Industrial Vision Automating Quality Control

Vision systems can offer fast, accurate and repeatable inspection capabilities at a highly competitive cost.

They can introduce automation into the production process at a number of different levels, from simply speeding up the inspection process to levels not possible using human inspectors through to being an integral part of a statistical process control system that can identify when a manufacturing process is moving out of specification.

While using vision as a final inspection process on finished product can ensure no defect product reaches the end-user, using it earlier in the process can bring real added value by bringing improved quality throughout the process, major savings in waste, improved process efficiency through energy saving and possibly all three! 

Vision Systems Overview

Vision systems typically consist of an illumination system and video camera or set of cameras linked to computers. The computer provides the platform for the image processing and decision making. These PC-based systems can be used for simple single camera applications or the most sophisticated multi-computer, multi-camera configurations. For many applications, a smart camera offers a cost effective solution. This is a self-contained, standalone vision system with image processing capabilities built into the housing of the camera, removing the need for a local PC. These systems are ideal where only one inspection view is required. A third variant is the compact vision system, where all processing capabilities are housed in an industrial controller which can be connected to multiple cameras. The choice of which system will be the most suitable will be determined by the requirements of the application. A good way of understanding just how vision can make a difference is to take a look at examples from three very different industries. 

INDUSTRY 1

Automotive Engine Assembly

In this highly demanding industry, an automotive engine manufacturer was faced with the problem that they were getting too many engines failing their final performance tests due to operator errors during assembly. A detailed examination of the problems showed that the part complexity, combined with the extensive teardown and rework required if an error is made, justified the use of vision-based inspection. The solution to the problem was to install three smart camera-based vision inspection stations to carry out a range of tasks from absence/presence to gauging/measurement. The first station featured a single smart camera to verify that the crank gear and water pump gear are aligned properly. The second station features 4 smart cameras. Cameras 1 and 2 both verify the presence and location of eight water seals. Camera 3 determines the presence and location of a drainback seal, another gasket, and eight water seals. Camera 4 verifies that only a single head gasket is installed. The final station features a single smart camera to verify that the timing mark (painted line) on the idler gear is between two painted teeth on the crank gear. The implementation of the vision systems has led to a reduction in engine failures and subsequent rework in a way that wasn’t possible with the existing human inspection and plans are in place for further vision systems to monitor many more assembly processes.

INDUSTRY 2

Plastic Moulded Components In The Food And Beverage Industry

A global leader in the food and beverage industry had a requirement for a fully automated quality control and inspection system to handle and inspect two plastic moulded components that differ in size and shape. In addition to meeting food and GMP standards, the system needed to be able to accommodate either component with a minimum tooling changeover as well as meeting a number of stringent requirements The inspection solution had to:

• not cause any damage to the components
• inspect from all three planes-

- Top for damage and optical character recognition

- Bottom for diameter and damage

- Side for damage, height and profile.

• be capable of operating at up to a rate of 1200 parts/minute
• be able to handle components either cold from storage (minimum 10 ˚C) or directly from a moulding machine (maximum 40 ˚C)
• detect and reject 100% of components that are outside the specified limits and generate the minimum amount of waste due to either damage caused to the components by the vision system or rejections that are not outside the limits of the specification (false rejects)

RNA specialise in handling and feeding technology combined with a vision systems integrator to address these challenges with a novel approach to component handling. The resulting vision system can achieve repeatability of measured values to 20 microns accuracy over 10,000 measured parts, with a one micron resolution.  This system has given the customer a huge benefit in terms of reduced percentage of false rejects, and reduced damage incurred during manufacture, helping them maintain their lead in a hugely competitive market place.

INDUSTRY 3

Medical Dressing Materials

A manufacturer of medical devices was experiencing difficulties with the thin film that is used as part of the process, due to biological, dirt and debris contaminants. Unfortunately the supplier could not guarantee the quality of the material and hundreds of thousands of metres were awaiting processing into a high value product and multiple production lines were stalled as no material was available. Manual inspection of the film is impossible and the only other solution would be 100% inspection of the finished product with costly waste if a contaminated product is manufactured. An inspection system capable of detecting minute defects running at 100m per minute was engineered with a short lead time by a vision systems integrator and smoothly integrated into the batching line. When a defect was detected, the line could be stopped, the contaminated section cut out and the good sections spliced together with information on the defects found fed back to the film manufacturer. The vision system allowed the device manufacturer to continue production knowing that quality was built into the process with minimal cost, orders were met on time and high quality product was being delivered.

This article was first appeared in the Autumn 2011 issue of Innovation into Success, edited by John Haddon, UK Industrial Vision Association

If you are interested in more details of RNA Vision Inspection Systems or  have a process that needs improving please contact sales on +44 (0)1217492566 begin_of_the_skype_highlighting            +44 (0)1217492566      end_of_the_skype_highlighting.

