[VIDEO] VeriSens® Smart Vision in contour tracking and part location in product inspection

Struggling with inconsistent product inspections, shifting component positions, or complex reflections on your automated packaging lines? 🛠️

Let’s check together a quick proof-of-concept run featuring the Baumer VeriSens® Smart Vision sensor with an inspection task: Detect and validate the diameter of the plastic spoon inside a high-contrast lid to distinguish between spoon types.

🎬 What you’re seeing in the video:

We have three lids with different spoon diameters. With this setup, showcasing real-time contour tracking and part location tools working simultaneously to determine where the spoon is located and its diameter.

Intuitive Interface: Displays real-time images captured by the sensor from the inspection area.
Dimensional Analysis: Software automatically locate the region of interest and measure the object’s diameter (plastic spoon), using green or red indicator lines depending on the result.
Classification Result (OK/NOK): The software provides immediate inspection status along with specific measurement parameters, enabling quick differentiation between spoon types or instant identification of defective products based on established standards.
Technical Specifications: Baumer’s software allows engineers to monitor production process stability directly on the screen.

Unlike conventional machine vision setups that require an external PC, separate controllers, and complex programming, Verisen integrates the image sensor, optics, illumination, and processing hardware into a single unit with configuration on the Verisens Application Suite from Baumer’s Design.

Why automation engineers are choosing VeriSens® to optimize their lines:

360° FEXLoc® Part Recognition: Eliminates the need for perfect mechanical alignment. If components arrive rotated or shifted on a conveyor, the sensor virtually realigns its tools to track them instantly.

Advanced Geometric & Brightness Toolkit: Moves past simple pixel counting. It easily checks for part presence, contours, angles, and high-precision physical dimensions (like measuring component diameters directly in millimeters).

FEX® Subpixel Image Processor: Calculates object contours in real time at a subpixel level, helping engineers navigate difficult transparent packaging layers and glare.

Bring edge-level intelligence straight to your PLC topology via PROFINET, EtherNet/IP, Modbus TCP, or TCP/UDP without the overhead of heavy software infrastructure.

Besides, using VeriSens® Smart Vision with up to 23 features checks for diverse inspection tasks. All-in-One sensor.

Part location

Part location on contours (FEXLoc): Determines the location and rotational position of a part based on its contours. All subsequent feature checks are aligned according to the determined position.

Part location on edges (FEXLoc): Determines the location and rotational position of a part based on a single edge or two edges at a right angle to each other. All subsequent feature checks are aligned according to the determined position.

Part location on circle (FEXLoc): Determines the location and rotational position of circular parts. All subsequent feature checks are aligned according to the determined position.

Part location on text line: Determines the location and rotational position of text within a field of view. The text can change. All subsequent feature checks are aligned according to the determined position.

Geometry

Distance: Determines the distance between two edges.

Circle: Determines the diameter, the location, and roundness compared to a reference circle.

Angle: Determines the angle between two edges.

Counting edges: Determines the number of edges along a tracing ray.

Point position: Determines the coordinates of one point.

Edge characteristics: Compares the distances of edges along a tracing ray.

Feature comparison

Count contour points: Determines the number of contour points within a field of view.

Contour comparison: Compares the contour of a taught-in part with the contour of the current part.

Color identification: Identifies the color within a field of view and its deviation from the reference color.

Brightness: Determines the average brightness in a field of view.

Contrast: Calculates the contrast in a field of view.

Area size: Identifies light or dark respectively color-defined areas in the image. Determines the total area or the largest continuous area.

Count areas: Counts the continuous light or dark respectively color-defined areas visible in the image.

Pattern comparison: Compares the field of view with a taught-in pattern.

Finding object positions: Finds several objects based on a taught one.

Color positioning: Verifies the presence of defined colors within defined image sections.

Identification

Barcode: Reads barcodes. Determines quality according to ISO / IEC 15416, results output via process interface, comparison to a set value possible.

Matrix code: Reads matrix codes (ECC 200, GS1, QR, PDF417) in any angle of rotation. Determines quality according to ISO / IEC 15415 or AIM DPM-1-2006, results output via process interface, comparison to a set value possible.

Text: Reads numbers and characters. Output of the read characters via process interface, comparison to a set value possible.

Click the image to explore VeriSens® Application Suite:

👉 How are you tackling vision inspection and part tracking challenges on your factory floor? Contact us!