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Mesh Inspection

Posted in Back Lighting, Featured, Flaw Detection, Inspection, Other, Precision Measurement, Presence/Absence

The Challenge: To check that all joints in a continuous web of metal mesh material. Also, to check the formation of each ‘diamond’ to establish correct size and shape. This needs to be done while the web is fed past at a rate of 5m/minute. The system needs to detect any deviations in the web to an accuracy of 0.5mm. Our Solution: A 2K line scan vision system that continuously acquires small “slices” of the web as it moves past and stitches them together to form a large image that is continuously checked for defects. The camera is integrated to a PLC and green / amber /red traffic light warning system, allowing the operator to make adjustments to, or stop the...

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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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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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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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Moulding and Printing Confirmation

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

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Braille Printing Plates

Posted in Dark Field Illumination, Featured, Inspection, Object Location, OCR (Optical Character Recognition), Other

The Challenge: To be able to detect and identify the braille characters marked on the surface of a metal plate. Our Solution: The braille alphabet was pre-programmed into the database for reference once the characters were identified with the machine vision system and lighting solution. Using a Dark Field Lighting Technique we were able to identify the braille characters on the surface of the product. The light does not fall directly onto the objective and the majority of the region of interest is dark, while the affected areas on the surface, the braille characters, appear bright. Once the impressions were identified and segmented, they were then referenced to the database and the string of characters were identified. Find out more about the European Braille Packaging Font Standards, and download font sets at...

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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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Bread Inspection

Posted in Colour Inspection, Diffuse Dome Light, Featured, Flaw Detection, Food & Beverage, Inspection, Presence/Absence, Uncategorized

The Challenge: Our customer wanted to be able to check the colour of every loaf to ensure that the ‘bake time’ was correct. The loaves exit the oven in batches of 12 tins.  The customer wanted to introduce a ‘closed loop’ system whereby consistent under or over baking adjusted the conveyor speed through the oven in order to compensate accordingly. Our Solution: A high resolution, colour area scan camera was installed along with diffuse LED lighting. The colour of each loaf in the batch is analysed and based upon statistical trend analysis the control system PLC adjusts the line speed as required. Additionally, individual loafs which fall outside acceptable colour limits are rejected from the line downstream. If more than 5 consecutive loafs are rejected the camera sends an ’emergency’  signal to the PLC so that the operator knows there was a major problem on the...

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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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Barcode Reading

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

The Challenge: A printer generates a product label ready for application onto a product. Prior to application, each label needs to be inspected to ensure that the print quality and the information  printed is of suitable quality and correct. The labels index at a rate of 2 per second. Our Solution: A high resolution camera system was employed to read the label information using OCR (optical character recognition) and also to grade the barcode to the ANSI standard. Labels with either incorrect, partially missing data or poorly graded codes are marked by an inkjet marker and removed from the line prior to...

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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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Cosmetics Cap Moulding Check

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

The Challenge A manufacturer of shampoo products need to check that the cap on every bottle was securely closed prior to packing and final despatch. Our Solution A high speed camera system was installed which checked each bottle on the production line at a rate of 5 bottles/second. Any bottles with unclosed caps are automatically rejected from the line using an air based rejection...

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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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Datamatrix Reading

Posted in 2D Datamatrix Reading, Featured, Inspection, Other, Part Identification

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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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Drive Plate Inspection

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

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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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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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Sandwich Assembly Inspection

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

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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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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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