BLISTER PACK INSPECTION PROTOTYPE for pharmAceutical industries
The project aims at a fully automated and customizable vision system for the inspection of blister packed tablets used in pharmaceutical industries. Inspection parameters include missing/broken tablets, tablet colour discrepancy, name, lot number and manufacturing date. The big picture target of this project is to promote the efficiency of Indian pharmaceutical industry by providing a low cost equipment to lower tier companies
BLISTER PACK DEMO VIDEO
needle inspection for titan industries hosur
The manufacture required automated quality control to be integrated in the assembly line of surgical Needles. Needle parameters / defects to be detected are:
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Inward / Outward Bend
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Blunt tiip
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Needle Alignment with base
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Glue fix(cone) at the base of needle
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presence of Red mark that indicates needle direction
To detect required features, multiple cameras are used to capture high-resolution images of different regions of the surgical needle, namely, tip, base and overall alignment. The​ cameras to two positions to capture image of both needles one after another. This reduces the number of cameras used in the system while achieving desired image resolution for error free inspection. The design also accounts for sufficient dwell time of camera for each part to achieve desired inspection rate. The complete inspection system consists of multi-camera assembly, illumination system based on LED arrays, position sensors, pneumatics for camera movement and ejector, high end computer system for real-time image processing, PLC for process control and power supplies. The inspection system is integrated with the automated production-line to achieve at speed inspection and sorting of good needles for packaging
NEEDLE INSPECTION DEMO VIDEO
assembly inspection for royal enfield chennai
The machine vision requirements were to find incorrect assembly based on the selected part-variant. The inspection process required detection of tappet plate and determine correct/incorrect assembly based om the part variant selected. Two different variants of the assembly allowed: one for 350cc engine and another one for 500cc engine. The vision system is used to capture the bar-code and tappet plate, extract bar-code information from the image and compare this information with tappet plate image, if the image tappet image match with bar-code information, assembly correct else assembly is incorrect.
ENGINE ASSEMBLY INSPECTION DEMO VIDEO
Automated rubber-cap inspection for calex rubbers
The manufacturer has high-volume production of rubber caps used in syringes. The molding process used in the manufacture can lead to defects such as flashes, cuts, incomplete parts and surface marks / scratches. To ensure quality parts, it is necessary to inspect individual parts and remove defective parts. Some of the defective parts, such as parts with flashes, can be re-processed and cleaned to yield good parts. A three-way sorting, namely, good-parts, re-work-parts and defective parts, can maximize manufacturing yield.
The stand-alone machine vision solution uses a vibratory bowl part feeder and a conveyor to realize automated and aligned part-feed for inspection. A camera and a Ring LED illuminator are located mid-way over the conveyor to capture an image of the part as they pass under the camera. An IR non-contact part sensor is located ahead of the camera over the conveyor to generate a trigger signal for image capture. Two air nozzles coupled to pneumatic switches are used to eject re-work and defective parts into corresponding bins. Good parts fall off the end of the conveyor into a collection bin. A PLC controls the inspection system process and maintains desired timings using conveyor speed as the reference. Several parts are in different stages of process on the conveyor at the same time. The PLC program is designed to track individual parts in different stages of process to ensure error-free binning. An industrial computer system is used to achieve real-time processing of captured images. An LCD console provides visual indications and process statistics to the operator.
The implemented system supports two part variants with adaptations to the vibratory-bowl part feeder and image processing software. The system achieved inspection rate of 6 parts per second.
RUBBER-CAP INSPECTION
DEMO VIDEO
FLYWHEEL ASSEMBLY CONTROL SYSTEM FOR ILJIN AUTOMOTIVE,CHENNAI
The flywheel consists of a ring-gear hot-pressed on to the flywheel base plate using a 70-ton hydraulic press. The same hot press is used for different variants of the flywheel. The machine-vision requirements were to prevent incorrect assembly by monitoring the nature of the mounted ring-gear, based on the selected part-variant before hot-press can be activated.The inspection process required detection of chamfer on the top-surface of the ring-gear and determine correct / in-correct assembly based on the part variant selected. Three different variants of the assembly are allowed; one model uses ring-gear with chamfer present on the top surface of the teeth, (an export model), a similar flywheel using ring-gear without chamfer, (a domestic model), and a third model with a different assembly using ring-gear with chamfer. Figures attached show images of the ring-gear with and without chamfer.The vision system for detection requires correct lighting to achieve visibility of chamfered teeth on the ring-gear. The camera needs to be located such that it does not obstruct the press operation.A smart camera is used to capture image of the ring-gear placed over the flywheel. Series-connected start buttons provide two-hand safe-trigger of the press operation cycle. The operator places the flywheel and ring-gear over the press-mount and hits the start buttons to trigger the press cycle. The start of operation is wired to trigger the light source and the smart camera to capture an image of the ring-gear. Image processing functions in the smart camera are used to detect presence / absence of chamfer and drive PLC system to continue or abort the press cycle with appropriate Indications to the operator. The system is operational in the flywheel manufacturing-line of Iljin Automotive. The system was recently upgraded to support additional part variants and enhanced features.