People on the move

A valued member of the RNA team, Ken Cotterill celebrated his retirement day at the end of August 2011 after more than 22 years with RNA.


Ken, one of the company’s longest serving employees, first joined RNA in 1989 as part of the sales department, he witnessed a lot of changes and growth at RNA over the last two decades. A popular member of the team he was held in high regard by customers who were often keen to be updated with his latest cruise ship holiday adventures. 


All members of the RNA team wish Ken the very best during his retirement and thank him for the hard work and contribution he has given to RNA during his time here. 


Alan Edmonds (Pictured) has joined RNA and will replace Ken’s sales role in the southern territory. Alan brings RNA a wealth of experience in the automation sector with a career starting in 1983. We welcome Alan as a new member of the RNA family and are very happy to have him on board. 


Contact Alan with any requirements please email alane@rnaautomation.com.

PPMA 2011

UK's leading processing & packaging machinery exhibition

Date: 27th - 29th  September 2011
Venue: Hall 5, NEC Birmingham, UK
Booth: F39
Contact: Ying Zhang

RNA showcases bowl feeder and robotic system at PPMA 2011

PPMA 2011 Preview

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Integrated with a vision system, the RNA vision guided robotic system will demonstrate high speed, accurate repeatability within a compact versatile setup.

Andy Perks, Sales Manager commented , “RNA have a proven track record for supplying a turn key package for part handling and robotic systems .Our systems are currently in use in a number of applications for the packaging and processing industries, mainly focusing on pharmaceuticals, food, cosmetics and repetitive machining operations.

RNA welcome its latest work experience student

Laurence Pied has joined RNA for 3 months work experience where she will gain practical knowledge of the mechanical handling industry.

Laurence, 22 is from La Rochelle, France and is currently studying for an engineering degree. She is being sponsored by Delphi Diesel a business where RNA have several installed systems.

Working alongside three RNA apprentices, Laurence will also gain exposure to 3D CAD Design and Vision Guided Robot programming.

Managing Director Stuart Brettell commented,’ Laurence is the 4th International student we have had here and is a reflection of the global nature of our business and aim to cement relationships with key customers.’

RNA celebrates 25 Years in Birmingham

RNA UK recently celebrated its 25th anniversary in the UK. Over the last 25 years RNA have developed and designed specialist handling systems in a host of different industries worldwide.

Full story can be found Here

Do you remember during 1986?

• Bad by Michael Jackson was the UK best selling album
• The 1986 FIFA World Cup: Argentina v England 2-1
• The M25 was finally completed
• British boxer Amir Khan was born
• 'Big Bang Day': London Stock Exchange is computerised
• RNA UK was founded.

More pictures are available on RNA Facebook page

CASE STUDY - Vision Guided Robot Handling & Press Loading Range of Fittings

Component: Range of fittings - Straight coupler, 90 degree elbow, 45 degree elbow, and Tee size range 

RNA were contracted to design and manufacture an automated press loading system for a range of copper plumbing fittings. The system incorporated a bowl feeder, vision guided robot and control system to accumulate and load fittings into a hydro form press. The project was for a global leader in the plumbing fittings industry that manufactured a diverse wide range of fittings often with short batch runs and short lead times.

Full story can be found HERE

To know more about RNA Vision Guided Robotic System please click HERE

Vision Systems for every business

By Mark Williamson, UKIVA Chairman

Vision system has four main application areas:- automation, inspection, process optimisation and traceability which can make a big difference to the process and packaging industry.

Systems range from simple vision sensors that can detect and inspect parts on production lines or check for the presence of specific features on products and packages, to full PC-based systems featuring single or multiple cameras connected to a PC running sophisticated software. The latest neural network processing even allows vision systems to 'learn' in order to allow decisions to be made on the difference between components. Developments in technology mean that vision systems are now easy to use and quick to integrate into existing manufacturing equipment.Crucially, cost doesn't have to be an issue as there are many effective low cost vision system that add real value to process or an OEM machine. More information can be found at the UK Industrial Vision Association's website: www.ukiva.org

To know more about RNA Vision Inspection System please click HERE

Source: PPMA News 2011, 'Vision Systems for every business' , Issue 17 Summer, p.13 

CASE STUDY - Robot gets a Grip on Spoons

Plastics Industry

Component: Disposable plastic spoons

Performance: Correct placing plastic spoon into a cap at a rate of 120 components per minute

A specialist supplier of plastic injection moulded components for the food industry approached RNA to automate a production line for disposable plastic spoons Some of the industries largest food and snack manufacturers use this type of spoon in ready meals and convenience snacks

For this particular project a foldable spoon needed to be placed into a cap, the cap is supplied to a manufacturer of milk based fast foods. A disposable plastic spoon is very difficult to orient due to the design of the moulding especially at 120 parts per minute.

