Chris Walker, an EPIC machine vision specialist, is now a Certified NI LabVIEW Developer (CLD). This Midlevel LabVIEW certification demonstrates his ability to create functional, well-documented LabVIEW code with minimal development.

NI LabVIEW will allow Walker to take on challenging projects related to measurement and control systems. The program allows developers the ability to acquire and analyze measurements, design embedded systems, control stand-alone instruments and automate test and validation systems. Walker is using his certification to program challenging, math intensive and customizable vision projects for clients.

The NI LabVIEW certification includes three steps. Walker completed the first step of Certified Associate Developer ( CLAD) after taking a LabVIEW Core 2 Class. Next, he took the Core 3 class and decided to take the Certified LabVIEW Developer test. He received his certification after completing a four hour application development test.

This intermediate level indicates the ability to design and develop functional programs while minimizing development time and ensuring maintainability through proper documentation and style. The third level, if he so chose would make Walker an NI Labview architect.

The post Walker earns Labview Certification for Advanced Vision Application Design appeared first on .

Q: What are the essential factors to consider before selecting a lens?

A: In order for an application to be a success, it is crucial to consider: focal length, f-number (f/#), resolution, field-of-view (FOV), and depth of field.

Q: Why are these factors so important?

A: Some machine vision applications could be successfully integrated by verifying lens focal length against the desired Field-of-View and Working Distance (distance from lens to object). More often than not, many applications require accurate and reliable measurement capability.

Q:  How would something like accurate measurement affect my vision system?

A:  With intricate applications, the resolution of the lens, for instance will greatly impact the amount of detail that can be examined. For the purposes of resolving specific features in an image accurately, factors such as contrast, image noise, and depth of focus must be considered.

Do you have a complex vision application or additional questions about installing and integrating a vision system? Contact an EPIC vision specialist for more about lens selection.

The post What to Consider when Selecting a Camera Lens appeared first on .

EPIC UPGRADES PERSONAL CARE PRODUCT LINE

CUSTOM MACHINE VISION SYSTEM

CONSUMER PRODUCTS PACKAGING

A consumer products manufacturer needed a custom machine vision system on a personal care product line that could be duplicated for multiple systems.

Industry: Consumer Products

KEY ENGINEERING FEATURES:

• Custom machine vision system to identify multiple defects in production
• Complete vision system programming includes low false identification rates
• Development of a standard vision kit to be used on domestic and international lines

CORE CHALLENGES:

• High speed process
• Remote installation without direct supervision by EPIC Systems
• Multiple defect inspection
• Repeatable performance in multiple systems

AN EPIC SOLUTION:

Front-End Engineering

EPIC first completed preliminary design to assure the most efficient process and accurate cost quotation. After reviewing the objectives and challenges with the client, EPIC’s engineers completed an analysis of the line and created an implementation plan that included the following elements:

• Cameras programmed separately to identify a unique set of defects at different stages in the continuous process
• Standard mechanical mount development and camera programming to create an easy to assemble and install kit
• Lighting and optics robustness study to determine capability to attain repeatable performance in multiple installations
• Standardized camera programs to identify proper features and parameters for defect identification over a wide range of operating conditions
• Standardized installation and calibration hardware and procedures to enable global rollout of standard hardware and software

EPIC Systems recommended an efficient option for advanced line automation and machine vision inspection for QA checks.

Final Solution

EPIC worked closely with the client to extract specifications for the defects to be identified. Multiple lighting and optics studies with different lenses and cameras were performed to determine the robustness of the application. Lighting strategy played a key role in the success of the defect detection. Camera mounting angles and brackets were explored and EPIC’s vision lab determined the optimum position for consistently capturing defects.

Once it was determined that consistent results that met the expectations of the client could be extracted by the machine vision system, standardized kits were developed. A standard mechanical bracket for each camera and a standard camera program were developed so that kits be sent to multiple locations and installed easily. These kits were installed on multiple lines by the client without direct supervision by EPIC.

