Camera and method for detecting objects moved through a detection zone

Abstract

A camera (10) is provided for the detection of objects (48) moved through a detection zone that has an image sensor (18) for recording image data, a reception optics (16) having an adjustable diaphragm (17), and a control and evaluation unit (38) to read the image data and to set the diaphragm (17), In this respect, the control and evaluation unit (38) is furthermore configured to set the diaphragm (17) per object (48) such that the object (48) is recorded in a depth of field range.

Claims

1. A camera for the detection of objects moved through a detection zone, the camera comprising: an image sensor for recording image data; reception optics having an adjustable diaphragm, the reception optics having a fixed focal position; a distance sensor for measuring a distance value from an object; and a control and evaluation unit to read the image data and to set the diaphragm, wherein the control and evaluation unit is configured to set the diaphragm per object dependent on the distance value measured from the object such that the object is recorded in a required depth of field range.

2. The camera in accordance with claim 1, wherein the depth of field range is determined from application-specific demands.

3. The camera in accordance with claim 1, wherein the control and evaluation unit is configured to read a code content of a code on the object using the image data.

4. The camera in accordance with claim 3, wherein the object is recorded in the depth of field range when a code can be read from the recorded image data.

5. The camera in accordance with claim 3, wherein the required depth of field range depends on a code type, on a module size, on an exposure, and/or on a decoding process.

6. The camera in accordance with claim 1, wherein the distance sensor is integrated in the camera and/or is configured as an optoelectronic distance sensor in accordance with the principle of the time of flight process.

7. The camera in accordance with claim 1, wherein the control and evaluation unit is further configured to set the diaphragm for the object using a function of the required diaphragm in dependence on the distance of an object.

8. The camera in accordance with claim 1, wherein the control and evaluation unit is further configured for a teaching process in which an object is arranged at a distance, image data are recorded, an image distinction is checked, and the diaphragm is adjusted until a suitable diaphragm setting for this distance has been found.

9. The camera in accordance with claim 1, wherein the fixed focal position is fixed for a maximum object distance.

10. The camera in accordance with claim 1, wherein the control and evaluation unit is further configured to set the diaphragm to a maximum diaphragm aperture for an object at a distance corresponding to the focal position and to increasingly close the diaphragm for different distances.

11. The camera in accordance with claim 10, wherein the different distances are smaller distances.

12. The camera in accordance with claim 1, wherein the control and evaluation unit is configured to set the diaphragm in dependence on a brightness.

13. The camera in accordance with claim 12, wherein the diaphragm is set in dependence on a brightness of the image data.

14. The camera in accordance with claim 1, wherein the diaphragm is installed in the reception optics or is placed onto the reception optics.

15. The camera in accordance with claim 1, that is installed in a stationary manner at a conveying device that guides objects to be detected in a direction of conveying through the detection zone.

16. A method of detecting objects moved through a detection zone comprising: recording image data with an image sensor through reception optics having an adjustable diaphragm, wherein the reception optics have a fixed focal position; reading the image data; measuring a distance value from an object; and setting the diaphragm per object dependent on the distance value measured from the object such that the object is recorded in a required depth of field range.

17. A camera for the detection of objects moved through a detection zone, the camera comprising: an image sensor for recording image data; reception optics having an adjustable diaphragm; a distance sensor measuring a distance value from an object; and a control and evaluation unit to read the image data and to set the diaphragm, wherein the control and evaluation unit is configured to set the diaphragm per object such that the object is recorded in a depth of field range, and wherein the control and evaluation unit is further configured for a teaching process in which an object is arranged at a distance, image data are recorded, an image distinction is checked, and the diaphragm is adjusted until a suitable diaphragm setting for this distance has been found.

Description

(1) The invention will be explained in more detail in the following also with respect to further features and advantages by way of example with reference to embodiments and to the enclosed drawing. The Figures of the drawing show in:

(2) FIG. 1 a schematic sectional representation of a camera;

(3) FIG. 2 a three-dimensional view of an exemplary use of the camera in an installation at a conveyor belt; and

(4) FIG. 3 a representation of a camera and of two sequential objects that are moved in its detection zone to explain the geometric relationships and the time behavior at a conveyor belt.

