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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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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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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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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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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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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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