Products and applications of machine vision systems
This section contains a summary of case history, products and solutions already developed.
Inspection machine of plastic flacon labels
The inspection machine has been designed to verify, in production line, plastic flacon labels of different formats, dimensions and colours.
The machine is based on two matrix cameras, multispectral illuminators that are automatically configured based on the production recipe, one cabinet and a touch monitor for the HMI.
The machine vision system is connected to the production line server by a PLC and is suited to inspect the label conformity, to detect the identification code at 7000 pc/hours velocity and to sort NOK products through pneumatic sorting.
As well as all Novasis inspection machines, it is equipped with remote communication module.
Conveyor tracking of food supplement sachets and bags
The machine vision system comprises one scanning camera, one LED illuminator and a fanless industrial PC.
X and Y coordinates and θ angle -respect to the centre- are calculated for each sachet or bag and provided to a DENSO scara robot which pick them on-the-fly.
The system is characterized by:
- automatic identification of the package format without the need to select the product receipt,
- grasping velocity up to 65 items per minute!
Laser tyre scanning and engraving machine
The automatic machine designed for offline and in-line use, comprises a 3D laser scanning system, a code reader, a laser marker, a cabinet and an aspiration unit.
The work cycle consists of the tyre scanning, the calculation of the marking area, the laser marking (barcode, numbers, letters, DMC) and the verification of the marked code.
Technical specs:
- Total footprint: 1900x2400x3100 mm (4.6 m2)
- tyre diameters: R17.5, R19.5, R20, R225
- tyre thickness: 210 – 450 mm
- cycle time: 50-120 seconds
Fully automatic vision inspection machine for automotive heat exchangers
The automatic vision inspection machine has the goal to analyse heat exchangers using several linescan cameras, linear LED illuminators, an industrial PC running Novasis machine vision algorithms and automation systems controlled by a PLC.
The latter ones allow the quality inspection of the heat exchanger -upper and lower cores, two manifolds- using linear stage actuators and conveyors. The industrial PC receives and analyses the acquired images based on the product receipt and provide a pass/fail output in less than 15 seconds.
Moreover, the PLC and the PC are connected to the production line server for product and output data exchange. The automatic machine vision inspection machine has been designed to be used both in-line and end-of-line.
3D vision-guided robots for Comau N-220 robot assembly
Vision systems have the function of
provide the coordinates of the modules constituting the Comau N-220 robot to the other robots of the automatic assembly line,
( https://www.comau.com/it/competencies/robotics-automation/robot-team/n-220-robot/ and
https://www.facebook.com/COMAU/videos/comau-n-220-27/394602088832533/?_rdr ).
The machine visions for the robot guidance, with the help of a laser measuring sensors, in addition to providing the x,y,z center coordinates and its qz orientation, provide the angles of inclination qx and qy for a correct grip of the components.
The machine vision system is supplied with a self-diagnosis procedure aimed at verifying the correct functioning of the cameras and lasers.
Control station presence of welding points and welded components
For a manufacturer of automotive components by sheet metal stamping a manual control station dedicated to the inspection of the battery basket has been built. In particular, with the help of an ad-hoc lighting system and 4 cameras, it was possible to inspect the presence of welding points and the assembly of components on different production models.
Machine vision solutions for battery production
Novasis developed several machine vision systems for the manufacturing process of cells and batteries:
1) machine vision station for the cell surface inspection and 2D code reading based on a conveyor, linear cameras and proprietary vision algorithms;
2) vision station for the battery module and tab inspections;
3) vision robot guidance for busbar mounting and cell welding gauging;
4) laser based 3D system for battery pack welding inspection;
5) 3D machine vision system for cell palletizing
Robotic vision inspection cell in automotive HVAC systems production line
The automatic vision inspection cell for HVAC production lines is based on a 3D TOF vision system for the model verification and one hand helded 2D vision system for a complete inspection of an HVAC in 10s (40 pictures) in NoStop Motion mode. The vision SW allows user to autonomously define new inspection regions. The robotic cell is supplied completed of safety and interfaces towards line production PLC, customized HMI and design and production of mechanics for in-line integration.
Automatic 3D machine vision system (AOI) for the in-line inspection of soldering leads for automotive temperature sensors
The automatic vision inspection system use, for the first time in Italy, the Keyence 3D vision sensor XR-HT15M in production line for the measurement and quality check of the soldering leads, parts of the automotive temperature sensors. The turnkey inspection system is provided to electrical cabinet, HMI with production statistics, connectivity to line PLC, MES and remote assistance (Industry 4.0 ready).
Automatic multispectral machine vision system for surface defect inspection in PET blowing machine
The machine vision system is based on two IR and one VIS cameras suited to detect surface defects like inclusions, holes, bubbles, etc. As part of the PET blowing production machine (9600pcs/hrs), it is a turnkey solution completed with electrical cabinet, machine vision controllers and I/O for the PLC communication and sorting.
OEM vision system for printing machines, MULTIVISION version
The MULTIVISION system provides a Color-to-Color automatic register adjustment and control based on a multiple camera scanning system.
It controls both machine and cross side of each single printing unit in real time (printing velocity up to 200m/min). The MULTIVISION system has been chosen as OEM component by OMET, it’s entirely manufactured at the Novasis Innovazione facilities and is supplied pre-calibrated to allow quick installation in every machine.
3D Robot guidance for Sealant Dispensing System
The application measures the 3D position of the engine flywheel and give the coordinates to a collaborative robot for its trajectory adjustment and the correct sealant dispense. The application system is also able to inspect the sealant bead to ensure the correct placement, size and shape.
