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Collet Leg Check

Posted in Automotive, Dark Field Illumination, Featured, Flaw Detection, Inspection, Lighting, Precision Measurement, Video

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Ceramic Ring Inspection

Posted in 3D Inspection, Featured, Flaw Detection, Inspection, LMI, Other, Precision Measurement, Video

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Bead Tracking

Posted in Automotive, Cognex, Featured, Flaw Detection, Inspection, Object Location, Precision Measurement, Presence/Absence, Robotic Guidance, Video

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Reliably Verify 2D Data Matrix Codes

Posted in 2D Datamatrix Reading, Automotive, Cognex, Featured, Flaw Detection, Inspection

The industry now has standards to reliably verify 2D Data Matrix codes. What metrics and methods can you use to assess a mark’s overall quality? By Carl W. Gerst III, Cognex Corporation, Senior Director & Business Unit Manager, ID Products INTRODUCTION Conventional bar codes (such as Universal Product Codes, or UPCs) have gained wide acceptance in applications ranging from checkout and inventory control in retail sales to tracking printed-circuit-board serial numbers in electronics manufacturing. To increase the character content and to store the information in smaller spaces, companies have developed two-dimensional alternatives. One of these, called Data Matrix, adopted as a standard, places square or round cells in a rectangular pattern. Its borders consist of two adjacent solid sides (the “L”) with the opposite sides made up of equally spaced dots. This symbology allows users to store information such...

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Verify & Monitor Direct Part Markings

Posted in 2D Datamatrix Reading, Automotive, Cognex, Featured, Flaw Detection, Inspection, Part Identification, Video

The Challenge: The customer wanted to read and verify 2D datamatrix codes that have been laser marked and / or dot peened onto the surface onto machined surfaces. The laser marked codes were not too much of a problem as there are no wear parts on the laser marking system. However, the stylus on the dot peen marker wore and as a result the quality of the code deteriorated. All codes marker need to meet at least a grade C on the AIM-DPM standard. Zero defect assemblies are crucial in the process so every code needs to be successfully read, therefore the code quality must meet the standards. When poor quality code is identified an alarm needs to be triggered to prompt the operator to remove it from the line so that the stylus can be replaced and the...

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Spot the Difference

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

See if you can spot the differences between these two images (hint … there’s 5), watch the video for the results....

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Barbie Vision

Posted in 3D Inspection, Featured, Flaw Detection, Inspection, Object Location, Other, Precision Measurement, Presence/Absence, Video

Get in touch with us to have a look at your vision application. The Vision Projects...

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Saw tooth blade inspection

Posted in Back Lighting, Featured, Flaw Detection, Lighting, Other, Precision Measurement

The Challenge To check saw teeth have been formed correctly, this needs to happen while the blade is moving at a rate of 6m/min. Defects are typically malformed teeth and material cracks. Our Solution We manged to detect all the defects on the saw blades. Additionally, if five appeared consecutively (indicating that there was a problem in the formation tools) the line was stopped. All results are displayed to the operator for analysis, to help determine where the fault...

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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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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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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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Robot Vision Inspection On A Panel

Posted in Automotive, Featured, Flaw Detection, Inspection, Object Location, Presence/Absence, Robotic Guidance, Video

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3D Tyre Profiling

Posted in 3D Inspection, Automotive, Featured, Flaw Detection, Inspection, Other, Precision Measurement, Video

A true breakthrough in the world of 3D profiling. Up to now, this solution was created by projecting a laser line on the profile, and then monitoring that line with a vision system. The obvious problems with this are that you would need to re-calibrate the system for every set up … this system eliminates the need to do...

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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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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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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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Drive Plate Inspection

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

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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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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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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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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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