The Vision Lock Detection System is delivered by Brolton was specified to deliver the following key attributes:
• Reliable
• Efficient
• Versatile
• Cost effective
The structure and components of this system were chosen after careful study and consideration of other systems including the use of sensors as opposed to a Vision camera system. It was found that in order to achieve the desired performance and not impacting into machine changeover time, an automated vision system must be used.
The architecture chosen allows the system to be interfaced with the customers machine seamlessly. This is achieved by incorporating the current HMI, Visual basic software and the I/O of the detection system. Alarm signals are sent to the Operator panel to alert operators of an unlocked pack whilst the machine is stopped allowing the operator to remove the offending pack. The option of marking the pack with a inkjet coder is also possible.
Vision PLC components
The central Processing acts as an interface between the existing machine structure and the vision detection system. It will also provide a means to modify conditions and access settings of the vision detection system
The chosen unit comprises of max 160 I/O 1x serial and 1x parallel port.
Some of the components required for this system are:
- A CJ1 series power supply 100-240VAC
- 16 I/O 24VDC input card
- 16 point NPN(sink) transistor
- Interface cable from PLC to touchscreen
- Power Supply 24VDC 10A
Vision Camera
The vision component of this system Comprises of a camera unit and lens, Bar lights, Programming device, Monitoring cables, Triggering PE sensor, 12V DC switch Mode power supply. The system functions by interpreting the quantity of pixels located in a given area. This area must be set up by the technician. Slight variations and sensitivities of the system can be adjusted via a touch screen by an operator. More complex settings can be modified by a specialist technician under password control. This password must be kept under strict control as the integrity and efficiency of this system depend on correct setup of the system.
The Vision system is housed in an enclosed box which does not permit ambient lighting to affect the performance of the system. A protective lens is installed over the camera in order to achieve a higher IP rating. Dust which can gather over the lens will be expelled by a stream of air which skims the surface of the lens at an appropriate interval.
Touch Screen
The touch screen used is a NS8 which features an 8 inch colour display. A resolution of 640x480 and an internal
Memory of 60MB. The screen serves two purposes one is the monitoring of the system, the other is setup and modifications. The screen will be mounted in a position to the machine where it will be within the area exiting the lock section.
Laser coding
The option of using a laser coder to mark packs that are determined to be unlocked is also possible.
Currently no detailed study has been done on this system but can be pursued further if required.
Design and Testing
The system has been designed and tested using machinery designed to replicate the actual situation and reactions of a pack as it travels through the customers packaging machine. Although in testing speed has been limited to 120ppm due to the length of travel that is available in the test machine. The camera speed easily satisfies the 200ppm required by the machine during production
Customer Satisfaction
Our customer was so pleased with this system that a further 3 order were made almost immediately after commissioning. This system has allowed our customer to further extend their competitive advantage over their competitors in the Food and Beverage industry.
Our customer is one of the world's largest packaging solutions suppliers with an annual turnover in excess of 6 billion dollars. Completing this type of development for a company of this calibre extends our confidence in supplying quality on budget and on time solutions to our customers.
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