Feature Machine Vision Turning up the heat
As a solution for the process and packaging market, Multipix Imaging is specifying the A5 thermal imaging camera from FLIR for use in combination with HALCON machine vision software
ecause process plants and pack- aging lines are required to be ever more resourceful with their con- tinuous improvement pro- grammes, the trend towards automation is now almost omnipresent. However, one of the common obstacles encoun- tered when looking to implement automation is a distinct lack of space. “Size was a major factor when we were sourcing a suitable infrared thermal imaging camera to partner with HALCON software,” said Multipix Imaging director, Julie Busby. “However, not only is the FLIR A5 extremely compact and good value for money, it also offers the plug-and-play compatibility of a GigE Vision interface, which means we can link directly to HALCON without any need for a separate frame grabber.” GigE Vision is a camera interface standard developed using the Gigabit Ethernet communication protocol. It is the first industrial standard to allow for fast image transfer using low cost standard cables, even over long distances. With GigE Vision, hardware and software from different vendors can interoperate seamlessly over GigE connections.
B
Automated infrared radiation imag- ing offers a vast potential for improv- ing a host of industrial production applications, including process moni- toring and control, and quality assur- ance. For instance, take a robotic gluing operation on a clay coated paperboard or plain corrugated pack- aging line. Using FLIR thermal imag- ing technology it is now possible for a camera to detect glue beads and verify seams. Before now, this was virtually impossible because adhe- sives for the packaging industry are almost always clear or opaque, making them difficult to view using standard vision cameras as these require a contrast between materials. Conversely, infrared radiation is
S6
emitted by all objects at temperatures above absolute zero. FLIR cameras convert that infrared radiation into a visual image that depicts thermal variations across an object or process.
Testing
Efficient ways of testing glued together boxes on high speed packag- ing lines are scarce - most tend to involve destructive testing on ran- domly selected samples, which is slow and cumbersome. In addition, glue application has a good deal of variability that is best monitored and recorded using statistical quality con- trol routines. Using a thermal imaging camera, images can be digitised and stored in a database for trend analysis and equipment monitoring. Ultimately, temperature is used to replace mechanical methods of inspection and testing.
A thermal image can easily detect incorrectly sealed boxes. It can also detect the correct positioning of glue spots and indicate failed boxes to remove from the line. Furthermore, a pass/fail process can be implemented that sounds an alarm in the event of pre- defined failures, thus helping prevent unscheduled down-time or the intro- duction of poor quality products into distribution. Similarly, because many manufacturers place more adhesive on their packages than needed for insur- ance purposes, the use of such a system allows tighter adhesive specifications and therefore reduced material costs. Using the measurement tools in HALCON, the list of potential benefits is expanded. For instance, it is possible to not only check the presence and integrity of a continuous glue bead, but also its position, width, height and straightness - all achieved within mil- liseconds. If there is a problem with the glue gun, for example, this feedback-
Above: the Multipix combination of HALCON vision software and a FLIR A5 thermal imaging camera provides peace of mind and savings in rejections from the retailer and/or end user
dissatisfaction
based system can stop the process before an entire batch of packaging is completed incorrectly and has to be subsequently scraped.
The system can also help identify trends for maintenance purposes. Incorrect bead size, position and occa- sional gaps can be detected and recorded, permitting scheduled pre- ventative maintenance instead of unscheduled corrective maintenance and the associated production down- time this incurs.
Packaging lines today are an integral part of modern manufacturing. Carton building, tray making, case erection and sealing have all become highly automated, complex operations. Growing innovation and intricate designs have become typical, placing increased requirements on the previ- ously simple adhering and sealing process. What’s more, recycled materi- als, complex coatings and finishes have seen the introduction of specialist hot melt adhesives, which on occasions can make adhesive application set-up and operation more difficult.
Among additional capabilities of the HALCON-FLIR solution are pattern matching, grading applications and adhesive temperature checking. Ease of use is another principal factor likely to score well. Using HALCON’s Image Acquisition Assistant, plugging in a FLIR A-Series camera will prompt the user to ‘detect’ and ‘connect’. Two clicks are all that’s needed to get up and running. “The use of FLIR thermal imaging for industrial automation projects could potentially be revelatory in many applications,” said Busby. “It is even possible to combine thermal and 3D vision cameras in the same system. This way, data from the former can overlay data from the latter. The result is a powerful solution that can monitor glue beads and seals using infrared, and deploy 3D vision for shape and content checking.”
The benefit of a combined camera verification system such as this is that a single set-up by the operator would be enough to permit the two systems to operate in conjunction with each other: are the glue runs in the correct place? are there any gaps? is the machine feed correct? If a manufac- turing log is required for the benefit of customers, then an integrated camera solution is the answer.
Multipix Imaging
www.multipix.com T: 01730 233 332
Enter 230 OCTOBER 2013 Machine Vision
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72