The solution chosen was a vision guided robotic system equipped with an RNA step feeder, a bulk storage hopper and a 6 axis robot.

The spoons are automatically fed from the hopper, into the step feeder and then on to a conveyor belt. A brush positioned above the out feed conveyor separates the spoons under a camera system. The image processing software pinpoints the exact location of the spoons and sends the information to the robot. The robot utilizes conveyor tracking software IE the components can be picked without stopping the conveyor belt. In order for the assembly to work correctly the spoons need to be fed with the oval side facing down. Components lying on the wrong side are therefore automatically recycled into the step feeder via camera recognition.

The robot is fitted with a special gripping unit which picks the spoon and places into the waiting cap positioned on the existing production line.

The spoon handling system has been running successfully since the beginning of 2009 and the customer is investing in further systems to cut operating costs and improve production.

The vision guided robotic system replaced manual handling by operators, and was designed to supply assembly machines, sorting equipment and other machinery that require short cycle times with multiple component handling.

As a standard in the RNA range delivery is also short thus reducing lead times and improving payback periods on the investment. RNA can offer alternative vision guided robotic systems, each of which is developed to match almost any specifications as an off the shelf package

Another main advantage of the system is the simplicity to teach in new components. To teach the system a new component takes just a few minutes. The teach-in is menu guided from windows PC software and requires no pre-requisites. The vision guided robotic system is robust, compact and prepared for 4 or 6-axis robots, Scara robots and suspended picker robots, offering new opportunities to automate the feeding of components.

If you are interested in more details of the “Lemon” system or have a process that needs improving please contact us at rna@rnaautomation.com

Find out more RNA specialist handling of sachets and pouches...Here

Find out more RNA special purpose machinery for food handling...Here

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Moseley School Students Visit RNA Factory

Nine students at Moseley School spent half day at the Castle Bromwich factory of RNA.

On arrival at RNA at 9.00am, Marketing Coordinator of RNA Ying Zhang warmly welcomed the students. The students were taken to the conference room for a presentation about the company and the various processes take place in the factory.

Stuart Brettell, Managing Director of RNA, gave a welcome greeting, introducing RNA's company background, and product range including RNA feeding systems and specialist handling systems.

RNA Group is world leaders in handling and feeding technology.

Complete with protective safety glasses, the students were then taken to the different workstations in the factory and explained how each workstation contributes to the whole process.

RNA staff explaining bowl feeder fabrication

Explaining how a bowl feeder works

RNA vision guided robot being built

Machinery guarding

Electricities

Machining

CAD drawing

After the factory tour, the students were given a short seminar on CAD drawing. 

After the lunch at 12.30, the students had a free time discussion on their education decision and future career plan.

Rachel Slowey, student tutor of Moseley School, thank all the staff at RNA who help the visit. 'The technical tour was really informative and gave students a chance to look close to the engineering world. 

We value the opportunities for local college and school students to visit our factory. The staff at RNA wish the students of Moseley School all the successes in their studies and future careers!

CASE STUDY - JIF Lemon

Food Industry

Component: JIF Squeezy Lemon

Performance: Open side uppermost all one way at 100 lemons per minute total

In the UK Shrove Tuesday is known colloquially as Pancake Day or Pancake Tuesday. Pancakes are served

immediately after cooking and are traditionally served with a sprinkling of sugar and a dash of fresh lemon juice this is where RNA formed an unlikely alliance with a customer.

RNA recently completed a project for Unilever that has delivered new efficiencies and cost savings to the process line.

When RNA were contacted with a request to handle one of UK’s most famous food condiments JIF Lemons, it was both a challenging and interesting project to tackle. JIF lemon juice comes in a squeezable yellow lemon shaped plastic container. The irregular shape of the components posed the most challenging part of the project. The request from the customer was to feed 50 components per minute from two outlets and present the component axis vertical open side uppermost two at a time.

The system was supplied with twin bowl feeders a puck loading station, orientation station, transfer linear and accumulation conveyor. Two opposite handed bowl feeders feed the lemons at random into pucks . Each bowl releases a lemon on demand via a Tic Toc type escapement, the lemon sits in the puck either way

up. The puck is released to a further station where a sensor checks for the presence of the open end of the lemon. Open side up lemons are released onto an accumulation conveyor and the open side below lemons are blown out of the puck into a tube which is fitted to a vacuum generator. This tube inverts the Lemon through 180 degrees and drops the Lemon into a waiting puck resulting in the correct orientation.

The JIF Lemon ‘puck’ system features a simple reliable accumulation and a consistent output rate. The ‘pucks’ allow reliable and robust movement of the Lemons around the system with no damage to the outer container. Efficiency for the overall machine and process line increased dramatically with a reduction in down time, resulting in higher output and shorter lead times to the high street.

