail
lGreen or red when active. You can configure the meaning of this LED in your
In-Sight job.
7Ethernet status
lOFF: The vision system does not detect Ethernet connection.
lON: Ethernet connection was established.
lBlinking: Data transmission is in progress.
8Status
lGreen: The vision system is online and running.
lBlank: The vision system is offline.
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Introduction

Working Distances and Fields of View
Number Specification IS3D-L4050 IS3D-L4100 IS3D-L4300
1. Clearance Distance (mm) 92 130 180
2. Near Field of View (mm) 55 75 95
3. Measurement Range
(mm)
90 180 460
4. Far Field of View (mm) 106 235 745
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Introduction

Theory of Operation
This section gives a brief overview about the theory of operation.
Operation of the Triangulation Sensor
A triangulation sensor measures objects by imaging the intersection of a uniform planar light source and an object. The
sensor projects a sheet of light through a measurement area. The vision system captures this area at an angle, out of the
plane of the sheet. When an object passes through the sheet, a laser stripe appears on the object's visible surface, which
is imaged onto the detector. The software reduces the image data to a representative profile. Profiles are combined into
a point cloud which contains 3D information (height, volume, etc).
The properties of the major elements of the system determines the sensitivity and accuracy of the measurement. The
light source is a laser with a large divergence in one axis (20 - 40 degrees) and minimal divergence and extent in the
perpendicular axis. Since the object plane is angled relative to the camera, you have to position the camera sensor to
achieve optimal focus across the field.
When the vision system reads the image from the system, the image is then processed to
ldetect the line and determine its location,
lcalibrate the line's position,
lassemble the calibrated profile data.
Note: There are certain image distortions that derive from the fact that the vision system has a fixed-point aspect,
has a lens, and the object is moving under the vision system. However, In-Sight Vision Suite uses the calibrated
profile data from the vision system (factory calibrated in manufacturing). As a result, the point cloud does not show
unwanted optical effects.
Raw 2D Images
The following overview illustrates how the vision system captures the raw 2D images, which is the first step in acquiring a
point cloud.
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Theory of Operation

Number Element
1. In-Sight 3D-L4000
2. Laser plane
3. Inspected object
4. Camera field of view
5. Working section
6. Laser stripe
The vision system (1) projects a triangular laser plane (2) onto the object under inspection (3), illuminating the object's
surface. The illumination of the laser plane determines the peak data of the raw 2D image and results in the 3D-L4000's
laser stripe (6) within its field of view (4). The surface of the object determines the shape of the laser stripe, which
provides the exact height profile information of the object; see the illustration below.
The following image illustrates the laser stripe as seen from the position of the vision system (on the left). The raw 2D
image is what the vision system sees (on the right).
12
Theory of Operation

The vision system then applies an algorithm to find the peaks to extract the uncalibrated peak data. On the image below,
the cyan blue lines represent a subregion of the field of view working section (see Working Distances and Fields of View
on page10), where the vision system is looking for peak data. You can replace the subregion in the In-Sight Vision
Suite. The purple stripe at the lower section of the image is created by the software and marks the peak of the
uncalibrated data.
Point Cloud
A point cloud is generated from a series of uncalibrated peak data. For example, the image below shows a raw 2D
image from a single intensity scan.
Each pixel value in the raw 2D image is mapped to a height value based on its intensity value, as seen on the image
below.
Factory calibration transforms the uncalibrated peak data into real-world coordinates and removes distortions such as
camera lens and perspective. This creates a profile which represents the physical contours of the object. The image
below shows a series of profiles.
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Theory of Operation

These profiles are assembled to create an image of the whole object. This is called a point cloud. The image below
shows an example.
Invisible Points
As the vision system views the object at a fixed angle from the laser plane, certain areas of the object under inspection
may be hidden from the vision system. The shape of the object blocks the laser from hitting some areas. By default, the
missing values appear as empty spaces in the point cloud.
The grey areas on the image below are invisible because they are hidden from the camera by the inspected object.
Compensation of Perspective
Due to its position, a laser stripe that is closer to the vision system appears closer and wider in the raw profile image.
This introduces perspective: a distortion in the uncalibrated peak data.
The following image illustrates the effect of perspective distortion with two laser stripes of the same width.
Although the two red stripes have the same width, the lower one seems narrower.
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Theory of Operation

The orange stripe shows the width of the lower red stripe, relative to the upper red stripe. The green portions show the
difference between the two widths.
Consider a Lego® block scanned by the vision system. As it passes under the camera, the laser stripe appears for each
step.
If the vision system produced an uncalibrated image, the image would look like the colorized image below.
Factory calibration converts the distorted image into the calibrated image. The calibrated image then allows the
calculation of parameters like the exact volume of the object. The image below shows the top view (left) and the
perspective view (right).
15
Theory of Operation