Each camera on the production line looks for a number of different defects as the product is formed. Based on size and shape of a defect free product, the camera can pick out defects as they form in the subcomponents, and signal the line to reject that product. A positively identified defect causes a product to be removed from the line.  Defect free products continue through the line and are packaged into bags and boxes.

IMPACT

• Production speed was maintained while inspections took place
• Dramatic reduction in the number of defective products leaving the plant
• Waste kept to a minimum by maintaining a low false identification rate
• Time and money expenditure kept to a minimum by creation of a standard kit
• Programs designed for simple interface to allow technicians to monitor and adjust camera detections as necessary

THE EPIC DIFFERENCE

Through customer review, EPIC was identified as an integral part of the client team.  The manufacturer viewed us as a partner, trusted to ensure the results met their needs.  The client could take advantage of EPIC’s vast machine vision expertise to get the best solution, knowing that their success was our success.

The EPIC Difference includes several key features that assure a projects success:

• Front-End Engineering to ensure that the proper steps are taken during project scope development
• Plant engineering experience that assists clients to identify needs, pinpoint objectives and provide the most appropriate manufacturing equipment for the application
• Open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering.
• Accountability to responsibly manage our clients’ projects from start-to-finish and beyond.
• A transfer of knowledge (not just a basic training) for the systems and equipment we provide
• Single point of direct contact during the entirety of the project
• State-of-the-art shop which decreases down-time and increases the speed of project completion

Find a solution that is right for your company. Contact EPIC or learn more about custom machine vision systems or consumer products packaging lines.

See more case studies and news from EPIC

The post Personal Care Product Vision System appeared first on .

BULK CHEMICAL PACKAGING

VISION SYSTEMS

The client receives empty 55 gallon drums strapped together in sets of four that will be filled with a chemical mixture at 180° Fahrenheit.

Client: Fortune 100 Company

Industry: Agricultural Chemicals

KEY ENGINEERING FEATURES:

• Fully automated, hands free bulk packaging system
• Custom vision system working with integrated packaging line and controls
• Custom filling machine
• Complete and correct individual machine programming and full line automation
• Pressure check, cap removal, and defective drum reject/marking system.

CORE CHALLENGES:

• 180º hot-fill industrial chemical that posses a potential safety risk to workers
• Varying orientation of drums within a set of four, which are strapped together
• Varying location of drum openings based on individual drum orientationUnknown drum integrity coming into the filling line
• Drums arrive with caps over both openings, which must be removed before drums can be filled

AN EPIC SOLUTION:

Front-End Engineering

EPIC first completed preliminary design to assure the most efficient process and accurate cost quotation. After reviewing the objectives and challenges with the client, EPIC’s engineers completed an analysis of the line and created an implementation plan that included the following elements:

• Custom vision system that allows for an automated filling system that can adjust to varying opening locations
• Packaging line that allowed the sets of four drums to remain strapped together throughout the process
• Automated systems to check the pressure of the drums and mark defective drums
• Automated system to remove the caps off the openings
• Hands-free packaging systems for maximum efficiency and worker safety

EPIC Systems recommended an efficient option for advanced line automation and machine vision inspection for QA checks.

Final Solution

EPIC managed every aspect of the project including: assessment, packaging line re-design, mechanical and structural design, applied engineering and fabrication, controls engineering, installation, plant integration, FAT testing, and start-up and support.

EPIC’s Line Integration team worked closely with the EPIC Vision Lab to take the packaging line from design to start-up. The final line includes a dual camera vision system that allows for a completely hands-free filling process.

The set of four drums are unloaded from the truck and placed on the line strapped together. As they move towards the filler, a camera locates the four drums and uses a grid system to locate the general location of each of the openings on top of the drums. A second camera pinpoints the location of both openings on top of the individual drums.