(5) FIG. 1 shows a schematic sectional representation of a camera 10. Received light 12 from a detection zone 14 is incident on a reception optics 16 that conducts the received light 12 to an image sensor 18. The optical elements of the reception optics 16 are preferably designed as an objective composed of a plurality of lenses and other optical elements such as diaphragms, prisms, and the like, but here only represented by a lens for reasons of simplicity. The reception optics 16 in a preferred embodiment has a fixed focal position (fixed focus); alternatively, the focal position is changed in operation (focus adjustment, autofocus).

(6) An adjustable diaphragm 17 is associated with the reception optics. The adjustment principle can be based on the most varied technologies, in particular on an iris diaphragm actuated by a motor, on an LCD display, on an opaque liquid while utilizing the electrowetting effect, or on a transparent membrane as briefly discussed in the introduction. Only the functional aspect will be looked at in the following that the diaphragm aperture of the adjustable diaphragm 17 is variable by electronic control. The adjustable diaphragm can be installed in the reception optics 16 or be placed on toward the image sensor 18 or toward the detection zone 14. The adjustable diaphragm preferably produces a round diaphragm aperture, but other geometries are also conceivable.

(7) To illustrate the detection zone 14 with transmitted light 20 during a recording of the camera 10, the camera 10 comprises an optional illumination unit 22 that is shown in FIG. 1 in the form of a simple light source and without a transmission optics. In other embodiments, a plurality of light sources such as LEDs or laser diodes are arranged around the reception path annularly, for example, and can also be multi-color and controllable in groups or individually to adapt parameters of the illumination unit 22 such as its color, intensity, and direction. The illumination unit 22 can be an external component or can be completely dispensed with in a manner differing from the representation and in the latter case the camera 10 only works with the environmental light.

(8) In addition to the actual image sensor 18 for detecting image data, the camera 10 has an optoelectronic distance sensor 24 that measures distances from objects in the detection zone 14 using a time of flight (TOF) process. The distance sensor 24 comprises a TOF light transmitter 26 having a TOF transmission optics 28 and a TOF light receiver 30 having a TOF reception optics 32. A TOF light signal 34 is thus transmitted and received again. A time of flight measurement unit 36 determines the transit time of the TOF light signal 34 and determines from this the distance from an object at which the TOF light signal 34 was reflected back.

(9) The TOF light receiver 30 in the embodiment shown has a plurality of light reception elements 30a or pixels and can thus even detect a spatially resolved height profile. Alternatively, the TOF light receiver 30 only has one light reception element 30a or offsets a plurality of measurement values of the light reception elements 30a to one distance value. The design of the distance sensor 24 is purely exemplary and other optoelectronic distance measurements without time of flight processes and non-optical distance measurements are also conceivable. The optoelectronic distance measurement by means of time light processes is known and will therefore not be explained in detail. Two exemplary measurement processes are photomixing detection using a periodically modulated TOF light signal 34 and pulse time of flight measurement using a pulse modulated TOF light signal 34. There are also highly integrated solutions here in which the TOF light receiver 30 is accommodated on a common chip with the time of flight measurement unit 36 or at least parts thereof, for instance TDCs (time-to-digital converters) for time of flight measurements. In particular a TOF light receiver 30 is suitable for this purpose that is designed as a matrix of SPAD (single photon avalanche diode) light reception elements 30a. For such a SPAD-based distance measurement, a plurality of light reception elements 30a are particularly advantageous that are not used for a spatially resolved measurement, but rather for a statistical multiple measurement with which a more exact distance value is determined. The TOF optics 28, 32 are shown only symbolically as respective individual lenses representative of any desired optics such as a microlens field.

(10) A control and evaluation unit 38 is connected to the adjustable diaphragm 17, to the illumination unit 22, to the image sensor 18, and to the distance sensor 24 and is responsible for the control work, the evaluation work, and for other coordination work in the camera 10. It therefore controls the adjustable diaphragm 17, preferably in dependence on a distance value of the distance sensor 24, so that a matching diaphragm aperture still to be discussed is produced for the respective object to be detected and reads image data of the image sensor 18 to store them or to output them to an interface 40. The control and evaluation unit 38 is preferably able to localize and decode code regions in the image data so that the camera 10 becomes a camera-based code reader. A plurality of modules can be provided for the different control and evaluation work, for example to perform the diaphragm adaptations in a separate module or to perform pre-processing of the image data on a separate FPGA.

