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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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Moulding and Printing Confirmation

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

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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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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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Dressing inspection pad position misshaped sterile pad

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

The Challenge The dressings are manufactured at a rate of 30 parts per minute and the travel down a conveyor. The machine vision system needs to check for the following defects: – A pad is present and  in the middle of the dressing – There is only one pad in each dressing – No significant contamination exists If any defects are detected, the pad needs to be removed from the line. The Solution Using a high resolution camera system we managed to achieve all of the customer’s requirements. 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...

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Cap Alignment Inspection

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

The Challenge: After bottles exit the filling line, the lids are screwed on each one at rates of up to 100 bottles per minute. The vision system needed to be able to operate in a wash down environment (ideally at least a IP65 system) and for each bottle the checks it carries out need to include: – that there is a bottle cap present – that the bottle cap has been screwed on properly (ie completely screwed on correctly and not cross threaded) – that the bottle cap has no significant defects in it. The system needs to trigger a reject station and let the operator know that a defect has been detected. Our Solution: A self-contained IP67 rated, stainless steel vision inspection solution to check every bottle cap ‘on the fly’, at a rate of up to 120 bottles...

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Connector Inspection

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

The Challenge: A manufacturer of electrical connectors needed to guarantee the correct print and number of holes were present on each connector head. The connectors are manufactured in a semi automated process and they produce hundreds of different variants, with new ones being designed every week. Therefore new connector configurations/jobs need to be easily programmed into the system. When a defect is identified this needs to be relayed onto the operator (with a display identifying the fault) so they can remove it from the line to be re-worked. Our Solution: A turnkey solution was created whereby the operators presented the connector head to the vision system after it has been assembled for it to be checked that it is correct and that there are no defects. To help easily train the system for new connectors, a front end was created for the operator to easily load...

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Washer Inspection

Posted in Featured, Flaw Detection, Inspection, Other, Precision Measurement

The Challenge: These  copper washers are manufactured at a rate of 5 per second. It is critical that no defects get sent to their customer (who will reject the whole order if this happens). The washers are 10mm diameter and typical defects are misshapes and burrs. Our Solution: We detected all the required defects. The Camera was connected directly to a reject station which removed any deformed products from the production...

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Tin Can Label Inspection

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

The Challenge: The cans (which are produced at a rate of one per second) have a label wrapped and glued around their circumference. Potential errors that can occur during this process include the label not being wrapped correctly (skewed, torn or completely missing), a second wrapper trailing behind the can (which should have been wrapped on the following can), or the wrong label being used. The vision system needs to be able to detect all of these defects, log them on the network, and display them to the operator working on the line. Our Solution: A turnkey vision system was created to identify any label defects. This connected to: – a reject station that removed the defects from prodcution – the network where is stored any failed images (with a date, time and production line stamp) – a display...

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Thread Inspection

Posted in Featured, Flaw Detection, Inspection, Other, Precision Measurement

The Challenge: Each screw needed to be checked to make sure it was machined correctly and defect free. The screws needed to be checked at a rate of 6 per second, as they were fed off a bowl feeder. Our Solution: Various dimensional measurements were carried out by a machine vision camera, eliminating the need for manual / operator inspection. The data obtained from each inspection was presented to the operator on a touch screen display. The pass/fail count of each batch was logged in a central database to ensure traceability in the future....

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Switch Print Quality Inspection

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

The Challenge: A machine vision system was required to check that the printed symbols on an automotive switch were complete and defect free.  Typical faults are missing symbols,  missing sections of a symbol and ink bleeding (over printed). The defects can be as small as 50 microns in size. Our Solution: A turnkey vision system was created to identify any print defects.  Failed parts were indicated to the operator so that they could subsequently be removed from the production line. All pass and fail images were saved on the network for quality monitoring purposes....

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Sweet Inspection

Posted in Back Lighting, Colour Inspection, Featured, Flaw Detection, Food & Beverage, Inspection, Lighting, Presence/Absence

The Challenge: A sweet manufacturer wanted to check the shape and colour of boiled sweets that they manufacture. They also wanted to check for any inclusions or defects that may have occurred during manufacturing. The sweets are being manufactured at a rate of 8 per second. The machine vision system will need to operate in a wash down environment so its important that the system is at least IP65 (ingress protection rating). Our Solution: A high resolution Stainless Steel, IP67 vision system was mounted directly above a backlight that was integrated into the conveyor system. The vision system inspects the sweets for the shape, colour, chips and inclusions and is connected directly to a reject station which automatically rejects any sweets that don’t pass the...

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Bottle Inspection

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

The Challenge: Each tray bottle needed to checked to ensure that: Each bottle needed to checked to ensure that: a) the bottle cap was present; b) it was correctly positioned; c) that it was not broken These are manufactured at a rate of 6 per second. Production data, such as current pass and fail rates,  needed to be displayed to the Engineering Manager that was situated elsewhere on site. Images of failed parts should also be displayed the operator on the line. The Solution: A self-contained vision system and associated backlight was used to inspect each bottle/cap.  The camera was connected to the factory floor network and its data and status could be viewed by management and operators, as required....

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Blister Pack Inspection

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

The Challenge: Medical blister packs are formed and filled at a rate of 3 packs per second. Each blister pack needed to be checked to ensure that: The right tablets/capsules are in the blister packs. That there are no missing tablets/capsules. That the tablets are not broken. The solution needed to meet the requirements of  CFR 21 Part 11 compliance standards. The cameras needed to be integrated to the PLCs / production line and reject mechanisms to ensure containment of the defective packs. Images of the defects need to be logged and displayed to the operator to help identify manufacturing faults. Our Solution: A turnkey vision inspection solution with a simple interface checked every pack at a rate of up to 5  packs per second. The cameras are enclosed in an IP68 rated Stainless Steel enclosure and the whole system meets CFR 21 Part...

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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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