FEATURE SOFTWARE, SCADA & DATA ACQUISITION
SCADA allows for precision in medical device manufacturing
The importance of data control accuracy is a requirement in most industries. Therefore recording data at each stage of the manufacturing process ensures a traceable product, and allows for an assurance of quality on every item. However, this recording this as part of an efficient production process can become more challenging when multiple layers of data are required. By Claire MacLean, business development, SP Technology
S
upervisory control and data acquisition (SCADA) is a control system of
software and hardware components that helps manufacturers to efficiently process data and communicate system issues, that ultimately mitigates downtime. SCADA solutions are used across many industries, and Dundee based SP Technology has designed a solution for the medical industry using a Beckhoff XTS system – the largest of its kind in the UK.
THE CHALLENGE Accurately labelling medical devices (the likes used to ease asthma attacks) was the challenge faced by the customer and to monitor data from every device. This required recording the 3D printed product barcode during loading, and matching this with the 3D barcodes on the labels, ensuring batch traceability on every device. With over 90 devices processed per hour, the customer required a system that could reliably monitor and record this data, while not deterring production output.
THE SOLUTION Designing a concept for a bespoke manufacturing system was the solution to the problem. Developed using three of Beckhoff’s XTS systems, controlled by its Twin CAT 3 software, measuring at over 14 metres long, the design involved passing the devices through a series of cells using mechanical, servo, labeling and vision equipment technologies. This system consisted of three cells: the first applying a cap label, the second a body label, and the third cell applying a bung label. The machine loaded eight devices at a
time from a stack of trays inputted by an operator. Each XTS mover holds up to three trays, that once loaded, travel to the
48 JUNE 2018 | AUTOMATION
The success of this project is the result of the collaborative approach of SP Technology, Cognex and Beckhoff Systems
first labeller. If the label is presented skewed a servo device re-orientates the label, then sends the center position of the label to the XTS mover to be recorded. A ‘pass’ or ‘fail’ result is attributed to every device as it travels through the machine that allows the devices to be tracked. When the devices are either rejected by the robot, or placed onto the output conveyor, all of the data corresponding to each operation performed throughout the machine is recorded and appended into a .csv file, available to the operator once the batch has been completed. The information supplied to the
operator includes all of the devices that have passed through the system in the current batch. This includes a history on which devices have passed or failed any points in the process, allowing the
operator to investigate what areas are potential hotspots for failure that might indicate a faulty station.
THE RESULT Collaborating with suppliers allowed SP Technology to develop this automated solution. The system’s exacting requirements compensated for inaccuracies in the labels supplied on reels, and enabled us to position the XTS movers to within +/- 0.2mm accuracy that allowed the reel to be moved should it begin to drift. Using a combination of Cognex vision systems, we were able to pass the label positions obtained from the vision systems into the XTS system, ensuring accuracy on every label. As there was no guarantee of the label position radially (theta axis), we also developed a servo orientation label placement head to detect and correct the theta position. This enables the user to identify additional offsets, and using the Beckhoff control system, orientate or wipe the label into place. The Cognex vision system also allows
the operators to connect remotely to each vision system. The operator can then record any failures, and make any necessary adjustments to the equipment that may be required. The success of this project is the result
of the collaborative approach of SP Technology, Cognex and Beckhoff Systems. By fully understanding the challenges faced by the client, a bespoke solution was developed using up-to-date technologies to capture data and whilst ensuring maximum production efficiency.
SP Technology T: 01382 880088
www.sptechnology.co.uk /AUTOMATION
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