Vision Systems and Lighting

Detect

Candle Label Detection

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Detecting a product label is a common application in automation. That effort can be made more difficult as the demand for attractive packaging results in inconsistent shapes and colors. In those situations our experience leads to unique solutions.

Cap Detect

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A common application for vision is verifying whether a cap is present and in its proper position. In this application the customer needed a compact camera with red lighting. The camera and its cables also needed to be able to withstand heavy washdown with srong cleaning agents. Sensors Integration specified the Cognex 7050, a Smartvision IP69K Red Brick ...

Full Description

A common application for vision is verifying whether a cap is present and in its proper position. In this application the customer needed a compact camera with red lighting. The camera and its cables also needed to be able to withstand heavy washdown with srong cleaning agents. Sensors Integration specified the Cognex 7050, a Smartvision IP69K Red Brick Light and an APG IP69K camera enclosure.

Detect Straw on Drink Box

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In addition to the obvious customer service reason, monitoring the straw position is critical to keep the packaging process from malfunctioning. A straw protruding from the carton can jam cartoners or shrink-wrappers. Baumer's VeriSens camera, used in conjunction with lighting that only illuminated the straw, is a rock solid solution.

Ice Cream Ingredient Monitoring

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To prevent errors in the ingredient mixing process at an ice cream plant, the Basler Scout GigE camera was used to scan each bag of dry ingredients as it was conveyed to the mixer. Used in conjunction with conveyor controls, the customer's SQL database of the hundreds of different ingredients, and the Cognex VisionPro, manufacturing errors were nearly ...

Full Description

To prevent errors in the ingredient mixing process at an ice cream plant, the Basler Scout GigE camera was used to scan each bag of dry ingredients as it was conveyed to the mixer. Used in conjunction with conveyor controls, the customer's SQL database of the hundreds of different ingredients, and the Cognex VisionPro, manufacturing errors were nearly eliminated and throughput increased.

Gauging and Measurement

3D Riverbed Imaging

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A large university was trying to conduct riverbed research. The objective of their application was to be able to measure the topography of the silt on the bottom of a river, and study how it changed over time. Ultimately, the university would like to have a clean 3D image of the riverbed floor. The challenge the university faced was finding a device ...

Full Description

A large university was trying to conduct riverbed research. The objective of their application was to be able to measure the topography of the silt on the bottom of a river, and study how it changed over time. Ultimately, the university would like to have a clean 3D image of the riverbed floor. The challenge the university faced was finding a device that would be able to give them accurate measurements of the river bed in 3D, quickly, with a high number of data points. Needing to consult with experienced vision experts to find the right product, they brought their application to Sensors Incorporated. Click "Documentation" for the complete PDF!

Broken Drill Bit Detection

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To help a customer detect when they had a broken drill bit to avoid damaging their equipment or the stock, Sensors Integration used a camera to measure the length of the drill bits in the fixture.

Guidance

PLB Parts Location in Bin

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Guiding a robot to find and pick up an object usually requires substantial programming, with little flexibility for revision. The PLB solves that problem by offering a flexible CAD-based teach-in of new parts without the need for programming. New applications can be configured within an hour.

Identification

Barcode on Ice Cream Tub

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A customer was having difficulty reading a barcode on the lid of a pail of ice cream. The problem was that multicolored (neapolitan) or dark (chococolate) product behind the translucent lid lowered the contrast between bars and spaces, making it impossible for the laser scan line to read the code. Using the Cognex Dataman 2d imager with its internal ...

Full Description

A customer was having difficulty reading a barcode on the lid of a pail of ice cream. The problem was that multicolored (neapolitan) or dark (chococolate) product behind the translucent lid lowered the contrast between bars and spaces, making it impossible for the laser scan line to read the code. Using the Cognex Dataman 2d imager with its internal lighting, they were able to successfully read the codes regardless of the colors behind the barcode.

Datalogic Pattern Sorting Tool

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Datalogic's new pattern matching tool, the PST (Pattern Sorting Tool), is a new approach to sorting applications. This patented algorithm is able to find thousands of different patterns in an extremely effective way, allowing products to be sorted regardless of orientation, perspective distortion, or partially obscured targets.

Date Code OCR

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A camera is used to verify that a date code is both present and accurate. This is used with our Fail-to-Safe CRIS system to prevent mislabeled product from getting into the hands of customers.

OCR for Serial Number

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A camera with Optical Character Recognition is used to read the serial number on a label to track the product from manufacturer to end user.

Inspection

Clear Membrane Inspection

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Demand for smart phones, tablets, monitors and flat screen televisions has created the need for cameras, lenses and processors that can detect microscopic flaws or cracks on or within the material. An array of Dalsa's Piranha HS-12k/5.2micron 256-stage TDI cameras scan at a line rate of 90kHz to cover the entire glass / membrane.

Foil Packaging Lighting for Inspection

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To confirm that foil wrapped cheese is properly sealed, a vision system is used to inspect the flaps. Unfortunately, the reflectivity of the foil (lower left image) makes that inspection difficult. The solution was a CCS America diffusion plate, which eliminated the harsh reflections.

Ovality Inspection

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For manufacturers of rod, pipe and tubing, monitoring the ovality of the product as it leaves the die is important for quality and process control. In this application, three of Basler's Ace GigE cameras were used at 3 different angles around the product, opposite 3 collimated light sources.

Snap Ring Inspection

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A manufacturer needed to verify that two snap-rings and a washer were in place before the fixture could move to the next station. Using a backlight, the camera was programmed to look for the stacked parts to verify their presence. If the stack was too short, or if there was a silhouette out of place, it was a fail.

Operator Inspection Stations

Catheter Inspection Station

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A local medical technology company found a re-occurring issue with their production process. As they manufactured their tube devices, they would experience stresses in the sheathing, which could later result in tears and breakages. To solve their production problem, they turned to the experts at and Sensors Integration.

Motor Test Fixture

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To test the electrical and emissions of a motor, a fixture was designed. To identify the motor, datamatrix codes are printed on tabs where a 2D imager can read them. Cameras and sensors verify that all components are present and that they match the data from the 2D code.

Lighting for Machine Vision

Machine Vision Lighting for Limited Space

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Lighting is the critical element in machine vision applications. You can benefit from Sensors Integration's experience with many challenging lighting applications. For example, Smart Vision's T-slot LEDs can be integrated directly into the slots on the existing extruded aluminum mounting frame.

Pattern Projectors for 3D Vision

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LED Pattern Projectors from Opto Engineering and Smart Vision Lights are designed for 3D profiling and for the measurement of objects with complex structures or inclined planes. They are successfully used in applications like quality control for food and packaging, reverse engineering, dimensional measurement of electronic components, and robot guidance ...

Full Description

LED Pattern Projectors from Opto Engineering and Smart Vision Lights are designed for 3D profiling and for the measurement of objects with complex structures or inclined planes. They are successfully used in applications like quality control for food and packaging, reverse engineering, dimensional measurement of electronic components, and robot guidance for pick and place and alignment applications.

Vision System Lighting

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When a vision system is having difficulty due to changes in the target (speed, size, finish, texture, color, etc.), updated lighting can often help the system continue to perform.