(11) The camera 10 is protected by a housing 42 that is terminated by a front screen 44 in the front region where the received light 12 is incident.

(12) FIG. 2 shows a possible use of the camera 10 in an installation at a conveyor belt 46. The camera 10 is shown here only as a symbol and no longer with its structure already explained with reference to FIG. 1. The conveyor belt 46 conveys objects 48, as indicated by the arrow 50, through the detection region 14 of the camera 10. The objects 48 can bear code regions 52 at their outer surfaces. It is the object of the camera 10 to detect properties of the objects 48 and, in a preferred use as a code reader, to recognize the code regions 52, to read and decode the codes affixed there, and to associate them with the respective associated object 48. In order in particular also to detect laterally applied code regions 54, additional cameras 10, not shown, are preferably used from different perspectives. In addition, a plurality of cameras 10 can be arranged next to one another to together cover a wider detection zone 14.

(13) FIG. 3 again shows a camera 10 having a downwardly directed detection zone 14 as in the situation of FIG. 2. A distance measurement field of view 56 of the distance sensor 24 is larger than the detection zone 14 in this example and includes it. Deviating, overlapping and non-overlapping configurations of the detection zone 14 and the distance measurement field of view 56 are, however, also conceivable. A distance measurement field of view 56 disposed at least partly upstream has the advantage that a distance measurement value is available earlier.

(14) A first object 48 to be recorded moves at a velocity v into the detection zone 14. The velocity v as a parameter known to a conveying device can be measured by an external sensor such as an encoder, can be reconstructed from earlier image recordings, or can be determined by the distance sensor 24. In the latter case, the distance sensor 24 preferably has a plurality of reception zones of light reception elements 30a into which the object 48 successively enters so that a conclusion can be drawn on the velocity v from the temporal sequence and the measured distances.

(15) The object 48 is detected on entry into the distance measurement field of view 56. The recording should preferably be triggered when it is located at the center of the detection zone 14. The path d.sub.1 has to be covered for this purpose and the time up to this point is given by t.sub.1=d.sub.1/v. The path d.sub.1 also depends on the distance h.sub.1 since objects 48 of different heights are detected for the first time at different positions. The distance h.sub.1 is in turn measured by the distance sensor 24 and itself has to be converted from the distance value h.sub.m1 measured obliquely instead of perpendicular by means of h.sub.1=h.sub.m1 cos α. Under the assumption that h.sub.m1 is measured immediately on entry into the distance measurement field of view 56, the angle α in the configuration shown corresponds to half the viewing angle of the distance sensor 24 and is at least known from the fixed configuration. d.sub.1=h.sub.1 tan α can now also be calculated using these values.

(16) Comparable considerations can be made for the further objects, with only one further object 48a of a height h.sub.2 having a path d.sub.2 still to be covered being shown as representative. The control and evaluation unit 38 thus has relevant geometrical information and trigger points in time that can be seen from FIG. 3. The diaphragm aperture of the adjustable diaphragm 17 can thus be set in good time for the recording of every object 48, 48a in accordance with the respective distance value of the distance sensor 24 or of the height h.sub.1, h.sub.2 that can be calculated therefrom.

(17) An object 48a that is further remote from the camera 10 and thus has a smaller height h.sub.1<h.sub.2 is perceived as darker due to the amplitude of the signal that drops quadratically with the distance. The code 52 additionally appears smaller on an object 48a having a small height h.sub.2 so that a better resolution is required. A closed diaphragm expands the depth of field range and reduces the resolution. Which reduction and which signal-to-noise ratio is still tolerable depends on the specific application. This becomes clear for the example of code reading: It is ultimately not a question of whether images satisfy physical contrast criteria, but rather whether the code can be read. The matching diaphragm setting for a distance value is consequently preferably calculated from whether it is ensured that a code is legible. This can vary depending on the code type, the module size, and the decoder used so that it can be sensible to know a plurality of diaphragm settings for respective distance values in dependence on these parameters and to use them in operation in dependence on the situation.