This information is used to accomplish several tasks. First, a magnetic torque wrench is used to tighten one of the two caps over the openings, and to remove the other cap in preparation for filling. A pressure check of the drum is performed by sealing the open hole and pushing air into the drum. A pressure switch must be flipped. If the switch is not flipped, the seal is re-established and the test tried again. Two failures result in that drum not being filled and marked as defective. Pass and fail is on an individual drum basis, so if one drum in a set fails, the other drums can still pass and be filled.

Once a drum proves to be leak free, the drum is filled by moving the filling head to the exact location of the open hole. The drum sits on a scale and is filled to an exact weight. After it reaches the target weight, the cap is screwed back on mechanically to a certain torque. All four drums are filled at the same time. Then the four full drums, still strapped together, go back to the forklift and are put back on the truck.

IMPACT

• Eliminated worker risks by automating a previously hands-on process
• Increased efficiency by allowing the four drums to remain strapped together for filling process, while still treating each drum individually for pressure check, filling and weighing process
• Streamlined entire packaging system by designing a line that receives drums off the truck, fills them, and returns them to the truck at the end of the line

THE EPIC DIFFERENCE

EPIC provided expert insight into how to design an efficient and safe packaging line with the utilization of a custom vision system. Because of EPIC’s experience in the field, EPIC was able to recommend the correct packaging equipment, and prevent problems before they arose.

The EPIC Difference includes several key features that assure a projects success:

• Front-End Engineering to ensure that the proper steps are taken during project scope development
• Plant engineering experience that assists clients to identify needs, pinpoint objectives and provide the most appropriate manufacturing equipment for the application
• Open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering.
• Accountability to responsibly manage our clients’ projects from start-to-finish and beyond.
• A transfer of knowledge (not just a basic training) for the systems and equipment we provide
• Single point of direct contact during the entirety of the project
• State-of-the-art shop which decreases down-time and increases the speed of project completion

Find a solution that is right for your company. Contact EPIC or learn more about packaging lines or custom machine vision systems.

The post 55 Gallon Drum Hot Fill Line appeared first on .

EPIC designed, built, and integrated an existing production line with a custom machine system to inspect dents on pressurized canisters and increase production rates for a major food and beverage company.

CUSTOM PACKAGING INSPECTION

CUSTOM TEST AND INSPECTION MACHINES

FOOD AND BEVERAGE PACKAGING

CLIENT: Fortune 500 Company

INDUSTRY: Food and Beverage

KEY ENGINEERING FEATURES:

• Custom machine designed, built and integrated into packaging line by EPIC
• Machine vision system with 360 degree view
• Custom form factor lighting
• Collimated lenses on cameras
• Color verification through machine vision inspection

CORE CHALLENGES:

• Graphic/art elimination for dent inspection
• Downstream tracking of rejects after machine exit
• Dent parameters definition 360 degree can inspection
• High speed application

EPIC SOLUTION

Front-End Engineering

The client required an upgrade of their can inspection from a manual to automated process. The pressurized product would explode due to can surface defects.

Surface dents on the canister would impede the rising of a puck through the inside after it was filled with

product. If the puck jammed, it could cause the can to explode and cause delay in the packaging line for cleanup.

Visual human inspection could not detect many of the dents that caused the jams. Machine vision inspection offered higher detection rates, faster speeds and minimized downtime.

EPIC completed preliminary design to assure the most efficient process and accurate cost quotation. After reviewing the objectives and challenges with the client, EPIC’s machine builders and engineers completed an analysis of the line and created an implementation plan that included the following elements:

• EPIC’s machine builders fabricating a custom built rotary canister inspection machine to be integrated into the packaging line, before the filler
• A custom lighting solution including collimated camera lenses to wash out graphics for dent inspection
• Platens to rotate canister 360 degrees through a 180 degree turn of the machine
• Six overhead cameras to inspect canisters d uring rotation
• One camera located at the beginning of the machine to check for coating on lip of canister and debris inside canister
• One common reject station after canisters exited machine but before being filled with product
• Integration of a shift register with a photo eye tracking system on the line to track rejects leavinginspection machine

Final Solution

The custom built rotatory inspection machine is integrated with the clients packaging line before the filler. Cans enter the inspection machine through an in-feed screw, which spaces them correctly into a star-wheel. An overhead color camera inspects for the presence of varnish on the lip of the canister and checks for unwanted debris inside the canister.

