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Spray Bottle Cap Inspection

Posted in Back Lighting, Featured, Flaw Detection, Inspection, Object Location, Other, Presence/Absence

The Challenge: The bottles are being produced at a rate of  60  per minute and travel at 100mm/second. Each bottle needs to be checked to ensure that the applicator has been attached correctly, that the lever is in the right position, and that it is not damaged in any way. Our Solution: The turnkey solution managed to check for the presence of the applicator using a contrast tool, a measurement tool ensured that the position of the lever was correct, and a mixture of various other tools ensured that there were no defects. If a defective bottle was detected, the camera triggered a reject station in order to remove it from the production...

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Sports Drink Cap Check

Posted in Featured, Flaw Detection, Food & Beverage, Inspection, Object Location, Other, Presence/Absence

The Challenge: The machine vision system needs to check that all of the sports bottle caps have been assembled correctly, at a rate of 100 bottles per minute. Defects can include misformed, misaligned or missing caps, and kinks. The solution also needs to cater for multiple variants and needs to be able to suitable for a food grade (wash-down) environment. Our Solution: A turnkey, IP65 machine vision solution was installed to check every bottle ‘on the fly’, at a rates of up to 120 bottles per minute. The vision system checked for cap presence, position, and shape. The system was also integrated to a PLC which operates a reject mechanism, thus providing containment of defective products. Images of any defects are stored on a server with a date and time stamp, they are also displayed to the operator to help...

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Sandwich Assembly Inspection

Posted in Colour Inspection, Featured, Food & Beverage, Inspection, Object Location, Presence/Absence, Uncategorized

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Plaster Inspection

Posted in Back Lighting, Featured, Flaw Detection, Inspection, Medical, Object Location, Presence/Absence

The Challenge Plasters are produced at a rate of 35 per minute. Defects that may happen during manufacture include a missing gauze, a misshaped gauze, an incorrectly positioned gauze, sometimes two or more gauzes may be present in one plaster. The machine vision system needs to detect all of these defects and trigger a reject station on the line to remove the defective product. The Solution Using a high resolution camera system we managed to detect all of the defects. The results are displayed on a screen situated right next to the production line (with the pass/fail images saved in a folder on a network for later analysis / traceability purposes). Any defective parts were removed from the line at a reject station that is triggered by the camera....

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Pill Inspection

Posted in Diffuse Dome Light, Featured, Flaw Detection, Inspection, Medical, Precision Measurement, Presence/Absence

The Challenge: To check that all the pills have been formed correctly, that they are the right size, shape, colour and free from any defects (inclusions, voids, contamination … etc) Accuracy of the measurement needed to be within 10 microns and had to be a 21 CFR Part 11 compliant system. The tablet finishes also vary (coated (film), bright or flat finish, white or coloured, uncoated, printed, embossed, potential multilayers, etc.) so it has to cope with that as well. Our Solution: A turnkey vision inspection solution to check every pill, down to 5 microns. The vision tools checked the perimeter and the center (break) line of each pill for any defects. It can cope with most finishes and the most common tablet shapes as well (round, almond, caplet, triangular, oblong, octagonal, oval, square, pentagonal, tear).  The system checks...

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Phial Tray Inspection

Posted in Back Lighting, Featured, Inspection, Medical, Presence/Absence

The Challenge: A manufacturer in the pharmaceutical industry wanted to ensure that each tray of products was complete before final shrink wrapping and subsequent despatch. The system needed to be self-contained, CFR Part 11 compliant and require no operator input. Our Solution: A high resolution monochrome vision system was mounted directly above the phial tray and a backlight integrated into the conveyor system, underneath. The vision system inspects for the correct number of phials and automatically rejects any trays with...

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Pack Reading

Posted in 2D Datamatrix Reading, Direct Bright Field Illumination, Featured, Food & Beverage, Inspection, Lighting, OCR (Optical Character Recognition), Packaging, Uncategorized

The Challenge: Each pack has a label printed and applied to it and the 2D barcode and expiry date of each code needs to be read as the pack passes down a conveyor at a speed of 8m/min. The 2D code needs to be checked to ensure it contains the expiry date that is also printed on the pack. Information on the production / batch run is also contained within the code, this needs to be logged in a database located on the network for future trace ability. Our Solution: A complete turnkey solution was provided to the customer to be able to read, verify and record the information contained in each label....

