Rick Roszkowski 0000-00-00 00:00:00
Vision Systems Add Accuracy USING MACHINE VISION ENABLES MANUFACTURERS TO INSPECT 100% OF THEIR PRODUCTS AND ENSURE THAT DEFECTS DON’T LEAVE THE PRODUCTION FLOOR. .Machine vision is a powerful tool for managing and improving product quality, and the cost of using vision, both in dollars and engineering time, continues to move in the consumer’s favor. Today it is more affordable than ever to put machine vision to work on production lines where these systems can deliver powerful benefi ts. Consumers today expect perfect quality, even in low-cost items. Using machine vision enables manufacturers to inspect 100% of their products and ensure that no defects ever make it off the production fl oor. In addition to eliminating defective parts, machine vision also helps manufacturers error proof the production process itself, so that fewer bad parts are made. Vision systems collect volumes of real-time process data that can help operators monitor, analyze and improve how the equipment is working. Using vision to alert fl oor operators about processes that are starting to move out of tolerance allows them to correct the process before defects appear A GROWING RANGE OF OPTIONS Vision can be used in many ways to reduce defects and ensure quality. The most common is inspection, in which vision systems inspect each item and make sure a process was performed correctly, such as verifying that caps and labels are present on every bottleVision also can add greater consistency and accuracy in assembly processes with precise robot guidance and part alignment, and by verifying that critical dimensions are within tolerance. It can be used to identify items during production, either by physical appearance or by reading an identifying code marked on each item, to ensure the right part is being used in an assembly, or that the labels being applied to a container match the contents. The vision industry now has 30 years of hands-on experience with manufacturing applications in a range of industries. This increased understanding of manufacturing processes has driven machine vision companies to build a diverse range of products suited to the specifi c quality control and inspection needs of manufacturers. Manufacturers today have an unprecedented wealth of options when it comes to selecting a machine vision system or vision sensor; whether they need programmable software, a plug-and-play smart camera or specialized ID reader, there is a system available to do the job, and these systems can be purchased in a wide range of resolutions, speeds and price points to meet the application’s needs. Today, even the most affordable solutions can be extremely powerful. There are dedicated presence/ absence vision sensors that can inspect multiple part features simultaneously at speeds of up to 6,000 parts per minute. These inspection tools are the right option in many cases where a general purpose vision system with more capability is unnecessary FACTORY COMMUNICATIONS The adoption of component object model (COM) technology and ActiveX controls starting about 10 years ago greatly simplifi ed how customers linked together devices fromMany different companies to have them all communicate effectively. More recently the transition to Ethernet and adoption of open network protocols like EthernetIP, Profi net, ModbusTCP and MC Protocol has allowed easier integration of sensor products into the control platform. This improvement in factory communications delivers some signifi cant benefi ts to operators. Vision systems collect data that factory fl oor managers can use to analyze their work in process or quality metrics. Today, it is possible to communicate that data easily to other factory controllers to help speed correction of process errors or archive quality information. Imagine a vision system inspecting label placement on bottles. The vision system can be set to send position data back to a controller, which can be programmed to send an alert to operators when labels begin to move out of tolerance, effectively enabling operators to take corrective action before the defect occurs. Also, it is now possible to easily save defect images and other graphics directly from vision systems to remote fi le servers. Stored images can be used for future failure analysis and troubleshooting. The trend toward GigE will further benefi t vision systems as image resolution increases and production line speeds increase. Bandwidth improvements also have enabled companies to transmit larger volume data at high speeds. Increasingly, quality engineers have an unprecedented wealth of qualitative data—not just pass/fail—to work with in order to analyze and improve their processes. Brand reputation is more important than ever, not just with consumers. Large buying organizations often refuse to do business with any supplier whose quality has been questioned. Vision systems give manufacturers the tools they need to guarantee product quality and provide proof of product quality to their customers.
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