FEATURE MACHINE VISION
INTELLIGENT FEEDBACK SENSOR for real-time processes
To simplify integration of different elements in a machine vision system one specialist is using cost-effective FLIR cameras whenever possible in its smart hardware module
S
etting up a machine vision system and making all the different elements work
smoothly can be complicated and expensive. To simplify this integration process Eigen Innovations (a specialist in real-time monitoring solutions for many industries) has developed a smart hardware module and whenever possible the company likes to include FLIR cameras exclusively because they are so cost- effective. Eigen Innovations systems make factories smarter by capturing real-time data from the factory floor and applying advanced analytics to improve operating processes automatically. This boosts productivity and ensures quality while reducing operating costs.
EASY INTEGRATION Building a monitoring and alarming system for fixed mounted automation is complicated because every application is different and this was the driving factor behind Eigen’s Smart Module (ESM). It was designed to eliminate the need for custom integration and provide rapid deployment. A robust thermal camera module, ESM is based on the FLIR A-Series product which uses the GigE Vision standard for fast image transfer using low cost standard cables, even over long distances. It allows for easy configuration of
temperature thresholds, enables PLC communications and performs temperature-based calculations on designated points of interest. A self-learning system, ESM can be used
as a standalone solution or as part of a larger system architecture and for more complex processing the module collects training data from the thermal camera, informs data in the cloud and then acts upon that knowledge. In effect, the software writes itself. “We discovered the FLIR A-Series at a
trade show and quickly realised this product is so much more than just camera; it’s an intelligent feedback sensor for real- time processes,” explains chief technical officer and co-founder of Eigen Innovations Scott Everett. “The great thing about this camera is that you can see the complete temperature distribution of an object not just one temperature point that thermocouples show you. This results in a
24 SPRING 2017 | IRISH MANUFACTURING
need to be controlled have a fixed position. In this case however, the quality check is initiated on a moving production line as the car comes into view. That is why the algorithms integrated into the ESM module need to determine the position of the car first. A further example is outdoor monitoring of sulphur piles to prevent self- combustion. FLIR cameras are used to look for hot spots indicating a potential outbreak of fire. Eigen’s module is particularly useful here for improving the detection performance and for reducing the number of ‘false positives’ such as a bird flying registering a heat source. The ESM can train the system to determine whether the heat signature belongs to a bird, truck or an actual fire.
huge amount of data complemented by other sensor information like pressure, speed and moisture. Our module combines all these information streams and makes sense of them.” Eigen Innovations’ ESM is suitable for a
variety of automation applications including parts manufacturing, pulp and paper production, food processing, fire prevention and condition monitoring. A typical example of its successful
deployment comes from an automotive manufacturer who is using the system on a car assembly line to detect any problems with the rear screen defogger; the defogger is turned on and the FLIR A- Series camera checks whether the heater bands are functioning effectively. In a normal automation set-up the parts that
The EIGEN module and FLIR thermal camera can be used for
automation applications including monitoring cheese quality
POWERFUL AND COST EFFECTIVE “We are very happy with our choice of FLIR A-Series and in particular the FLIR A65 which generates excellent high resolution images,” continues Everett. “It is impressive how something so powerful can be built so small.” The cost efficiency of the FLIR cameras
You can see the complete temperature distribution of an object not just one temperature point that thermocouples show
means Eigen Innovations can now easily include three or four cameras in an installation. The camera can replace a conventional line scanner application. The difference is that a FLIR camera is not just scanning one line, it is presenting a complete image. The inclusion of thermal cameras in its systems makes the sales job easier. Sales cycles tend to be very long but Scott Everett confirms a thermal image clearly demonstrates what’s happening in the production process and often hastens decision making. “In our line of work there is much talk about the industrial internet where complex machinery is connected to networked sensors and software,” concludes Everett. “To use the data to its full potential we fundamentally need qualitative sensors that deliver qualitative data and in that respect I believe FLIR and Eigen Innovations are facing a very exciting and promising future.”
FLIR Systems T: 01732 220011
www.flir.com
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