KEYENCE ALIGNMENT ADVANTAGE

The industry’s largest lineup and best problem-solving ability

Industry
Leading
 ALIGNMENT APPLICATION
EXAMPLES

Glass/liquid crystal substrate lamination Positioning of irregular workpieces

Polarising plate lamination ACF/FPC lamination

Camera module mounting Positioning of an adhesive dispenser

Wafer notch angle alignment

and positioning Wafer exposure and print positioning

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Various applications are possible including alignment of several cameras or alignment for assembly.
The flexible solving ability has provided many successful applications in various manufacturing
processes such as LCD, FPD, solar cells, semiconductor, touch panels, camera modules, lithium
ion batteries, and other products.

IC chip defect inspection and

tray placement positioning Pick positioning for robot picking

Printing and pre-inspection Screen frame position and print position

positioning of solar cells determination for screen printing

Head positioning for laser processing Probe contact positioning

Lamination positioning of electrodes and

post-lamination inspection Print positioning for laser markers

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 The required processing speed, number of camera pixels,
Optimal equipment configuration and other factors vary according to the application. With
KEYENCE’s high-speed hardware and lineup of high-
thanks to faster hardware and speed camera including 22 different models, customers are
a wide variety of camera lineup able to obtain the optimal equipment configuration that best
suits their application.

High-speed hardware with 14 cores—the industry’s largest number of cores—for high-speed processing XG-X Series

Looking at searches—an essential aspect of alignment—using a camera with 5 million pixels enables speeds three times those of
conventional cameras.
Whether using a 310000 pixel camera or a high-resolution camera, high-speed alignment is possible with no search wait times.

Alignment start Alignment complete

1st measurement 2nd measurement 3rd measurement

PLC Image Stage PLC Image Stage PLC Image Stage

Conventional system command processing movement command processing movement command processing movement

Approx. 1/3 the processing time for faster searches

Faster image
PLC Stage PLC Stage PLC Stage processing for
XG-X Series command movement command movement command movement reduced alignment
time

Background settings changeover XG-X Series

Program settings can be changed over in just 5 ms,

the fastest in the industry. Capabilities that were
previously only available through branching and the
like are now available through simplified Settings
configuration, including support for inspection of changeover
in as little as
mixed lines with multiple product types as well as 5 ms!
multi-location inspection of large workpieces.
* Some restrictions apply when performing background
settings changeover. Contact KEYENCE for details.

Type A: Large workpiece Type B: Small workpiece

Up to 21 million pixels — Lineup of 22 area cameras

KEYENCE’s lineup of vision and alignment cameras consists of 22 models, including the industry’s highest-resolution camera at
21 million pixels. This wide variety allows users to select the camera that best suits the application.
310000
pixels
480 Conventional systems (including a camera with less than 21 million pixels)
1200
2 million
640 pixels 2040 Inspections of small components are only possible with multiple
1600 cameras or by moving a single camera. This results in additional axes
5 million pixels and decreased processing times.
4092
2432
XG-X Series + 21 megapixel camera
The 21 megapixel camera allows a high-resolution image to be
21 million pixels captured in a wide field of view with no degradation. This improves
processing time while reducing costs associated with additional
5104 camera axes as well as eliminates the need for tooling changes. In
addition, using ShapeTraxTM3 allows processing to be performed in
as little as 20 ms even with 21 megapixel pictures. Enjoy stress-free
processing even with high-pixel images.

21 million pixels 5 million pixels 2 million pixels 470000 pixels 310000 pixels

16 16 16 16

5104 × 4092 pixels 2432 × 2040 pixels 1600 × 1200 pixels 784 × 596 pixels 640 × 480 pixels

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 KEYENCE can provide a sample alignment program that
Easy programming and flexible allows precise alignment with easy operation. Since the

customisation software is fully customisable, it can be changed freely by the

user themselves.