(18) A basis for the setting of the diaphragm can be given as follows. The resolution Res.sub.img correlates with the pixel size p and the magnification mag as follows:
Res.sub.img=p/mag.

(19) The magnification mag can furthermore be approximated with a known focal length f and for distances r>f as
mag=f/(f−r).

(20) If the diaphragm is closed too much, diffraction effects can occur that can have an influence on the resolution. Such diffraction effects are described by the Raleigh criterion:
Res.sub.diff=1.22*lambda/(N*mag).

(21) Lambda is here the wavelength; the mean value can be used with polychromatic LEDs, for example. N is the f-stop and thus inversely proportional to the diameter of the diaphragm. The factor 1.22 corresponds to a zero point position of the Bessel function and can alternatively be selected differently.

(22) The resolution limit is then given by the maximum of the two values Res.sub.img,Res.sub.diff:
Res=max(Res.sub.img,Res.sub.diff).

(23) The depth of field range DOF is approximated by:

(24) $\mathrm{DOF}=\mathrm{alpha}*\frac{2r^2*N*C}{f^2}.$

(25) alpha is an empirical correction factor therein and C is the so-called “circle of confusion” that correlates with the resolution limit and illustratively represents the smallest unit that should still be resolved. The smaller the object to be examined, the smaller the depth of field range DOF becomes due to the linear dependency. C can now be replaced with the desired resolution limit, still corrected by an empirically determined factor α. Provided that the diaphragm is not too small and the resolutions is therefore not limited by diffraction, the replacement of C with Res results in accordance with the above equations as:

(26) $\mathrm{DOF}\left(r\right)=\mathrm{alpha}*\frac{2r^2*N*a*p*\left(f-r\right)}{f^3}\cong \mathrm{alpha}*\frac{2r^3*N*a*p}{f^3}.$

(27) The following optimum therefore results for the diaphragm setting: If the object is small, the diaphragm should be opened. The depth of field range DOF thus becomes small. A static focal position of the reception optics 16 should therefore be designed for large distances or small objects so that the small module size can be read in a code reading application. At smaller distances or with larger objects and an unchanging focus position, the diaphragm is closed, and indeed so far until the depth of field range DOF is sufficient to be able to read the code. Thanks to the smaller distance value, the module size becomes larger in pixels so that the further closed diaphragm is tolerated.

(28) This diaphragm adaptation is also of advantage because it partly compensates the brightness dynamics. The number of photons that reach the camera 10 depends on the diameter d of the diaphragm:
signal˜1/d.sup.2.

(29) This just corresponds to the quadratic drop of the amplitude with the distance:
signal˜1/r.sup.2.

(30) Due to N=f/(d/2), the depth of field range DOF simultaneously grows linearly as the diaphragm becomes smaller.

(31) A function diaphragm(distance) can be found with this knowledge with which the control and evaluation unit 38 locates the matching setting for the adjustable diaphragm 17 for the respectively measured distance value. The image is sharp due to the depth of field range that is expanded as necessary by the diaphragm with this dynamic diaphragm setting and delivers a sufficient signal so that the decoder can read the code (Good Read). It is sensible under certain circumstances to store a plurality of such functions for different scenarios with respect to code type, module size, exposure, and/or decoder and to use one of these functions in dependence on the actual conditions in the application.

(32) A start point can first be located to teach or calibrate the required diaphragm settings or the function diaphragm(distance) in that a lowest object to be expected is positioned with a correspondingly smallest module size in the detection zone 14. This preferably corresponds to its focal position in a fixed focus system. The diaphragm is opened so far so that the code is still read and this corresponds to the value to be set for the diaphragm at this distance. The diaphragm is closed further for higher objects to compensate the blur. It is conceivable to calibrate at least one further value of the function diaphragm(distance) with the aid of an object of the corresponding height. Interpolation or extrapolation can take place from the taught diaphragm settings for different distance values or heights.