Imaging software


A vision system was constructed to validate ceiling profiles. The profiles are validated for correct dimensions, connection points, paint and dents in the surface.
Each profile is verified and accordingly sorted into three main categories: Accepted, Dirty and Damaged.
The ceiling profiles are transported on a conveyer running at the speed of up to 60 m/min., passing approximately 20.000 profiles per production line per day.

Vision System
The Vision system is divided into four main components: a "product quality decision maker", and three specialised "product inspectors".
The Server (the decision maker) gathers information from each of the Clients (product inspectors), on which it decides if the product should be passed on to automatic packaging or be sorted out.
To allow different products to be inspected and provide flexibility, the system was designed to be completely configurable, allowing the operator to specify the position, sensitivity and tolerance on each measurement.
To keep track of the production and faults, the vision system generates a report for each production shift, listing each detected fault, statistical data on the faults and the total production down time.
Based on the statistical data, the server can automatically stop the production if either a specific or an overall group fault occurs repeatedly, allowing the operator to quickly correct the production tools.

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In terms of hardware, the vision system consists of :
  • A computer rack containing industrial computers, monitor etc.
  • A gallows fixing cameras, light and lasers.
  • Line scan cameras, measuring dimensions and painted surface.
  • Fibre line guide and solid state light sources.
  • Lasers, performing touch free distance measurement on the profile surface.
  • PLC Interface, to the production and sorting machines.
Checking dimensions
The connectors at the product ends are measured and verified, and the connection holes are counted, by a Line scan camera.
For illumination, a fibre guide line was used for transmitted light, providing quality contour image of the product. A solid state light source was used for reflective illumination, highlighting the edges of the pressed shapes in the connectors.
All measurements are performed with an accuracy of 0,05 mm.

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Touch free distance measurements
The surface on the profiles is checked for dents with a resolution of 3 um, down to a size as small as 10 um. In the direction of movement the profiles are measured for each 0,05 mm.

Detecting oil, dirt, dots and scratches
The surface on the product is check for dots, scratches, oil and paint quality. Again the spatial measurements are performed with an accuracy of 0,05 mm.

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