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Vision and scanning systems using sensors, smart cameras and fixed industrial readers perform quality control in the production department or warehouse. They enable automatic inspection of products moving on production lines in various industries. The task of the quality control system is to separate products that are not made in (...)
Application
Advanced vision systems are designed to meet individual customer needs. Our automatic quality control systems are complete solutions, based on industry standards and using modern technologies and devices. We develop and adapt systems to individual requirements, using 2D, 3D, linear cameras and multi-camera systems as well as special lighting techniques (...)
Vision systems constitute an integral part of Industry 4.0 as a solution that is being developed for automated quality control. The wide range of applications and increasingly precise operation of machine vision are the main factors responsible for their growing popularity. At Etisoft, we have developed vision control systems for manufacturing, warehouses, sorting plants, wholesalers, and many other entities in various industries. We offer the most innovative and indispensable solutions which are ideal for modern companies. How do they benefit manufacturers? They increase production quality, improve inspection, eliminate defective products, and thus reduce the number of complaints and costs.
According to the definition, a vision system consists mainly of a system of vision cameras and sensors, and software responsible for image processing and analysis. The camera that captures the image is the basis of the system. Vision sensors are also important. However, while the first industrial vision systems were frequently limited virtually to vision cameras alone, today they are much more sophisticated systems that consist of numerous electronic devices and software, that communicate with the customer’s systems. How machine vision operates depends on the process, the object of inspection, and the customer’s guidelines. The most common practice is to implement systems whose operation is based on comparing the inspected object with the saved pattern. If they match, the product is directed to subsequent production processes on the line. On the other hand, if a nonconformity is detected, the system can perform one of several actions, depending on the issue and customer needs, including, for instance:
In each case, the software analyzing the actual condition, the pattern data, and a specific reaction manner is necessary. Moreover, modern vision systems, including those offered by Etisoft, are connected to the production line to ensure that the inspection process can take place efficiently, without stopping the line, and reactions occur automatically. We also provide the appropriate lighting system that ensures continuous, correct object evaluation, regardless of the time of the day.
Here are the most important components of vision systems for quality control:
Machine vision in industry can process, analyze, and measure various parameters depending on the established objective. Vision systems analyze the indicated objects in terms of particular features, among which the most significant are usually shape and color, or the position of the item and its parts in relation to one another.
For vision systems in automation to properly perform their tasks, the following processes must be completed:
Manufacturing companies face a variety of challenges on a daily basis. Modern quality control systems can be an extremely helpful tool in a few specific cases.
First of all, in the case of frequent returns and complaints, vision systems are good at detecting defects that arise during manufacturing. The second situation is the emergence of new quality standards or customer expectations that companies must satisfy. The third is the necessity to replace quality control employees with machines. The next is a health and safety issue. Vision systems reduce the need for human presence in hazardous conditions.
Vision systems for quality control offer various functionalities:
Every day they facilitate work on production lines, in warehouses, and in sorting plants. They operate 24/7, in harsh conditions, replacing tedious human work. Therefore, it is no wonder that the market demand for vision systems in manufacturing is constantly growing.
There is no doubt that vision systems play key roles in process automation. However, to be really useful, they must be properly installed and programmed. It should be emphasized that installation involves not only the vision camera itself but also the lighting, the management panel, and the cabling responsible for the connection with the production line. An important task at this stage is performed by the integrator, or a properly prepared person responsible for the correct implementation of the vision system. They should select the proper camera and lighting parameters. It is also essential to select the right equipment for the type of tasks the system will have to perform in a specific application.
Nowadays, industrial vision systems are more than simple systems that identify deviations from the standard. If the system notices a product defect, it will automatically take action to eliminate it. Such are the current expectations of entrepreneurs regarding vision systems in manufacturing, assembly, packaging, and any other application. Thus, it is crucial to establish proper communication with customer’s systems and the production line. We recommend leaving these activities to Etisoft professionals who have many years of experience in this field. In addition, we install and implement vision systems in automation in many different industries.
Products are varied on lines, whether in production, wholesalers, sorting plants, or many other places. How is it possible that vision systems can handle different tasks and products? Our modern industrial vision systems, with the right software, can adapt to individual tasks and inspection points. It is possible to program the system to perform multiple tasks for one inspection point or product, which ensures automatic inspection of several different features. In other words, the user does not have to make any intervention for the vision system to start performing a completely different task than it did a while ago. Having previously identified incorrect product shapes, after a moment it can determine the positions of components of a completely different product in relation to one another. However, this requires the prior work of an experienced integrator.
The above question can only be asked in a completely different way – why do we need automation at all? Well, vision systems in automation are essential, in fact, they constitute its integral element. In other words, they are among the systems with the largest impact on the development of automation. Even the most focused and scrupulous employee can sometimes make mistakes because human perception has its limitations. This is influenced by several factors, including, among other things, the time of the day, the multitude of stimuli in the production hall, and the employee’s condition. Replacing human work with a robotized system is a solution that has been used for a long time. But today it is taking on a completely different dimension, as demonstrated by industrial vision systems. Automation makes sense due to better, more efficient, and more precise work performed by robots rather than humans. This is perfectly illustrated by vision systems that:
Vision systems are basically used for quality control. However, this refers to quality control of both the product and the manufacturing or packaging process itself. The main task of vision systems is to identify errors, which is conducted based on pattern analysis. Vision systems are most commonly used in manufacturing.
Vision systems in manufacturing can operate at several stages of the product development process. They begin by analyzing the correctness of the manufacture of individual components and then connect them. Identification of an error results in the emission of a signal that triggers the operation of robots or individual manipulators responsible for fixing errors. If this is not possible, the product is transported to the beginning of the production line or just removed from it.
Vision systems in packaging control the positioning of the product against the vertical and the horizontal planes, and against the package. All this is done to avoid damage to the goods and to ensure that the position of individual products in the package is correct. Moreover, the vision system analyzes the quality of the packaging, identifying any irregularities in color, creases, and other defects.
In picking, vision systems have similar tasks as in packaging. However, this time the bulk packaging is analyzed. The location of each individual package as well as the number of pieces in a bulk packaging is inspected.
The most common applications of vision systems have been listed above. Nonetheless, today there is more to it than that. Machine vision is used wherever its presence can:
The above-mentioned actions always directly or indirectly increase the company’s profits. This is sometimes due to increased production, other times due to fewer complaints, or in yet another way.
A vision camera is one of the main components of vision inspection systems. The type of camera is selected taking into account the specifics of the industry, inspection type, and product. Here are some examples of the types of cameras most commonly used in vision systems:
To fully enjoy the advantages of such solutions, while selecting a supplier of industrial vision systems, it is worth taking into consideration the following factors:
Etisoft provides all this to its customers. We have operated in the market for years, ranking among the leading European manufacturers of vision systems. We collaborate with customers operating in various industries, so we have gained knowledge and experience in finding solutions tailored to individual needs. We use top-quality hardware and software that analyzes 2D and 3D images. Our vision systems make easy configuration with Manufacturing Execution Systems possible. Industrial vision systems, supplied, installed, and implemented by Etisoft, are a guarantee of entering another level of automation. They provide more efficient and smoother manufacturing processes and beyond, thus improving the functioning of the whole enterprise and increasing customer satisfaction.