High Definition Line Scan Imaging Machine for Defect Inspection

EPIC designed, fabricated, and integrated a state-of-the-art 2K color line scan imaging machine. The company required detailed, high resolution product imagery for QA purposes. The system delivered market leading inspection capabilities and eliminated the need for in-person QA manufacturing facility visits.

Epic

Project Summary

  • Industry: Specialty Chemical (Agriculture)
  • Division: Vision Systems
  • Application: Damage and Defect Inspection

System Features

  • PLC-based integrated-control system with lab view programming
  • Revolving conveyor belt powered by servo drive motor
  • 2D Cognex barcode scanner for product batch identification
  • 2K color line scan cameras for high-resolution imagery

Engineering Challenges

  • Achieving clear product and defect imaging at high conveyor belt speeds
  • Accurate identification of product batches for inspections
  • Correct display of product images and filing of batch images
  • Incorporation of manual steps by the system operator

Project Impact

  • Solution exceeded the client’s high expectations for image quality
  • Minimized time-consuming product inspections and on-site visits
  • System clearly displayed qualities and defects in batched products
  • Achieved higher QA protocol than direct competitors

The Epic Solution

EPIC designed, fabricated, and integrated a state-of-the-art 2K color line scan imagery machine to showcase detailed product imagery in the highest possible resolution. The project successfully created a PLC-based integrated-control batch identification system that showed clear, high-resolution images of the products’ qualities and defects.

The system exceeded the client’s high demands and requirements for each image passing through the servo-powered product line. It achieved a higher QA protocol than the client’s competitors.

EPIC’s solution ensured that product inspection experts were sent detailed, high resolution images of product batches for Quality Assurance Inspectors to examine. The images were of such high detail it eliminated the need for these experts to visit each of the manufacturing facilities to conduct inspections.

Product batches were first scanned using a 2D Cognex barcode for proper identification. The cylindrical products were then moved along to a high-speed revolving conveyor belt, where the vision imagery process began after the system’s operator used the pressure-activated start button.

As the operator continuously placed product batches on the conveyor the system’s 2K color line scan cameras were activated. These cameras captured high-resolution images at the conveyor belt’s high speeds and displayed them on an HMI monitor programmed with lab view technology.

The client achieved a fully functioning batch identification system that provides high resolution images to showcase the qualities and defects of batched products. The fully automated vision system for uniquely shaped products allows the company to have a higher QA protocol than its competitors.

Process Systems

Machine Vision

Robotics

Industrial Automation