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Optical Character Recognition

Posted in Automotive, Featured, Inspection, OCR (Optical Character Recognition)

The Challenge: The customer wanted to correctly identify 15 alphanumeric characters which had been laser marked onto the surface of an electrical component. The quality of the part marking was poor and the marked surface uneven in nature. Our Solution: A self-contained Vision Camera was used to correctly identified the characters and relayed the information to a PLC for verification of correct codes. The powerful in-built OCR algorithims were able to reliably read the codes even under these challenging conditions. Read rate...

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Needle Inspection

Posted in Back Lighting, Featured, Flaw Detection, Inspection, Medical, Object Location, Precision Measurement, Presence/Absence

The Challenge: To check that each needle is present in each off the plastic applicators, that they have been inserted correctly and not broken. Needed to be 21 CFR Part 11 compliant system. Our Solution: A turnkey vision inspection solution to check every applicator. The vision tools checked the presence, size, and position of every needle. The cameras are integrated to machine, PLCs and screens for the operator to help...

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Moulding and Printing Confirmation

Posted in Featured, Flaw Detection, Inspection, Object Location, Other, Precision Measurement, Presence/Absence

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Label Position Inspection

Posted in 1D Barcode Reading, Inspection, Object Location, Uncategorized

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Insert Detection

Posted in Automotive, Featured, Inspection, Object Location, Part Identification, Presence/Absence, Robotic Guidance

The Challenge: A moulded automotive housing travels down a conveyor at a linear speed of 10m/minute. Brass threaded inserts are pressed into the moulding at eight locations. Sometimes the inserts are incorrectly inserted or occasionally missing all together. The vision system needs to check that all inserts are present and correctly inserted into the part. Our Solution: A self-contained vision system locates the moulded part in 360 degrees of potential rotation on the conveyor. The inserts are then inspected as required. Any inserts/location that fails the inspection is relayed to operator in order for them to perform corrective action. This helped improved the factory automation on site and reduced human operator...

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Hot Cross Bun Inspection

Posted in Colour Inspection, Direct Bright Field Illumination, Featured, Flaw Detection, Food & Beverage, Inspection, Lighting, Object Location, Presence/Absence

The Challenge: Each tray of buns needed to be checked to ensure that the “crosses” were present (and in the right place and the right size) and that the bake was right (by checking the colour of the buns). All the information needed to be displayed to the bakery manager, in his office, and to the operator on the line so they could change the settings on the oven if they we’re not correct. This needed to happen at a rate of  6m/min on 600mm wide conveyor. The Solution: All buns were inspected successfully with a colour machine vision system. The camera were connected directly to the factory network so the images and results could be displayed to the bakery manager, and on a large display right next to the production line. Additionally  all the pass/fail images are stored on the network for production analysis at...

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Gearbox Inspection

Posted in Automotive, Diffuse Dome Light, Featured, Flaw Detection, Inspection, Precision Measurement, Presence/Absence, Robotic Guidance

The Challenge: A manufacturer of gearbox assemblies needed to guarantee a watertight seal . The assemblies  move on a an indexed conveyor and at various stations different operations to the gearbox take place. There are numerous variants of gearbox being assembled on the same line. At one station a 2mm bead of sealant is applied automatically by a robot. The sealant needs to be checked for presence, position, voids and any variations in its width. Zero defect assemblies are crucial in the assembly and the sealant is a major part of this. When a defect is identified an alarm needs to be triggered to prompt the operator to remove it from the line so it can be re-worked. Our Solution: The sealant is located, measured and checked for defects using a machine vision system incorporating a ‘bead detection’ algorithm. The results are displayed to the operator on a touchscreen and...