High-accuracy alignment through easy operation

High-accuracy alignment is possible just by following the step-type menu to configure settings.
Configure the settings using a simple 4-step approach that includes camera settings, search settings, stage settings, and
calibration settings.

Program

The interface is customisable and offers high compatibility. Users are able to build programs using either a controller or a PC.
Since the software is fully customisable, finding the right configuration according to customer specifications is quick and easy.

XG-X controller screen example XG-X Vision Editor screen example

Optimal equipment configuration and calculation method according to application

The wide range of cameras in the lineup allows Ex. 2: Centre of mass alignment with
Ex. 1: Single-sided alignment of 2 cameras a single 21 megapixel field of view
customers to select the configuration and approach that
best satisfies their needs—from single-sided standard
alignment to centre of mass alignment—according to the
number of cameras required and the shapes of products
being handled.

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 Calibration is an important factor that may affect accuracy
and process time. Performing calibration according to the
Calibration for maximum accuracy application specifications and selecting optimum
transformation calculations provide best accuracy.

Stage calibration

With the ability to recognise the movement of the stage in relation to the cameras, calculations including “camera and stage tilting”,
“camera view/pixel resolution”, and “central rotation position of stage” are possible.

STEP 1: XY calibration STEP 2: θ calibration

The stage is moved in the X and The stage is moved in the θ
Y directions. direction.

Supported conversion methods

Choose from a variety of conversion methods according to the equipment features and stage configuration.

Non-orthogonal axis Single-axis drive system Diagonally mounted camera Wide field of view and
short working distance

90°? X axis

X axis

Y axis

Affine transformation Helmert transformation Projective transformation Affine transformation +

Orthogonal error correction Cartesian coordinate Camera tilt correction Lens distortion correction
system formation Lens distortion correction

Supported stage examples

XYθ stage UVW stage Xθ + Y stage Various robot stages

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 Stable detection of targets is essential for alignment. To ensure
stable detection, it is necessary to select not only algorithms,
Stable detection using various but also illumination and preprocessing as a whole according to
the surrounding environment and the properties of the target
imaging techniques workpiece. These are the suggestions that can only be made
by a direct sales manufacturer who understands actual factory
environments.

ShapeTrax™3 XG-X Series

KEYENCE’s newly developed automatic feature extraction algorithm allows users to ascertain optimal outline settings. Optimisation
through basic automatic setting configuration allows for simpler menus and easier operations even with settings that conventionally
required a certain level of familiarity.

Conventional ShapeTrax™3
With noisy markings, Image noise is analysed automatically,
suitable contour extraction making it possible to extract contours
required an understanding just as envisioned. Regardless of who
of complex parameters. configures the settings, searches that
take full advantage of the device’s
performance can be performed.

ALGORITHM

Perform searches reliably even in

adverse conditions.
MISSING SECTION UNFOCUSED IMAGE

LOW CONTRAST THICKENING

Trend edge

This tool detects up to 5000 edges within the inspection region and Circular/Arc processing Linear processing (Abnormal
outputs their positions and widths. In addition to all edge data, maximum/ point removal)
minimum/average widths, tip position, and peak-to peak width can be
measured without complicated calculations. It is also possible to find a
virtual circle or approximate line from the information of the detected Abnormal data is
multiple points. cancelled

ALGORITHM
Segment movement direction

Detection of wafer notch Detection of a virtual intersection

position at the corner of a smartphone
Edge detection
direction

Detected
peak Detected
bottom

Segment width Amount of movement

Detection algorithms capable of handling a variety of workpiece shapes

Using ShapeTraxTM3 and trend edges provide compatibility

with a variety of different workpiece shapes. This detection
method is designed to take full advantage of KEYENCE’s
algorithms.

Ex. 1: Workpieces for which straight lines Ex. 2: Chamfered workpieces

can’t be obtained

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 Effective countermeasures are available for dealing with
Effective problem solving methods unexpected problems. The ability with dealing with sudden
issues is essential for quick solutions.