From the star-wheel, cans are transferred to a platen which are timed to rotate a can 360 degrees within a 180 degree turn through one-side of machine. Six overhead cameras scrutinize the can as it is rotated. The cameras are spaced and angled from above to capture a full 360 degree view of the can.

Cans are checked for dents that might impede the puck rising. A custom lighting set-up is required to complete the inspection. The canisters must be lit so that the camera is immune to art work on the surface on the cans. A custom form factor is used, with the circuit boards on the inside outer diameter of the domed machine. The custom lighting is on the inside inner diameter of the dome, and the can carousel is in the middle of the dome.

Collimated lenses are used on the cameras. These special lenses align the bright light rays to make graphics disappear into shades of grey and make dents show up as dark shadows.

Defining the type of dent that might impede the puck is a difficult process for a machine vision integrator. A shallow but large dent or a small but sharp dent may stop the puck. These differences had to be combined into one fail process.The inspection machine has an 80% successful identification rate, which exceeded customer specifications. An 8th camera was added later to inspect for crushed or misshapen can lips.

If a can fails inspection, for missing varnish, debris, crushed lip, or dents it triggers a shift register. The shift register mechanically moves the ‘failed switch’ with the can as it continues through the inspection machine. Cans leaving the machine continue onto a conveyor.

The conveyor is unable to mechanically track ‘fails’ due to conveyor slippage. At this point, the shift register hands off the ‘fail’ signal to a photo eye system which detects the cans based on position in queue. Rejects are eliminated from the packaging line after they pass a second photo-eye.

IMPACT:

• Reduced number of faulty products
• Greatly improved ability to detect surface dents on cans
• Improved reliability of capping and better seals
• Reduced can explosion, line stoppage and problems in filler
• Minimized quality complaints

THE EPIC DIFFERENCE

EPIC provided expert insight during the design, machine build, automation and start-up process. Because of EPIC’s experience in the field, we were able to recommend the correct custom parts, including the custom machine vision system, and prevent problems before they arose.

The EPIC Difference includes several key features that assure a projects success:

• Front-End Engineering to ensure that the proper steps are taken during project scope development
• Plant engineering experience that assists clients to identify needs, pinpoint objectives and provide the most appropriate manufacturing equipment for the application
• Open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering
• Accountability to responsibly manage our clients’ projects from start-to-finish and beyond
• A transfer of knowledge (not just a basic training) for the systems and equipment we provide
• Single point of direct contact during the entirety of the project
• State-of-the-art shop which decreases down-time and increases the speed of project completion

Find a solution that is right for your company. Contact EPIC or learn more about custom machine vision systems, custom machines or food and beverage packaging.

The post Custom Canister Inspection Machine by EPIC appeared first on .

CONSUMER PRODUCTS PACKAGING

MACHINE VISION CAP AND CLOSURE INSPECTION

A consumer products company approached EPIC Systems with a challenging project to re-design a packaging line to accommodate a newly re-designed bottle and cap with a unique shape. 

CLIENT: A Fortune 500 company

INDUSTRY: Consumer Products

KEY ENGINEERING FEATURES:

• High speed packaging line
• Integrated control system
• Custom in-feed line, un-scramblers, filler, case erector, robotic case packer, sprayer inserter
• Complete and correct individual machine programming and full packaging line integration with production line
• Specialized machine vision systems for customized quality checks
• Automated packaging line that protects workers from contact with chemicals

CORE CHALLENGES:

• Packaging line must accommodate special rounded shape of bottles and spray nozzles
• Line must accurately match custom shaped nozzles to bottles and seal the package
• High line speed must be maintained
• Correct amount of solution must be present in each bottle: over/under filled bottles must be automatically rejected from the production line