If you are interested in more details of the “Lemon” system or have a process that needs improving please contact us at rna@rnaautomation.com

Find out more RNA specialist handling of sachets and pouches...Here

Find out more RNA special purpose machinery for food handling...Here

Advice on Maintenance of your Feeding Equipment

THE BASICS
RNA equipment is synonymous with quality and reliability and strives to maintain its reputation in the field.

Often equipment supplied is ran on a 24/7 basis leaving little time for preventative maintenance, below are a few suggestions to help maintain peak performance.

If possible try to inspect the equipment prior to the start up of a production run, if the equipment has been recently purchased always  read the manual before operating the machine. Check the utility services (voltage, compressed air, and electrical equipment) before running the equipment often ancillaries such as sufficient air supply are overlooked.

In the case of a bowl feeder the internal lining should be clean and free of dust and the surrounding area clear.

If possible, have a checklist available; be sure that each operator is familiar with the operating instructions supplied. RNA supply clear instructions with each feed system with pre set parameters documented as a quick reference guide.

OEM spare parts are available of the shelf but for unforeseen problems try and carry minimum spares and be aware of the fitting procedure. If a problem occurs off the shelf spare parts allow you to schedule a replacement at the most convenient time.

TIPS FROM THE TECHNICAL DIRECTOR 

RNA Technical Director, Mick Keane, gives his advice on protecting and maintenance of bowl feeding systems.

Regularly clean the machine

 “Machine cleaning is often a standard requirement in the pharmaceutical and food industries. In fact, all feeding systems will benefit from regular cleaning to improve the reliability and life-span. Debris and dust on the component tracks will greatly decrease the performance of the feeder; in this case, cleaning a feeder is essential at the start of a production run”.

“RNA can provide simple dust covers or even full acoustic covers to protect the equipment.”

“Check the bowl top is tightened down correctly and that the area surrounding the feeder is clean and tidy any cables should be fastened securely and away from edges of the machine.”

“Spring packs and coils should be periodically checked, cracked or rusted spring packs should be replaced immediately .Coils should be set at the correct factory tolerances as set out in the manual.

RNA dive units are low amplitude and as a result have low noise characteristics any increase in noise levels should be investigated immediately.”

Training is recommended

“Most special purpose machines perform in different ways. RNA continues to develop each system’s performance to meet customer’s requirements, although it is beneficial if operators have received training. Training helps the operator achieve maximum machine performance and take ownership of the equipment. To meet production goals and maximize equipment investment, I advise operators to be involved at the beginning of the project even at the concept of the system.”

Set up an in-house maintenance plan

“Scheduling a maintenance plan focuses on setting up core maintenance tasks and ensures the machines performance. A maintenance plan can include routine inspection, testing and performance trials and cost analysis.”

“Setting up a maintenance plan is a cost-effective way to maintain peak performance of equipment.”

www.rnaautomation.com

Improve efficiency with Discrete Event Simulation

RNA has establishedRNA has established a manufacturing consulting service, Rhein-Nadel Consultancy www.rnaconsultants.com

Rhein-Nadel Consultancy (RNC) have launched Discrete Event Simulation (DES) to assist clients in understanding the
performance of manufacturing and production processes.

A discrete event simulation model can assist in a multitude of ways including:

■ Benchmarking the operational efficiency of your existing plant 
■ Simulations to support 'invest/don't invest' decision making 
■ Simulation of work flow concepts with 'what if' scenarios
■ Supporting lean techniques with analysis of working inventory and personnel involvement
■ Modelling work flow and plant changes without disruption

NEWS: RNA expands its 'Lean Thinking'

RNA has established a manufacturing consulting service, Rhein-Nadel Consultancy, providing expertise to manufacturing and production enterprises seeking to implement process improvement and sustainable change.

Veteran Entrepreneur Tom Farmer who built up the highly successful Kwik Fit brand was recently quoted as saying that the thing that he has learnt over the years is that it is better to outsource specialist skills than to try to attempt in-house solutions. Provided that the business and the consultant are clear about the objectives, he found that specialist advice proves to be very cost effective...Read more

NEWS: Project in your pocket

RNA Extranet is now available on your mobile phone!

RNA Extranet is an online management tool integrated with the current website to support RNA project management and client communications. Since launched in 2008, it has become one of the most popular tools to communicate with our clients.

Now RNA Extranet is available on-the-go. It allows to access your projects, exchange files, leave comments using any of the following mobile phones and devices: iPhone, iPad, Motorola Droid, Samsung Galaxy S, HTC, Palm Pre 2, BlackBerry Torch, or any other device running iOS 4+, Android 2.1+, webOS 2, or BlackBerry 6.

No applications to download or install - once you sign in our login page, you’ll automatically be redirected to the mobile site.

More information on RNA Extranet is available here.