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Gear Inspection

Posted in Automotive, Featured, Flaw Detection, Inspection, Part Identification, Precision Measurement

The Challenge: An injection moulding process manufactures gears at a rate of 1 every 10 seconds. Each one needs to be checked to ensure there are no short shots, voids, contaminants or other formation defects. Our Solution: A turnkey machine vision inspection solution was designed to to check each gear. The system counted the number of complete teeth and checked for any defects in size, shape or inclusions. The cameras are integrated to a reject station, a network and information screens. Defective products are detected, rejected and an image stored on the network....

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Gasket Impurity Inspection

Posted in Automotive, Featured, Flaw Detection, Inspection, Presence/Absence

The Challenge: Moulded Gaskets travel down a conveyor at rates of up to 10 per second. Each one needs to be checked for any impurities that may have been included during the moulding process. Various different sized gaskets can travel down the same conveyor, so the vision system needs to be able to detect which size it is, and assign the tool checks accordingly. Our Solution: A self-contained turnkey vision system checks all the gaskets to ensure they do not contain any impurities. Any that fail the inspection are rejected from the conveyor and the information is relayed on to operators for them to perform the corrective actions. This helped improved the factory automation on site and reduced human operator...

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Fuse Box Assembly Check

Posted in Automotive, Colour Inspection, Featured, Inspection, Object Location, Presence/Absence

The Challenge: The machine vision system needs to be able to identify which fuses has been used in the fuse box and ensure they are all in the correct place. This needs to happen on the fly while the box is moving on a conveyor at a rate of 5m/min. The system needs to be able to connect to the network and recognise which job is being broadcast so it can ensure the configuration is correct for each instance. Our Solution: A high resolution colour vision camera was installed which detects the fuse types on the basis of their colour. The detected fuses are compared against the expected configuration and incorrectly inserted fuses are highlighted on the operator interface screen. The re-worked fusebox is placed back up-stream and rechecked by the vision...

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Food Label Reading

Posted in 1D Barcode Reading, Featured, Food & Beverage, Inspection, OCR (Optical Character Recognition), Part Identification, Uncategorized

  The Challenge: Product information is printed directly onto the outer case of food products as they travel down a conveyor at a speed of 10m/min. The information contains a barcode, the product’s weight, best before dates and the price. All of the information needs to be read and checked against the database and weight sensors situated on the line. Information on the product type is contained within the code, which also needs to be checked. All data needs to be logged in a database located on the network for future traceability. Our Solution: A complete turnkey solution was provided to the customer to be able to read, verify and record the information contained in the printed information....

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Fish Finger Inspection

Posted in Colour Inspection, Direct Bright Field Illumination, Featured, Food & Beverage, Inspection, Precision Measurement, Presence/Absence

The Challenge: The customer needed to check that every fish finger had the right amount of breadcrumb coating, that it was the right size, and was not deformed in any way.  These travelled down a 600mm wide conveyor at a rate of 100mm/second.  If a predetermined quantity of rejects are detected within a period of time then the system needs to be able to stop the line. Our Solution: A high resolution colour camera was used to inspect the entire width of the conveyor. Each fish finger was measured to ensure it was the right shape and size, and the coating of each was checked by checking the colour of it’s surface. All of the information collected was displayed on a screen on the side of the line and if the “critical” number of defects were  detected the line...

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ECU Assembly Inspection

Posted in Colour Inspection, Diffuse Dome Light, Featured, Flaw Detection, Inspection, Lighting, Object Location, Other, Presence/Absence

The Challenge: To ensure that certain components have been correctly assembled on the PCB. Our Solution: A high resolution colour camera and white LED dome light was used to acquire an image of each PCB. Major components, such as electrolytic capacitors, chokes and the semiconductor chips are checked for presence and orientation (capacitors).  Incorrectly assembled PCBs are rejected and the machine operator...

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Since our foundation in 1967, ABCON has supplied automation controls and sensor technology into most types of manufacturing process and industry sectors. We have always moved with the times, supplying the latest sensing technology as it becomes commercially available. Throughout our history we have continually formed alliances with some of the Worlds leading manufacturers of sensor technology.

vpteam@visionprojects.co.uk

+44 (0)114 244 2424

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