A flexible approach to inspection
A flexible approach to inspection
Keywords: Inspection, Machine vision
In the current manufacturing climate, the pressure for greater productivity and better quality is forcing companies to look to new technologies for solutions. Vision systems have been used for many years, but until recently have tended to be too expensive or unable to perform complex tasks.
Machine vision systems save manufacturing companies' time and money by increasing the output of saleable product, eliminating operator handling and ensuring that no defective product reaches the customer. Their inherent reliability and consistency means that product quality can be maintained day after day.
Over the last few years, "smart" camera systems have attempted to satisfy these inspection needs. These cameras integrate image acquisition and processing into a single unit. They can be programmed using a selection of preset tools, giving a pass or fail result. Although useful for simple tasks,this approach is limited by the systems' lack of flexibility and customisation. User interfaces are often primitive and cannot be modified to fit in with existing production systems.
PC-based vision systems offer a far greater level of sophistication. Systems can be developed from a vast range of well proven image hardware and software. Custom software and methods can be easily added to provide the exact functionality required. This gives the customer the feel and presentation that suits their production environment. Systems can be upgraded, reprogrammed and expanded to suit changing production requirements. This protects the customer's initial investment in the equipment.
Since the core of the system is a PC platform, the vision system can take advantage of the wide range of available peripherals. This can include printers,networking, high resolution displays, data storage, digital communication and touch screens. The vision application can also be integrated with a number of different programs including SPC packages, graphing tools and SCADA. The system could even be made to e-mail your maintenance staff a service request!
APS Vision develops custom-built automatic inspection equipment for use in many manufacturing sectors. APS designs flexible systems identifying defective products and removing them from production lines. These defects can include incorrect assembly, contamination, surface finish and malformed parts. Adam Brown, a systems engineer at APS said, "We provide systems that can detect faults at the early stages of production, saving time and money for our clients. Our flexible system architecture provides a superior, future proof solution compared to other vision systems".
A major automotive company TRW, has recently taken advantage of this approach. They had a requirement to accurately verify the correct assembly of seatbelt retractors (Plate 1). The system was developed to check the colour,shape and position of a number of components. A major aim was to provide a high level of flexibility when configuring the system. This was achieved by the development of a custom interface based around the companies' own terms and conventions.
Plate 1Flexible assembly verification system (FAVS) for TRW
Three systems have been successfully installed at TRW's Peterlee plant. Steve Jones, manufacturing engineer at TRW said, "The vision system developed by APS gave us all the features we wanted at the right price. The system is able to cope with the wide range of products we manufacture now and in the future".
The network capabilities of the vision system have enabled TRW's engineering support to remotely monitor all three from a single PC away from the factory floor. The engineer can observe, change settings and view inspection results without interrupting production. Modem options on the system allow APS Vision to do the same thing from their offices.
A good example of the flexibility of APS Vision's approach is the additional functionality added to the TRW system since installation. A further camera was added to check additional features. This was added into the existing vision system at a minimal cost, unlike a "smart" camera where you pay again for a complete inspection system. In addition, a part code printer was added to the production cell. The vision system provides the printer with the current part code, eliminating possible operator error.
APS Vision Limited have provided solutions for companies ranging from British Energy to Waterford Crystal. A flexible approach to quality control maximises product lifetime and keeps you at the forefront of automated inspection technology.
For further information contact: APS Vision Limited, Sunderland Business and Innovation Centre, Wearfield, Sunderland SR5 2TA, UK. Tel: +44 (0)191 5166233;Fax: +44 (0)191 5166234; http://www.apsvision.com;E-mail: apsvision@bicne.co.uk