AN EPIC SOLUTION

Front-end Engineering

EPIC first completed its front-end engineering approach to assure the most efficient process and accurate cost quotation. After reviewing the state of the current packaging line with the client EPIC’s engineers completed a line analysis and created an implementation plan that included the following elements:

• Customized unscramblers for  bottles and nozzles
• Customized filler, star wheel and nozzle conveyor
• Vision system to check for correct mating of nozzle to bottle
• Check weigh stations with automated reject for individual bottles and full cases
• Conveyors, date-coder, case erectors, case tapers, robotic palletizer and stretch wrapper

EPIC Systems recommended an efficient option for advanced line automation and machine vision inspection for QA checks.

The Final Solution

EPIC designed, integrated and completely installed the fully functioning packaging line that met the end user’s strenuous expectations. The packaging line originates with in-mold labeled bottles in an un-scrambler that orients the bottles in an upright position with the labeled side facing out. The spray nozzle tops also begin in a separate un-scrambler and are simultaneously oriented so that they are facing the correct direction to be mated with the bottle bottoms.

Bottles travel down a line to a screw and star-wheel that orients and spaces the bottles for the filler. In the filler, the bottles are filled and mated with the spray nozzles, which enter the filler from above. Liquid production is filled directly from the production line into the bottles as they travel through the filler. Nozzles are tightened down before the bottle leaves the filler. A machine vision system is integrated with a special camera which checks for an accurate mating of spray nozzle to bottle. Bottles then pass over a check weigher that sends under or over-weight bottles to a reject station.

Correctly filled bottles continue down the production line to a date coder that applies a date code to the filled product, followed by a camera that visually checks for the correct code. Bottles continue to a laner that prepares the bottles to be dropped into a box that has been assembled by a case erector, taped on the bottom, and slides beneath the bottles with flaps. Bottles drop into the case and the case flaps are then folded down and taped in an automated process.

The full cases pass over an additional check weigher which monitors for the correct weight in each case. Under or over weight cases are rejected. Correctly filled cases continue to a palletizer and stretch wrapper, where they are stacked and wrapped on pallets to be shipped out.

IMPACT:

• Fully functioning packaging line that consistently runs high speeds matching the rate of mixture production
• Fully automated packaging line for a uniquely shaped bottle that allows the company to stand out from competitors
• Integrated vision system that reduces errors and waste by checking every bottle for correct spray nozzle mating

THE EPIC DIFFERENCE

EPIC provided expert insight during the design, automation and start-up process. Because of EPIC’s experience in the field, EPIC was able to recommend the correct custom parts, including the custom machine vision system, and prevent problems before they arose.

The EPIC Difference includes several key features that assure a projects success:

• Front-End Engineering to ensure that the proper steps are taken during project scope development
• Plant engineering experience that assists clients to identify needs, pinpoint objectives and provide the most appropriate manufacturing equipment for the application
• Open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering.
• Accountability to responsibly manage our clients’ projects from start-to-finish and beyond.
• A transfer of knowledge (not just a basic training) for the systems and equipment we provide
• Single point of direct contact during the entirety of the project
• State-of-the-art shop which decreases down-time and increases the speed of project completion

Find a solution that is right for your company. Contact EPIC or learn more about packaging lines or cap and closure inspection

The post High Speed Bottling Line by EPIC Systems, Inc. appeared first on .

EPIC Trivia Night was hosted by Frank McCormack and Craig Geil and involved a paper airplane engineering contest, silent auction with autographed memorabilia, tribute to the troops and multiple raffles.  Prizes included a new Kindle Fire, wine baskets and a wireless router.

ABOUT THE USO:  Millions of times each year at thousands of locations around the world, the USO lifts the spirits of America’s troops and their families. A nonprofit, congressionally chartered, private organization, the USO relies on the generosity of individuals, organizations and corporations to support its activities. The USO is not part of the U.S. government (and accepts no federal funds), but is recognized by the Department of Defense, Congress and President of the United States, who serves as Honorary Chairman of the USO.

