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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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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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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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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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Drive Plate Inspection

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

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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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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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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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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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Cashew Nut Colour Inspection

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

The Challenge: The customer was having problems with the nut roast time (under / over cooking) and they needed a system to be able to monitor it. The nuts travel through an oven on a conveyor and the roasting can be controlled by either the temperature of the ovens, or the speed of the conveyor (to reduce errors, the bake is controlled by the conveyors only). Initially they wanted the system to run independently of their ovens / conveyors but ultimately they would like to create a closed loop whereby the systems could connect directly to the conveyors, 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 average colour of the roasted nuts is analysed and based...

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Bottle Wrap Inspection

Posted in Back Lighting, Featured, Food & Beverage, Inspection, Object Location, Presence/Absence

The Challenge: At a rate of 100 bottles per minute, the machine vision system needed check that the  bottle wrappers were positioned correctly and that they had no significant defects in them (tears, holes or kinks). The solution needed to cater for approximately 20 different variants of sleve design and be suitable for a food grade (wash-down) environment. Our Solution: A self-contained vision inspection solution to check every bottle ‘on the fly’, at a rate of up to 120 bottles per minute.  The machine vision system checked presence, position, shape and consistency of every wrapper. The cameras are integrated to a PLC which operates a reject mechanism, thus providing containment of defective products. Images of any defects are displayed to the operator to help...

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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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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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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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Assembly Operation Inspection

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

The Challenge: An automotive engine manufacturer needs to check that operations have been carried out correctly during the assembly process. The assemblies  move on a an indexed conveyor and at various stations different operations to the engine take place. There are numerous variants of the engines being assembled on the same line. Zero defect assemblies are crucial in the process so nothing can be missed. 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 assemblies are checked using a turnkey machine vision system with various pattern recognition and contrast tools. The results are displayed to the operator on a touchscreen and transmitted to the PLC for further information processing. The camera is integrated to machines, PLCs and screens for the operator to help...

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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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