19 Apr

Testing the New Cognex 7802 with SurfaceFX

Cognex In-Sight 7802 Lineup

Update: After writing this article, we did extensive in-depth testing of the new SurfaceFX tool.  Be sure to check out our larger write up on SurfaceFX with many more example images here!


KTM Research has been testing the new Cognex 7802 camera and its SurfaceFX capabilities. We are very impressed with this new camera! First, the camera is one of the best built cameras we have seen from Cognex yet. It is clear that there’s been a lot of thought put into the design that will make implementing the camera much easier than before. One of the most notable new features is the the integrated lighting which allows for individual control over the four quadrants. This gives the new camera and software the ability to pick out hard-to-resolve features and text that otherwise is difficult to identify using InSight Explorer.

Compared to the first generation 7000 series sensor, it feels very robust and has a good heft.  The Cognex In-Sight 7802 is a 2MP camera with 1600×1200 resolution.  The new design offers many more options for configuration than before.  Just look at this chart from Cognex showing some of the available options:

Cognex In-Sight 7802 Options


In our tests, we have found SurfaceFX capable of minimizing glare from shiny parts and picking out fiducial marks on plates without the need for any off-camera lighting. Another useful application of SurfaceFX is finding raised or sunken marks that are covered by printed text.

wrench image

Small wrench with normal illumination.

wrench with surfacefx

After processing with the Cognex 7802 camera and SurfaceFX, the letters and logo are now legible.

For more information on SurfaceFX, check out our more in depth look here, or click the image below.

Cognex SurfaceFX Featured Image

We have been running long-term target acquisition repeatability studies the last few weeks on the Cognex 7802 and are impressed with the results. Using a 16mm lens, a blue filter, and a blue four quadrant ring light, we have taken about 40,000 images. With the camera riding on the end of a Denso robot, we found 4 pixels of range in X,Y coordinates and 2 degrees of rotation range in finding the intersection of two fiducial lines. This result was repeated with both fiducial marks (using SurfaceFX) and vision targets (using “all banks on imaging” four quadrant lighting image acquisition) through a variety of warehouse lighting conditions. With the camera held still and under fixed lighting conditions, the camera is capable of 0.5 pixel range in X,Y coordinates and 0.2 degree rotation range.

Even under aggressive “torture test” lighting conditions, the stationary camera only has 1.5 pixel range when stationary. The take-away is that the Cognex 7802 camera paired with the quadrant ring light and using the new software tools released in InSight 5.4 has impressive accuracy and repeatability. The Cognex 7802 does better than a Denso robot’s positioning accuracy.

Cognex 7802 riding on the end of a Denso robot for long-term testing.

About KTM Research:

KTM Research is an engineering firm that specializes in industrial machine vision systems for quality control and vision-guided robotics.  Formed in 2009, we are located in Tualatin, Oregon.  We serve industries in the fields of advanced manufacturing, consumer electronics, bio-tech, food and beverage, research, and logistics.  Our systems have been successfully used by customers across North America and Asia.

Our goal at KTM Research is to be the first call you make when faced with a vision challenge.  Our team of engineers view themselves as an extension of your organization and strive to be your trusted vision partner.  Our success is our clients’ success.  Our collaborative approach to projects with our conservative and robust design process allows KTM Research to successfully complete projects that many others cannot.

Contact KTM Research at info@ktmresearch.com for more information on our vision solutions.