The post EPIC Raises $3,781 to Benefit USO appeared first on .

The standardized control box has one part number to reduce time consuming specification requirements. Insta-Panel is pre-tested for reliability, and is engineered to make connecting processes in a manufacturing facility easy. The complete system allows you to install the first standard building block of distributed plant automation architecture.

EPIC’s industrial PLC control system is equipped with an HMI, Operator Interface, NEMA 4 Enclosure, CompactLogix Processer, I/O and power supply with room for additional expansion and future upgrades.

ABOUT EPIC SYSTEMS: Founded in 1995,EPIC Systems, Inc. is a leading multi discipline engineering and fabrication firm that provides project automation solutions for modular process plants and systems, packaging and assembly line integration, custom machine manufacturing and advanced machine vision system integration.

To learn more about EPIC, visit the website at www.epicsysinc.com or contact them today for an engineering evaluation of your application.

See more news from EPIC

The post New Standardized Control System for Industrial Applications appeared first on .

1. Determine The Key Properties Of Your Product
The first step involves the product, part or element of the product or packaging that needs to be inspected. What it is made out of – glass, paper, plastic or metal –will have an impact of the types of tools used to examine it. If the object has multiple layers, or asymmetrical features, it may require more programming and a clever lighting solution to be successfully inspected.

2. Establish Clear Goals
Setting goals defines success for your vision system. What do you want inspect and what pass/fail rate is acceptable? What conditions are flexible and what metrics have to be met? Some goals include improving the accuracy (by a measurable amount) of an aspect of your manufacturing process, reducing the number of defects present in finished products, or improving the pass/fail rate of a current vision system. Whatever your goal – make sure it is measureable.

Start with what you are trying to “see.” Is it the object’s texture? Is it a defect, tear, hole? What about dents, surface details or a fixture that needs closer examination? How will you see it? Why do you need to “see” it with a vision system? What is the definition of success for your project? For example: if you are looking for dents on the side of can, are dents of shallow depths okay, but not deep dents? Are you eliminating dents because of aesthetics, or does it inhibit your products functionality?

One project EPIC worked on involved finding tiny pieces of glass in a product designated for children. It was important to find all the glass because of the safety risk to the young end-users. Knowing about the flaw and the weight of the problem for the client’s customers, allowed our vision specialists to create a specialized system to solve this problem that took advantage of the special properties of the glass.

3. Call in the Vision Expert
How do you select the proper lighting to correctly light the defect? Which camera is best? For a camera to detect different aspects of a product – proper lighting, glare elimination, camera angle, proper programming – many things must be done correctly. Someone with years of vision system design, programming and integration experience can help make your project a success.

EPIC’s vision experts are comfortable figuring out all types of challenging vision inspections using the latest tools because they have been faced with hundreds of custom vision systems. For example: during a recent project, the EPIC vision team designed a system to detect a crushed bottle. To the eye it is easy to detect a crushed clear, opaque or frosted bottle with damage. For a camera, this can be harder, especially because clear objects are hard to detect with a camera lens. Without their extensive knowledge of lighting, programming and so on, this system could have taken a long time to get working correctly, or it might not have been successful at all.

4. Select the Type of Camera or Cameras Needed
Different inspections require specified camera selection. When conducting a 3D surface inspection of a timing belt, the camera of choice might be a High Speed Sick Ranger Camera – a high-speed camera developed to measure shape color of 3D objects. Using this camera, your inspection could enhance productivity by accurately measuring shape, contrast, and surface defects, to ensure product quality and production reliability. At other times, cameras like the Cognex Insight 5600-11 smart camera, can be used at different positions on the line to create the most accurate image.

5. Determine the Type of Lighting

It may take some testing in a vision lab to figure out the best lighting solution for your surface inspection application. It is most common to use low-angle backlighting to best illuminate the object being inspected. For an opaque object, it may be necessary to use glancing illumination, from an LED spot light, which has a sharp angle of incidence that enhances the object’s surface structure. A structured light, such as a laser, can be used to bring out surface features. If the object is translucent, like a clear bottle or glass, than it may require darkfield illumination using an LED Darkfield Ring Light. This will best show surface details like scratches, bubbling, cracks or tears.