When search error occurs due to defective marking

When an unexpected search error occurs,

the system accepts manual intervention for
manual alignment based on user-specified
position. This method is especially useful
for large products or products with high
unit costs.
Manual
position
specification

When search is unstable due to the vibration of the instrument or floor

The system repeats image capture and First image capture Second image capture Third image capture Fourth image capture Average coordinate value
search several times for one trigger signal,
then averages the resulting coordinate
values. This minimises the influence of the
vibration and improves detection accuracy.

X=130.211 X=130.508 X=130.345 X=130.499

Y=870.318 Y=870.355 Y=870.401 Y=870.383

X=130.391
Y=870.364

Multi-line deployment of similar settings

The recipe function allows individual Program settings

configuration of recipe settings for 0000 Recipe setting 0000 Recipe setting 0001 Recipe setting 0002
settings that only require different
values to be configured between Registered Registered Registered

products. This function allows for pattern pattern pattern

significantly less start-up time and

Pre- Pre- Pre-
labour during modification. processing Averaging processing Expansion processing
Blur
processing

Image calibration including tilt, and lens distortion correction

Using a calibration unit allows for correction of camera tilting and lens distortion.

Lens distortion correction Tilt correction

The calibration function also corrects for lens distortion. A uniform
image can be acquired on the entire screen, allowing for accurate
dimensional measurements, positioning and part inspection to be
achieved.
The calibration function corrects for the camera angle that occurs
during mounting. Unlike trapezoidal correction, this accurately
corrects the entire image by making use of numerous calibration
patterns across its field of view.
This resultant normalised image is also effective for image processing
when forced to mount the camera at an angle due to space
restrictions.

Measuring the cell width for solar batteries Tilt correction that uses calibration patterns

Original Image Calibrated Image Original Image Calibrated Image

Improves problems where measurement results differ at the centre Corrects tilt using chess board or dot patterns. It can also
and edge of the screen due to the occurrence of lens distortion. simultaneously correct lens distortion in addition to tilt.

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 As a comprehensive manufacturer of factory automation

Total support from a comprehensive equipment, KEYENCE allows customers to select from a broad
lineup that extends beyond simply image sensors in order to
factory automation equipment find the specifications that best suit their needs. In addition,
single-manufacturer systems allow for a smoother customer
manufacturer support experience and high-speed control with greater
reliability.

Lineup including all the equipment necessary for alignment control

PLC Marking
Motor

Camera
Motor HMI

PLC

Image processing PLC Servo motor

XG Series KV-7000 Series SV2 Series

Image processing and oscilloscope function taking advantage of high-speed PLCs

The KV-7000 Series allows users to visualise all timings related to alignment control, including image processing flag ON/OFF,
motor control operation timing, and communication transmission/reception.

Imaging trigger

Deviation data from 3 axes

retrieved from the image

Data reception complete

Positioning start

Positioning complete

Current stage coordinates from

3 axes

From imaging to
output
From positioning start to end

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 When it comes to high-resolution alignment, a telecentric lens
with no field angle is the ideal choice. KEYENCE offers
Peripheral equipment for optimal customers a wide range of telecentric lenses capable of
meeting the required accuracy and field of view specifications.
alignment control Moreover, in support of narrow installation spaces, KEYENCE
also offers a selection of side-view mirrors and wavelength
conversion sheets.

Lineup of telecentric macro lenses ideal for high-precision alignment

CA-LMH Series CA-LMHR Series

Resolving
power CA-LMHR Series CA-LMHE
Distortion-free Series
Field of view D : 0.1%
D : 0.02%
(viewing angle: 0.5 mm or less) VPR equipped Variable magnification
3.5 µm Ultra high resolution
CA-LM0210
D : 0.1%
D : TV distortion CA-LM0510/0307
Variable magnification
D : Up to -0.1%
VPR : Pixel resolution adjustment Variable magnification
5.0 µm mechanism High resolution
: Telecentric Macro Lens
CA-LMH
Series
D : 0.01%
7.5 µm CA-LM Series Standard resolution
D : Up to -0.1% Wide angle area
when using a normal lens