Installation
Read this section to learn how the vision system connects to standard components and accessories. For a list of options
and accessories, contact your Cognex sales representative.
Note: Cables are sold separately.
CAUTION:All cable connectors are keyed to fit the connectors on the vision system. Do not force the connections
or damage may occur.
See the list of Cables on page7.
Mount the Vision System
In order to operate the vision system accurately, make sure to mount the In-Sight 3D-L4000 firmly and perpendicular to
the motion of travel. In this way, the acquired point clouds will be repeatable and accurate.
Number Guideline
1. The origin of the X-axis is the optical centerline of the sensor projected onto the
Working Section.
2. Arrange the vision system in a way so that the motion of travel is perpendicular to
the laser plane.
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Installation

Mount the Vision System: Top Housing
1. Align the holes on the mounting surface with the mounting holes on the vision system.
2. Insert the M4 screws into the top mounting holes and tighten. The maximum torque is 2.00Nm (17.70in-lb). Do not
exceed the maximum insertion depth of 8 mm for the M4 screws. The maximum insertion depth does not include
the thickness of the mounting material.
17
Installation

Mount the Vision System: Rear Housing
1. Align the holes on the mounting surface with the mounting holes on the vision system.
2. Insert the M5 screws into the rear mounting holes and tighten. The maximum torque is 3.00 Nm (26.55 in-lb). Do
not exceed the maximum insertion depth of 8 mm for the M5 screws.. The maximum insertion depth does not
include the thickness of the mounting material.
Mount the Vision System: Through-Body
1. Insert M4 screws (or appropriate hardware) through the 5mm holes on the vision system.
2. Attach the screws to a mount to prevent the sensor from shifting during operation. The maximum torque is
2.00Nm (17.70in-lb).
18
Installation

Connect the Ethernet Cable
CAUTION:The Ethernet cable shield must be grounded at the far end. Whatever this cable is plugged into
(typically a switch or router) should have a grounded Ethernet connector. A digital voltmeter should be used to
validate the grounding. If the far end device is not grounded, a ground wire should be added in compliance with
local electrical codes.
1. Connect the Ethernet cable's M12 connector to the vision system's ENET connector.
2. Connect the Ethernet cable’s RJ-45 connector to a switch, router or PC, as applicable.
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Installation

Connect the Breakout Cable
For more information, see Breakout Cable on page27
CAUTION:To reduce emissions, connect the far end of the Breakout cable shield to frame ground using the
exposed drain wire.
Note:
lPerform wiring or adjustments to I/O devices when the vision system is not receiving power.
lYou can cut exposed wires short or trim wire ends. You also can tie the wires back if you use a tie made of
non-conductive material. Keep bare wires separated from the +24VDC wire.
1. Verify that the 24 VDC power supply is unplugged and not receiving power.
2. To make sure the laser functions correctly, make sure that the LASER ENABLE (White/Violet wire) and IN
COMMON (Green wire) are connected.
lFor NPN lines, connect LASER ENABLE to ground and connect IN COMMON to +24 VDC.
lFor PNP configurations, connect LASER ENABLE to +24 VDC and connect IN COMMON to ground.
Note: The IN COMMON signal is shared with the TRIGGER and LASER ENABLE inputs. Therefore, the
operating mode (NPN or PNP) must be identical for both ports. The voltage difference between the
TRIGGER or LASER ENABLE inputs and IN COMMON needs to be at least 10 V to turn the input on and
less than 3 V to turn the input off.
CAUTION:If LASER ENABLE is not wired properly, the laser will not turn on after triggering the vision
system. This will result in black profile images and the In-Sight 3D software will not generate a point cloud.
3. Optionally, connect the I/O wires to an appropriate device.
4. The PHA+ (Brown wire) and PHA- (White/Brown wire) and PHB+ (Yellow wire), PHB- (White/Yellow wire) are
used for an encoder connection. Make sure to configure your sensor using the In-Sight 3D software to define how
these lines are used.
Note:
lThe encoder signals are referenced to the same GND as the 24 VDC power. If the encoder uses a
different power supply from the 24 VDC supply, the encoder supply and the 24 VDC supply need to
have a common GND connection.
lCognex recommends to ground unused encoder connections. If you configure the In-Sight 3D
software to use an encoder but do no connect the encoder signal inputs, the behavior of the encoder
counter is undetermined.
5. Attach the Breakout cable's +24 VDC (Red wire) and GND (Black wire) to the corresponding terminals on the
power supply.
CAUTION:Never connect voltages other than 24 VDC. Always observe the polarity shown.
6. Connect the Breakout cable's M12 connector to the vision system's PWR connector.
7. Restore power to the 24VDC power supply and turn it on if necessary.
Powering the Vision System
The 3D-L4000 has no dedicated power switch. The vision system powers on when you connect a power supply through
a breakout cable.
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Installation