Machine Vision

A machine vision system is only as reliable as the PC that receives its images, triggers its cameras and talks to the rest of the line. IT managers, engineers and buyers usually face the same question: how many LAN, serial and digital connections the setup needs, and which computer provides them without extra boxes, adapters or rewiring. Get the port count wrong and you may need a second PC, a reworked cabinet or a delayed commissioning.

This page shows how to scope a machine vision installation, count the ports it needs and match that count to the PICOPC systems listed below. The six models differ in processor and in how many serial and digital I/O connections they offer, so the choice usually comes down to a few clear checks. Examples include Intel® i3-9100 6 LAN and Intel® i5-9600 6 LAN.

What a Machine Vision Setup Is Built From

A typical setup has five parts: a camera, a lens, lighting, a processing PC and the cabling that links them. The camera captures the image, and the lens sets the field of view and sharpness. Lighting controls contrast, which often matters more than any other choice for reliable inspection. The processing PC runs the image analysis and makes the pass or fail decision.

Before buying hardware, decide whether the job suits a machine vision PC or a smart camera. A smart camera processes its own images and outputs a result, which suits one simple check at one station. A separate PC makes more sense when you need several cameras, heavier software, a large library of inspection recipes, or connections to PLCs, robots and other equipment. It also leaves more room to upgrade later.

Answer these questions first:

• How many cameras feed each station, and how many stations share one PC?
• How much processing does each part need, and how quickly must the decision arrive?
• Which factory equipment must receive a signal or send a result?
• Will the line expand within the next few years?

Port Counts for LAN, USB and Expansion Slots

Port planning starts with a simple count: one LAN port for each networked camera, plus ports for the factory network and a service connection. Add USB ports for local devices, then count any interface cards that need PCIe slots. Keep a port or two spare so that a change on the line does not force a new PC.

Counting LAN Ports for Each Camera

List each camera, its connection and the port it will use, then add the factory network and a maintenance connection. Every listed system provides 6 LAN ports, which covers six networked devices with little spare capacity. If a station needs more cameras than that, plan a second PC instead of chaining cameras through extra switches, which makes faults harder to trace.

Wired LAN Versus Wi-Fi on the Line

Wi-Fi suits a laptop, a handheld reader or a temporary link during commissioning. For camera data and for any signal that drives a machine, a wired connection is the safer choice. Radio links share airspace with forklifts, mobile devices and neighbouring networks, so their throughput varies. Wired connections are predictable and easier to diagnose. The listed systems include Wi-Fi for engineering access, but keep camera and control traffic on the wired ports.

PCIe Slots, Frame Grabbers and GigE Cameras

Some cameras do not connect through a standard port. A camera that needs a frame grabber usually requires an expansion card in a PCIe slot, which captures image data for the PC. Ethernet cameras use the LAN ports directly and need no card, but each still takes one port. Check the camera documentation before buying, and if a frame grabber is needed, confirm that the PC's slots fit the card. The listed systems provide 2 PCIe slots, so compare the number of cards you need with that figure.

Serial COM Ports and Opto-Isolated I/O for Factory Equipment

Serial COM ports connect devices that communicate over a serial link, such as barcode readers, scales, some sensors, legacy controllers and printers. Each device usually needs its own port, so count them and keep a spare. The listed models come with either 4 COM ports or 6 COM ports, which is one of the main differences between them.

Digital I/O handles on-off signals. A sensor reports that a part has arrived, the PC triggers the camera, and the PC sends a reject signal back to the line. The 16 opto-isolated DIO models keep the PC's electronics electrically separate from factory equipment, which protects it from voltage spikes, ground loops and faults in machine wiring. Confirm the signal levels and channel requirements of your equipment before wiring anything.

Choosing Among the Intel i3, i5 and i7 Models

The six listed systems form two port layouts, each available with three processors. Use this comparison as a starting point:

• Intel® i3-9100, 6 LAN, 4 COM, 8 USB, 2 PCIe, Wifi (PICOPC): the entry processor with 4 COM ports and no 16 opto-isolated DIO channels. Suits single-camera inspection with serial devices and no machine signals.
• Intel® i5-9600, 6 LAN, 4 COM, 8 USB, 2 PCIe, Wifi (PICOPC): a mid-range processor with 4 COM ports and no opto-isolated DIO. Suits stations with higher processing demand where machine signals are handled elsewhere.
• Intel® i7-9700, 6 LAN, 4 COM, 8 USB, 2 PCIe, Wifi (PICOPC): the highest processor in this range, with 4 COM ports and no opto-isolated DIO. Suits heavier processing where serial connections are enough.
• Intel® i3-9100, 6 LAN, 6 COM, 8 USB, 16 opto-isolated DIO, Wifi (PICOPC): the entry processor with 6 COM ports and 16 opto-isolated DIO. Suits simple stations that must exchange signals with machinery.
• Intel® i5-9500, 6 LAN, 6 COM, 8 USB, 16 opto-isolated DIO, Wifi (PICOPC): a mid-range processor with 6 COM ports and 16 opto-isolated DIO. Suits stations with both higher processing demand and machine integration.
• Intel® i7-9700, 6 LAN, 6 COM, 8 USB, 16 opto-isolated DIO, Wifi (PICOPC): the highest processor, with 6 COM ports and 16 opto-isolated DIO. Suits demanding inspection tied directly to factory equipment.

Area-Scan or Line-Scan Cameras and How They Connect

An area-scan camera captures a full two-dimensional frame at once. It suits parts that stop or pass in front of the lens, such as components on a tray or labels on a package. A line-scan camera builds the image one line at a time as the object moves past, which suits continuous material such as web, film or sheet. Choose by how the object moves and how large the image must be.

To connect a camera:

1. Confirm the camera's interface and match it to a port on the PC: LAN, USB or a card in a PCIe slot. Do this before buying.
2. Check that the camera's driver supports your operating system and version.
3. Assign a fixed network address to each networked camera and label every cable.
4. Connect the camera, trigger input and lighting controller, then test image capture at the required line speed.
5. Set exposure, focus and trigger timing, and record those settings.

Software and Long-Term Upkeep on the Factory Floor

Machine vision software usually has three layers: the camera driver that delivers images, the vision tools that locate and measure features, and the application logic that decides and sends results to the line. Choose software that supports your camera's interface and your equipment's communication method, and keep a record of the versions and settings that passed validation.

Plan maintenance as part of the installation. Clean lenses and housings on a schedule set by dust levels, check cable strain and connector seating, verify trigger timing, and back up the PC image and inspection recipes after every change. Keep spare cables and a tested disk image so that a failed unit can be replaced quickly.

Put these questions to suppliers:

• How long will the model be supplied, and what spare or replacement options exist?
• What warranty applies, and is support available on site or remotely?
• Which drivers, operating systems and software updates are supported?
• What documentation covers the port layout, I/O wiring and recovery steps?

This range is part of Computer Systems.

What You Get When You Order Machine Vision from PonDesk

A machine vision installation has to work with the cameras, sensors and machines already on the line. Buyers need a computer with enough network, serial and digital connections to handle that work without extra boxes or rewiring, and they need hardware that is genuine when it reaches the factory floor.

PonDesk, a UK-based supplier, sources its technology through trusted channels and checks it before supply, so the equipment you order is genuine and suited to industrial use. The platform keeps the range in one place, the technical team can help you match a configuration to your station, and orders ship to customers worldwide.