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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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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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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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Robot Vision Inspection On A Panel

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

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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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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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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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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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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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Label Position Inspection

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

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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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Moulding and Printing Confirmation

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

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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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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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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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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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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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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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Datamatrix Reading

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

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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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