6 mm 9 mm 11 mm 16 mm 23 mm Supported image circle size

1/3" 1/1.8" 2/3" 1" 4/3"

Why use telecentric lenses (A comparison between CA-LM0510 and CA-LH50)

Distance from target to camera Distance from target to camera
Telecentric lens Close Far Standard lens Close Far
CA-LM0510 CA-LH50
(1.0× optical magnification) (with close-up ring = 44 mm)

The telecentric lens maintains A standard lens is affected by the height

the correct image size despite change in the target. When the distance
the 4.5 mm height difference in from the lens is short, the captured image
the target (right to left). size becomes large. When the distance
from the lens is long, the captured image
size becomes small.

Utilise side-view mirrors for installation in Obtain transparent lighting effects with just
narrow spaces one wavelength conversion sheet

Application example Application example

Alignment during Alignment using

screen printing transmitted light on a
stage without space for
lighting equipment

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 For general-purpose robot positioning applications, a dedicated
robot coordinate conversion unit is available. This allows users
Vision-guided robotics and laser to design a system that best suits the application, including

alignment systems stage positioning control or robot positioning control. A

dedicated sample flow is also available for positioning during
laser marking.

Vision-guided robotics

Direct connections are possible with compatible robot controllers. This allows for automatic calibration with no PLC programs
required.

Direct connection with robot + Robot coordinate conversion unit

Simply selecting the manufacturer of the robot to use easily enables direct
communication between the robot and the XG-X device. Moreover, the addition of
the dedicated conversion unit makes it possible to build a robot vision system with
incredibly simple programming.

Min. 5-unit configuration

Laser alignment system

Using a camera with a laser marker coordinate system eliminates the need to perform cumbersome offset adjustments. Such a
combination allows users to achieve high-precision printing and processing position correction with ease.

Laser alignment-specific sample flow One-shot camera coordinate system to laser coordinate system conversion
Create a laser alignment system with as few units as possible. Instantly convert to a laser coordinate system using dot pattern
recognition.

Min. 7-unit configuration

Application examples

Ex. 1: 2D code marking position correction on smartphone substrates Ex. 2: High-accuracy marking position correction on chip components in trays

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 A VARIETY OF COMMUNICATION INTERFACES
Various communication protocols are supported, which enables integration with existing systems.
PLC link connections with PLCs from different companies are supported, which helps reduce process
numbers when preparing.

Ethernet/RS-232C
Serial Interface

KEYENCE KV-7000 Series OMRON SYSMAC Series

PLC link Mitsubishi Electric MELSEC Series YASKAWA Electric MP Series

(Ethernet/RS-232C)
For these PLCs manufactured by companies as shown above, PLC link connection via Ethernet/RS-232C is possible.
All the sending and receiving of data is performed by reading and writing the DM. No need for preparing a program for
communicating with the XG.

CONSULT WITH US FOR ALL OF YOUR NEEDS

KEYENCE has decades of industry knowledge and can offer many solutions with a broad product
lineup. Count on us to provide high quality products and help your company achieve your goals
quickly and effectively.

Vision system Company It is troublesome to consult

A with different companies. PLC Company B

Customer

KEYENCE can...
KEYENCE Quickly solve questions
Staff specialised in Staff specialised in concerning both devices!
vision system control devices

Cooperation
Customer

Vision
system

PLC

Drive instruments
Displacement sensor

Encoder

SAFETY INFORMATION
Please visit: www.keyence.com Please read the instruction manual carefully in
order to safely operate any KEYENCE product.

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The information in this publication is based on KEYENCE’s internal research/evaluation at the time of release and is subject to change without notice. WW11-1086
Company and product names mentioned in this catalogue are either trademarks or registered trademarks of their respective companies.
Copyright (c) 2016 KEYENCE CORPORATION. All rights reserved. XGAlignment-WW-TG2-GB 1116-1 600K91