Thermographic measurement system for hot plate welding
The system comprises an electrical cabinet, industrial PC, monitor and connectivity (to PLC and for remote assistance). The thermographic measurement system is based on two thermal cameras, installed next to the welding station.
Conveyor tracking and optical inspection of diamond wire saw beads
The machine vision system is based on two linear cameras, telecentric lenses and laser illumination. Saw beads coordinates are communicated to two KUKA robots for the pick and place of only good pieces.
Production rate: 50k pcs/day
Beads diameter tolerance: ± 0,1mm
Beads height tolerance: ± 0,5mm
Machine vision system for the inspection of composite sheets in production line
Two linear cameras and illumination systems are placed inside a mechanical isolated gate installed on the production conveyor line. The vision system is able to automatically detect holes, creases, bubbles, etc. communicating to the line PLC for sorting.
End-of-line morphological checking system
The system is inclusive of a vibrating feeder, conveyor line, machine vision system and pneumatic sorting. The machine vision system performs the morphological and presence/absence checking of plastic springs at 150 pcs/min rate.
Machine vision system for the morphological checking of automotive mechanism
The machine vision system is based on three cameras, three backlight illuminators, industrial PC, electrical cabinet with monitor for the morphological checking of hand brake levers mechanism on production line.
Model / Code Recognition System
The vision system recognizes the embossed code on the evaporator flank (hollow binary code) and communicates it to the production line control PLC via Industrial Ethernet.
Conveyor tracking for evaporators pick & place
The vision system must provide the robot with the coordinates (x, y) of the evaporator position to be picked up on the belt, the rotation relative to its center (θ), the distance between the sides (W) and the pick-up condition (proximity or overlapping). All this information is sent to the PLC (via S7 protocol) and directly to the robot for the conveyor tracking synchronization signal. In addition to the power board where the PC is compiled. The system consists of two linear cameras with respective lens, two LED illuminators and a portal support structure.
Robot guidance for evaporator assembly line
The vision system has the function of guiding the robot during insertion into the connection of the sealed test gripper.
The system consists of a camera equipped with a high-resolution monochrome sensor, a suitable optic and a circular led illuminator positioned by means of special brackets on the robot’s wrist.
The system, by moving the camera on a robot pulley, calculates the robot path for subsequent approximations by providing the x, y, z information for centering the caliper.
The interaction between robots and vision system is direct. For communication, we rely on the PLC to enable / disable the vision system, inspection result, shift offset.
Seal/absence check for gaskets, fastening levers and defects
The application consists of two vision systems positioned on two revolving boards. In the first, the vision system is positioned above the place where the operator performs the positioning of the gaskets. In the second, four cameras are positioned on a removable support to allow station tuning. Defects control is obtained by comparing the acquired images and a template
Quality control on plastic molding machine
The application consists of a multi-camera system, integrated on-board injection molding machine, for inspecting cable tie straps of different colors and for managing the results of the inspection (pass/fail) of a printed ties. You can also save captured images and modify the parameters for managing waste prints.
The system is suitable for integration on all molding machines and is an example of integration on standard production machines that can be replicated and usable as an additional tool, not only for users but also for machine manufacturers.
Display system for platemounter machines
The display system for two cameras (GigE or USB3.0) allows customization of the UI. The software is able to: Manage pre-defined ROIs and patterns on images, work files, generate reports, allow alignment between camera image and user-set reference, and measure any defects starting from a simple calibration process, optical zoom and digital zoom, etc.
OEM vision system for printing machines, iVISION version
The task of the iVision system is to recognize a reference graphic, or cross-mark, printed in various colors on a glossy white paper.
The system consists of “vision heads” (one for each print roller, made up of a plastic casing inside which there is a lens camera and an ad hoc illumination designed to be integrated into the machine.
The visual system, in addition to the “optical group”, is complemented by an industrial PC on which the image processing program with dedicated graphic interface is installed. The IVision system has been chosen as OEM component by OMET, it’s entirely manufactured at the Novasis Innovazione facilities and is supplied pre-calibrated to allow quick installation in every machine.
Robot guidance for dashboard mounting line
The application allows you to check the presence or absence of clamps intended to be securing screws and anchor inserts for the details that will be mounted later to complete the dashboard. The vision system is comprised of an “optical group” (camera, optics, illuminator) mounted on the robot wrist, and is complemented by an electrical cabinet containing an industrial PC on which the image processing program is installed. The PC communicates with the S7 protocol to the PLC that manages the line. The vision system allows you to work in continuous moving mode (captured image while the robot is in motion) for cycle time optimization.
In-line geometric inspection system for checking pin integrity on press mold
The system consists of a 3D laser head (laser blade) that guarantees, acquiring 32kHz, up to 200mm to 4m / s. The system is supplied with an electrical cabinet with laser controller, industrial PC and interface for communication with the line PLC.
Vision system for color recognition and type of plastic bottle preforms
The vision system consists of a high-resolution matrix camera and a backlighting system. Dedicated image processing algorithms allow to statistically evaluate color and shape variations by means of thresholds.
Automatic vision detection system for stators defects
The application consists of a rotating table in which two stations are dedicated to controlling stator defects with 5s cycle time. The inspection is done with three matrix cameras, in a fixed position and a ring illuminator for each camera. The system is supplied complete with electric panel and custom user interface.
Vision system for checking the correct assembly of rockers
The system consists of 2 “vision heads” arranged in succession, for the simultaneous analysis of two punteries.
The heads consist of a compact optic set (camera, lens, illuminator) connected to a signal amplifier.
The vision system is complemented by an industrial PC, which houses the PLC communication protocol program and the image visualization interface.