AI-Powered Imaging: Keyence Introduces IV4-H Series Vision Sensor

Machine vision systems use complex parameters and vision tools to inspect images of parts or assemblies for presence, flaws, and even text. Incorrectly configured parameters can prevent a vision inspection system from operating reliably.

Keyence recently announced a new vision sensor that uses AI to aid in the development of vision parameters and speed up the training process. The company designed these new features to greatly reduce the learning curve for machine vision applications.

Keyence's latest lineup of vision sensors, the IV4-H series, features built-in AI. Image courtesy of Keyence

IV4-H Vision Sensor Series

Regardless of application complexity, setting up a vision system requires optimizing exposure times, aperture settings, image filters, and many other parameters to achieve a clear and reliable image for inspection. These parameters can result in thousands of setting combinations, which is where AI can ease workloads. To address this, Keyence’s new IV4-H vision sensor uses built-in AI to comb through over 10,000 different parameter setting combinations to provide the best image clarity for an inspection.

Background noise during flaw detection is often a root cause of false calls in traditional vision systems, but the IV4-H has a trick up its sleeve. Utilizing AI to determine the targeted area, the IV4-H can remove background noise from the image and optimize the inspection process, thus reducing false negative or positive inspections. This feature also helps in harsh environments that might otherwise skew inspection images.

A typical application of the IV4, using AI to inspect the contents of an assembly. Image courtesy of Keyence

AI-Powered Machine Vision

Similar to the other vision sensors in the IV4 lineup, the IV4-H is an all-in-one vision sensor with integrated lighting. It is capable of identifying parts and flaws, outputting positional data, reading numbers or text, and counting objects. All of these features use AI to enhance not only the inspection process but also the tuning and parameterization of the tool. Along with these enhanced inspection tools, the IV4-H incorporates brighter built-in lighting and flexible lens options to handle a wider range of fields of view.

The IV4-H can be installed without the need for a hardwired or control trigger. Image courtesy of Keyence

Automated Image Setup

Installing a flexible vision sensor can save engineering teams hours of setup time down the road.

The IV4-H has an AI trigger that detects incoming parts and triggers the system to snap a picture and start the inspection at the optimal time, reducing the need for a control system or a hardwired trigger.

Power over Ethernet (PoE) allows a single cable to handle both power and communication. The IV4-H sensor head supports PoE, carries an IP67 rating, and offers optional high-flex cables for robotic installations.

Inspection Powered by AI

One of the many benefits of AI is the ability to handle thousands of different scenarios in a matter of seconds. By using AI to trial different filters and brightness settings to achieve the best image, users can virtually eliminate the learning curve that comes with vision systems. During integration, the trial-and-error method of choosing an image filter or inspection parameters consumes a lot of time. With the release of the IV4-H, Keyence delivers a comprehensive vision sensor packed with features built for stable, reliable inspections.