6. Determine The Programming Requirements
Various defects require different types ofprogramming, and most are not out-of-the-box solutions. For example, surface inspection may include the texture of an object. For that, a vision expert may select NI LabVIEW’s vision software tool to conduct texture analysis. However, if you were interested in finding a certain defect on a products surface, the smart camera may be programed using Insight Explorer 4.7.0 to communicate pass/fail outputs. In this case, the camera must be trained on the various heights, shapes and textures in order to have the most accurate pass/fail rate.

7. Install, Integrate and Train

Installation often requires mechanical brackets or hardware, integration of the new vision system with existing line equipment, and training of your line personnel. While these steps are easy to list out, they can be harder to complete. Further programming may be needed to properly integrate the vision system with existing plant equipment or resource management programs. Mechanical design and parts fabrication may be needed to position the vision system on the production line. This is another area where we believe a vision expert provides invaluable help.

——————————

EPIC is a machine vision system integrator located in St. Louis, MO that specializes in custom part and product inspection. To learn more about turnkey vision solutions, visit our Machine Vision website or contact an engineer today.

The post 7 Steps to a Successful Surface Inspection appeared first on .

Quality Magazine compares do-it-yourself vision system installation with attempting to save money by caulking your bathtub. Something that looks easy at first glance may turn out to be a lot more complicated and costly down the road.

TOP FIVE REASONS TO CHOOSE A VISION INTEGRATOR

1. Knowledge of Cameras, Lighting and Optics:

Lighting, color, line scan or area scan, lens requirements are all types of considerations when determining the vision requirements.

A turnkey machine vision system, as the name implies, is built to custom specifications and is delivered ready to go. A turnkey system may seem more costly upfront, but with the costs come the experience of a system integrator who has vast knowledge of cameras, lighting and optics. A vision specialist will be able to properly assess the use of a smart camera, lens requirements and image resolution which can all make or break a vision system.

2. Previous Application Experience:

A vision expert has worked with image filters, 2D and 3D pattern matching and all types of mechanical, electrical issues to determine the feasibility of the project.

“Right away, an expert in Machine Vision integration will be able to point out a variety of potential pitfalls, mechanical or electrical issues/constraints, application feasibility, product fixturing problems, and many other “unexpected” problems,” says Walker. The previous application experience a machine vision expert carries is invaluable.

3. Knowledge of System Integration:

From former experience, the vision expert understands how to integrate the communication controls to match the existing controls.

With this experience comes the ability to fully integrate the system using existing controls (i.e. Ethernet TCP/IP, Profibus, Modbus, and Serial) and determine the programing for tracking or rejecting, how to trigger the camera and what type of data storage is needed.

4. Mechanical and Electrical Design Knowledge:

A properly designed system is innovative and built correctly to justify the upfront costs.

Knowledge of mechanical and electrical design is important for this reason. For example, when completing mechanical design Chris recommends “centerlining” – a technique that enables continuous improvement, and resolution of problems due to variability, to achieve production consistency.

5. Experience in System Maintenance Requirements:

An expert can train someone at the plant or factory on the nuances of the system.

This prevents having to shut down the system or hire an additional engineer. On-going support and training is another benefit of using a vision expert. When the project is finished, a vision system expert is able to ensure that the end-user is properly trained to know the basics, like proper lens cleaning. Recommendations on preventative maintenance, product setup, alignment, calibration and troubleshooting provided by an expert will make a big difference in a systems success.

——————

EPIC is a machine vision systems integrator located in St. Louis, MO that specializes in custom part and product inspection and process automation and control. To learn more about turnkey vision solutions, visit our machine vision website or contact an engineer today.

The post Why a Turnkey Vision System? appeared first on .